Brake System

BRAKE
GENERAL ............................................................................. BRa - 2

SPECIFICATION ................................................................... BRa - 8
SERVICE STANDARDS ....................................................... BRa - 9
TIGHTENING TORQUE .........................................................BRa-12
TROUBLESHOOTING ..........................................................BRa-15
SERVICE PROCEDURES
Air Compressor ..............................................................BRa-18
Air Dryer ..........................................................................BRa-29
Dual Brake Valve .............................................................BRa-33
Air Pressure Governor ...................................................BRa-43
Check Valve .....................................................................BRa-46
Safety Valve/Low Air Pressure Switch ......................... BRa-47
Brake Chamber ...............................................................BRa-48
Auto Slack Adjuster........................................................BRa-54
Relay Valve ......................................................................BRa-68
Quick Release Valve .......................................................BRa-69
Double Check Valve........................................................BRa-70
Reducing Valve ...............................................................BRa-71
Cab Control Valve ...........................................................BRa-73
Wheel Brake ....................................................................BRa-75
Disk Brake ....................................................................... BRa-85
Exhaust Brake System ................................................... BRa-92
BRa-2 BRAKE
GENERAL
Brake valve
Air tank
Air tank
Exhaust
Relay valve
Quick release valve
Exhaust
Slack adjuster Brake drum
Brake shoe
Cam Exhaust
Return spring
Brake chamber Cam

Air compressor
Slack adjuster
Brake shoe
Brake drum
Return spring
Brake chamber
AC58001
The compressed air is constantly supplied to the delivery port of the air brake.
When the pedal (air brake valve) is depressed, the compressed air flows by way of the relay valve (quick release valve in
the case of the front wheels) to the brake chamber to actuate the slack adjuster. The slack adjuster turns the cam which
forces the brake shoes against the brake drum to decelerate or stop the vehicle.
When the pedal is released, the compressed air is released to atmosphere and the brake shoes return to the original
position.
GENERAL BRa-3
Brake System Diagram

<Full Air Brake With ABS and ASR>
9 11
14
1 6 2 5 4
8 20
3 7
13
Door
Clutch
Retarder 17
Air seat
19
16
15
23
23
22
22
18 14
21 12 24
10
1. Air compressor 9. Air gauge 17. Magnetic valve

2. Air dryer 10. Dual brake valve 18. Low air pressure switch
3. Purge tank 11. Parking brake valve 19. Exhaust brake valve
4. PR-4 protection valve 12. R-12 relay valve 20. QR1C valve
5. Air reservoir 13. Check valve 21. Quick release valve
6. Surge tank 14. Double check valve 22. ABS modulator valve
7. Inversion double check valve 15. Brake chamber 23. Speed wheel sensor
8. Drain valve 16. Spring brake chamber 24. ASR solenoid valve
ECYBR02A
BRa-4 BRAKE
<Full Air Brake With ABS >
9 11
14
1 6 2 5 4
20
8
7
13
Door
Clutch
Retarder
Air seat 17
19
16
15
23
23
22
22
18
21
12
10

8. Drain valve 16. Spring brake chamber
ECYBR03A
GENERAL BRa-5
Air Compressor
The air compressor is driven with revolutions of half the number of From the air pressure governor
engine revolutions by injection pump gear that is in mesh with the To air tank
Unloader valve
timing gear on engine. The cylinder head of the air compressor is From the air
provided with the suction valve, delivery valve, and unloader valve Delivery valve cleaner
Suction valve
allowing the system to accomplish the suction discharge and ex-
Piston
haust operation. Cylinder
Injection pump
head
Cyliner gear
liner
Crank shaft
Crank case
JMS58A-005
1. Suction stroke
Air intake is by negative pressure in cylinder when piston goes Air inlet
down.
Air is introduced into cylinder because suction valve that has
Valve spring
been intercepting the inlet opens the inlet by compressing the Suction valve
valve spring if negative pressure is large in cylinder.
But suction valve is again pushed down by valve spring so as
to intercept air inlet of valve seat if piston goes up to the rising
Piston
reciprocation step. JMS58A-006
2. Delivery stroke Air tank

As piston moves upward on its compression stroke, discharge
side valve spring causes suction valve to close. Pressure of
air being compressed in cylinder overcomes delivery valve
spring tension pushing the delivery valve open to send air to Delivery valve spring
air tank under high pressure. If piston goes down the recipro- Delivery valve
cation step, delivery valve being pushed again by valve spring
closes air exhaust exit of valve seat.
JMS58A-007
3. When unloader valve is actuated

When air pressure inside the air tank exceeds predetermined Compressed air (from air pressure governor)
level, air pressure governor is actuated. Unloader valve
Then air pressure governor sends compressed air to unloader
valve, which causes unloader valve to be pushed down. At the Unloader valve
same time, governor maintains suction valve in open position; spring
as a result, no air is compressed and air compressor runs un- Suction valve
der no load. As air pressure in air tank drops below predeter-
mined level, air pressure governor is again actuated to dis-
charge compressed air above unloader valve. This results in JMS58A-008
unloader valve being returned to its original position by unloader

valve spring, thus actuating the suction valve.
BRa-6 BRAKE
Dual break valve

Dual brake valve is control unit that (dis) connects and regulates
compressed air from air tank so as to operate, release and control
the brakes.
1. When pedal is depressed
Piston is pushed down by plunger to force inner valve to open.
Compressed air from air tank passes inner valve to actuate
Compressed air Front brake
relay valve or quick relay valve.
chamber
Compressed air Rear brake

2. When pedal is released
chamber
Piston and inner valve are returned to their original positions by
return spring to cut off compressed air supply. At the same
JMS58A-009
time, compressed air supplied in air line escapes from exhaust
valve to atmosphere.
Compressed air
Compressed air
Exhaust gas
JMS58A-010
GENERAL BRa-7
Exhaust Brake System
Meter cluster Clutch Micro

switch switch
Exhaust Air tank

brake 3-Way
magnet valve
Control Control
cylinder cylinder
Intake silencer Exhaust brake

valve valve
To
To starter Netural
battery
switch switch
relay
Exhaust brake
switch
Fuse Power relay
AC58B001
The exhaust brake system, functioning as an auxiliary brake for the

On exhaust stroke
foot brake, consists of the butterfly valve type exhaust brake unit Exhaust brake
and the intake silencer that minimizes intake noise occurring when valve
the exhaust brake is activated.

Exhaust manifold
When the exhaust brake switch is turned ON, the 3-way magnet
valve actuates causing air pressure in the air tank to be delivered to
the control cylinder of the exhaust brake unit. This closes the ex-
haust brake valve, thus activating the exhaust brake. At the same AC58B003
time, the air pressure is delivered to the control cylinder of the in-
take silencer, which closes the intake silencer valve. Depression of
either clutch pedal or accelerator pedal, or shifting into natural turns
OFF the electric circuit temporarily, deactivating the exhaust brake
system.
The pressure inside the exhaust pipe building up when the exhaust
pipe is closed is applied to the piston as a counteracting force dur-
ing the exhaust stroke, which offers the braking force.
BRa-8 BRAKE
SPECIFICATIONS
Item Specification
Brake type Compressed air actuated, internal expansion leading-trail-
ing shoe brakes acting on all wheels (With spring brakes)
Brake line system Completely dual system
Dual brake valve (brak pedal) type Dual type
Cab controal valve working pressure of the spring brake 180 to 250 kpa (1.8 to 2.5 kgf/cm2)
Air pressure governor type Piston type
Air pressure regulation range
Low pressure Vehicle with leaf spring 665 to 705 kpa (8.5 to 11.5 ± 0.4 kgf/cm2)
Vehicle with air suspension 715 to 775 kpa (8.5 to 11.5 ± 0.4 kgf/cm2)
+ 20
High pressure Vehicle with leaf spring 805 -10 kpa (8.2
+ 0.3
-0.2 kgf/cm2)
Vehicle with air suspension 870 + 20
-10 kpa (8.9 + 0.3
-0.2 kgf/cm2)
Working pressure of the safety valve 850 to 1150 kpa (8.5 to 11.5 ± 0.4 kgf/cm2)
Brake chamber type Front #24
Rear #30 with spring brakes
Maximum push rod stroke Front 57 mm
Rear 63.5 mm
Wheel Brake
Inner Diameter of Front
410 (414) mm
Brake Drum (Limit) Rear
Brake lining Front 156 x 19 (6.3) mm
Width x thickness (Limit) Rear 207.5 x 19 (6.3) mm
Clearance between drum and lining 0.3 ~ 0.5 mm
Exhaust brake Control method Combined electrical and pneumatic
system Valve type Butterfly valve
SERVICE STANDARDS BRa-9
SERVICE STANDARDS
All values in mm unless otherwise specified
Norminal value Remeday and
Check item Service limit
[Basic diameter Remarks
Brake Push rod stroke when 590 kpa (6 kgf/cm2) #20 52 Correct or
chamber air pressure is applied from service brake #24 replace
system. (for vehicle, with spring brake, #30 67
apply 590 kpa (6 kgf/cm2) air pressure with
to spring brake system) spring
brake
Push rod stroke when air pressure is #30 67
released in the above condition with
spring
brake
Relay Inlet and outlet pressure difference kpa 25 (0.25) or less Correct or
valve (kgf/cm2) replace
Piston spring Load N (kgf)/ 16 (1.65)/10.3 13 (1.35)/10.3 Replace
Inlet valve spring Installed length 29 (3.0)/15.7 24 (2.4)/15.7
Quick Operating pressure kpa (kpa/cm ) 2
280 kpa Correct or
release (2.8 kg/cm2) Replace
valve
Dual Brake pedal play Pedal end 160° ± 4° Adjust with
brake Depressing angle 3.5° ± 1.5° adjusting
valve Screw
Pressure stroke Depressing angle 12° Air pressure :
170 to 250 kpa
(1.75 to 2.55 kgf/
cm2)
Depressing angle 17° Air pressure :
325 to 460kpa
(3.3 to 4.7 kgf/cm2)
Full stroke Pedal end 73 Air pressure :
Depressing angle 19.5°±1.5° 685 kpa(7 kgf/cm2)
Pedal straight pin inner diameter [ø9.5] ø9.68 Replace pedal
assembly
Diameter of pedal Roller mounting end [ø9.5] ø9.44 Replace
straight pin Pedal mounting end [ø9.5] ø9.45
Roller I.D. [ø9.5] ø9.67 Replace
O.D [ø18.3] ø18.15
BRa-10 BRAKE
Unit : mm
Norminal value Remeday and
[Basic diameter in [ ]} Remarks
Dual Peal straight pin hole dia meter [ø9.5] ø9.67 Replace plate
Brake assembly
Valve Plkate bushing inner diameter [ø20] ø20.08 Replace
Plunger O.D. [ø19.9] ø19.8 Replace
Spring Piston top inner Load N (kgf) / 60 (6.1)/19.1 Replace
Piston top outer Installed 215 (21.8)/26.5
Self locking bolt length 215 (22)/12.6
Piston bottom 97 (9.9)/17.0
Primary inlet valve 37 (3.8)/14.3
Secondary inlet valve 47 (4.8)/12.9
Relay piston 47 (4.8)/12.8
+ 29 + 0.3
Air High set pressure Vehicle with leaf spring 805 -20 kpa (8.2 -0.2 ) Correct or
+ 29 + 0.3
pressure kpa (kgf/cm ) 2
Vehicle with air suspension 870 -20 kpa (8.9 -0.2 ) Replace
governor Low set pressure Vehicle with leaf spring 665 to 705 kpa
kpa (kgf/cm2) (6.8 to 7.2)
Vehicle with air suspension 715 to 755 kpa
(7.3 to 7.7)
Check Inlet and outlet Correct or
valve pressure difference For service brake 29 kpa (0.3) or less replace
kpa (kgf/cm ) 2
Double Sliding pressure kap (kgf/cm2) 39 to 59 kpa Correct or

check (0.4 to 0.6) replace
valve When air pressure of 49 to 835 kpa (0.5 to 8.5 No air leakage
kgf/cm ) are applied from either right or left side
2
to be tolerated
and retained for 5 or 6 seconds
Safety Operating pressure kpa (kgf/cm2) 840 to 1156±40 kpa Replace
Valve (8.5 to 11.5±0.4)

SERVICE STANDARDS BRa-11
Nominal value Remedy

(Basic diameter in [ ]} and remark
Exhaust Exhaust Spindle to bushing clearance [12] 0.25 to 0.35 - Replace
brake brake Clearance between butterfly valve A,B 0.1 or more - Adjust
system and body at operating position (A+B)/2 0.1 to 0.4 -
Control Return Load/ 81 N (8.3 kgf)/106 70 N Replace
cylinder spring load installed length (7.1 kgf)/106
Intake Valve shaft to bushing clearance [16] 0.03 to 0.11 - Replace
silencer Clearance between butterfly A, B 1 or more - Adjust
valve and coupler or air duct (A+B) D2 2 to 3 -
at operating position
Control Return Load/ 72 N (7.3 kgf)/109 61 N Replace
cylinder spring load installed length (6.2 kgf)/109
3-way Air- When outlet port "2" is plugged To be free of - Replace
magnet tight- and air at pressure of 295 to 980
air leaks
kPa (3 to 10kgf/cm2) is applied to
valve ness
inlet port "1", and valve operated.
Minimum When air at a pressure of 20V or less -
operating 980 kPa (10 kgf/cm ) is
2
voltage applied to inlet port "1".

BRa-12 BRAKE
TIGHTENING TORQUE
Screw size Tightening torque
Location tightened
O.D x pitch (mm) Nm (kgf·m)
Air pipe 6.35 M12 x 1.5 19 to 25 (1.9 to 2.6)
M12 x 1.5
10 M16 x 1.5 39 to 50 (3.9 to 5.1)
12 M20 x 1.5 59 to 78 (6.0 to 8.0)
15 M22 x 1.5 69 to 93 (7.0 to 9.5)
Dual brake valve Pedal assembly bolt - 12 to 19 (1.2 to 1.9)
Body to cover attaching bolt - 4.9 to 7.8 (0.5 to 0.8)
Self locking bolt - 4.9 to 7.8 (0.5 to 0.8)
Relay piston screw - 4.9 to 7.8 (0.5 to 0.8)
Sleeve - 1.0 to 2.9 (0.1 to 0.3)
Adjusting screw lock nut M6 x 1.0 4.9 to 7.8 (0.5 to 0.8)
Air pressure governor Lock nut - 3.9 to 6.9 (0.4 to 0.7)
Air compressor Cylinder head bolt D2 1-cylinder M10 x 1.25 23 to 27 (2.3 to 2.8)
type
2-cylinder M10 x 1.5 39 to 49 (4 to 5)
type
Cylinder liner mounting bolt M10 x 1.5 25 to 29 (2.5 to 3.0)
Injection pump gear nut M24 x 1.5 215 (22)
Bearing holder bolt 1-cylinder type M8 x 1.25 14 to 18 (1.4 to 1.8)
Bearing holder net 2-cylinder type M8 x 1.25 14 to 18 (1.4 to 1.8)
Connecting rod nut M8 x 1.25 23 to 25 (2.3 to 2.6)
Joint D2 PT 1/8 15 to 20 (1.5 to 2.0)
Unloader valve guide M28 x 1.5 98 to 115 (10 to 12)
Delivery valve holder M36 x 1.5 98 to 115 (10 to 12)
Suction valve holder M45 x 1.5 98 to 115 (10 to 12)
Air drier Case cover mounting nut - 3.9 to 6.9 (0.4 to 0.7)
Case mounting screw - 3.9 to 6.9 (0.4 to 0.7)
Oil filter mounting nut - 3.9 to 6.9 (0.4 to 0.7)
Valve complete mounting bolt - 3.9 to 6.9 (0.4 to 0.7)
Heater - 20 to 29 (2 to 3)
Thermostat complete area clip tightening screw - 1.5 to 2.5 (0.15 to 0.25)
Bracket tightening nut - 4.9 to 5.9 (0.5 to 0.6)
Relay valve Valve body to cover attaching - 12 to 19 (1.2 to 1.9)
TIGHTENING TORQUE BRa-13

Location tightened
Quick release valve Body - 17 to 23 (1.7 to 2.3)
Straight connector PT 3/8 29 to 39 (3 to 4)
Elbow connector 23 to 59 (2.3 to 6)
Check valve Cap - 44 to 54 (4.5 to 5.5)
Double check valve Joint M20 x 1.5 34 to 44 (3.5 to 4.5)
Reducing valve Lock nut M12 x 1.25 15 to 4.9 (1.5 ± 0.5)
Spring cage body mounting scrw - 1.0 to 1.5 (0.10 to 0.15)
Diaphragm mounting nut - 4.9 ± 7.8 (5 ± 1)
Drain valve - 4.9 ± 7.8 (5 ± 1)
Cab control valve Valve attaching nut - 2.0 to 2.1 (0.20 to 0.21)
Koub attaching lock nut - 3.9 to 5.9 (0.4 to 0.6)
Brake hose M20 x 1.5 39 to 44 (4.0 to 0.6)
Wheel Anchor pin lock plate bolt M10 x 1.25 16 to 24 (1.6 to 2.4)
brake Rear dust cover bolt M10 x 1.25 16 to 24 (1.6 to 2.4)
Chamber bracket bolt Rear M14 x 1.5 78 to 115 (8 to 12)
Chamber nut No. 20 M14 x 1.5 44 to 66 (4.5 to 6.7)
No. 30 M16 x 1.5 135 to 195 (14 to 20)
(with sprifng brake)
Brake No. 20 Clamp band bolt M8 x 1.25 15 to 20 (1.5 to 2.0)
Chamber No. 30 Cap scrw - 9.8 to 18 (1.0 to 1.8)
(with sprisng Clamp band bolt - 26 to 32 (2.7 to 3.3)
brake)
Exhaust Exhaust Control cylinder mounting bolt - 21 to 25 (2.1 to 2.6)
brake brake Lever mounting nut M8 x 1.25 9.8 to 16 (1.0 to 1.6)
system valve Stopper plate adjusting bolt lock nut M6 x 1.0 4.9 to 6.9 (0.5 to 0.7)
Intake Control Plate mounting nut - 9.8 to 16 (1.0 to 1.6)
silencer Cylinder Cover mounting bolt - 9.8 to 16 (1.0 to 1.6)
Plate mounting bolt M8 x 1.25 8.8 to 12 (0.9 to 1.2)
Lever mounting bolt M12 x 1.25 37 to 45 (3.8 to 4.6)
Lock mounting bolt - 20 to 24 (2.0 to 2.4)
Control Plate mounting nut - 9.8 to 16 (1.0 to 1.6)
cylinder Cover mounting bolt - 9.8 to 16 (1.0 to 1.6)
BRa-14 BRAKE

Location tightened
O.D. x pitch (mm) Nm (kgf·m)
Exhaust Exhaust Control cylinder mounting bolt - 21 to 25 (2.1 to 2.6)
brake brake Lever mounting nut M8 x 1.25 9.8 to 16 (1.0 to 1.6)
system valve Stopper plate adjusting bolt lock nut M8 x 1.0 4.9 to 6.9 (0.5 to 0.7)
Intake Plate mounting bolt M8 x 1.25 8.8 to 12 (0.9 to 1.2)
silencer Lever mounting bolt M12 x 1.25 37 to 45 (3.8 to 4.6)
Lock plate mounting bolt - 20 to 24 (2.0 to 2.4)
TROUBLESHOOTING BRa-15
TROUBLESHOOTING
Problem Probable cause
Insufficient brakes Oil or air leakage
• Wheel cylinder
• Set air pressure lowered
• Valves and gaskets of equipment defective
• Piping
Spongy pedal
Insufficient effective pedal travel
• Worn lining
• Excessive shoe clearance
When pedal operates properly
• Lining in improper contact
• Drum deformed or unevenly worn
• Back plate distorted or loose
• Oil or grease on lining
• Hardened lining surface.
Miscellaneous
• Overloading
• Fading
• Entry of water in drum
• Tire worn
Insufficient Compressed air system
brakes (air brake) • Air cleaner clogged
(Air master and allied parts) • Air pipe and for hose defective
• Poppet valve not air-tight
• Air relay valve not air-tight
• Power piston damaged
• Diaphragm damaged
• Air compressor defective
• Pressure governor defective
• Valve of equipment not air-tight
Hydraulic system
• Relay valve piston and cup defective
• Hydraulic piston cup defective
• Air trapped
• Hydraulic piston check ball not tightly held
• Oil seal defective
BRa-16 BRAKE
Problem Probable cause

Uneven brakes Brake drum
• Damage or distortion
• Entry of water
Brake adjustment
• Inequal shoe clearance right and left
Backing plate
• Distortion
• Looseness
Tire
• Inequal inflation pressures
• Malfunction of wheel cylinder
Brake lining
• Differential materials
• Oil or grease on surface
• Poor contact
Brakes Service Air master
dragging brakes • Relay valve not air tight
• Poor maxibrake chamber return
• Air line frozen
Brake shoe return spring deteriorated
Brake shoe displacement
Insufficient shoe clearance
Parking Poor parking brake lever return
brakes Return spring deteriorated
Out of adjustment
Flexible wire rusted
Frozen
Brake Brake shoe
Squealing • Improper lining material
• Lining surface hardened
• Improper lining contact
• Displacement, looseness
• Rivet contact due to worn linings
• Brake shoe distortion
Brake drum
• Uneven wear, distortion
• Surface hardened
• Loose installation
TROUBLESHOOTING BRa-17
Problem Probable cause Remedy

Exhaust Exhaust Abnormal air pressure Check for air compressor
brake brake performance and piping
ineffective and correct as required
Faulty electrical circuit Check and repair clutch
switch, microswitch, and
exhaust brake harness
Air piping crushed Replace
3-way magnet valve inoperative Replace
Exhaust brake valve inoperative Clean
Exhaust brake valve shaft sticking Replace
Control cylinder inoperative Disassemble control cylinder
and replace defective parts
Exhaust brake 3-way magnet valve inoperative Replace
cannot be Exhaust brake valve inoperative Clean
released Exhaust brake valve shaft sticking Replace
Faulty electrical circuit Check and repair clutch
switch, microswitch, and
exhaust brake harness
BRa-18 BRAKE
SERVICE PROCEDURES
Air Compressor
Removal and Installation
1. Remove the injection pump assembly.
1-cylinder 2-cylinder
Outer air pipe Outer water Suction air pipe

valve
Unloader pipe
Outer air pipe

Inlet oil pipe
Suction Outer water pipe
air pipe Unloader pipe
Inlet water Inlet oil pipe

pipe
CYBR006A
2. Disconnect all connections.

SERVICE PROCEDURES BRa-19
Installation Procedure Pointer

1. Crank the engine to align the pointer with the inscribed line "1.6"
and to move the No. 1 cylinder piston to its TDC on the com-
Pulley
pression stroke.
Pointer : Front cover
Inscribed line : Crankshaft pulley periphery
Where there is no valve clearance, No. 6 cylinder piston is at
the top dead center on the compression stroke. Turn the engine CYBR006B
through 360°.
The same result can be obtained by aligning the pointer in the Injection pump
Inscribed line on
flywheel housing inspection window with the inscribed line "1.6" injection pump gear Idler gear
Air Inscribed
on the flywheel periphery. Compressor line on
"C"
rear plate
NOTE:
Bolt
Whenever the engine is to be cranked, crank it by hand (M10x1.5;
180° or more in the direction of normal rotation. approx.100
mmlong
Injection pump CYBR006C
2. Insert a bolt (M10 x 1.5; approx. 100mm long) from the rear end
Sensor mounting position
of the flywheel housing to support the air compressor. With the
bolt used as a guide, insert the air compressor into the mount-
ing hole of flywheel housing. At a position where the end faces
of injection pump gear and idler gear C come in contact with
each other, align the mark line of rear plate with that of injection
pump gear teeth surface. Then push the air compressor.
Flywheel housing
3. Remove sensor from flywheel housing.

Sensor plate projection
Make sure that the sensor plate projection is positioned at the
center of the sensor mounting tapped hole, then secure air com-
pressor.
If the projection is out of position, pull out the air compressor
and perform step(2) again.
CYBR006D
NOTE:
If the injection pump gear is in mesh with idler gear C one Apply sealant to threads
(THREEBOND 1211 OR 1212 or
tooth off the specified tooth, about a half portion of the equivalent)
sensor plate projection disappears from the tapped hole. Hexagonal part
4. Mounting the sensor : Apply sealant to the threads of the sen-

sor and screw in the sensor until its hexagonal part bottoms.
CYBR006E
BRa-20 BRAKE
Disassembly
1-Cylinder Type
10
6
7 11
Setting 8 12 Setting
13
9
14
} Wear, damage
4
18
17
} Wear, damage
5
16 Setting
15
Cracks,
scratch
19
24
23
20
21
22
Cracks, wear bush-
ing clogged oil hole 27
1 Cracks, wear
Damage of circle, wear 29 2
3
31 Cracks
Scratch, clogged oil hole
33
30
29 Crankshaft end play
Damage 28 L 1.0mm L...Limit
of circle
wear
Wear, damage 26 32
25
Disassembly sequence
1. Sensor plate 12. Delivery valve spring 23. Piston pin
2. Injection pump gear 13. Delivery valve 24. Piston
3. Collar 14. Delivery valve seat 25. Bearing holder
4. Cylinder head 15 Suction valve holder 26. Oil seal
5. Stud bolt 16. Suction valve spring 27. Connecting rod
6. Snap ring 17. Suction valve 28. Connecting rod cap
7. Unloader valve 18. Suction valve seat 29. Connecting rod bearing
8. Valve spring 19. Cylinder liner 30. Crankshaft
9. Valve guide 20 Compression ring 31. Crankcase
10. Valve holder 21 Oil ring 32. Bearing
11. Spring 22. Snap ring 33. Bearing
For parts with an encircled number, refer to disassembly procedure that follows.
CYBR006F
2-Cylinder Type
9
5
6 10
Settling 11 Settling
7
12 Wear, damage
8
13
}
4 17 Wear damage
16 }
Cracks, scratch 23 21 15 Settling
14
22
21
Cracks, wear of bushing, clogged 26
Damage of circle, wear 28

3 2 1 Cracks, wear
32 30
28
Damage of circle, wear
27
24 31 29
25
Wear, damage Crankshaft end play
L 1.0mm L ... Limit
1. Sensor plate 12. Delivery valve 23. Piston
2. Injection pump gear 13. Delivery valve seat 24. Bearing holder
3. Collar 14 Suction valve holder 25. Oil seal
4. Cylinder head 15. Suction valve spring 26. Connecting rod
5. Snap ring 16. Suction valve 27. Connecting rod cap
6. Unloader valve 17. Suction valve seat 28. Connecting rod bearing
7. Valve spring 18. Cylinder liner 29. Crankshaft
8. Valve guide 19 Compression ring 30. Crankcase
9. Valve holder 20 Oil ring 31. Bearing
10. Spring holder 21. Snap ring 32. Bearing
11. Delivery valve spring 22. Piston pin
For pats with an encircled number, refer to disassembly procedure that follows.
MA580190
BRa-22 BRAKE
Disassembly Procedure
1. Removal of suction valve
NOTE:
Since the suction valve holder is staked by punching, do Suction Valve Tool
not attempt disassembly unless trouble is evident.
CYBR006H
2. Removal of piston ring

NOTE: Piston Ring Tool
When a piston ring is removed, do not widen the open ends
of the piston ring more than 26 mm.
CYBR006I
Inspection and Correction

1-Cylinder Type
Deterioration load/installed length

NV 4.5N (0.46kgf)/9.5mm
L 3.6N (0.37kgf)/9.5mm
Clearance
BD 85mm
L Top 0.3mm
Skirt 0.2mm

NV 4.4N (0.45kgf)/5mm
L 3.5N (0.36kgf)/5mm
Clearance between piston ring
and piston ring groove
L 0.1mm
Piston ring end gap
L 1.0mm
Clearance
BD 18mm
L 0.08mm
Clearance
BD 18mm
L 0.07mm
Clearance
BD 34mm
L 0.1mm
Clearance
BD 42mm
L 0.1mm
Crankshaft end play

L 1.0mm
BD ... Basic Diameter

NV ... Nominal Value
L ... Limit
AC59005
BRa-24 BRAKE
2-Cylinder Type

NV 4.5N (0.46kgf)/9.5mm
L 3.6N (0.37kgf)/9.5mm
Clearance
BD 85mm
L Top 0.3mm
Skirt 0.2mm
Deterioration load/
installed length
NV 4.4N (0.45kgf)/5mm
L 3.5N (0.36kgf)/5mm
Clearance
BD 16mm
L 0.08mm
Clearance Connecting
BD 16mm rod end play
L 0.07mm L 0.5mm
Clearance between piston ring

to piston ring groove
L 0.1mm
Piston ring end gap
L 1.0mm
Crankshaft end play

L 1.0mm
Clearance Clearance
BD 42mm BD 34mm
L 0.1mm L 0.1mm
BD ... Basic Diameter

L ... Limit
CYBR006J
Reassembly
1-Cylinder Type
98 to 115 Nm
98 to 115 Nm 98 to 115 Nm (10 to 12 kgf·m)
(10 to 12 kgf·m) (10 to 12 kgf·m)
Apply 0.2 to 0.3cc of
THREEBOND Thread 23 to 27 Nm
Lock Cement 1323B (2.3 to 2.8 kgf·m)
or equivalent to three
threads
15 to 20 Nm
(1.5 to 2.0 kgf·m)
23 to 25 Nm
Apply engine
(2.3 to 2.6 kgf·m)
oil to lips 215 Nm
(22 kgf·m)
Bend lock washer
14 to 18 Nm
(1.4 to 1.8 kgf·m)
Reassembly sequence
31→32→33→ 30 →29→ 28 → 27 →25→26→24→23→22→21→20→19→5→4→
3→2→1
14→13→12→11→10→18→17→16→ 15
8→7→6→9
For parts with an encircled number, refer to Reassembly Procedure that follows.
MA580260
BRa-26 BRAKE
2-Cylinder Type
Apply 0.2 to 0.3 cc of

THREEBOND thread Lock cement
1323B or equivalent to
98 to 115 Nm three threads
(10 to 12 kgf·m)
98 to 115 Nm
4 9 8 (10 to 12 kgf·m)
39 to 49 Nm 10 5
(4 to 12 kgf·m) 11 6
19 7
18 12
20 13 14 98 to 115 Nm
23
22 25 to 29 Nm
17 15 (10 to 12 kgf·m)
15 to 20 Nm 21 (2.5 to 3.0 kgf·m)
(1.5 to 2.0 kgf·m) 16
31
Apply engine 215 Nm
oil to lips (22 kgf·m)
Dowel pin
25
24
14 to 18 Nm Bend lock washer
(1.4 to 1.8 kgf·m)
26 27 28 29 30 32 3 2 1
23 to 25 Nm
(2.3 to 2.6 kgf·m)
Reassembly sequence
30→32→31→29→24→25→28→ 27 → 26 →23→22→21→ 20 → 19 →18→4→3→ 2 → 1
13→12→11→10→9→17→16→15→ 14 →
7→6→5
For parts with an encircled number, refer to Reassembly Procedure that follows.
CYBR006K
Reassembly Procedure
1. Assembly of Connecting Rod
Assemble the connecting rod with the matchmarks on the con- Connecting rod Nut
23 to 25 Nm
necting rod and connecting rod cap at the same side. (2.3 to 2.6 kgf·m)
Bend lock washer
Match marks
Connecting Face the cut side of
rod cap CYBR006L
bolt gead inside
2. Installation of piston rings

Piston Ring Tool
CYBR006I
Make sure that the correct piston rings are installed at the
correct positions and their sides with letters stamped faces Face side with letters
up. Keep the compression ring ends 120° apart from one stamped up
another; place the oil ring ends at the center between the ends 1st compressioning
2nd, 3rd
of compression rings; place the side ring ends 45° further away
compressioning
to the right and left from the oil ring ends. Side ring
DC Oil ring
Side ring
2nd compression
ring ends
Approx. 120°
Approx.
120°
1st
3rd compression
compression
ring ends Oilring
ring ends
Side ring ends Side ring ends
<DC> <DC>
CYBR006M
3. Installation of suction valve holder
Suction Valve Tool
CYBR006H
BRa-28 BRAKE
Stake the cylinder head at three places shown over the suction
Punch at three places,
valve holder. except the head gaske
surface
Cylinder head
Suction valve
holder
CYBR006N
4. Installation of injection pump gear Align "O"mark with "U"mark

Install the injection pump gear, sensor plate, and nut as shown
above.
Face this
side to
gear
Injection pump gear
Align notch in sensor plate
with "O" mark in gear
Align catch with notch
Nut in sensor plate CYBR006O
Air Dryer
Maintenance and Inspection
It is recommended to perform maintenance and inspection at the
following intervals.
1. Every 3 months or 15,000 km

1) In order to check normal operation of the unit, open the
drain cock of the tank and check for drain. If a small amount
of drain flows out, disassemble the unit and check the des-
iccant for color change. If more than a fifth has been
changed in color, replace with new desiccant.
NOTE:
A small amount of condensate may accumulate if the
temperature fall around the tank exceeds 16°C.
2) Check closely the drain that is discharged from the exhaust
port of the unit. If abnormal discharge of oil is found, check
the air compressor and correct the problem of oil working
up through the oil ring(s).
2. Every year or 100,000 km
Disassemble and check the unit. If more than a fifth of the
desiccant has been changed in color, replace the desiccant,
oil filter and all the rubber parts with the repair kit.
Air drier
69 to 93Nm
(7.0 to 9.5 kgf·m)
19 to 25Nm 69 to 93Nm
(1.9 to 2.6 kgf·m) (7.0 to 9.5 kgf·m)
NOTE:
Check for air leakage after installation.
CYBR006P
BRa-30 BRAKE
Disassembly and Inspection
1
11
22
12 35
13 3
14
28
1
27
15
36 29
2
16 32
30
17 31
5
18 26
19
20 25
4
24
8 23
34
6 33
7
9
34
10 21
1 Bracket 13 Desiccant 25 O-ring
2 Cord 14 Filter 26 Valve
3 Stopper plate 15 Filter plate 27 Piston
4 Stopper ring 16 Gasket ring 28 O-ring
5 Purge chamber 17 Oil filter 29 Valve spring
6 Case 18 Gasket ring 30 Valve body
7 Case cover 19 O-ring 31 O-ring
8 Check valve 20 Spacer 32 O-ring
9 O-ring 21 O-ring 33 Thermostat complete
10 Spring 22 O-ring 34 Heater
11 Filter plate 23 Retaining ring 35 Body
12 Filter 24 Nipple 36 Elbow
NOTE:
Wash the disassembled parts (excluding the rubber parts, desiccant and oil filter)
all in a clean cleaning oil to remove deposits and dry them.
In case the rubber parts have to be used again, wipe clean with rag, etc.
CYBR006Q
Reassembly
8 5 7 10 9
1
Outlet port
3.9 to 6.9 Nm
(0.4 to 0.7 kgf·m)
11
Control port 12
4.9 to 5.9 Nm 13
(0.5 to 0.6 kgf·m)
3 6
19
36
2 14
1.5 to 2.5 Nm 15
Inlet port View A
(0.15 to 0.25 kgf·m) 16
33
3.9 to 6.9 Nm 18
(0.4 to 0.7 kgf·m) 20 17
29
21
22
4 27
30
3.9 to 6.9 Nm
(0.4 to 0.7 kgf·m)
34 28
20 to 29 Nm
(2 to 3 kgf·m) 32
35
31 25 26 24 23
3.9 to 6.9 Nm
(0.4 to 0.7 kgf·m)
Reassembly sequence
30→31→32→29 26→35 23→34→33 5→36→4→3→2→1
27→28 24→25
15→16→17→18→19→20→6→14→13→12→11→10
8→7
NOTE:
1. Apply grease (NA-Y141M or equivalent) to O-rings and piston sliding surfaces.
2. Install the filter so that its side with a softer layer faces the desiccant.
AC59011
BRa-32 BRAKE
Inspection after Reassembly

1. Plug the outlet port of the air drier and apply air pressure at 49
kPa (0.5 kgf/cm²) and 880 kPa (kgf/cm²) to the inlet port. There
must be no air leakage from each parts, however, leakage from
the valve must not exceed 20 cc/min.
2. Apply air pressure at 880 kPa (9 kgf/cm²) to the control port of
the air drier. There must be no air leakage from any parts.
Dual Brake Valve
Air pressure
Air pressure To front
brake chamber
Air pressure To rear

Air pressure
brake chamber
Exhaust
[When pedal is released] [When pedal is depressed]
MA580080
The air brake valve connects, disconnects and regulates the compressed air from the air tank to operate, release and
control the brakes.
When the pedal is depressed, the piston is pushed down by the plunger to force the inner valve to open. The compressed
ai from the air tank actuates the air master (air-over hydraulic brake) or, quick release valve (front side) or relay valve (rear
side).
When the pedal is released, the piston and inner valve are returned to their original positions by the return spring to cut off
compressed air supply. At the same time, the supplied air escapes from the exhaust valve to the atmosphere.
BRa-34 BRAKE
Valve Assembly
T : 20 Nm (2kgf·m)
T : 20 Nm (2kgf·m)
T : 30 to 50 Nm (3.9 to 5.1kgf·m)
T : 59 to 78 Nm (6 to 8 kgf·m)
[Straight Joint]
T: 29 to 39 Nm (3 to 4 kgf·m)
[L-joint]
T: 29 to 115 Nm (3 to 12 kgf·m)
NOTE:
Put plugs to the removed brake pipes and dual brake valve ports
(including connectors) to prevent ingress of dirt and dust.
CYBR001A
Disassembly, Inspection
1. Disassemble in the order of the pedal section, the primary valve section and the secondary valve section.
2. Wipe clean or wash the disassembled parts as follows:
• Rubber parts : Wipe clean with cloth, etc. moistened with alcohol.
• Metallic parts (excluding plate assembly and pedal) : Wash in cleaning solution (triclene, metaliclene) and blow
with air to dry for complete removal of cleaning solution.
NOTE:
1. Before disassembly, remove dirt and dust throughly from the surface and work carefully to prevent
ingress of foreign matter, dust, dirt and muddy water.
2. Before dissembly, put an alignment mark each joining portion.
3. Never wash rubber parts in cleaning solution.
Dual Brake Valve

Disassembly
Spindle I.D. Roller I.D.

BD 9.5mm BD 9.5mm
5 L 9.67 mm
L 9.68mm
6 1 Roller O.D.
Straight pin O.D,
BD 18.3 mm
(roller mounting)
L 18.15 mm
BD 9.5 mm
L 9.44 mm 4 7
3 Plunger O.D. Roller contact surface wear,
(pedal mounting) 2 sliding surface damage,
8 BD 9.9 mm
BD 9.5mm ridge wear
L 9.8 mm
L 9.45 mm 9
Spring deteriorating 11 10
Load N (kgf)/Installed length Plunger sliding surface
23
L 215 (22)/12.6 mm damage
FL 13.7 mm 24 Straight pin hole O.D.
BD 9.5 mm
25 L 9.68 mm
Spring deteriorating
Load N (kgf)/Installed length Bushing I.D.
L 215 (21.8)/26.5 mm 21
BD 20 mm
FL 29.5 mm 26
22 L 20.08 mm
Corrosion
Spring deteriorating 27
damage 14
Load N (kgf)/Installed length
28
L 60 (6.1)/19.1mm 12 Corrosion, damage
FL 20.9 mm 13
29
15
Spring deteriorating 16
Load N (kgf)/Installed length 38
L 97 (9.9)/17 mm 17 Deterioration
FL 60.5 mm
20 18 Deterioration
37
Spring deteriorating
Load N (kgf)/Installed length 36
19
L 51 (5.16)/12.8 mm
FL 58.5 mm 34
35 33 39
32
Spring deterioration 31
Load N (kgf)/Installed length 30 49 Inside damage,
L 37 (3.8)/14.3 mm wear, corrosion
FL 41.3 mm 48
47
I.D : Inner diameter 46
O.D : Outer diameter 45 Spring deterioration
B.D : Basic diameter 44 Load N (kgf)/Installed
N.V : Nominal value 43 length
L : Limit 42 L 47 (4.8)/12.9 mm
FL : Free length
41 FL 24.4 mm
40
CYBR001B
BRa-36 BRAKE
1. Snap ring 17. Sleeve outer spring 33. O-ring
2. Straight pin 18. Sleeve inner spring 34. Washer
3. L-pin 19. Screw 35. Primary inlet valve spring
4. Roller 20. Relay piston spring 36. Washer
5. Pedal cover 21. Bushing 37. Primary inlet valve
6. Pedal assembly 22. O-ring 38. Body
7. Boot 23. Self-locking bolt 39. O-ring
8. Plunger 24. Spring seat 40. Retaining ring
9. Plate assembly 25. Primary piston outer spring 41. Exhaust cover assembly
10. Retaining ring 26. Primary piston inner spring 42. Washer
11. Spring 27. Primary piston 43. O-ring
12. Relay piston 28. O-ring 44. O-ring
13. O-ring 29. Primary piston spring 45. Secondary inlet valve retainer
14. O-ring 30. Retaining ring 46. Secondary inlet valve spring
15. Sleeve 31. Primary inlet valve retainer 47. Valve retainer
16. Washer 32. O-ring 48. Secondary inlet valve
49. Cover
NOTE :
1. Before disassembly, remove dust, dirt, and other foreign matter from the surface. During the procedure,
use utmost care to prevent entry of any foreign object.
2. Wipe or wash clean the disassembled parts using the following procedure:
1) Rubber parts
For rubber parts seeming intact, wipe surfaces clean of deposits with a soft cloth dampened with
alcohol or right oil.
Never allow them to be dipped in trichloroethylene, Metalclen, other similar solution.
2) Metallic parts
(a) Clean plates in light oil, then blow air to dry.
(b) Use a cleaning solution (trichloroethylene, Metalclen) for metallic parts other than plates.
1. Make alignment marks on each joint before disassembly.
Part A Plate assembly
• Part A : Plate assembly and body
• Part B : Body and cover
Body
Part B
Cover
G7BR0660
2. Removal of Relay Piston

Screwdriver
Clamp socket wrench in a vise. Secure the body so that the
Relay piston
piston bolt is aligned with socket wrench. Then, gradually loose
the screw.
Socket wrench Screw
NOTE:
When the screw is loosened, the tension of the spring in
the body may cause the piston and spring to jump out. Be
sure to hold down the body, together with the relay piston,
G7BR0670
when loosening the screw.
Removal of O-ring.
In relay piston
Needle
3. Remove the O-rings. O-ring
1) Using the needle, remove the O-ring from the relay piston. Relay piston
O-ring
G7BR0680
2) Using the needle, remove the O-ring from the bushing. At bushing
O-ring
Bushing
Needle
G7BR0690
3) Using the needle, remove the O-ring from the piston. At piston
O-ring
Needle
Piston
G7BR0700
BRa-38 BRAKE
4. Remove the retaining rings. In cover

1) Using the needle, remove the O-ring from the cover. Needle
Cover
O-ring
G7BR0710
2) Using the pliers, remove the retaining ring from the inlet At inlet valve
valve. Retaining ring
Pliers
G7BR0720
3) Using the pliers, remove the retaining ring from the exhaust At exhaust cover assembly
cover assembly.
Pliers
Retaining ring
G7BR0730
Reassembly
3
Apply lithium base grease 12 to 19 N·m
highly resistant to load and (1.2 to 1.9 kgf·m)
wear (NLGI No.2) Li soap.
2 6
5
1
Section G-G
Pack with 1cm³ of lithium base grease
Adjusting screw 8 highly resistant to load and wear
(NLGI No. 2) Li soap.
7 4.9 to 7.8 N·m
10 11 (0.5 to 0.8 kgf·m)
4.9 to 7.8 N·m 23 4.9 to 7.8 N·m
(0.5 to 0.8 kgf·m) 24 (0.5 to 0.8 kgf·m)
25
21 26
9
38 28
22 1 to 2.9 N·m
27 29 15 (0.1 to 0.3 kgf·m)
17 16 36
35
19
37 18 34 4.9 to 7.8 N·m
20 33 (0.5 to 0.8 kgf·m)
12 13 30
31 14
32 39
47 43
48
42
40
49 46 45
41
44
NOTE
1. Apply lithium base grease [multi-purpose type (NLGI No.2) Li soap] to the O-rings and their sliding
surfaces, inter-metal sliding surfaces, and O-ring grooves.
2. Apply lithium base grease highly resistant to load and wear [(NLGI No.2) Li soap] to the plunger
sliding surfaces.
Reassembly sequence
49→48→47→46→42→41→ 40 →39
→
45→44→43
27 →28→21→22
→
38→37→36→35→34→ 30 →29→26→25→24→23→ 20 →11→10→9→8→7→6→4

→
31→32→33 5←1←3←2
→
19→18→17→16→15→ 12 → 14 →13
For reassembly of parts with an encircled number, see procedure given in the following.
G7BR0740
BRa-40 BRAKE
1. Installation of retaining ring

1) Exhaust cover assembly Pliers
Retaining ring
G7BR0750
2) Inlet valve
Retaining ring
Pliers
G7BR0760
2. Installation of relay piston O-ring.
Insert tool
O-ring
Relay piston
G7BR0770
3. Locking of piston
After inserting the piston into the body, install the retainer to Retainer
prevent the piston from jumping out.
JJR58-044
Inspection and Adjustment after Installation

1. Install pressure gauge [capable of measuring 980 kPa {10 kgf/
cm²} or more] to the primary outlet port of the dual brake valve.
Fit foot pressure gauge to the brake pedal. Increase the air
Foot pressure gauge
tank pressure to 685 kPa {7 kgf/cm²} and check for possible air
leaks. Pressure
gauge
G7BR0790
2. Tighten the push rod in dual brake valve and set screw on the
pedal to adjust the brake pedal angle so that the following
3° to 5°, 12 to 20 mm (play)
characterictic diagram can be met.
Adjusted with adjusting screw
Air pressure setup A B
1 2
A 12° 1 22±4.0 kpa

B 19.5°±1.5° (2.2±0.4 kgf·cm2)
2 70 kpa (7kgf·cm2)
G7BR0800
3. Use the adjusting screw to adjust the play at the tip of the pedal. Increase
Play
Turn clockwise to decrease
Decrease paly and turn counter clockwise
to increase play
Adjusting screw
G7BR0810
BRa-42 BRAKE
Dual Brake Valve Characteristic Diagram

Referring to the characteristic diagram, check the relationship among the pedal depressing angle (pedal travel), air output
pressure and foot pressure.
If the output pressure is low, replace the spring.
Output pressure
Foot pressure
kPa (kgf/cm2)
N (kgf)
7
6
Output pressure
5
4 40
2.3 0.5kg/cm2 32 2kg
3 30
2 Foot pressure 20
1 10
10.2 10.2 kg/cm2(2.3kg/cm2)
0 2 4±1.5° 6 8 10 12 14 16 18 20 22
Pedal depressing angle(°)
CYBR001K
Air Pressure Governor

Inspection
3 9 Clogged air path
4 10 Deterioration
11
Deterioration 5 12
13
6
7 16
Sliding surface and valve
6 seat damage, uneven wear
13
Disassembly Sequence
15 1. Cover
Seal deterioration, crack
14 2. C-ring
8 Deterioration 3. Nut
18 4. Upper spring seat
Piston sliding surface 5. Spring
damage, crack 6. Lower spring seat
7. Spring guide
8. Adjusting screw
9. Exhaust stem
10. Exhaust stem spring
17 11. Washer
Clogging 12. O-ring
13. O-ring
14. Valve spring
15. Valve
16. Piston
17. Filter
18. Body
CYBR001L
Functional Check
Remove the check valve from the air tank and connect a 980 kpa (10 kgf/cm²) pressure gauge in its place. While keeping
watch to the pressure gauge, slowly increase the air pressure to check that the pressure gauge reads nominal pressure
of 834-785 kpa (8.5-8 kgf/cm²) when the discharge noise of the compressor ceases to be heard.
BRa-44 BRAKE
Reassembly
Cover
Approx. 47.6 mm
Apply grease (LIMAX

No. 2 or equivalent) to
Exhaust body inside, piston
port
outside, O-ring. etc.
Piston
Stake washer hole
Exhaust stem
edge.
Valve To air tank
Air compressor
Filter
NOTE:
1. Wash metallic parts in cleaning solution or gasoline and blow dry with air.
2. Wipe rubber parts with dry cloth.
3. When O-rings, filters, etc. have been disassembled, be sure to replace with new ones.
AC58027
Inspection And Adjustment After Reassembly

1. Connect a pressure gauge as in the functional check and crank
the engine to build up the air pressure in the brake system.
Meassure the pressure when air is no longer fed by the com-
pressor (high pressure.)
2. With the engine running, depress the brake pedal repeatedly

to decrease the air pressure in the brake system and measure
the pressure when air is again fed by the compressor (low
pressure).
Nominal pressure
Nominal pressure Nominal pressure
Leaf spring 640 kpa(6.45 kg/cm2) 805 +-20°
29°
kpa
suspension (8.2+-0.2°
0.3°
kgf/cm2)
Air suspension 710 kpa(7.15 kg/cm2) 890±35 kpa

(8.9±0.35 kg/cm2)
3. Loosen the lock nut and adjust the pressure by turning the ad-
Turn clockwise to increase
justing scrw with a screwdriver. pressure.
After the adjustment, tighten the lock nut to 3.9 to 6.9 Nm Turn counter clockwise to
(0.4 to 0.7 kgf·m) decrase pressure.
CYBR001M
BRa-46 BRAKE
Check Valve
Disassembly
2 NOTE:
1. Replace O-ring if disassembled or
3
once a year.
2. When installing, note the arrow
4 Deterioration
mark on the valve body indicating
the direction of air flow.
5 1. Cap Do not install in the wrong direction.
Damage, crack
2. O-ring 3. When the valve is to be installed
3. Valve horizontally, position correctly as
4. Valve spring indicated by the top and bottom
5. Valve body marks.
CYBR001N
Reassembly
1 2 3 4
1. Valve
2. Valve Spring
3. Valve
4. Cap
NOTE:
Description Specification
The check valve cannot be disassembled.
If faulty, replace as an assembly. Inlet and outlet port Less than 29 kpa
Pressure difference (0.3 kgf/cm2)
CYBR001O
Safety Valve
1. Spring
2. Spring retainer
3. Ball valve
4. Dust cover
5. Wire
6. Valve body
Description Specification
Working pressure 850 to 450 kpa
(8.5 to 11.5 kgf/cm2)
AC58035
Low Air Pressure Switch
For sprifng 430 to 480 kpa

ON brake (4.4 to 4.9 kgf/cm2)
Pressure
For air 470 to 510 kpa
gauge (4.8 to 5.2 kgf/cm2)
AC58037
BRa-48 BRAKE
Brake Chamber (For #24, #30)

Components
2
3
4
5 Deterioration
1 1. Clamp ring
2. Pressure plate
7
3. Diaphragm
6 4. Push rod complete
5. Return spring
6. Dust cover
7. Nonpressure plate complete
NOTE:
Before disassembly, pull out and
fix the push rod complete.
Work carefully to prevent popping
out of the return spring.
MA580810
Disassembly
NOTE:
1. Replace the diaphragm and return spring as a set for each axle.
2. Before disassembly, put mating marks on the cylinder assembly (vehicle with spring brakes), pressure plate
and clamp.
Reassembly
A 1 2 3 4 5
6 Stroke (mm)
52 (#24)
58(#30)
B
7
1. Pressure plate NOTE:

2. Diaphragm 1. Assemble with mating marks aligned.
3. Clamp ring 2. After assembly, apply an air pressure of 980 kpa
4. Return spring (10 kgf/cm²) to the brake chamber inlet port to
5. Non-pressure plate complete check for air leaks.
6. Push rod complete
7. Service brake
Nm kgf·m
A 1.5-2.0 1.5-2
B 44-66 4.5-6.7(#20, #24)
67-100 6.8-10.2(#30)
CYBR001P
BRa-50 BRAKE
Brake Chamber (#30 For Vehicle With Spring Brakes)

Disassembly
22
23
Deterioration 8
25
Deterioration 9 26
10
11
12
4
3
1 2 6 7 5
21
20
19 1
18
17
16 14
15 13
1. Clamp band 10. Return spring 19. O-ring

2. Spacer 11. Spring retainer 20. Nylon bushing
3. Pressure plate assembly 12. Push rod assembly 21. Cylinder assembly
4. Diaphragm 13. Cap screw 22. O-ring
5. Clevis 14. Filter holder 23. Felt wiper ring
6. Boot 15. Filter cover 24. Piston assembly
7. Flange nut 16. Cone filter 25. Spring
8. Shaft seal 17. Strainer 26. Spring support
9. Spring retainer 18. Filter
CYBR001Q
Disassembly
1
1. When removing the spring, insert the Spring Setting Tool in
place of the push rod as shown in (1) and tighten the nut (A).
03727-13001
Then, remove the cap screw and slowly loosen the nut (B) to
remove the spring.
A Cap screw
CYBR001R
2. Do not remove the nylon bushing unless defect is evident.

2
AC58045
AC58047
BRa-52 BRAKE
Brake Chamber (With Spring Brake)

Reassembly
Felt wiper ring

Apply engine oil
Cap screw (SAE30 or equivalent)
Apply sealer
(THREEBOND or equivalent to Apply silicone grease (equivalent
threaded portion.) A to G30M) to O-ring and cylinder inside.
4
Stroke 67 5 6 7
Stroke 67 1. Push rod assembly
3
2. Return spring
2
3. Diaphragm
1 4. Service port
5. Spring
5
6. Piston assembly
7. Spring port
8 8. Flange nut
10 C 9. Cylinder assembly
6 10. Pressure plate assembly
B
Service port Service port Service port
spring port Nm kgf·m
A 9.8-18 1-1.8
B 26-32 2.7-3.3
Spring port C 26-32 2.7-3.3
View S
CYBR001S
Operation Check after Assembly

1. Spring Brakes
1) Set the air pressure in the air tank to 685 to 805 kpa
(7.0 to 8.2 kgf/cm²).
NOTE:
When the spring brake air pressure is below 540 kpa
(5.5 kgf/cm²), the spring brakes could fail to return com-
pletely, resulting in a dragged braking.
2) Check that pulling out of the cab control valve when the air
tank inside pressure is normal at 685 to 805to kpa (7.0 to
8.2 kgf/cm²) causes the air on the spring brake side to be
discharged, applying the spring brakes and depressing it
causes air to be supplied to release the spring brakes.
3) Check the push rod stroke is 67 mm.
2. When installing, make sure that the filter section faces

downward.
BRa-54 BRAKE
Auto Slack Adjuster

General
As for brake lining, because gap between drum and lining gows larger according to use, control is necessary to maintain
adequate lining gap through its adjustment when lining gap is adjusted by slack adjuster in case of full air S-cam brake.
But if it is not adjusted in due period cycle, brake performance is deteriorated because brake chamber stroke is length-
ened owing to excessive lining gap when braking so that brake shove phenomenon arises.
The reaseon is that it has characteristics to decrease the brake power in region where brake chamber stroke is larger than
about 80% of maximum stroke. Therefore because lining gap adjustment is a very important maintenance service item in
S-cam brake, auto slack adjuster herein
1. Pursue stability by securing always stable brake performance by automatically adjusting and maintaining the lining
with adequate gap and maintaining the adequate chamber stroke.
2. Reduces maintenance service time because there comes no need of lining gap adjustment by hand after installation
until complete wear-out.
In case when adjusted manually

Gap
In case when adjusted automatically
Time
The effect of Auto-Slack-Adjuster(compared to “By-Hand-Adjust”)
JMS58B-001
Component
24 9 8
2
7
18
19
25
15 14
6 5 4 16 24
11
23
23
21
22
17
12
24
20 13
10
1 . Housing 11. Rack 20. Screw

2 . Bushing 12. Return spring 21. Nipple
3.4.Worm gear 13. Plug 22. Gasket
5 . O-ring 14. Coil spring 23. O-ring
6 . Bearing 15. Thrust washer 24. Rivet
7 . Oneway clutch 16. Cover 25. Plug
8 . Needle bearing 17. Control disc
9 . Cover 18. Clutch spring
10. Cotrol unit 19. Gear wheel
CYBR007A
BRa-56 BRAKE
1. Housing is cast in nodular iron and tenifer treated to give a low

Bushing
coefficient of friction and high wear resistance.
Housing
JMS58B-003
2. Worm gear transmits force from housing to the S-cam shaft.

Worm gear
The tooth profile of the gear is asymmetrical, and both parts
are made of specially treated high-grade steel.
O-ring Worm O-ring

gear
JMS58B-004
3. Rack converts the rotation of control disc to a reciprocating

liner action. Return spring keep the rack in contact with the
lower flank of the recess in the control disc when one way clutch
and is disengaged.
Rack Return spring
Plug
JMS58B-005
4. Control unit supplies the motion required for the compensatory

action of the adjuster. The unit consists of control disc, control Gasket
Cover
arm and cover. The control arm and disc are rigidly joined to
Control unit
each other and can rotate freely as a unit in the cover.
Control disc
Control arm
Screw
JMS58B-006
5. Needle bearing, thrust washer and screw cover control the Cover
Needle bearing
thrust from coil spring. Coil spring is held by four springs to be
Thrust washer
in touch with clutch ring; rivet lets cover to be fixed at proper Coil spring
position and also allows it to be easily dismounted. Cover
JMS58B-007
6. One-way clutch converts the linear motion of the rack to rotary

Clutch ring
motion. The clutch consists of gear wheel, clutch spring and Clutch spring
clutch ring. Gear wheel
Bearing
one
-way
clutc
h
JMS58B-008
Operation Principle
Maintaining gap is secured by gap A between the rack rotating
together with slack adjuster and the control disc in control unit fixed Slack adjuster
at anchor bracket etc. as shown in right figure.
Namely it is not adjusted until rack end comes in touch with control
disc when slack adjuster rotates in direction at time of braking
whence gap is adjusted in the afterward region.
Control
disc
Control disc
JMS58B-009
1. When brake is operated with excessive gap between drum and

brake lining, slack adjuster slope may be divided into the fol-
lowing factors:
1) Clearance angle C: normal gap.
2) Excessive clearance angle(δ) : for excessive gap that is
made by wear of brake lining etc.
3) Elasticity angle E: determined by elasticity of component
parts transmitting between wheel brake, brake cylinder, JMS58B-010
brake drum and lining.

BRa-58 BRAKE
2. The working cycle of the brake adjuster can be divided into the
following stages:
1) Starting position
Slack adjuster control arm is located so that the rack is at
the bottom of its travel and its tooth is in contact with the
upper flank of the recess in the control disc. Angle A (clear-
ance angle) between the lower flank of the recess in the
control disc and the tooth of the rack determines the nor-
mal angle that will be obtained between brake lining and
brake drum.
Rack 13
Control 21
disc A
JMS58B-011
2) Application of brake with excessive clearance

c Movement through clearance angle (C)
The slack adjuster moves through angle A until the toe
of the rack pushes against the lower flank of the re-
cess in the control disc.
The brake shoes expand, but not enough to touch the
brake drum. Thus normal clearance (C) corresponds
to the clearance angle (A).
Rack 13
Control disc 21
JMS58B-012
d Movement through excess clearance angle (Ce)

The control disc pushes the rack upwards so that it
turns the gear wheel(7) of the one-way clutch(7, 8, 9). Gear wheel 7
Clutch spring 8
The one-way clutch is disengaged in this sense of rota- Clutch ring 9
tion. At the same time the S-cam shaft expands the
brake shoes until the linings are in contact with the brake
Rack 13
drum. Control disc 21
JMS58B-013
e Movement into elasticity zone (E)

The worm screw is displaced axilally and compresses
the coil spring so that the cone clutch between screw
and (9) is disengaged.
This happens when the torque on the S-cam shaft rises
rapidly as a result of the brake linings being pressed
with increasing force against the brake drum.
Clutch ring 9
Worm 4 17
screw Coil spring
JMS58B-014
f Movement through elasticity angle (E)

The control disc continues to push the rack upward.
Now, however, the rack turns the whole one-way clutch
assembly (7-8-9) because the cone clutch and 9 is dis-
engaged.
7
8
9
4
13
21
JMS58B-015
3) Release of brake with excess clearance

c Movement through elasticity angle (E)
The return springs 14 and 15 hold the tooth of the rack
7
13 against the lower flank of the recess in the control 8
disc 21. The rack 13 turns the one-way clutch because 9
4
the cone clutch 4 and 9 is disengaged.
13
21
JMS58B-016
BRa-60 BRAKE
d Movement into clearance zone (C)

The cone clutch 4 and 9 engages when the torque on
the S-cam shaft falls to a level at which the coil spring
17 can push the worm screw 4 into contact with the
clutch ring 9.
17
9
4
21
JMS58B-017
e Movement through clearance angle (C)

The force exerted by the return spring 14 and 15 on
the rack 13 is not enough to turn the one-way clutch 7-
8-9 when the cone clutch is in engagement. As a re-
sult contact between the tooth of the rack and the re-
cess in the control disc shifts from the lower to the
upper flank (angle A).
13
21
The control disc 21 pushes the rack down to its bottom position in
the housing 1. As both clutchs are now in engagement the worm JMS58B-018
screw 4 is turned by the rack and the wheel 3 and the S-cam shaft
turn with it.
The net result is an automatic adjustment which keeps the clear- 1
ance between the brake shoes and the drum at a constant value. 9
8
If the clearance is abnormally large, e.g. after the slack adjuster 7
4
has been removed in connection with repairs, the brake will have 14,15
3
to be applied many times to adjust the slack adjuster to its normal 13
21
stroke. Alternatively the excess clearance can be taken up manu-
ally by turning hut clockwise. The takeup of the slack adjuster per JMS58B-019
stroke is determined by the gear ratio.

4) Braking at normal clearance

Working cycle in this case is generally same as described
above but there is difference as follows. In case when brake
was applied with normal clearance, lining is installed in drum
just after slack adjuster rotated through angle A. Result is
as Be and Bf when brake was applied forcibly.
When brake is released, slack adjuster is operated as ex-
plained in Ce and the following action takes place.
Slack adjuster moves through clearance angle A. Rack
tooth is in contact with top part in recess of control disc 21
and at the same time rack is in touch with housing bottom
so that slack move upward no more.
Service Standards
Maintenance items Nominal value Limit value Remark

Front 45 mm max.
Chamber stroke
Rear 50 mm max.
Worm screw slip torque (anticlockwise) 1.8 kgf.m
Worm screw in axle direction play 0.15~0.6mm 0.6mm 0.6mm
Conical clutch (serration portion) 0.08mm 0.08mm
Coil spring tension 380~20kg
Special Tools
Tool name Part number Shape Application
Spanner 76025
JMS58B-020
Distant tube 76026
JMS58B-021
Extension piece D.T1 76034
JMS58B-022
BRa-62 BRAKE
Tool name Part number Shape Application
Spanner 76035
JMS58B-023
Lubricating tool 76843
JMS58B-024
Holder 76591
JMS58B-025
Mandrel 76493
JMS58B-026
Spline key 76494

1½″-10C
JMS58B-027
SErvice Procedures
Disassembly
1. Release the screw and remove the control unit and the gasket.
After that disassemble the rack, plug and the return spring.
2. Remove rear screw cover with a hexagon wrench, and remove
the spring and the thrust washer.
JMS58B-028
3. Check the worm screw play. If the axial play is beyond 0,6mm,
the housing is worn and replace auto slack adjuster assembly
without removal check.
Worm screw travel in axle direction 0.6mm or less
4. Remove the front screw cover using the spanner(76025) and

take out the needle bearing, O-ring and the one way clutch.
5. Remove the worm screw and bearing using the mandrel(76493)
and distance tube(76126).
JMS58B-029
NOTE:
If remove, remove the same direction of the arrow in the
housing
6. Remove the worm wheel with its O-rings.
7. Replace the following parts without fail in case auto slack ad-
juster assembly has been disassembled:
1) O-ring
2) One-way clutch
3) Clutch
4) Rivet
JMS58B-030
5) Plug
Reassembly
1. Place the worm wheel with the two O-rings in the housing with
flange uppermost. Fit the worm screw against the recess in
the housing. At that time, hexagonal head part should be lo-
cated toward the arrow position of the housing.
NOTE:
Before reassembly all part materials are to be begun ad-
justment after coating grease of lithium series. JMS58B-031
2. Fit the bearing over the worm screw and press it into the hous-
ing by means of mandrel(76493).
NOTE:
Ensure that the bearing is correctly seated against its re-
cess in the housing, and that fit the bearing to the hexago-
nal head side of worm screw and check the worm wheel
turn aroud the worm screw one time.
JMS58B-032
BRa-64 BRAKE
3. Mount clutch ring, clutch spring and gear wheel of one-way

clutch and confirm the contact state of gear wheel surface with
clutch ring.
4. Fit the O-ring on the worm screw.
5. Assemble the front screw cover with the needle bearing.
6. Tighten the front screw cover against recess in housing with a
torque of (5.1kgf·m).
Recheck that the worm screw train revolves easily.
7. Recheck worm screw play in axle direction using the spline

key (76494) and the holder (76591) that are special tools of
dial gauge.

NOTE:
If worm screw travel in axle direction that is axial play of
worm screw “ worm movement ” is outside tolerance then
substitute a new one and at this time also if adjuster limit
JMS58B-033
value is exceeded then change auto slack adjuster
assembly.
8. Compress the two return springs with the spring inserter fit
rack. Check that the rack sits correctly in its slot, and that the
springs are correctly placed on the abutment of the rack.
9. Place a new welch plug in the recess of the hole for the two
return springs with the convex surface outwards. Lock by punch-
ing it in the centre.
JMS58B-034
10. Measure serration part height of conical clutch using special

tools of holder (76591), spline key (76594) and 18mm spanner.
If below limit value, a new worm screw is required.

NOTE:
During measuring, the rack must be kept in position by
using the thumb. Please see picture. JMS58B-035
11. Lock the front cover using rivet.

12. Place the thrust washer into the housing with its bearing sphere
foword the worm screw. Insert the coil spring against the thrust
washer.
13. Screw the rear cover by means of a hexagon wrench about 4
turns against the coil spring.
14. Fit the lubricating tool(76593).

Fill the adjuster with prescribed grease and dismantle the lu-
brication tool.
JMS58B-036
15. Place a new gasket on the control unit place the control unit in
the housing ensuring that the toe of the rack enters the cut out
in the control disc. Tighten six screws.
16. Adjust the spring force by means of an end load tester(76035)
to (380-20kg).
NOTE:
Spring force adjustment shall be precise because it plays
important role in auto slack adjuster function.
1) To ensure proper function of the auto slack adjuster, the

force of the coil spring has to be adjusted to 380~20kg.
This force is reached when the gauge pointer is inside the
red area.
NOTE:
The minimum gap of the vice must be 215mm.
JMS58B-037
2) Place the auto slack adjuster in the tool so that the hexa-
gon wrench in the hexagon of the rear screw cover and
that the hexagon on the worm screw is fitted into the lock-
ing plate.
JMS58B-038
3) Load the adjuster until the pressure gauge is about half-

way to the red area. Rotate the control arm clockwise so
that the rack of the adjuster is moved fully up in its slot.
Then rotate the control arm backwards over the control
angle A.
JMS58B-039
BRa-66 BRAKE
4) Load the adjuster until the gauge pointer is whin the red
area. The control arm should then return to its starting point
due to the release of the conical clutch. If the control unit
should only move slowly it may be necessary to press it
lightly by hand to return it to the normal position.
NOTE:
The gauge must be read at the same time as the con-
trol arm begins to return to its starting position. JMS58B-040
5) (Un)fasten rear screw cover by spanner to control tensile

force if control arm starts to return when gauge pointer is
before or beyond red area.
6) Sufficiently return the vice so that adjuster will receive no
load.
7) The above f~h must be repeated until accurate spring
force is got.
17. Lock rear screw cover using a rivet.

Periodical Check
Operation Status Check
1. Check per drive distance 20,000 km whether chamber push
rod stroke is within nominal value.
Chamber push rod ≤ 45mm ≤ 45mm

Stroke(mm) ≤ 50mm ≤ 50mm
2. If the stroke is beyond nominal value then confirm whether it is

auto slack adjuster abnormality or other parts abnormality by
means of reverse adjustment torque checking.
Reverse Adjustment Torque Check

1. Reverse adjustment torque shall be checked per six months.
2. Check if slip occurs below nominal torque of one-way clutch by
measuring the torque by turning the worm screw hexagon head
anticlockwise.
Nominal torque 1.8kgf⋅m
3. The above reverse adjustment torque shall be measured more

than three times and then if one-way clutch slips below nomi-
nal torque then auto slack adjuster function is abnormal.
NOTE:
Take heed that phenomenon is frequent that mainly one-
way clutch spring is broken.
Wear Limit
Min ∅15.90mm
Min ∅61.87mm
Max ∅16.15mm
Max ∅62.2mm
A
Max 9.4(Nom 9.0)mm
A
CYBR007B
BRa-68 BRAKE
Relay Valve
Disassembly
1. Retaining ring
2. Exhaust cover assembly
Spring deterioration 3. Retaining ring
Load N (kgf)/Installed length (mm) 4. Valve guide
NV 16 (1.65)/10.3
5. O-ring
L 13 (1.35)/10.3
6. O-ring
Spring deterioration 7. Spring
Load N (kgf)/Installed length (mm) 8. Valve retainer
NV 29 (3.0)/15.7
9. Inlet valve assembly
L 24 (2.4)/15.7
10. Cover
11. O-ring
NV : Nominal Valve
12. Piston
L : Limit
13. O-ring
14. O-ring
15. Spring
16. Body
MA58101
Reassembly
12 to 19 Nm 10
(1.2 to 1.9 kgf·m)
12
13
11
15 16
14
9
5 8
7
4 6
2 3
1
Reassembly sequence NOTE:

16→98→7→6→5→4→3→2→1→11→15 →10 Apply multipurpose type grease Li soap to sliding
12→14→13 O-ring, their sliding surfaces, metal-to-metal sliding
surfaces, and O-ring grooves.
CYBR001T
Quick Release Valve

Disassembly
4 Cracks
3 Deterioration 1. Body
2. O-ring
3. Spring
2 4. Retainer
5. Ring
6. Digphragm and ring assembly
1 Inside rust
7. Housing
CYBR001U
Reassembly
From brake valve
2
To brake
chamber To brake
chamber
1. Housing
3 2. Diaphragm and ring assembly
3. Spring
A
Nm kgf·m
Exhaust A 6.9-23 0.7-2.3
Inspection
NOTE:
Description Specification Wash removed metallic parts throughly
Operation strting pressure 4.9 to 15 kpa and work carefully to prevent ingress of
(0.05 to 0.15 kgf/cm²) metal chips and dust.
CYBR001V
BRa-70 BRAKE
Double Check Valve

Disassembly
7
8
5 1. Joint C
2. Packing
6 3. Joint A
4. Packing
9 5. Check valve
6. Sleeve
3 4
7. Joint B
8. Packing
9. Body
AC58057
Reassembly
1 Apply THREEBOND 2310

Joint C or equivalent to PT 3/8
threaded portion (Joint A)
3 Nm kgf·m
A 34-44 3.5-4.5
2 Apply THREEBOND 1101 B 34-44 3.5-4.5
or equivalent
C 34-44 3.5-4.5
7 Joint B
4 8
6 5 9
Apply THREEBOND 1101 Apply THREEBOND 1101
or equivalent or equivalent
Inspection NOTE:
1. Check that the check valve makes sliding motion at an air pressure The joint C should not be removed unless
of 39 to 59 kpa (0.4 to 0.6 kgf/cm²). it is replaced.
2. Apply an air pressure of 39 to 59 kpa (0.4 to 0.6 kgf/cm²) and 635 to
735 kpa (6.5 to 7.5 kgf/cm²) from either right or left side and hold the
pressure for 5 to 6 seconds check that no air leak is detected.
CYBR001W
Reducing Valve
Disassembly
Sliding surface damage 16

4
5 Deterioration
6
7
Outer circumference wear, 15 8
rubber part wear, damage
14 9 Damage, aging
13 10
12 11
1. Spring cage 9. Diaphragm
2. Adjusting bolt 10. Diaphragm washer
3. Lock nut 11. Packing
4. Spring seat 12. Drain valve
5. Spring 13. Packing
6. Cotter pin 14. O-ring
7. Nut 15. Valve
8. Diaphragm plate 16. Body
NOTE:
Do not remove parts 2 and 3 unless for adjustment or replacement.
CYBR002A
BRa-72 BRAKE
Reassembly
2 15 ± 4.9 Nm
(1.5 ± 0.5 kgf·m)
3
4
49 ± 9.8 Nm 1
(5 ± 1 kgf·m) 5
6
8
7
1.0 ± 1.5 Nm
(0.1 ± 0.15 kgf·m)
10 9
11
15
14
13
16
12 12
49 ± 9.8 Nm
(5 ± 1kgf·m) 1. Spring cage
2. Adjusting bolt
3. Lock nut
4. Spring seat
5. Spring
Reassembly sequence 6. Cotter pin
15→14 10→11 2→3 7. Nut
8. Diaphragm plate
16 9→8→7→6→5→4→1 13→12 9. Diaphragm
10. Diaphragm washer
11. Packing
NOTE: 12. Drain valve
1. Apply grease (heat proof multipurpose type grease Li soap) to 13. Packing
O-ring and O-ring grooves. 14. O-ring
2. Apply sealant (THREEBOND TB1110B or equivalent) on taper 15. Valve
threads of connectors to be reinstalled to each ports. 16. Body
CYBR002B
Adjustment Procedure Adjusting bolt

Set up a piping circuit as shown above and apply air at a pressure Lock nut
Pressure gauge 15 to 4.9 Nm
of 735 kPa (7.5 kgf/cm²) to the inlet port. (1.5 to 0.5 kgf·m)
Air
Turn 705 ± 29 kPa (7.2 ± 0.3 kgf/cm²). Tighten the lock nut to the outlet
Pressure
specified torque. gauge
Air inlet
Outlet air pressure Inlet air pressure

705±29kPa 735 kPa
CYBA002C
(7.2±0.3 kgf/cm2) (7.5 kgf/cm2)
Cab Control Valve

Disassembly and inspection
10 Disassembly sequence
1. Snap ring
11 2. End cap
3. O-ring
12 4. Shim
5. Valve spring
6. Nut
7. Washer
8. Valve assembly
13 9. Knob
8 10. Nut
11. Piston
7
12. O-ring
6 13. Body
5
NOTE:
4
1. Wash metal parts in cleaning solvent or
2 gasoline and blow dry using pressure air.
2. Wipe rubber parts with a dry rag, etc.
3 1 3. Replace O-rings with new ones.
AC58067
BRa-74 BRAKE
Reassembly
11 10 3.9 to 5.9 Nm
(0.4 to 0.6 kgf·m)
(installed on vehicle)
12
13
7
8
Reassembly sequence
13→12→11→10→9→8→7→6→5→4→3→2→1 3
5 2
NOTE:
1
Apply silicone grease MOLYKOTE 33-M or equivalent to the 4 6 2.0 to 2.1 Nm
sliding surfaces and o-ring. Outlet
(0.20 to 0.21 kgf·m)
CYBA002D

Outlet air pressure kPa (kgf/cm2)
Knob 685
(7)
Pressure gauge
275 ± 34
(2.8 ± 0.35)
Plug 0 685(7)
275 ± 34
(2.8 ± 0.35)
Pressure
Inlet air pressure kPa (kgf/cm2)
CYBA002E
Set up a piping circuit as shown above and apply air pressure at approx. 390 kPa (4 kgf/cm²) to the inlet port. Gradually
decrease the pressure. The knob must pop-up automatically when the air pressure falls to 275 ± 34 kPa (2.8 ± 0.35 kgf/
cm²). If faulty, replace
Wheel Brake
Front Wheel Brake
Removal and installation
Brake hose Brake
39 to 44 Nm
Remove the brake hose of the frame side first. At reassembly, in- hose
(4.0 to 4.5 kgf·m)
stall it to the wheel brake end first.
NOTE :
Make sure that the brake hose is not twisted during installation. CYBR002F
Disassembly, inspection and Correction
Lining thickness
NV 16 mm
NV 6 mm Load/installed length
NV 410N (41.8 kgf)/265 mm
10 1112 6 L Any gap between coil
17 loops or between coil and
13 18
cover
3
2
Anchor pin to bushing clearance
15
19 1 BD 35 mm
17 NV 0.05 to 0.14 mm
16
14 L 0.3 mm
5
4
Camshaft to bushing clearance
8
BD 40 mm
NV 0.16 to 0.21 mm 9 7
L 0.5 mm
6
BD...Basic Diameter Streaks on inner Brake drum
NV...Nominal Value wall, uneven wear Inner diameter
L ...Limit NV 410 mm
L 414 mm
Cylindricity
NV 0.05 mm
L 0.2 mm
1. Return spring 11. Washer
2. Anchor pin lock washer 12. Slack adjuster
3. Anchor pin lock plate 13. Spacer
4. Anchor pin 14. Camshaft
5. Bushaing 15. Dust cover
6. Brake shoe assembly 16. Oils seal
7. Roller pine 17. Dust seal
8. Roller 18. Bushing
9. Return spring pine 19. Anchor bracket
10. Snap ring
CYBR002G
BRa-76 BRAKE
Removal of return spring
Retum Spring Setter

CYBR002H
Removal of anchor pin
MA580640
Replacement of brake lining

1. Service points of removal
When drilling out the brake lining rivets, use care not to enlarge
or damage the brake shoe hole by the drill.
2. Service points of installation
• Rivet starting from the center portion and working toward
the ends. Make sure that no gap is produced between the
shoe and lining. AC58081
• Stake the rivets to 17 to 19 kN (1700 to 1900 kgf).
• Select the lining according to the operating conditions of
the vehicle. Use linings of the same size and paint color on
right and left wheels of the same axle.
• After relining, check contact with the drum inside and
correct poor contact if any. Correct the lining as incorpo-
rated into the wheel and brake assembly.
3. Correction of drum
If the drum a cylindricity of 0.2 mm or poorer or is scratched,
correct to the repair limit. After machining, use an oversizze
lining.
Brake drum I.D. Repair limit Limit

410mm 412mm 414mm
NOTE :
Machine the brake drum together with the wheel hub.
Reassembly
Install oil seal to be flush with Make sure of the bushing inserting
surface. Make sure of the bushing direction printed on its outside
inserting direction printed on its surface and press-fit it to be
outside surface and press-fit it to be flush with this surface.
flush with this surfaces.
Install dust seal
16 17 to be flush with this surface.
18
(Apply wheel grease MP-2 or
equivalent to bushing inside
surface after press-fitting it.)
7 8 1
6 14
11 12
Direction
of drum
9
rotation
for 10
13
forward
travel 16 to 24 Nm
(1.6 to 2.4 kgf·m)
19
16 to 24 Nm
(1.6 to 2.4 kgf·m) 4 5
3 2 (Apply wheel grease MP-2 or
equivalent to bushing inside
(Bend securely after tightening bolt.)
surface after press-fatting it.)
Reassembly sequence
19→17→16→15→14→13→12→10→4→3→2→1
6→5→8→7→9
NOTE:
1. Use 2mm thick washer in the slack adjuster only when 1.2 mm thick
washer cannot be sued.
2. Keep the drum inside and lining surface free of grease and oil.
AC58089
BRa-78 BRAKE
Rear Wheel Brake

Brake hose for
spring brake
Remove the brake hose from the connector. At reassembly, install
it to the brake chamber end first.
NOTE:
Make sure that the brake is not twisted during installation. Brake hose
for 39 to 44Nm
Brake chamber service (4.0 to 4.5 Connector
brake kgf·m) CYBR002I
Disassembly, Inspection and Correction
Spring deterioration
Bushing to camshaft
Load/installed length
clearance
NV 565N(57.9 kgf)/268 mm
BD 40 mm
L Any gap between coil loops
NV 0.16 to 0.21 mm
and between coil and cover
L 0.5 mm
Streaks on inner wall.

uneven wear
10 BD 410 mm
6 L 414 mm
11 Cylindricity
12 1 NV 0.05 mm
13
14 18 16 L 0.2 mm
17 20
19 15
8 Brake drum
3 7
2
21 22
4 9
Bushing to anchor pin clearance
BD 35 mm
6
NV 0.05 to 0.14 mm 5
Cracks, burn damgae
L 0.3 mm
Lining thickness BD...Basic Diameter
NV 16 mm NV...Norminal Value
L 6 mm L ... Limit
1. Return spring 9. Return spring pin 17. Oil seal
2. Anchor pin lock washer 10. Brake chamber 18. Bushing
3. Anchor pin lock plate 11. Snap ring 19. Dust seal
4. Anchor pin 12. Washer 20. Bushing
5. Bushing 13. Slack adjuster 21. Dust cover
6. Brake shoe assembly 14. Spacer 22. Anchor bracket
7. Roller pin 15. Camshaft
8. Roller 16. Chamber bracket
CYBR002J
Adjustment of Brake Shoe Clearance

Inspection before adjustment
1. Perform the following checks after removing the clevis pin of To increase
brake chamber push rod. shoe clearance
Turn the worm shaft in the direction of arrow as shown in illus-

tration to make sure that the turning torque is 4.9 Nm (0.5 kgf·m)
or more.
Worm shaft
MA580760
2. If the torque is smaller than the specified, replace the spring

and set screw of slack adjuster with new ones, adjust the set Stake (Punch)
screw to obtain a turning torque of 5.8 to 14.5 Nm (0.6 to 1.5
kgf·m), then lock the screw by staking it at two points.
Set screw
Spring
MA580770
3. Turn the slack adjuster to right and left to check
Looseness:
Less than 4
MA580780
BRa-80 BRAKE
Reassembly
Install bushing aligning with this surface,

noting correct direction of installation
(print mark on bushing outside)
Install oil seal aligning Install dust seal

with this surface aligning with
19
17 this surface
20 18
10
Apply multi-
purpose type
grease (NLGI
7 8 15 No.2) li soap
1
6 9
This side up when 16 14 12 11

installed on vehicle 135 to 195 Nm
(14 to 20 kgf·m) 16
Direction of drum 16 to 24 Nm
rotation when 22 (1.6 to 2.4 kgf·m) 13
78 to 115 Nm
vehicle moves forward 4
2 21 (8 to 12 kgf·m)
3 16 to 24 Nm 5
Apply multi-purpose type grease (NLGI No.2)
(Bend securely after tightening bolt) (1.6 to 2.4 kgf·m) Li soap to the inside surface.
Reassembly sequence
22→21→16→20→17→18→19→15→14→13→12→11→4→3→2→1
6→5→8→7→9
NOTE:
1. Use 1.2 mm thick washer at the slack adjuster only when 2mm thick washer
cannot be installed.
2. Install bushing on the anchor bracket side of the camshaft after installation
of the chamber bracket.
3. Keep the drum inside and lining surface free from oil and grease.
AC58099
No. 30 for with Spring Brake
22
23
24
Deterioration 8
25
26
Deterioration 9
10
11
13
5
4
1 5
2
6 7
21
20
19 18 1
17
16
14
15 13
1. Clamp band 10. Return spring 19. O-ring
2. Spacer 11. Spring retainer 20. Nylon bushing
3. Pressure plate assembly 12. Push rod assembly 21. Cylinder assembly
4. Diaphragm 13. Cap screw 22. O-ring
5. Clevis 14. Filter holder 23. Felt wiper ring
6. Boot 15. Filter cover 24. Piston assembly
7. Flange nut 16. Cone filter 25. Spring
8. Shaft seal 17. Strainer 26. Spring support
9. Spring retainer 18. Filter
AC58101
BRa-82 BRAKE
Adjustment
(Front)
1. Connect the push rod and check the air line for leaks and the
push rod for smooth movement.
2. Increase the air pressure to 785 kPa (8 kgf/cm²) and check
that the fall of the air pressure gauge reading in 30 minutes
Push rod stroke
does not exceed 78 kPa (0.8 kgf/cm²)
Also check that compressed air is working to the spring brake
side of the spring brake chamber and high air pressure is work- CYBR002K
ing to the main brake.
3. To adjust the brake shoe clearance, press the brake shoes (Rear)
against the brake drum by turning the worm shaft of the slack
adjuster until it does not move any further. With the brake pedal
fully depressed, back off the worm shaft to adjust the brake
chamber push rod stroke to the standard value (25 mm front,
30 mm rear) and now the correct clearance is obtained. Push rod
stroke
4 When the brake chamber push rod stroke has reached the limit
(40 mm front, 50 mm rear), readjust by the slack adjuster. CYBR002L
NOTE:
1. The brake chamber push rod length should be set at
the standard value at reassembly. Do not change the
setting.
2. When the brake shoe clearance is adjusted, make sure
that there is a air pressure of 685 to 805 kPa (7.0 to 8.2
kgf/cm²) in the air tank.
Brake Chamber
Disassembly and inspection
2
1. No. 20 4 3
5 Deterioration
1
7
6
1. Clamp ring
2. Pressure plate
3. Diaphragm
4. Push rod complete
5. Return spring
6. Dust cover
CYBR002M
7. Non-pressure plate comp
2. No. 30 for with spring brake
Apply sealant
(THREEBOND or equivalent)
to threaded portion.
Apply silicone grease(equivalent
9.8 to 18 Nm(1 to 1.8 kgf·m)
to G30M) to O-ring and cylinder
Apply engine oil inside.
Service port (SAE 30 or
equivalent)
13 Spring port
26 23
25 22
4 24
10 Stroke 67 Stroke 67
6
11
A
12 8
9 19 20
7 5
3
Nut tightening torque
18
21 at assembly
1 17 135 to 195 Nm
16 15 14 (14 to 20 kgf·m)
26 to 32 Nm
(2.7 to 3.3 kgf·m)
Service port
spring port
2
View A
Reassembly sequence
24→23→22→25→26→21 20 19→8→9→10→11→12→7→6→5→4→3→2→1
18→17→16→15→14→13
CYBR002N
BRa-84 BRAKE
Piston Spring
1 2 3
Spring
setting Tool
Nut
Cap screw Nut Spring

Piston Piston
Cylinder support
1 Remove the push rod. Set the Spring Setting Tool, and tighten the nut. Then, remove the cap screws.
2 Remove the piston from the cylinder.
3 Gradually loosen the nut and separate the piston and spring support
CYBR002O
Reassembly
1
3 5
15 to 20 Nm 7
(1.5 to 2 kgf·m) 2
Nut tightening torque at assembly

44 to 66 Nm
(4.5 to 6.7 kgf·m)
Reassembly sequence
7→6→5→4→3→2→1
CYBR002P
Reassembly Procedure
Reassembly of piston
1 2 3
Spring Cylinder Piston

Piston Spring support Spring
Nut support
Spring setting Tool
Nut
Cap screw
Cylinder
1 Install the spring and spring support to the piston and set the Spring Setting Tool.
2 Insert the piston into the cylinder.
3 Install the cap screws which hold the spring support to the cylinder.
Loosen the nut gradually and remove the spring setting tool.
CYBR002Q
Disk Brake
Components
Carrier
Rotor
Pad
Bus
Bridge
Housing
Lever
Pad
Tapper
Adjuster
Plate
Needle race
Washer
Thrust race
Operating shaft
Adjuster wheel
Fixed pump Guide pin

AA58006A
BRa-86 BRAKE
Reassembly and Disassembly
11 6
3
7
10
14
8
12
11 9
13
<Reassembly sequence>
1. Clevis pin
9. Carrier
2. Chamber assembly
10. Long guide pin
3. Operating lever
11. Short guide pin
4. Pad retainer plate
12. Guide pin dust cover
5. Pad spring
13. Terminal cap
6. Pad
14. Terminal cover
7. Bridge
15. Dust cover
8. Housing
<Assembly sequence>
Reverse of disassembly sequence.
AA58049A
Pad Replacement Procedure

When pad is remained 5mm from the back plate after abrasion or pad wear alarm unit is operated so that ( L ) sign is
displayed on instrument panel, it tells that pad is in complete weared condition so that immediate replacement should be
done.
Pad wear condition shall be inspected per 5,000km or per week.
When change the pad, maintain the air pressure at least over 6kg/cm2 and release the parking brake.
1. Disassembly procedure
1) Disassemble bolt pad retainer by tool.
AA58008A
2) Remove by lifting the pad retainer plate.
AA58009A
3) How to return pad

Remove the stem cover (3) by the hand.
Loosen the lock nut (5) to the end of the adjuster stem
1
(4) 2
3
Connect the adjuster stem (4) by pulling to the grooe
4
(6) of the adjuster wheel.
5
Return the pad by turning the adjuster stem.(4) 6
Disassemble the pad by the hand. AA58200A
CAUTION :
When removing the contaminants of the disk brake by
using the compressed air, it may be cloged the oil
passage. Do not the compressed air. If necessary, clean
with the vacuum cleaner.
AA58015A
BRa-88 BRAKE
4) Remove the pad from the disk brake.
AA58010A
CAUTION :
When returning the pad, do the procedures 3),4) by
pullng the spreader plate in order not to separate the
spreader plate like the right illustration. If the tappet
pin and the spreader plate are to be separated, the pad
return work can be achieved normally. Certainly do it
by the hand, and do not air tool. Do not turn the tappet
head, it damages the adjuster stem. In this case of the AA58011A
pad return, spreader plate should be attached to the

tappet like the illustration. After disassembling the pad,
check the each part.
AA58012A
2. Assembly procedure(New pad assembly)

1) Check the rotational torque of the disk brake. If the torque
is over 20kg, check the sliding pin part.
AA58013A
2) After assembling a new pad, push the brake as the right

illustration.
AA58014A
3) Assemble the inner pad.

If the pad can not be correctly, it means the spreader plate
has not been pushed completely.
In this case, assemble the pad after returning the pad.
* How to adjust pad clearance
1 Turn the adjuster stem for pad to be in contact with
rotor.
2 Turn the adjuster stem 3/4 in opposite direction. AA58015A
4) Take off adjuster stem using a driver and then fix by turning
the lock nut.
(Tightening torque : 1~1.5kgm)
CAUTION :
In this case of not be doing the former procedure the
pad clearance adjustment can not be done properly.
After doing it, assemble the stem cover.
AA58016A
5) Assemble the pad spring to the pads

- New disk rotor thickness : 45mm
Wear limit : 35mm
- When using the new disk rotor, use a pad back plate
thickness is 8mm.
- If the disk rotor thickness is worn out over 3mm in one
side, use a pad the back plate thickness is 10mm.
AA58017A
6) Fix the pad retainer with the bolt after assembling.
AA58008A
3. Pad and disk brake rotor wear limits A

C
1) Disk rotor thickness : 45mm (A) B
2) Disk wear limit : 37mm (B)

3) Pad and back plate thickness : 30mm (C)
D E
4) Back plate : 9mm (D)
5) Pad wear limit : 5mm (E)
6) Pad and back plate wear limit : 13mm (F) F
AA58018A
BRa-90 BRAKE
Disassembly and of the Brass Bushing in the Brake Housing

1. Disassembly
Before disassembling mark the alignment marks on the housing and the brass bushing using a punch etc.
AA58918A
2. Reassembly
Press-fit the brass bushing in the housing using a special tool.
50mm
40mm
40mm
31.7mm
AA58919A/AA58920
50mm
40mm
10mm
50mm
31.7mm
35.7mm
AA58921/AA58922
Disassembly and Assembly of Long and Short Guide Pins

1. Removal
Remove guide pin out of carrier using a plastic hammer.
Guide pin
assembly
AA58923A
2. Reassembly
Mount dust cover and terminal cap to guide pin and then mount it on carrier.
Terminal cap 3.5mm
Guide pin
Guide pin
Dust cover
Dust cover
Guide pin sleeve

Terminal cap
AA58916A
BRa-92 BRAKE
EXHAUST BRAKE SYSTEM

Exhaust brake valve
10
Wear, seizure
9
1
2
3
1. Snap pin 6. Stopper plate
2. Pin 7. Seal ring (small)
3. Clevis 8. Seal ring (large)
4. Lever 9. Bushing
5. Control cylinder 10. Valve and body assembly
NOTE:
If the valve, spindle and lever side bushing are defective, do not disassemble
but replace the valve and body assembly.
CYBR004A
EXHAUST BRAKE SYSTEM BRa-93
10
9 1
Wear, seizure
8
4 Wear
1. Snap pin 6
2. Pin
3. Clevis
4. Lever
5. Control cylinder
6. Insulator
7. Seal ring (small)
8. Seal ring (large)
9. Bushing
10. Valve and body assembly
NOTE:
If the valve, spindle and lever side bushing are defective, do not disassemble but
replace the valve and body assembly.
JMS58A-117
How to Disassemble Hammer

1. Spindle removal Valve
Remove control cylinder plate cover.

Put bar at spindle and strike with hammer so that spindle comes Spindle Bushing
(Lever side) Bushing
out. Make body only clean after removing the spindle.
(cover side)
NOTE:
Spindle
At this removing, valve and spindle shall be replaced by Sealing
new ones. FJR58A-151
BRa-94 BRAKE
Reassembly and Adjustment
6
9 4
1
Fully
2 opened
Turn adjusting screw so that 30°
the butterfly valve runs 7 21 to 25 Nm
30° Fully
parallel with the valve (2.1 to 2.6 kgf·m)
8 closed
body when it is opened 5 9.8 to 16 Nm
and clearances A and B 3 (1.0 to 1.6 kgf·m) 4.9 to 6.9 Nm
are up to specification (0.5 to 0.7 kgf·m)
when it is closed.
Valve body
10
Clearance between valve and

body when valve is closed
NV A, B 0.1mm or more
(A + B)/2 0.1 or 0.4mm NV ... Nominal Value
Reassembly sequence
10→9→8→7 4→3→2→1
6→5
NOTE:
To install the control cylinder, place the valve at full open position, pull out the control
cylinder shaft 2 mm or more from the free state and connect it with the clevis.
CYBR004B
6
Turn adjusting screw so that the
2.1~2.6kgf·m
butterfly valve runs parallel with
5 the valve body when it is opened
2 and clearances A and B are up
to specification when it is closed.
1 Clearance between valve and
body when valve is closed
NV A,B 0.1mm or more
3
4 A+B/2 0.1~0.4mm
1.0~1.6kgf·m 7
Fully opened
10
8 44.5°
9
30.5°
Fully closed
0.5~0.7kgf·m
1.0~1.6kgf·m
Adjusting bolt
NV : Nominal value
JMS58A-119
How to reassemble
Spindle installation Body
1. Support with spindle after taking close contact with inner wall
Valve
of body centerline while taking A and B of valve by hand.
FJR58-154
2. Firstly insert spindle lever side into inside of valve body using a
Valve
press fitting tool. Strike press fitting tool end by hammer so as Spindle Spindle
to install spindle at valve. Install cover side spindle in same (Lever side) (Cover side)
manner.
Press-
fitting tool Press-fitting
Machining surface to
install lever Body tool
JMS58A-155
BRa-96 BRAKE
3. Insert until jawed surface of the press fitting tool comes contact
Spacer
with body. Press fitting Press fitting
tool tool
Maching surface to install lever

JMS58A-156
4. Install short bushing at lever side and long bushing at cover

side spindle install the sealing on the spindle. Short bushing Long bushing
(lever side) (cover side)
JMS58A-157
Control Cylinder
Lost tension Load/installed length

NV 82N (8.3 kgf)/106mm
L 71N (7.2 kgf)/106mm 8
12 1. Cover
2. O-ring
9 3. Retainer
4. Packing
5. Plate
6. Wear ring
11 1 7. Shaft assembly
10 2 8. Spring
3
4 9. Dust seal
5 10. Retaining ring
6
11. Filter
7 12. Cylinder
CYBR004C
Reassembly
9.8 to 16Nm 9.8 to 16Nm

(1.0 to 1.6 kgf·m) 1 (1.0 to 1.6 kgf·m) 12 10 11
4 6 5 7 8 9
Reassembly sequence NOTE:

9→7→6→3→2→1→8 1. Apply grease (NICHMOLYL2 by Nichincly Century System Eye Co. or
4→5 equivalent) 2 cc to inner surfaces of the cylinder.
Apply the grease also to Ø12 section of shaft assembly.
Packing surfaces, and dust seal inside.
2. Apply sealant (HERMETIC GA by Sanno Kogyo or equivalent) to the
area in the shaft assembly to which the plate is fitted.
CYBR004D
BRa-98 BRAKE
Intake Silencer
5
8
9
11
4
7
Seizure
Clearance 1
(repalce bushing)
BD 16mm
NV 0.03 to 0.11mm
12 2
Cracks 11
10
Wear, damage 3
Wear
6
1. Snap pin 7. Bracket
2. Pin 8. Plate
3. Cleivs 9. Valve shaft
4. Control cylinder 10. Oil seal
5. Valve 11. Bushing
6. Lever 12. Silencer coupler
CYBR004E
Reassembly and Adjustment
Opened
80°
Closed
Apply sealant to threads

(LOCTITE No. 271 or equivalent)
A B
Butterfly valve to coupler clearance
NV A, B 1mm or more
(A + B) 2 to 3mm
Bend lock washer

4 7 Replace lock washer
12
3 Pack grease (JT-6)
1 grease or equivatant)
2
37 to 45Nm 6 8
(3.8 to 4.6kgf·m)
8.8 to 12Nm
Apply sealant to threads (0.9 to 1.2kgf·m)
(LOCTITE No. 271 or equivalent)
Replace gasket
Replace O-ring
10 9 11 5
20 to 24Nm
(2.0 to 2.4kgfm)
Identification
mark “O”
Apply sealant to threads
NV ... Nominal Value (LOCTITE No. 271 or equivalent)
Reassembly sequence
12→11→10 8→7→6→4→3→2→1
9→5
NOTE:
To install the control cylinder, place the valve at full open position, pull out the control cylinder
shaft 2 mm to 4 mm from the free state and connect it with the clevis.
CYBR004F
BRa-100 BRAKE
Control Cylinder
Lost tension Load/installed length

NV 72N (7.3 kgf)/109mm
L 61N (6.2 kgf)/109mm
8
12
11 1
10
2
3
4
5
6
7
L ... Limit
1. Cover 7. Shaft assembly
2. O-ring 8. Spring
3. Retainer 9. Dust seal
4. Packing 10. Retaining ring
5. Plate 11. Filter
6. Wear ring 12. Cylinder
CYBR004C
Reassembly
9.8 to 16Nm 9.8 to 16Nm

(1.0 to 1.6kgf·m) 1 (1.0 to 1.6kgf·m) 12 10 11
4 6 5 7 8 9
NOTE:
Reassembly sequence
1. Apply grease (NICHIMORY L2 by Nichimoly Century System Eye Co. or
12→11→10 →8→2→1→9
equivalent) 2 cc to inner surfaces of the cylinder.
7 4→3
Apply the grease also to Ø 12 section of shaft assembly and packing surfaces.
5→6
2. Apply sealant (AERMETIC GA by Sanno Kogyo or equivalent) to the area in
the shaft assembly to which the plate is fitted.
CYBR004D
Exhaust Brake Control

Removal and installation
1. 3-way magnet valve 3way magnet
valve
NOTE:
1. Install air pipe and hose, making sure that they do not
Air pepe(Ø 0.03)
interfere with other parts. 19 to 25Nm
2. Do not twist or bend the hose excessively; keep them (1.9 to 2.6kgf·m)
in natural position CYBR004G
2. Clutch switch(Refer to Group Clutch.)

3. Combination switch (exhaust brake switch)
(Refer to Group Steering.)
Inspection
1. 3-way magnet valve ⊕ 0.75R
1) Airtightness check
0.75B
With output "2" completely plugged and with a 295 to 930
kPa (3 to 10 kgf/cm2) air pressure applied from input "1", Output Output "3"
apply and shut down alternately a 24 V voltage to check for "2" (plugged)
possible leaks. Input "1"

980 kpa (10kgf/cm²)
CYBR004H
BRa-102 BRAKE
Air circuit
Port
Input "1" Output "2" Output "3"
Voltage
ON
OFF
2) Operation check
⊕
With a 980 kPa (10 kg/cm2) air pressure applied to input
0.75R
"1". apply voltage, gradually increasing from 0 V. Then, make
0.75B
sure that the voltage at which the valve is actuated is up to Output
specification. "2"
(plugged)
Output "3"
Nominal value 20 V or less
Input "1"
980 kpa (10kgf/cm²)
CYBR004H
Clutch switch continuity check

Check to see if there is no continuity when the push
rod is in the advanced position and there is continuity
when the push rod is retracted. Push rod
Combination switch continuity check
ON
OFF
CYBR004I
Adjustment and Inspection after Installation

1. Adjusting of microswitch
Microswitch
With the engine running at about 1000 rpm under no load, turn
ON the exhaust brake switch. Slowly release the accelerator
pedal and adjust with the adjusting screw so that the exhaust
Adjusting
brake activated when the engine speed reaches 600 to 700
screw
rpm. Injection pump
assembly
2. Exhaust brake system operation check
CYBR004J
Start the engine and turn ON the exhaust brake switch. Then,
make sure that the exhaust brake valve and intake silencer
valve are operated.
Make also sure that the exhaust brake and intake silencer de-
activate when the clutch pedal and accelerator pedal are
depressed.
PARKING
BRAKE
GENERAL ............................................................................. BRb - 2
SPECIFICATIONS ................................................................. BRb - 3
SERVICE STANDARDS ........................................................ BRb - 3
TIGHTENING TORQUE ......................................................... BRb - 3
SERVICE PROCEDURE ....................................................... BRb - 4
TROUBLESHOOTING .......................................................... BRb - 7
BRb-2 PARKING BRAKE
GENERAL
Air tank Spring chamber
Supply valve
Parking position Quick release

check valve
Cap control
valve Control pressure
from cap control
valve ceased to exist Brake shoes
Exhaust expand
Exhaust Air pressure form
spring chamber
Exhaust
ECYBR01A
The wheel parking brake sources are its braking force from the spring brake mechanism of the brake chamber provided
with the spring brake. It is operated by means of the cab control valve.
When the cab control valve knob is pulled, the air pressure of the spring brake mechanism is discharged through the relay
valve as the controlled pressure of relay valve is discharged through the cab control valve.
This results in the spring brake mechanism to extend, pushing the piston; which in turn moves the slack adjuster to
provide braking force.
When the cab control valve knob is pushed in, the air pressure from the air tank is sent under pressure to the spring brake
mechanism as the controlled pressure from the cab control valve actuates the relay valve.
As a result, the spring of spring mechanism is compressed by the piston, which moves the slack adjuster to release the
parking brake.
When the air pressure from the air tank drops to 240 to 310 kPa (2.45 to 3.15 kgf/cm2 ), the cab control valve knob
automatically pops out, activating the emergency brake (wheel parking brake).
SPECIFICATIONS BRb-3
SPECIFICATIONS
Item Specification
Operating pressure of the cab control valve 240 to 310 kPa (2.45 to 3.15 kgf/cm2)
SERVICE STANDARDS
Nominal value
Maintenance item Limit Remedy and remark
(Basic diameter in [ ])
Cab Operating pressure 240 to 310 kPa Replace
control
valve (Return pressure of depressed knob) (2.45 to 3.15 kgf/cm )2
Relay Inlet and outlet pressure difference 29 kPa (0.3 kgf/cm2) - Correct or replace
valve
or less
Piston spring load N(kgf)/ 16 N (1.65 kgf)/ 13 N (1.35 kgf)/ Replace
installed length 10.3mm 10.3
Inlet valve spring load N(kgf)/ 29 N (3.0 kgf/cm2)/ 24 N (2.4 kgf)/
installed length 15.7mm 15.7
Check Inlet and outlet pressure difference 29 kPa (0.3 kgf/cm ) 2 - Replace
valve
or less
Double Air leak from either left or right supply port No air leak allowed - Replace
check
valve when a 49 to 835 kPa (0.5 to 8.5 kgf/cm2)
air pressure is applied from the opposite port
TIGHTENING TORQUE
Screw sized Tightening torque
Location tightened
Cab control Valve attaching nut - 2.0 to 2.1 (0.20 to 0.21)
valve Knob attaching lock nut - 3.9 to 5.9 (0.4 to 0.6)
Relay valve Valve body to cover attaching bolt - 12 to 19 (1.2 to 1.9)
Check valve Cap - 44 to 54 (4.5 to 5.5)
Double check Joint - 34 to 44 (3.4 to 4.5)
valve
BRb-4 PARKING BRAKE
SERVICE PROCEDURE
Relay Valve
Disassembly, Inspection and Correction
10
12 Disassembly sequence
Spring deterioration 14 1. Retaining ring 9. Inlet valve assembly
Load/installed length 13 2. Exhaust cover assembly 10. Cover
NV 16 N (1.65 kgf)/10.3mm 15 3. Retaining ring 11. O-ring
11
L 13 N (1.35 kgf)/10.3mm 4. Valve guide 12. Piston
16
5. O-ring 13. O-ring
Spring deterioration 9 6. O-ring 14. O-ring
Load/installed length 8 7. Spring 15. Spring
7 8. Valve retainer 16. Body
NV 29 N (3.0 kgf)/15.7mm 6
L 24 N (2.4 kgf)/15.7mm NOTE:
5
4 1. Wash the disassembled metallic parts in a
NV... Nominal value 3 cleaning solution and work carefully to prevent
L ... Limit 2
ingress of metal chips, dust, etc.
1
2. Never wash rubber parts in a cleaning solution.
MA58101
12 to 19 Nm 10
(1.2 to 1.9 kgf·m)
12
13
11
15 16
14
9
5 8
7
4 6
2 1 3
NOTE:
Reassembly sequence
Apply multipurpose type grease Li soap to sliding
16→9→8→7→6→5→4→3→2→1→11→15→10
O-ring, their sliding surfaces, metal-to-metal sliding
12→14→13
surfaces, and O-ring grooves.
MA580530
SERVICE PROCEDURE BRb-5
Inspection after Installation

Pressure gauge
In the above test setup, the difference in operating pressure be- Air pressure for checking control pressure
tween the control and delivery pressures should be 25 kPa (0.25
kgf/cm2) or less when air pressure is supplied to the air supply port
Pressure gauge
and control port. If the specification is not met, replace each spring for checking control
or the whole assembly. pressure)
Air supply
(1) (2) (3) (4) (5) (6) (7)

98 196 296 390 490 590 685
Output pressure
kPa(kgf/cm²)
0 (1) (2) (3) (4) (5) (6) (7)

98 196 296 390 490 590 685
Control pressure kPa(kgf/cm²)

CYBR003B
Check Valve
In/cut pressure difference 29 kPa (0.3 kgf/cm2) or less 1 44 to 54Nm
(4.5 to 5.5 kgfm)
2
3
4
5 Lost tension
Damage, cracks
1. Cap 4. Valve spring
2. O-ring 5. Valve body
3. Valve CYBR003C
Double Check Valve

34 to 44Nm
(3.5 to 4.5 kgf·m)
1
Apply sealant 2 7
(THREEBOND 8 (3.5 to 4.5
TB1101 or 5 kgf·m)
equivalent)
6 Apply sealant
(THREEBOND
9 TB1101 or
4 Apply sealant equivalent)
3
(THREEBOND
34 to 44Nm TB1101 or
(3.5 to 4.5 kgf·m) equivalent)
1. Joint C 6. Sleeve
2. Packing 7. Joing B
3. Joint A 8. Packing
4. Packing 9. Body
5. Check valve
CYBR003D
BRb-6 PARKING BRAKE
Cab Control Valve

9
1. Snap ring
10 2. End cap
11 3. O-ring
4. Shim
12 5. Valve spring
6. Nut
7. Washer
8. Valve assembly
9. Knob
13
10. Nut
8 11. Piston
12. O-ring
7
13. Body
6
5 Lost tension NOTE:
1. Wash metallic parts in a cleaning oil or
4 gasoline, then blow air to dry.
3
2. Wiped dirt and dust off the rubber parts with a
soft cloth.
2 1
3. Replace the O-ring with a new one.
CYBR003E
Reassembly
10
11 3.9 to 5.9 Nm
(4.0 to 0.6 kgf·m)
(Where installed on vehicle)
13 12
7
8
3
Reassembly sequence 5 2
13→12→11→10→9→8→7→6→5→4→3→2→1
1 6 1
NOTE: Exhaust 2.0 to 2.1Nm
(0.20 to 0.21 kgf·m)
Apply silicone grease MOLYKOTE 33-M or equivalent
to the sliding surfaces and O-ring.
CYBR003F
TROUBLESHOOTING BRb-7

In the test setup shown above, apply an air pressure of about 390
kPa (4 kgf/cm2) to the air supply port while pushing the knob in.
Then gradually lower the air pressure and make sure that the knob
automatical ly pops out when the pressure gauge read 275 ± 34
kPa (2.8 ± 0.35 kgf/cm2). If any defect is evident, replace the valve
spring or the whole assembly.
Air pressure
685(7)
Output pressure
kpa(kgf/cm²)
275 ± 34
(2.8 ± 0.35)
0 275 ± 34 (7)
(2.8 ± 0.35) 685
Supply pressure
kpa(kgf/cm²)
CYBR003G
TROUBLESHOOTING
Symptom Probable cause Remedy
Wheel Parking brake is not Spring chamber malfunctioning Correct or replace
parking operative Relay valve malfunctioning Correct or replace
brake Parking brake cannot Low air pressure or air leaking Correct or replace
be released Spring chamber malfunctioning Correct or replace
Relay valve malfunctioning Correct or replace
ANTI-LOCK
BRAKE SYSTEM
(ABS)
GENERAL .............................................................................. BRc - 2
CIRCUIT DIAGRAM ............................................................... BRc - 6
PRINCIPLE AND FUNCTIONS ..............................................BRc - 8
ABS CONTROL .....................................................................BRc-12
ASR CONTROL .....................................................................BRc-14
OPERATING RANGE IN THE ABS FAULTY ......................... BRc-15
ABS SELF-DIAGNOSIS ......................................................... BRc-17
OPERATING RANGE IN THE ABS/ASR FAULTY .................BRc-23
ABS/ASR SELF DIAGNOSIS ................................................BRc-24
WHEEL SPEED SENSOR INSTALLATION ...........................BRc-32
CHECK SHEET ......................................................................BRc-35
ABS ECU CONNECTOR PIN .................................................BRc-43
BRc-2 ANTI-LOCK BRAKE SYSTEM (ABS)
GENERAL
(Wheel lock)
Wheel slip
Relation between road surface friction coefficient and wheel slip
ABS001
ABS Function
Under rapid braking or slippy road condition by rain or snow, braking a vehicle in running is apt to generate skid condition.
The skid may decrease braking force to increase braking distance, generate spin by traverse slipping, and/or disable
steering control, resulting to an accident. Therefor the ABS system is designed to prevent from wheel locking and slip
upon braking for ensuring :
1. Stability
2. Steerability
3. Optimum braking power and stopping distance.
Á Skid : A vehicle may slip to move without wheel rotation upon braking.
λ)
Slip Rate (λ
Upon braking a vehicle which is running, slip rate changes from 0 to 100% until the wheels are locked and the vehicle
stops completely. The slip rate (λ) may be indicated as the below :
Vehicle speed – Wheel speed

λ = × 100(%)
Vehicle speed
GENERAL BRc-3
The slip rate (λ) and the surface friction coefficient (µB) may be correlated as the illustration. The slip rate (λ) at the max.
µB differs by the road condition but the max. range is approx. 8~30%. The cornering force (transversary slip preventing
force) decreases with increasing slip rate. Once wheels are locked, surface friction coefficient µB decreases and slip
friction coefficient µS becomes to '0', and then wheels are easy to slip.
In fact locked rear wheels generate spinning and locked front wheels disables steerability. The ABS system controls
braking force to maintain the slip rate in the range of 8~30%, in order to generate max. surface friction coefficient, control
slip friction coefficient at higher range, and provide stability and steerability.
ASR (Brake control)

When one side wheel is caught at slippy road or muddy surface, the slipping wheel idles, that the vehicle is hard to run
and powertrain (differential, axle shaft). In order to compensate idling for stability, the ASR, feature controls to brake the
idling wheel properly and transfer the rotating force to the other wheel to enable launching. The ASR feature is traction
control, and an extensive application of the ABS system. Only ASR control valves (solenoid valves) integrated on the
ABS system to make the ASR feature.
ABS Effect
The ABS system provides stable braking under extreme condition. Even braking rapidly on frozen or snowy road,
wheels are not locked and maintain max. friction with the road surface to provide optimum braking distance. Restricting
the pressure in the chamber locked at the wheel side on the road surface, the system ensures straight forward motion.
The driver may acquire correct alignment of the vehicle by adjusting the steering wheel only a little.
ASR Effect (Brake control)

Upon starting or accelerating the vehicle, a wheel may idle on a slippy road surface or so. Then the vehicle may not start
or may be unstable to incur accident. When speeds of both side wheels are different, the ASR system brakes operate to
the faster wheel (idling wheel) to make the both wheels speed same. The system does not operate at an above 30km/h.
1. Starting at a surface of which one side is frozen (ex : bus stop) or accelerating or starting at a cornering range, the
system provides optimum drivability.
2. Idling wheels as well as locked wheels do not transfer driving force, to decrease steerability and put the rearmost
part of the vehicle out of track. The ASR system maintains the vehicle under control.
3. The system decreases wear of driving mechanism (differential, axle) and tires.
ABS Configuration
6
1 3
3 1
3
5
2
1
5
3
5 1
4
1 3
1. Wheel speed sensor

2. ABS(ECU)
3. Pressure control valve
4. ABS warning lamp
5. Brake chamber
6. Service brake valve
GENERAL BRc-5
ABS/ASR Configuration
6
3
1 1
73 7
13 14 15 16
10
5
11
2
7
1
7 3 4 3
1 17 18
12
8
9
1. Wheel speed sensor, plug ring 10. Diesel engine

2. ABS/TCS (ECU) 11. EDC (Electronic Diesel Control) actuator
3. Pressure control valve 12. CAN communication resistance
4. TCS solenoid valve 13. Warning lamp
5. Shuttle valve 14. TCS information lamp (INA)
6. Service brake valve 15. ABS function switch
7. Wheel brake cylinder 16. TCS function switch
8. Actuator pedal sensor 17. Stop lamp switch
9. EDC (Electronic Diesel Control) control unit 18. Stop lamp bulb
AA58101A
The ABS control unit is designed to accommodate the ASR feature within modifying the size of pulse ring, wheel speed
sensor, and pressure control valve that are used for the ABS system, are used for the ASR feature, as well. The ABS
control unit, microelectronics is extended to accommodate the ASR logic. Only the solenoid valve that sends com-
pressed air to the corresponding cylinder to the rear axle brake circuit when a wheel is idling, is added. Two shuttle
valves facilitate the service brake system and the ASR operation. The front axle yaw moment restriction function is built
in the ABS/ASR control unit, as well. Besides the ABS/ASR control unit has "self-diagnosis feature" or "in-car diagnosis
feature". In case of system failure during driving, the feature will enable sooner repair in the service shop. Pressing
buttons, the diagnostic lamps flash failure codes to indicate cause of failure.
CIRCUIT DIAGRAM
Full Air Brake(ABS)
9 11
14
1 6 2 5 4
20
8
7
3
13
Door
Clutch
Retarder
Air seat 17
19
16
15
23
23
22
22
18
21
12
10

8. Drain valve 16. Spring brake chamber
KCYBR03A
CIRCUIT DIAGRAM BRc-7
Full Air Brake(ABS, ASR)
9 11
14
1 6 2 5 4
8 20
3 7
13
Door
Clutch
Retarder
Air seat 17
19
16
15 23
23
22
22
18 14
21 12 24
10

8. Drain valve 16. Spring brake chamber 24. ASR solenoid valve
KCYBR02A
PRINCIPLE AND FUNCTIONS

Principle
1. ABS
Relay valve
U_PMV
U_ECU
Output stages
Input circuit
SS_SR REL_SL
µC HLD_SR
SS_DL GND_SL
REL_SR
SS_SL HLD_SL
µC GND_SR
REL_DL
SS_DR HLD-DR
GND_DL
REL_DR
HLD_DL
GND_DR
GND
(DIAK/SAE_A) ISO Ground solenoid

(DIAK/SAE_B) 14230
SAE
(Warning Lamp)
J1708
Warning lamp ground
CAN_H
CAN (Retarder)
CAN_L J1939
CAN_SLD
SS _ * * : Speed sensor REL_* * : Output

_SR : Front right HLD_* * : Input
_DL : Rear left
_SL : Front left U-PMV : Pressure modulate valve (+)
_DR : Rear right GND : Ground
µC : Micro computer
ATBRA004
PRINCIPLE AND FUNCTIONS BRc-9
2. ABS, ASR
Input circuits Microcomputers Output stages
Valve relay
Supply voltage for the
pressure control valves
Supply voltage for ECU

Power
supply
ECU ground
Longitudinal-lock valve/shut off valve

TCS solenoid valve
TCS-valve ground
Outlet valve FL
Wheel FR
Inlet valve FL
WSS Pressure control valve ground FL
Speed RL Outlet valve RR
Sensor Inlet valve RR
Pressure control valve ground RR
Outlet valve FR
Inlet valve FR
FL Pressure control valve ground FR
WSS
Outlet valve RL
RR Inlet valve RL
Pressure control valve ground RL
CAN H
CAN G
CAN L
FL,RR
Pressure control GND-FET
Valve ground
FR,RL
Function switch
(ABS)
Warning lamp
Slip switch
(ASR)
Inform. Lamp(TCS)
diagnosis lamp,
diagnosis push-button.
Stop-lamp switch
(BLS)
Interface-reduction input
Reduction input
Retarder relay
K-line
L-line
ECU block diagram (ECU with maximum equipped features)
JMTB002
Parts Functions
The 4-channel ABS uses four wheel speed sensors. The sen-
sor consists of a permanent magnet connected to metal rod,
around which a coil has been wound. A pulse wheel mounted
to the hub induces an alternating voltage in the sensor coil.
The frequency of the alternating voltage is managed signal in
the control unit.
2. ABS/ASR control unit

The ABS/ASR control unit is designed in digital type and pos-
sess dual microprocessors, with the following four features:
1) Input stage
The unit checks the wheel speed signal
2) Computer
The computer calculates the brake slip/traction and wheel
deceleration/wheel acceleration control signal, and ener-
gize the output stage when wheels are about to be locked
or spin.
3) Output stage
The unit energizes interface and axle weight distribution
unit for controlling the pressure control valve, the solenoid
valve, and the engine control.
4) Power supply
The unit supplies stable voltage for the control unit
operation. The built-in protective device prevents electri-
cal interference from applying to the vehicle electrical
circuit.
3. Pressure control valve (1 channel) 1 2
Each wheel is controlled by a 1 channel control valve. The
pressure control valve consists two diaphragm type valves (for
pressure modulation, and for outlet) that are guided and con-
trolled by the solenoid valves. Upon normal braking, com- 3 4
pressed air freely pass through the pressure control valve to
the brake cylinder. If one of wheels is about to be locked, the 5 6
7
ABS/ASR control unit energizes both solenoid valves to lower
the pressure in the brake cylinder. The pressure modulation
7
valve operates to modulate the pressure. When the pressure
1. From service brake valve
is rising no current flows in the two solenoid valves. 2. To brake cylinder
3. Pressure modulation valve
4. Exhaust valve
5. Solenoid valve
(pilot control of pressure modulation valve)
6. Solenoid valve
(pilot control of exhaust valve)
7. Ambient air
JMTB004
PRINCIPLE AND FUNCTIONS BRc-11
4. Solenoid valve
The solenoid valves are connected with two 3/2 solenoid valves
1
that are pilot-controlled. When wheel's are about to spin, the
valve energizes the axle brake cylinder driven by compressed
air. Two control plungers are controlled by the solenoid valves.
2 2
When current is interrupted, power supply 1 is close and the
3 3
cylinder connections are open outwards.
4 4
1. From air tank

2. Control plunger
3. From pressure modulation valve
4. Solenoid valve
5. Ambient air
JMTB005
ABS CONTROL
Speed
Acceleration
Slip
Brake cylinder
pressure
Valve back force
Time t
VR : Vehicle speed HV : Pressure modulation valve of pressure control valves

AR : Wheel acceleration or deceleration, λ : Slip AV : Pressure control exhaust valve
Pz : Brake cylinder pressure speed
<ABS operation diagram>
JMTB006
When the drive press the brake pedal, the pressure is supplied to the brake cylinder (or air chamber), and result to wheel
deceleration. When the brake slip is lower than the ABS system reaction limit value, the braking power is not controlled.
The ABS/ASR valve rises. In order to provide the most proper pressure in the brake cylinder, the pressure decreases, is
maintained, or increases in accordance with friction coefficient between tires, road surface, and vehicle steering. The
illustration 6 indicates the ABS control feature on wheels upon braking. At time t1, the pressure in the brake cylinder
increases and the wheel speed decreases. At time t2, the wheel deceleration and the slip rate increase above the limit,
and the wheel is about to be locked. With closing the pressure modulation valve and opening the exhaust valve, the
pressure in the brake cylinder increases until the wheel speed increases again at time t3. Closing the exhaust valve, the
pressure is maintained at a certain level to time t4. Then the slip value λ =0 approximately, and the wheel acceleration
reached the value that may raise the pressure again. Then instantly opening and closing the pressure modulation valve,
the pressure becomes pulse-up until time t5. The wheel deceleration and slip is higher than the limit again, and the
pressure rise again. The control cycle repeats until the vehicle stops actually.
ABS CONTROL BRc-13
Yaw Moment on the Front Axle

When the friction coefficients are significantly different between
Braking force coefficient µ , Traverse force coefficient µ

right and left wheels (for example when the road is frozen at outer
side), corrective control feature is applied to the front axle accom-
modating between short braking distance and steering corrective
value. Constraining pressure rising and braking force on wheels,
the yaw moment is restricted within the range that vehicle control
is possible under rapid braking condition.
Friction Force Between Tire and Surface

Friction force between tires and road surface when other condi-
tions are same, friction forces between tires and road surfaces
are virtually same for starting and braking conditions. Friction force
measurement (friction coefficient) differs by road condition, weather
condition, tread type, and especially braking and wheel slip. In Brake slip λ
usual, braking motive force is within the stable area of slip curve. Braking and traverse force coefficients
Correlation between brake slip λ and slip
In general rapid braking increases brake slip and decrease fric-
angle a on a dry concrete surface
tion force. With higher brake slip, wheels have lower traverse force JMTB007
for stability and steerability of the vehicle. The ABS system is de-
signed primarily for stability and steerability of the vehicle. Friction
force on running as well as on braking relies particularly on slip
between tires and road surfaces. With higher wheel slip, traction
and running stability decreases. With lowest wheel friction, differ-
ential function provides driving power.
ASR CONTROL
Speed
Brake cylinder
pressure
Valve back force
ASR operation diagram
VF : Vehicle speed VR : Wheel speed PZ1.PZ2 : Braking pressure of started driving wheels in the brake cylinder
HV, HV pressure modulation valve of pressure control valves by driving
AV, AV exhaust valve of pressure control valves by driving wheels
JMTB008
On starting and accelerating, power transfer depends on the wheel slip between tires and road surface. When wheel slip
is lower than ASR responding limit wheel slip is not controlled.
The ABS logic in the ABS/ASR control unit detects driving wheels' speed, when wheel spin is about to occur, senses it.
ASR controls driving wheels' speed. Up to 30km/h, when driving wheels are about to spin, wheels are braking and wheel
speed is synchronized (limited-slip differential operation). To achieve this operation compressed air comes from the air
tank through the solenoid valves to the brake cylinder. The corresponding pressure control valve modulates braking
pressure. When a driven wheel is about to spin, ASR indication lamp comes on immediately (warn slip condition). The
illustration indicates starting condition of a ASR vehicle. At time t1 the car starts and the driving wheels are about to spin.
At time t2, wheel spin begins and it will brake wheels through the control circuit. At time t3, wheel speed approaches to the
vehicle speed again and wheel braking pressure is 'pulse-downed'.
OPERATING RANGE IN THE ABS FAULTY BRc-15
OPERATING RANGE IN THE ABS FAULTY

Speed Sensor Errors
System configuration : Full air brake
ABS control
Failure Front Front Rear Rear WL
left right left right
Front left speed sensor N O1) IC1) IC IC ON
1) 1)
Front right speed sensor IC NO IC IC ON
Rear left speed sensor MIC MIC NO IC ON
Rear right speed sensor MIC MIC IC NO ON
Mixed up speed sensors NO NO NO NO ON
Tire size, aligment error NO NO NO NO ON
Two speed sensor errors or one speed NO NO NO NO ON
sensor error and one PMV error
Note :
IC :Individual C ontrol
MIC : Modified individual control
1) MIC if affected wheel is on high µ side.
PMV Errors
System configuration : Full air brake
ABS control
Valve solenoid front left shorted low or broken NO IC IC IC ON
wire or valve ground front left broken wire
Valve solenoid front right shorted low or broken IC NO IC IC ON
wire or valve ground front right broken wire
Valve solenoid rear left shorted low or broken MIC MIC NO IC ON
wire or valve ground rear left broken wire
Valve solenoid rear right shorted low or broken MIC MIC IC NO ON
wire or valve ground rear right broken wire
Any valve solenoid or valve ground shorted high NO NO NO NO ON
Valve ground shorted low MIC MIC IC IC ON
Two valve error or one valve error and one speed NO NO NO NO ON
sensor error
Power Supply Errors
ABS control
GND shorted high or broken wire NO NO NO NO ON
1)
U_PMV or U_ECU over voltage or low voltage NO NO NO NO ON
U_PMV or U_ECU broken wire NO NO NO NO ON
Note :
1) Errors are reversible (can reset) provided they do not occur during ABS cycles.
Miscellaneous Errors
ABS control
Internal ECU failure or internal relay switch No No No No
failure
Internal relay always ON Yes1) Yes1) Yes1) Yes1) ON
1) 1) 1) 1)
RET shorted high or shorted low or broken wire Yes Yes Yes Yes ON
1) 1) 1) 1)
CAN interface bus off Yes Yes Yes Yes ON
CAN interface error on message ERC1 Yes1) Yes1) Yes1) Yes1) ON
Note :
1) Control mode according to selected system configuration.
ABS SELF-DIAGNOSIS BRc-17
ABS SELF-DIAGNOSIS
Safety Monitoring
Control configuration 4S/4K IRM/IR (wheel speed sensors vehicle is controlled through 4 channels)
S : sensor K : channel IR : Each wheel of a vehicle is controlled individually

2. ABS control unit
3. 1-channel pressure control valve
4. Solenoid valve
Control diagram
JMTB009
1. Safety monitoring
The ABS system satisfies highest safety and reliability require-
ments. Prior to starting the vehicle, microcomputers perform
self-diagnosis and check other computers, and then monitor
wheel spin sensor, pressure modulation valve, wiring harness,
and the whole ABS system. Finding a failure the ABS system
becomes wholly or partly inoperable and the warning lamp
comes on. The service brake system is still operable.
2. Self-diagnostic feature
In addition to the safety monitoring system, the self-diagnostic
1
feature built in the ABS control unit enables to remove the fail- Tester
ure immediately and safely. Upon failure detection by the ABS 2
ABS Switch
control unit, the failure code is stored in the computer that may
be read later at a service shop. Then temporary failures includ- Light
ing poor contraction at plug connection may be found and elimi-
nated soonest.
3. How to read the failure code

Failure codes may be read using a Hi-scan and self-diagnosis
by blink signals of the ABS lamp.
Self-diagnosis on a vehicle
1. ABS lamp
When a problem occurs in using the ABS system, the red ABS lamp comes on for warning in order to facilitate finding
the trouble area by self-diagnosis.
In normal condition, the ABS lamp comes on upon switching the battery power on and extinguished upon starting the
vehicle and during running. If a trouble occurs in the ABS system during running, the ABS lamp comes on even or
running.
ECYBRB1A
2. Diagnostic method
The blink code device reads out error codes of 16 systems that are stored in the ECU system configuration and error
memory. The device checks the brake signal, as well.
The blink codes may be read using the ASR lamp, and troubles read with the self-diagnostic button may be identified
using the blink code table.
3. Blink code configuration
In order to operate the blink code, keep the self-diagnostic button pressed for two seconds and then release it.
Pressing the button once it will indicate the system configuration and an error code. Press the self-diagnostic button
once again to read error codes.
The ASR lamp indicates an error code each time pressing the button.
After reading out all error codes stored in the memory using the blink codes, the last stored code may be read
continually.
Quitting self-diagnosis for 5minutes or more, or switching the starting key off and on again, the self-diagnostic
feature reads all information again from the beginning, the system configuration.
Each error code including the brake signal failure, includes three blocks.
The first block may be read at 100's digit, the second block at 10's digit, and the third block at 1's digit.
(Configuration block I) (Configuration block II)
(Warning lamp) (1stdigit) (2nddigit) (1stdigit) (2nddigit)
ON
OFF
1.5s -0.5s 1.5s 4.5s
(Diagnosis button)
ON
<1.5s
OFF
0.5...8s 0.5...8s
ATBRA006
4. Failure memory erasion

Then ABS ECU will erase all error codes when the diagnostic push button is pressed during power on.
Ignition Switch
ON
ON
<3s Failure memory

completely earased
D iagnosis push button
ON
OFF
ATBRA008
5. Safety device
Failed circuit Operate as a non-ABS brake

Upon ABS failure
Other circuits ABS operation
At least the ABS system may operate just same as a non-ABS

brake.
Hi-scan check
1. Turn the starting key off.
2. Connect a Hi-scan with the data link connector located under the low crash pad panel.
3. Turn the starting key on.
4. Using the Hi-scan, check the diagnosis trouble code.
5. Upon repairing or correcting the problem, turn the starting switch and clear stored error codes using the clear key.
6. Disconnect the Hi-scan.
ATBE-001/EJA9033B
Blink Codes
Configuration Codes
Block Digit Number of pulses Description
I 1 12V
1st
2 24V
2 4 sensor/4 pressure modulation valve
3 4 sensor/3 pressure modulation valve (Front axle)
4 4 sensor/3 pressure modulation valve (Rear axle)
2nd
5 4 sensor/2 pressure modulation valve (Front axle, rear axle each one)
15 Invalid configuration
1 No retarder link, No retarder relay
I 2 With retarder link, No retarder relay
1st
3 No retarder link, With retarder relay
4 With retarder link, With retarder relay
2nd 2 No ASR
Error codes
Blink code
Description
Comp. Error
1 1 No failure
Wheel speed 2 1 Large air gap
sensor front left 2 2 Missing sensor signal at drive off
2 3 Bad tooth wheel, long term ABS control
2 4 Long term instability
2 5 Loss of sensor signal
2 6 Shorted low/high or broken wire or two sensors ahorted
sensor front right 3 2 Missing sensor signal at drive off
3 6 Shorted low/high or broken wire or two sensors ahorted
Blink code
Description
Comp. Error
sensor rear left 4 2 Missing sensor signal at drive off
4 6 Shorted low/high or broken wire or two sensors shorted
sensor rear right 5 2 Missing sensor signal at drive off
5 6 Shorted low/high or broken wire or two sensors shorted
Pressure modu- 8 1 Release solenoid shorted high
lation valve front 8 2 Release solenoid shorted low
left 8 3 Release solenoid broken wire
8 4 Valve ground broken wire
8 5 Hold solenoid shorted high
8 6 Hold solenoid shorted low
8 7 Hold solenoid broken wire
8 8 Valve configuration error
lation valve front 9 2 Release solenoid shorted low
right 9 3 Release solenoid broken wire
lation valve rear 10 2 Release solenoid shorted low
left 10 3 Release solenoid broken wire
Blink code
Description
Comp. Error
lation valve rear 11 2 Release solenoid shorted low
right 11 3 Release solenoid broken wire
Pressure modu- 10 10 Valve ground shorted high
lation valve, valve 10 11 Valve ground shorted low or int. ground solenoid defective
ground
ECU internal 15 1 Internal
failures 15 2 Internal
15 3 EEPROM data error
15 4 Internal
15 5 Internal
15 6 Internal
15 7 Internal
15 9 Invalid configuration in EEPROM
15 10 Internal
15 11 Internal
Power supply 16 1 Battery temporary over voltage
16 2 Battery temporary low voltage
16 2 Battery low voltage during ABS control
16 3 Battery broken wire
16 9 Ignition temporary over voltage
16 10 Ignition temporary low voltage
16 10 Ignition low voltage during ABS control
Retarder relay 17 1 Shorted high
17 2 Shorted low or broken wire
CAN data-link 17 3 Bus off detected
17 4 Timeout or invalid data range on ERC1
Tire size aligment 17 5 Front to raer out of range
Warning light 17 10 GND-WL shorted high or broken wire or WL shorted low or breken wire
Miscellaneous 17 12 Wheel speed sensor failure in previous power on cycle
17 13 Wheel speed sensors on front or rear mixed up
OPERATING RANGE IN THE ABS/ASR FAULTY BRc-23
OPERATING RANGE IN THE ABS/ASR FAULTY

As said, when the ECU detects failure, the ABS/ASR system operates partly or wholly unable to operate. Partly operating
features as per failed part is as the below table. Upon failed of two or more parts, the ABS/ASR system is wholly inoperable.
ABS
Failed part Indication Failed part Other diagonal ABS ABS
diagonal features* features
One of front wheel ABS Sensor-failed wheel side is ON ON 1)
sensors warning lamp inoperable
One of rear wheel ABS Sensor-failed wheel side is ON 2) OFF
sensors warning lamp inoperable
PCV : ground circuit ABS Failed side wheel is ON ON 3)
break or short, warning lamp inoperable
Short with UZ or UB ABS OFF ON ON OFF
warning lamp
DBR relay ABS ON ON OFF ON
warning lamp
ASR valve ABS ON ON ON OFF
warning lamp
UB circuit break ABS OFF ON ON OFF
warning lamp
ECU internal ABS OFF ON ON OFF
GND-FET failure warning lamp
ON : The system part feature is operable

OFF : The system part feature is inoperable
Notes : 1) ON, but slip increases

2) ON, but operates depending on unfailed sensors.
3) Upon front wheel pressure modulation valve failure : ON
Upon rear wheel pressure modulation valve failure : OFF
DBR : Exhaust brake or retarder, UZ : Starter key first step power, UB : Battery power
* Diagonal feature : The ABS system is applicable in the diagonal direction of the vehicle (FR and RL, or FL and RR).
ABS/ASR SELF-DIAGNOSIS
Safety Monitoring
Control configuration 4S/4K IRM/IR (wheel speed sensors vehicle is controlled through 4 channels)
S : Sensor K : Channel IR : Each wheel of a vehicle is controlled individually

2. ABS/ASR control unit
3. 1-channel pressure control valve
4. Solenoid valve
Control diagram
JMTB009
1. Safety monitoring
The ABS/ASR system satisfies highest safety and reliability
requirements. Prior to starting the vehicle, microcomputers
perform self-diagnosis and check other computers, and then
monitor wheel spin sensor, pressure modulation valve, wiring
harness, and the whole ABS/ASR system. Finding a failure
the ABS/ASR system becomes wholly or partly inoperable and
the warning lamp comes on. The service brake system is still
operable.
2. Self-diagnostic feature
In addition to the safety monitoring system, the self-diagnostic
feature built in the ABS/ASR control unit enables to remove 1
Tester
the failure immediately and safely. Upon failure detection by 2
ABS
the ABS/ASR control unit, the failure code is stored in the com- Switch
ASR
puter that may be read later at a service shop. Then tempo- Light
rary failures including poor contraction at plug connection may
be found and eliminated soonest.
3. How to read the failure code

Failure codes may be read using a Hi-scan and self-diagnosis
by blink signals of the ASR lamp.
ABS/ASR SELF-DIAGNOSIS BRc-25
Self-Diagnosis On a Vehicle
1. ABS lamp
When a problem occurs in using the ABS system, the red ABS
lamp comes on for warning in order to facilitate finding the
trouble area by self-diagnosis.
In normal condition, the ABS lamp comes on upon switching
the battery power on and extinguished upon starting the ve-
hicle and during running. If a trouble occurs in the ABS sys-
ECYBRC1A
tem during running, the ABS lamp comes on even or running.
2. Diagnostic method
The blink code device reads out error codes of 16 systems
that are stored in the ECU system configuration and error
memory. The device checks the brake signal, as well.
The blink codes may be read using the ASR lamp, and troubles
read with the self-diagnostic button may be identified using
the blink code table.
Installed in driver side left control box
JMTB010
3. Blink code configuration

In order to operate the blink code, keep the self-diagnostic
button pressed for two seconds and then release it. Pressing
the button once it will indicate the system configuration and an
error code. Press the self-diagnostic button once again to read
error codes.
The ASR lamp indicates an error code each time pressing the
button.
After reading out all error codes stored in the memory using
the blink codes, the last stored code may be read continually.
Quitting self-diagnosis for 5minutes or more, or switching the

starting key off and on again, the self-diagnostic feature reads
all information again from the beginning, the system configura-
tion.
Each error code including the brake signal failure, includes

three blocks.
The first block may be read at 100's digit, the second block at
10's digit, and the third block at 1's digit.
4. Reading error codes

For example the below blink code indicates no brake signal failure, the system configuration, and two error codes,
312 and 322.
Configuration : Last-stored fault: Last-but-one stored fault :

2 312 322
Indicator lamp ON
Indicator lamp
OFF
Press button
Release button
t/s
0 5 10 15 20 25 30 35 40 45 50
Sketch Blink-code example
AA58301A
1) Time delay from "power-on" to pressing the self-diagnostic button : 1.25seconds or more (>1.25s)
2) Pressed-in time of the button for reading
DTCs : 2seconds or more (>=2s)
3) Time delay from releasing the self-diagnostic button until indicating output signal : 3seconds (3s)
4) Blink code blinking time : 0.5seconds (0.5s)
5) Blink code time in 100's digit and 10's digit/10's digit and 1's digit : 3seconds
6) Time interval between blink codes in 1's digit : 1second
5. Reset procedure
In order to clear out all information stored in the fault memory, “Power-On” the system with the self-diagnostic button
pressed in, turn “Ignition-On” and wait 5seconds, and release the self-diagnostic button.
Then wait with “Ignition-On” for 5seconds or more and turn “Ignition-Off”. Now the system is reset.
6. Safety measure
Failed circuit Operate as a non-ABS brake

Upon ABS failure
Other circuits ABS operation
At least the ABS system may operate just same as a non-ABS

brake.
Hi-Scan Check
1. Turn the starting key off.
2. Connect a Hi-scan with the data link connector located under
the low crash pad panel.
3. Turn the starting key on.
4. Using the Hi-scan, check the self-diagnosis on a vehicle.
5. Upon repairing or correcting the problem, turn the starting
switch and clear stored error codes using the clear key. AA51021A
6. Disconnect the Hi-scan from the data link conector.
ABS
Power K-line Ground

EJA9033B
Blink-Code Table
Block 1 : System Configuration
Blink time Configuration

2 ABS, front wheel IRM control
3 ABS, front wheel IRM control, ASR-engine control
4 ABS, front wheel IRM control, ASR-brake control
5 ABS, front wheel IRM control, ASR-engine control/brake control
6 ABS, front wheel SL control
7 ABS, front wheel SL control, ASR-engine control
8 ABS, front wheel SL control, ASR-brake control
9 ABS, front wheel SL control, ASR-engine control/brake control
Blink Code Block
DTC Symptom Remedy

121 Normal
Supplementary Output, CAN Communication Failure

DTC Symptom Remedy
211 Communication failure Reconnect the connector securely
212 CAN: C3 signal failure Check EDC
213 CAN communication abnormal Reconnect the connector securely
214 Communication delay between transmission Check CAN-ABS/ASR circuit and CAN-rear box
and CAN circuit
215 Communication delay between engine and Check CAN-ABS/ASR circuit and CAN-EDC
CAN circuit
216 Communication delay between retarder and Check CAN-ABS/ASR circuit and CAN-EDC
CAN circuit
217 Brake signal abnormal Check or repair stop lamp switch wiring
817 Retarder battery short Securely reconnect the retarder connector
818 Securely reconnect the retarder connector
ECU Failure
221
222
223
224
ECU Failure Replace the ECU
225
226
227
244
Other Failures
228 Parameter setting error Correct the parameters

232 Tire of unspecified size Install specified tires and use specified pulse ring
Voltage Failure
242 Low voltage valve output voltage (pin x 1,9) Check or correct valve output voltage ground
and connection
243 Valve output voltage circuit break (pin x 1,9) Check or correct valve output voltage ground
and connection
251 M-1R or M-2L ground short Repair the short circuit.
252 M-1R or M-2L battery voltage short Repair the circuit.
253 M-1R/2L circuit break (pin x 1, 12) Check or correct valve ground
254 Reversed polarity between M-1R/2L and valve Check or correct valve output voltage ground
output voltage (pin x 1, 12 x 1,9) and connection
255 M-1L or M-2R ground short Repair the circuit
256 M-1L or M-2R battery voltage short Repair the circuit
257 M-1L/2R circuit break (pin x 1,11) Check or correct valve ground
258 Reversed polarity between M-1L/2R and valve Check or correct valve output voltage ground
output voltage (pin x 1, 11 x 1,9) and connection
TCS(Traction Control System) Solenoid Valve Failure

712 Circuit-break Securely reconnect the ASR solenoid valve circuit
713 Ground short Check short circuit
714 Battery voltage short Check short circuit
721 Outside magnetization Securely reconnect the ASR solenoid valve circuit
726 Configuration error In case of TCS brake control failure, check ASR
connector, valve, and ECU values
Wheel Speed Sensor, FL Side Failure

322 Cut/Ubat, ground, short to another sensor Securely reconnect the wheel speed sensor connector
326 Pulse ring error, ABS control abnormal Use a good pulse ring
421 Air gap error, speed detection is disabled, Correct air gap and securely reconnect the wheel
unstable signal speed sensor
Pressure Control Valve FL Side Failure

512 Inside valve circuit-break
513 Inside valve ground short
514 Inside valve battery voltage short
515 Valve ground circuit-break (pin x 3.3)
Securely reconnect pressure control valve
611 Inside valve or outside valve magnetization
616 Configuration error Securely reconnect each IRM or pressure
control valve of SL
Wheel Speed Sensor RR Side Failure
342 Cut/Ubat, ground, short to another sensor Securely reconnect the wheel speed sensor
346 Pulse ring error, ABS control failure Check, adjust, or correct plate pulse ring, and
air gap
441 Pulse ring error, ABS control abnormal Check air gap, and wheel speed sensor connector
Pressure Control Valve RR Side Failure

535 Valve ground circuit-break (pin x 4,12)
538 Battery voltage short
Wheel Speed Sensor FR Side Failure

366 Pulse ring error, ABS control failure Check, adjust, or correct plate pulse ring, and
air gap
461 Pulse ring error, ABS control abnormal Check air gap, and wheel speed sensor connector
Pressure Control Valve FR Side Failure

656 Configuration error Securely reconnect each IRM or pressure
control valve of SL
Wheel Speed Sensor RL Side Failure
316 Pulse ring error, ABS control failure Check, adjust, or correct plate pulse ring, and air gap
411 Air gap error, Speed detection is disabled, Check air gap and wheel speed sensor connector
unstable signal
Pressure Control Valve RL Side Failure

Caution for ABS Vehicles

1. Upon ignition on, the ABS warning lamp (red) shall be on and
go out at 10km/h or more after starting the vehicle.
2. Braking normally on a normal road surface, the driver is hard
to feel the ABS effect. The ABS effect is designed to feel at
braking on a certain surface that wheels are apt to be locked
as slippery road-frozen, snowy, rainy road.
NOTE: ECYBRC1A
On rapid braking or braking on a slippery road, do not

pump the brake pedal as a non-ABS vehicle. Press the
pedal properly depending on situation (hard or light) at
once and continuously for optimum ABS effect.
3. An ABS vehicle an integration of the ABS system on a non-

ABS vehicle. The basic braking system shall be maintained
Wheel speed
properly, and the ABS system cannot improve the serviceabil-
ity.
4. For optimum ABS effect, regularly put the wheel speed sen-
sors to bottom into the pulse ring. Upon removing the hub and
drum assembly to replace the lining/clean off dirts (lining, par-
ticles, dust, oil, etc) on the speed sensor. JMTB011
WHEEL SPEED SENSOR INSTALLATION

Front Wheel Side
Anchor bracket Section "B"
Bush
Clamping Wheel speed sensor
Bracket Pulse ring
sleeve Spindle
Hub
Rod
inserting
direction
Anchor bracket
Wheel
speed
sensor
Section "A"-"A"
NOTE:
Install the anchor bracket to spindle first and the wheel speed sensor later
JMTB012
[Assembly sequence]
1. Insert the clamping sleeve into the bush and push the wheel speed sensor to bottom of the bush end.
2. Connect the bracket with the anchor bracket using bolts and washers.
3. Put the wheel speed sensor wire end through the anchor bracket hole (φ7). The end shall come out of the hole.
4. Push the wheel speed sensor through the spindle hole (φ5) until it touches the pulse ring using a rod (φ4).
Specified clearance 0.2mm
NOTE:
Do not apply excessive force.
5. Lightly turn the hub and drum assembly one round.
WHEEL SPEED SENSOR INSTALLATION BRc-33
Rear Wheel Side
Hub and drum assembly
Clamping sleeve Anchor bracket

Wheel speed
sensor Retainer
Rear holder
Rear axle housing
JMTB013
[Assembly sequence]
1. Connect the bracket assembly with the rear axle housing.
2. Insert the clamping sleeve in the rear holder, and install the wheel speed sensor in the rear holder hole.
3. Connect the rear holder with the wheel speed sensor installed, at the rear axle housing.
4. Lightly push the wheel speed sensor with hand until it touches the surface.
5. Put the wheel speed sensor wire end through the anchor bracket hole (φ7). The end shall come out of the hole.
6. Assemble the hub and drum assembly.
7. Push the wheel speed sensor through the retainer hole (φ5) until it touches the pulse ring using a rod (φ4). Lightly turn
the hub and drum one round.
Inspection
1. Measure resistance between the wheel speed sensor terminals.
Specified value 1.75kΩ±1 0 % Ω 1 2
EJA9031E
2. Turning the wheel lightly, measure the wheel speed sensor

voltage between two sensor terminals.
NOTE:
When measuring the wheel speed sensor voltage with the
V 1 2
vehicle suspended, set MUT at the AC voltage checking
mode.
Service standard value : AC voltage checking
EJA9031F
CHECK SHEET BRc-35
CHECK SHEET
BOSCH NFZ-ABS/ASR RAPID CHECK LIST
VEHICLE GROUP : TRUCK/TRACTOR/BUS AGENCY/BRANCH :

ABS SYSTEM : 4S/4K(1-CHANNEL PVC)
ADJUSTING SURFACE :012/ / CUSTOMER :
CONTROL UNIT : 0 265 150 301 305 PLACE :
PRESSURE-CONTROL VALVE (PCV) : DATE :
SPEED SENSOR : VEHICLE :
ASR-VALVE : VEHICLE-TYPE:
BOSCH-NFZ-SYSTEM-TESTER : 0 684 101 605 REGISTRATION :
SYSTEM-CONNECTOR(1) : 1 684 463 204 VIN :
CIRCUIT DIAGRAM : Y 481 C O 5023 MILEAGE-COUNT :
MEASURING INSTRUMENT :
TEST REQUIREMENTS : - Vehicle serviceable

- Battery and charge o.k.
- Brake system o.k.
- Driving switch OFF
- ABS fuses o.k.
- Disassemble ECU harness and connect the connector of tester
In vehicles with leading or trailing axles, check that the “hold pressure” and “reduce pressure” functions at drive
and leading or trailing axle operate according to specifications of vehicle manufacturer.
TEST RESULTS : Compensation/fault :

Fault components :
Check test performed :
ABS SYSTEM O.K : YES:

NO:
(Signature of tester)
BOSCH-NFZ-ABS ABS/ASR 4S/4K E-CO5023 EnGLISH 03.90 page : 1

Measuring
Test instrument Additional Driving Actual
Test Test-connector on Set value o.k. Couses of failure
step NFZ-SYSTEM-
procedures switch value
TESTER
OFF 0V -Constant positive at pin9
+ ← V= → ON 21~29V -Positive lead to ECU pin9
1 ECU voltage
9 27 -Ground lead to ECU pin27
-Fuse
-Plus lead to VR1 term. 86 and 87
WL ON -Lead VR1 term. 85 and 30 ECU
pin 25 and 19
-Press
2 PCV-Relay 1 ON -Leads as in test step 8
button R1 K2 ON -Fuse, WL
-PCV relay/WL relay 2
K3 OFF -Positive lead to WL
-Plus lead to VR2 term. 86 and 87
WL ON -Lead VR2 term. 85 and 30 ECU
pin 8 and 1
-Press
3 PCV-Relay 2 ON -Leads as in test step 8
button R2 K3 ON -Fuse, WL
-PCV relay/WL relay 1
K2 OFF -Positive lead to WL
-Positive leads to WL relay term. 86
-Ground leads of WL relay term. 30
-Press WL ON -Leads from WL relay term. 85 to
buttons
PCV relay term. 85
4 WL-Relay R1+R2 ON
-Leads from WL relay term. 87 a
simulta-
K2 and K3 to WL
neously
ON -PCV relay/WL realy, fuse
-Positive terminal to exhaust

Engine brake relay terminal 86
5 Exhaust brake brake,
-Press button ON -Exhaust brake relay terminal 85
relay retarder
S1 to ECU pin 11 terminal
switch OFF
-Exhaust brake relay fuse
-Lead from INA to ECU pin 28
-Connect D2 -Positive lead to INA
6 ASR INFO- D2 ← Lead →
and with ON INA ON -Fuse
LAMP (INA) 26 27
lead -INA
Warning lamp- D2 ← →
α
7 -ECU pin 26 to warning lamp

OFF 2~4, 5
terminal 26 27 terminal
+ ← → DF -
α
DF -Press switch - :-Open connection between

A1L 15 32 1L OFF
ECU and speed sensor
Internal + ← → DF -
α
DF -Press switch
8 A1R 17 34 1R OFF -Speed sensor plug
resistance 950~1450
+ ← → DF - -Approx.0 : -Short circuit in
α
sensor DF -Press switch

A2L 18 35 2L
OFF speed sensor lead
+ ← → DF -
α
DF -Press switch
A2R 16 OFF - Speed sensor
33 2R
+ ← →
α
DF -Press switch -Short circuit in speed sensor

A1L 32 27 1L
OFF
9 Insulation lead
+ ← →
α
speed DF -Press switch

A1R 34 27 1R
OFF -Speed sensor faulty
sensor >30 -Chafing
+ ← →
α
DF -Press switch
(DF) A2L 35 27 2L
OFF
+ ← →
α
DF -Press switch
A2R 33 OFF
27 2R
+ ← →
α
EV -Press switch -leads from ECU plug to PCV

A1L 23 OFF
27 1L
10 Internal -Ground lead PCV
+ ← →
α
EV -Press switch
resistance A1R 6 OFF -Short ciruit on lead
27 1R 14~21
+ ← → -P C V
α
PCV (EV) EV -Press switch

A2L 21 OFF
27 2L
+ ← →
α
EV -Press switch
A2R 4 OFF
27 2R
CHECK SHEET BRc-37
Measuring
step NFZ-SYSTEM-
TESTER
AV ← → DF -Press switch
A1L 24 27 1L
OFF
11 Internal AV ← → -Press switch
A1R 7 27 1R OFF
resis- 14~21
tance AV ← → -Press switch
A2L 22 27 2L OFF
PCV(AV)
AV ← → -Press switch
A2R 5 27 2R OFF
12 Hold A1L 1. Press switch
ON
1L
pressure
2. Press EV -Test step 10, 11
PCV
button -Fuse
3. Press No pressure -PCV relay
brake pedal at wheel A1L, -leads wrongly connected
does not
brake
4. Release EV Wheel A1L
button increases
5. Keep brake pressure,
pedal does not
pressed brakes
Reduce A1L 6. Press AV Wheel A1L
pressure button reduces
PCV 7. Release AV pressure,
button and does not
brake pedal brake
Hold A1R 1. Press switch No pressure

pressure 1R at wheel A1R,
PCV 2. Press EV does not
button brake
3. Press
brake pedal
Wheel A1R
4. Release EV increases
button pressure,
5. Press the EV brake
button
Reduce A1R 6. Press AV Wheel A1R
PCV 7. Release AV pressure,
button and does not
brake pedal brake
Hold A2L 1. Press switch ON
pressure 2L
PCV 2. Press EV
button
3. Press
brake pedal No pressure at
wheel A2L,
does not brake
4. Release EV Wheel A2L
button increases
5. Keep brake pressure,
pedal brakes
pressed Wheel A1L
Reduce A2L 6. Press AV reduces
button pressure,
pressure
7. Release AV does not
PCV
button and brake
brake pedal
Measuring
step NFZ-SYSTEM-
TESTER
12 Hold A2R 1. Press switch 2R
pressure 2.Press EV No pressure
PCV button at wheel A2R,
3.Press brake does not
pedal brake
4.Release EV Wheel A2R
button increases
5.Keep brake pressure,
pedal brakes
pressed
Reduce A2R 6.Press AV Wheel A1R
PCV 7.Release AV pressure,
button and does not
brake pedal brake
13 *Function Built-in display Press switch -No display

speed A1L instrument 1L ON SS lead open circuit
sensor SS lead shot circuit
(DF) Built-in display Press switch SS wrongly connected
A1R instrument 1R O N ≥8 scale If too few scal divisions
divisions SS gap too large
Built-in display Press switch deviation SS faulty
A2L instrument 2L O N max. +25% If deviation too large
from smallest Pulse ring has axial eccentricity
Built-in display Press switch display value Pulse ring damaged
A2R instrument 2R ON Wheel bearing play
(bearing clearance)
When testing the function of the SS, the appropriate wheel must be driven (using brake dynamomenter or by hand) so
that the UD F-lamp on the NFZ-SYSTEM-TESTER shines steadily.
All other wheels have to be stopped during this test in standstill.
ASR + ← →
α
14 Internal Press switch -Lead from ECU pins 2 and 20 to ASR valve(s)
OFF
resistance L 2 27 2L -Ground lead to ASR valve(s)
42~52
of ASR ASR + ← →
α
Press switch -Short circuit in lead

R OFF
valve 2 27 2R -ASR valve(s)
15 Pressure 1.Do not Wheel -Test step 14
increase brake. A2L -Fuse
in ASR valve 2.Press 2L increases
L ON
IMPORTANT: switch. pressure,
When testing 3.Press ASR brakes
on rooler-type button.
dynamometer : 1.Do not Wheel
secure vehicle brake. A2R
against rolling increases
2.Press 2R ON
away/ Drive R
switch. pressure,
wheel produces
full brake 3.Press ASR brakes
pressure. button.
16. Connection OFF 3~6 -Open connection between ECU
ASR ← →
α
between pin 12 pin 12 and 14

and pin 14 26 27
CHECK SHEET BRc-39
How to use Bosch check sheet
Receive the report of ABS problem occurrence
Is the ABS
warning lamp still on
after running at 10km/h
or more
Check the brake system and adjust or Prepare a check list.
replace lining.
Fill in bus registration No. and all required data on

ABS is normal the check list.
Acquire client's information.

When did the warning come on?
How often did the warning come on? What was the vehicle speed then?
How was the road condition? Was it frozen?
Record the above information as detailed as possible on the check list.
How to use blink code diagnosis (blink code for ABS defect diagnosis)
In order to read blink codes, turn the ignition key off and on again, and press the diagnostic button for a few seconds
and then release the button. When the button is released the ARS lamp (INA) generates pulse codes of 3 blocks
(3steps) in approx. one second.
Pulse time (the diagnostic lamp is in) : 0.2seconds
Interval between pulses (the diagnostic lamp is off) : 0.4seconds
Interval between blocks : 1.5seconds
After reading blink codes by the blinking, wait at least 2 or 3 seconds for checking blink codes again by pressing the
diagnostic button, if required.
Record blink codes on the check list.
Compare blink code block 2 and block 3 using the error code table.
Diagnosis :
For diagnosing 4S/4K ABS, wait at least 2 or 3 seconds before using the diagnostic button after pulse
codes disappear from the ASR lamp (INA).
A diagnostic code contains 3 block blink code. The first block shows information about the system
configuration. The second block indicates defects on diagonal I (L1, R2). The third block says about
defects on diagonal II (R1/L2), 1R/2L.
1. Axle (Front)
Circuit I
Circuit II rack
2. Axle (Rear)
NOTE:
It is hard to expect that a defect may occur in a very ABS part. However be careful, defects may
occur in wiring between the ECU and each part.
Defects ABS lamp pulse Check list step

No defect at present 1 OK
ECU internal defect occured 2 Perform resetting
Speed sensor problem
Air gap (clearance between speed sensor 3 13
and impulse ring) is excessive or the front
wheel sensor wire is short-circuited
Air gap is excessive or the rear wheel sensor 4
wire is short-circuited
Damaged sensor wiring 6 8, 9, 13
Damaged sensor wiring 7 Check the battery and
Low voltage or the PCV relay is inoperable 9 Reset.
PCV problem
Front wheel PCV 10 10, 11, 12
Rear wheel PCV 11
PCV relay defect 13 Replace the relay.
ASR relay defect 14 14, 15
CHECK SHEET BRc-41
ASR defect The INA lamp stays on - Reset

Example) Reading blink code 4-1-4:
4 - 1 - 4
(Blcok 1) (Blcok 2) (Blcok 3)
ABS and ASR Circuit I Circuit II
system configuration FL wheel FR wheel
RR wheel RL wheel
OK OK defective
(Check list item 13)
Considering the above ABS problem, check the bus and solve the problem.
In most cases, those problems may be found in step by step procedure in accordance with
the check list. Use this procedure to find the problem.
Important! Using the above test procedure, check the battery switch at each step. After
finding defects and correcting them, using a tester perform complete testing procedure as
provided on the check list.
Reset
Turn the battery switch on hold the diagnostic button pressed, then all of wrong information stored in
the ECU will be erased, and simultaneously the ECU will reset the features to the new normal condition.
Block 1 Lamp pulse
ABS and ASR system configuration Block 1
ABS 24V 2
ABS + ASR Electronic engine modulation 24V 3
ABS + ASR Brake control 24V 4
ABS + ASR Brake control + Electronic engine modulation 24V 5
ABS 12V 6
ABS + ASR Electronic engine modulation 12V 7
ABS + ASR Brake control 12V 8
ABS + ASR (rear wheel) + Electronic engine modulation 12V 9
ABS (front wheel selector low) 24V 10
ABS (front wheel selector low) + ASR Engine control 24V 11
ABS (front wheel selector low) + ASR Brake control 24V 12
ABS (front wheel selector low) + ASR Brake control + Engine control 24V 13
ABS (front wheel selector low) 12V 14
ABS (front wheel selector low) + ASR Engine control 12V 15
ABS (front wheel selector low) + ASR Brake control 12V 16
ABS (front wheel selector low) + ASR Brake control + Engine control 12V 17
Run the bus at 10km/h or more and check it the warning lamp
goes out.
If the lamp goes out, the system is normal
No
Perform blink diagnosis using the diagnostic button.
Repeat three times. If the

Does the blink code 4.1.1(4 channels) occur? result is still not ok,
(12, 1, 1 will occur in case of 3 channels)
Record the check list and keep the list for the next occurrence Call Bosch for help.
of problems.
The bus ABS operation Is normal
ABS ECU CONNECTOR PIN BRc-43
ABS ECU CONNECTOR PIN

Four plugs are used for the connections. The figure below is a plan view of the ECU and shows the assignment of the
connectior pins.
BRA29P
PIN NO PIN NAME Abbreviation PIN NO PIN NAME Abbreviation

X1-1 CAN-L, Low line CAN-L X3-1 Outlet valve-front,left AV-1L
X1-2 CAN-G, Shield CAN-G X3-2 Inlet valve-front,left EV-1L
X1-3 CAN-H, High line CAN-H X3-3 Pressure-valve ground-front, left M-1L
X1-4 Longitudibal-lock valve/shutoff valve LSP/ASP X3-4 Wheel speed sensor-front, left DF-1L
X1-5 Function switch (off-road ABS) FKTSCH1-ABS X3-5 Wheel speed sensor-front, left DF-1L
X1-6 Slip switch (ASR) FKTSCH2-ASR X3-6 -
X1-7 Supply voltage for the ECU USG X3-7 Wheel speed sensor-front, right DF-1R
X1-8 - X3-8 Wheel speed sensor-front, right DF-1R
X1-9 Supply voltage for the pressure UB X3-9 -
X1-10 ECU-ground M-SG X3-10 Outlet valve-front, right AV-1R
X1-11 Valve ground-front, left/rear, right M-1L/2R X3-11 Inlet valve-front, right EV-1R
X1-12 Valve ground-front, right/rear, left M-1R/2L X3-12 Pressure-valve ground-front, righ M-1R
X1-13 Diagnosis K-line DIAK X4-1 Outlet valve-rear, left AV-2L
X1-14 Diagnosis L-line DIAL X4-2 Inlet valve-rear, left EV-2L
X1-15 - X4-3 Pressure-valve ground-rear, left M-2L
X1-16 Retarder relay (retarder, engine brake) DBR X4-4 TCS valve ground M-ASR
X1-17 Information lamp (TCS), diagnosis lamp INA X4-5 Wheel speed sensor-rear, left DF-2L
X1-18 Warning lamp WL X4-6 Wheel speed sensor-rear, left DF-2L
X2-1 - X4-7 TCS solenoid valve U-ASR
X2-2 - X4-8 Wheel speed sensor-rear, right DF-2R
X2-3 Stop-lamp switch FKTSCH3-BLS X4-9 Wheel speed sensor-rear, right DF-2R
X2-4 Control command DKV X4-10 Outlet valve-rear, right AV-2R
X2-5 - X4-11 Inlet valve-rear, right EV-2R
X2-6 - X4-12 Pressure-valve ground-rear, right M-2R
X2-7 Interface-reduction input DKR X4-13 -
X2-8 - X4-14 -
X2-9 - X4-15 -
ABS Wiring diagram
BRA28P

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GENERAL ............................................................................. BRa - 2

Quick release valve

Brake chamber Cam

Brake System Diagram

1. Air compressor 9. Air gauge 17. Magnetic valve

<Full Air Brake With ABS >

1. Air compressor 9. Air gauge 17. Magnetic valve

2. Delivery stroke Air tank

3. When unloader valve is actuated

unloader valve being returned to its original position by unloader

Dual break valve

Compressed air Rear brake

Exhaust Brake System

Meter cluster Clutch Micro

Exhaust Air tank

Intake silencer Exhaust brake

The exhaust brake system, functioning as an auxiliary brake for the

the exhaust brake is activated.

Double Sliding pressure kap (kgf/cm2) 39 to 59 kpa Correct or

Valve (8.5 to 11.5±0.4)

Nominal value Remedy

voltage applied to inlet port "1".

Screw size Tightening torque

Screw size Tightening torque

Problem Probable cause

Problem Probable cause Remedy

Outer air pipe Outer water Suction air pipe

Outer air pipe

Inlet water Inlet oil pipe

2. Disconnect all connections.

Installation Procedure Pointer

3. Remove sensor from flywheel housing.

4. Mounting the sensor : Apply sealant to the threads of the sen-

Cracks, wear of bushing, clogged 26

Damage of circle, wear 28

not attempt disassembly unless trouble is evident.

2. Removal of piston ring

Inspection and Correction

Deterioration load/installed length

Deterioration load/installed length

Crankshaft end play

BD ... Basic Diameter

Deterioration load/installed length

Clearance between piston ring

Crankshaft end play

BD ... Basic Diameter

Bend lock washer

Apply 0.2 to 0.3 cc of

2. Installation of piston rings

3. Installation of suction valve holder

Suction Valve Tool

4. Installation of injection pump gear Align "O"mark with "U"mark

1. Every 3 months or 15,000 km

Removal and Installation

Disassembly and Inspection

Inspection after Reassembly

Air pressure To rear

[When pedal is released] [When pedal is depressed]

Dual Brake Valve

Spindle I.D. Roller I.D.

2. Removal of Relay Piston

4. Remove the retaining rings. In cover

38→37→36→35→34→ 30 →29→26→25→24→23→ 20 →11→10→9→8→7→6→4