BRAKE LOCK

@ FVZ34PMX

1/18
Medium truck’s parking brake
have installed at the end of the
transmission. While operated, it
should be stopping the rear
wheels but not 100% locked,
depend on free-play of
propeller-shaft / cross-joint,
differential gear, and axle-shaft.
And both of front wheels has
still free, not braking. Compare
to brake lock system, it should
be braking all of wheels.

2/18
Medium Truck’s Air Brake Piping

3/18
Air Brake Piping Which Completed With
Brake Lock System

4/18
 Preparation

• Stop the vehicle on the flat and level ground.

Wheel chock
• Stop the engine (key OFF) and pull out the key.
• Apply the wheel block to the rear wheel.

•Remove the negative terminal of the battery.

※Take care not to short-circuit the battery

• Open four drain valves of the air tank to bleed air until its noise (psss)
ends.
※Wear protective glasses because dust on the floor will be blown up by
strong air flow from the valve.

5/18
 Brake Lock Parts Position

Brake Lock operation condition : Green color Indicator lamp

Brake lock switch • Hand brake “ON” 1831195861
8980113410 • Engine running

1. Magnetic valve &

pressure switch
2. Double check
valve
3. Hand brake
switch

Air piping w/o brake lock Air piping w/ brake lock

6/18
 Brake Lock Cabin Parts Position

Cabin harness 8980805430

B

Relay & switch Cable splitter at frt Cable splitter at

connector junction box cluster meter

Brake lock control unit External wire

1825503150 harness grommet

7/18
 Brake Lock External Parts Position

• Hand brake sensor

1463601231
• Ext. parking cable
• Bolt, 0286510300
• Nut, 0911802100
• Rod, S305106942
or 8944374040
Cabin wire harness • Nut, 0911801080
8980805430 • Torque : 2 kg.m

The alarm 1834601040

would be rung-out while
the brake lock have
operated with low of air
External wire harness pressure
8976217961

8/18
 Magnetic Valve & Pressure Switch

Parts involves :
1. Bracket, P/N : 8982506170
2. Magnetic Valve Asm, P/N : 1463621120
3. Brake Valve Connector, P/N : 1096606930 (2 pcs)
4. Air Valve Connector, P/N : 1096609670
5. Pressure Switch, P/N : 8976092510
45o 6. Nylon Connector, P/N : 1096609580
7. Screw + washer, P/N 0362205140 (3 pcs)
Torque of screw : + 0.6 kg.m

Note :
Apply white seal-tape (5 layers) at the thread portion
when installing all connectors to magnetic valve

45o

9/18
 Primary Double Check Valve

Parts involves :
1. Bracket, P/N : 8982506220
2. Double Check Valve, P/N : 1484105311
3. Brake Valve Connector, P/N : 1096609590
4. Brake Valve Connector, P/N : 1096609650
45o (re-used)
5. Brake Valve Connector, P/N :
6. Bolt + Washer, P/N : 0280508120
Torque of bolt : 1.0 kg.m

Note :
Apply white seal-tape (5 layers) at the thread
portion when installing all connectors to double
check valve.

10/18
 Secondary Double Check Valve

Parts involves :
1. Bracket, P/N : 8982506220
2. Double Check Valve, P/N : 1484105311
3. Brake Valve Connector, P/N : 1096609590
(2 pcs)
4. Brake Valve Connector, P/N : 1096609650
(re-used)
5. Bolt + Washer, P/N : 0280508120
Torque of bolt : 1.0 kg.m

Note :
Apply white seal-tape (5 layers) at the thread
portion when installing all connectors to double
check valve.
45o

11/18
Drilling Position @ Air Tank Bracket

Installation of magnetic valve & pressure

switch, primary double check valve, and
secondary double check valve :
• Bolt, P/N : 0286510300
• Nut, P/N : 0911802100
• Torque of bolt : 2 kg.m

12/18
Nylon Tube Installation

13/18
 Nylon Tube Installation

3
4

1
7 5
6

Air-Tube Length
1 8741 10120 NYLON TUBE φ12, 6m 4 000
Pipe Number Length(mm)
1 250 *
2 280
3 570
1096612210 CONNECTOR; AIR TANK 4 580 *
5 1795 *
1096612210 CONNECTOR; AIR TANK 6 1680
7 1370 *
TTL 6525
14/18
 Resetting Servo Unit & Main Air Tank

Original servo unit w/o B/L Re-setting servo unit w/ B/L Re-used @ double check valve
Connector P/N: 1096609590 Connector P/N : 1096609650

Re-setting main air tank :

• Connector 1096565861
• Connector 1096608760
• Connector 1096566770
• Nylon Tube

Extended primary nylon tube and

secondary nylon tube from brake
valve to double check valve :
Connector 1096612210

15/18
 DTC Checked by Tech-2

Leak test of all connectors by using water + soap

16/18
 Brake Lock Parts List & Installation Labor

Index Parts Number Parts name Q'ty Remark Index Parts Number Parts name Q'ty Remark
1 1463621120 VALVE; CONT,BRK LOCK 1 34 8982506170 Stay 8982506160(146362112) 1
2 1096612210 CONNECTOR; AIR TANK 2 35 8982506220 Stay 8982506200(148419531) 2
3 1874110120 NYLON TUBE φ12, 4m 2 36 EXT PARKING CABLE 1
4 1874110250 CORRUGATE TUBE φ15,2m 1
37 SPLITTER CABLES CONNECTOR 4
5 8944374040 CONNECTOR; HARNESS (2P FEMAIL) 1
6 8980805430 HARNESS;EXT,BRAKE LOCK 1 38 SQUARE TERMINALS 10 x 7.5 (MALE&FEM) 1
7 8976217961 HARNESS;EXT,BRAKE LOCK 1
39 ROUND TIP TERMINALS (FEMALE) 2
8 1831195851 INDICATOR　Green 1
9 0362205140 BOLT;HEX-HD,FLANGE,R,A POINT 3 40 RING BRASS TERMINAL 1 Handle by
10 1096606930 CONNECTOR;ELBOW INTER 2 41 CABLES 0.5 mm IAMI
NPN 10
11 1096609580 CONNECTOR; ELBOW 1
12 1096609670 CONNECTOR;NYLON TUBE STRAIGHT 1 42 White Seal Tape 1
13 8976092510 SWITCH; PRESS 1 43 Black Insulator Tape 1
14 0280508120 BOLT 4
44 Red Insulator Tape 1
15 1484105311 VALVE;DOBLE CHECK 2
16 1096609590 CONNECTOR;NYLON TUBE ELBOW 5 45 Yellow Insulator Tape 1
17 0286510300 BOLT;HEX-HD,FLANGE,R,A POINT 8 CSO Parts
46 Green Insulator Tape 1
18 0911802100 NUT;HEX,FLAMGE 8
19
20
1096565861
1096566770
CONNECTOR;3WAY
CONNECTOR;3WAY AND 4WAY
1
1
Labor time for Brake Lock installation
21 1096608760 CONNECTOR;NYLON TUBE 1 (including harness modification) i.e. : 4 hours
22 1463601231 SENSOR; BRAKE LOCK 1
23
24
1825503150
5097070301
BOX; CONT,BRAKE LOCK
CLIP; BAND,HARNESS
1
10
Other material which needed i.e. :
25 8971730351 RELAY; PTO CONT 4 white seal-tape, black insulator-tape, red
26 8980113410 SWITCH; BRAKE LOCK 1
27 0911801080 NUT; BRKT 1
insulator-tape, yellow insulator-tape, green
28 1834601040 ALARM; AIR SUS 1 insulator-tape, soldering, tin & lotfett.
29 8971786720 CASSETTE RELAY BLOCK ASSY 2
30 1096610070 CONNECTOR;NYLON TUBE 1
31 7123162000 HOUSING:2P 1
SST which needed i.e. :
32 7157602070 REAR HOLDER 1 Nylon tube cutter, AVO meter
33 7116123100 TERMINAL 2
17/18
 Installation Process & Check List

Flywheel PTO Installation Check List

Modification date , , - , , Approved Acknowledge
VIN / ENG Number /
Mechanics Name Operation Item Dealer Name/Branch
1. All Engine Chassis
2. All Engine Chassis W/S Head IAMI Mkt
Check Signature
No. Item Manual page Remark
Torque Total
1 Applied anti rust @ flywheel PTO housing None
2 Propeller Shaft & Transmission removal None Check Workshop Manual
3 Oil Pan removal None Check Workshop Manual
4 Air Compressor & Motor Starter removal None Check Workshop Manual
5 Flywheel housing removal None Check Workshop Manual
6 Setting PTO Idle Gear assembly 4, 5
7 Setting SEALLING CUP for new Flywheel Housing 6
8 New Flywheel Housing installation 4, 7
9 Gear Crank PTO installation 8
10 Engine Foot installation 9
11 PTO ASM installation 10
12 Flywheel Housing Inner Cover installation 11
13 Charge Pipe Bracket modification 12, 13
14 Exhaust Manifold Heat Protector modification 14
15 Oil Pipe Asm fixed 15, 16
16 Air Compressor & Motor Starter installation None Check Workshop Manual
17 Air Charge pipe fixed 17, 18
18 Air Governor Pipe fixed 19
19 Air Charge & Governor Hose fixed 20
20 T/M Cont. Cable Bracket modification 21
21 Engine Harness modification 22, 23, 24, 25
22 Engine Harness fixed 26, 27
23 Relay Box Harness relocated 28
24 Oil Pan installation None Check Workshop Manual
25 Transmission & Propeller Shaft installation None Check Workshop Manual
26 (Cab) PTO Switch Cover change 29
27 Hand Brake Cable Adjustment 30
28 T/M Cont. Cable Adjustment 31
29 Engine Oil & Radiator Coolant refilled None Eng. Oil & Coolant re-use
30 Harness & Lever with Cab for Body Builder 32
31 Finishing, checking, and testing the flywheel PTO none

18/18