TABLE OF CONTENTS

Chapter 5: Brake System

Description ................................................................................................................................... 5.1
Automatic Adjusting Device ..................................................................................................... 5.1
General Information ................................................................................................................. 5.1
Master Cylinder
Disassembly ............................................................................................................................. 5.2
Inspection after Disassembly ................................................................................................... 5.3
Reassembly.............................................................................................................................. 5.3
Service Brakes
Disassembly
(E3000 - EC4000) ............................................................................................................... 5.4
(E4000 - E6500) .................................................................................................................. 5.5
Inspection after Disassembly ................................................................................................... 5.7
Reassembly
(E3000 - EC4000) ............................................................................................................... 5.8
(E4000 - E6500) .................................................................................................................. 5.9
Wheel Cylinders
Disassembly ............................................................................................................................. 5.12
Inspection after Disassembly ................................................................................................... 5.13
Reassembly.............................................................................................................................. 5.13
Inspection and Adjustment....................................................................................................... 5.14
NOTES

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 BRAKE SYSTEM

Description
Automatic Adjusting Device

205955

General Information
This device adjusts the drum-to-lining clearance
automatically. As the clearance increases due to
lining wear, the lever mechanism of this device
turns the adjusting screw by one notch or tooth to
reposition the shoes closer to the drum. This cor-
responds to 1/24 of one rotation or 15°. In the
course of usage, the adjusting process repeats
itself at long intervals.

99759-8B110
5.1
BRAKE SYSTEM

Master Cylinder
Disassembly

9
8

4 7
10
6
5

*3
91484-37100 E3000 - EC4000
91246-65300 E4000 - E6500
1

97146-10000A

1. Taper plug 6. Oil tank assembly

2. Master cylinder body 7. Push rod
3. Repair kit 8. Jam nut
4. Cap assembly 9. Clevis
5. Level sensor 10. Push rod assembly

NOTE

The parts* to be changed periodically are

included in the Repair Kit.

99759-8B110
5.2

Inspection after Disassembly
Brake Fluid Level Sensor
1. Fill the reservoir with brake fluid. Connect the
level sensor connector at the bottom of the
fluid reservoir and turn the key to ON.
DOWN = ON UP = OFF
200270
2. The sensor is satisfactory if the brake fluid
level warning lamp on the monitor flashes
when the reservoir filler is in the DOWN posi-
tion and goes off when it is in the UP position.
Cylinder Body
1. Check the bore of the cylinder for rust, corro-
sion, and scoring.
2. Check the inlet port and relief ports for cleanli-
ness. Also check the threads in the screw con-
nection of each joint for damage. Make sure
the boot is free from defects.
99759-8B110
BRAKE SYSTEM
Piston
Replace the piston if it is damaged. Check the pis-
ton clearance in the cylinder body. Replace the
cylinder body and piston if the clearance is in
excess of the service limit.
Clearance A 0.020 to 0.105
between piston (0.00079 to 0.00413)
and cylinder B 0.2 (0.008)
Unit: mm (in.)
A = Assembly Standard B = Repair or Service Limit
Return Spring
Replace the return spring every year.
Primary Cup, Secondary Cup, and Valve
Check these rubber parts for swelling, tearing,
and deterioration from aging. Replace them every
year.
Reassembly
To reassemble, reverse the procedure for disas-
sembly and do the following steps.
1. Clean all metal parts with a volatile cleaning
solvent. Dry them with pressure air.
2. Apply a thin coat of rubber grease (Metal
Rubber #20) or brake fluid to the piston cups
and the cylinder bore.
Master Cylinder Adjustment:
Adjust master cylinder only after pedal height
adjustment has been made (See pg. 5.18). With
master cylinder installed and push rod connected
to brake pedal, use the clevis pin to adjust the
master cylinder push rod so there is 0.5 to 2.8mm
of free play between the end of the push rod and
cylinder position contact. Tighten jam nut on push
rod clevis assembly.
5.3
BRAKE SYSTEM

Service Brakes
Disassembly (E3000 - EC4000)
1

2
16 23 3 24 13 9 9 21

20

19

7
22
6
26
4 10
27 17
15
11
14

18 25
8
12

97146-11800A

Components
1. Service Brake Assembly 15. Spring
2. Wheel cylinder assembly 16. Pin
3. Backing plate 17. Spring
4. Primary shoe and lining assembly 18. Strut
5. Secondary shoe and lining assembly 19. Spring washer
6. Parking Lever 20. Retainer
7. Adjusting screw 21. Bolt with washer
8. Adjusting lever 22. Snap ring
9. Spring 23. Cover
10. Cable guide 24. Parking cable assembly
11. Fitting cable 25. Spring
12. Spring 26. Spring washer
13. Shoe guide plate 27. Bolt
14. Cup
99759-8B110
5.4
 BRAKE SYSTEM

Disassembly (E4000 - E6500)

2
16 23 10 3 24 13 27 28 29 21

26
9
20
19

7
22
6
31
30 4
14 17
15
14
18 11

12 8 25

97246-10900A

Components
1. Service Brake Assembly 10. Self-locking nut 21. Bolt with washer
2. Wheel cylinder assembly 11. Fitting cable 22. Snap ring
3. Backing plate 12. Spring 23. Cover
4. Primary shoe and lining 13. Shoe guide plate 24. Parking cable assembly
assembly 14. Cup 25. Spring
5. Secondary shoe and lining 15. Spring 26. Spring
assembly
16. Pin 27. Pin
6. Parking Lever
17. Spring 28. Sheave
7. Adjusting screw
18. Strut 29. Plain washer
8. Adjusting lever
19. Spring washer 30. Bolt
9. Spring
20. Retainer 31. Spring washer

99759-8B110
5.5
BRAKE SYSTEM

Start By:
1. Remove the front wheel. 4. Disconnect the brake pipe from the wheel
2. Remove the wheel hub and brake drum. brake assembly.
3. Separate the parking brake lever and cable
at the bottom of the wheel brake.

Suggestions
Removing Return Springs Removing Hold-Down Springs
Use a special tool to remove the return springs. Use a special tool to remove the hold-down springs.

Special Tool Part Number Special Tool Part Number

Spring remover 64309-15411 Spring remover 64309-15412

200271 200272

99759-8B110
5.6
 BRAKE SYSTEM

Inspection after Disassembly

Backing Plate Brake Drums
1. Check the backing plate for cracks. Check the inside (friction) surface of the drum for
abnormal wear, grooving, and other defects. Minor
2. Tighten the backing plate mounting bolts to
grooving can be removed by grinding, provided
the specified torque.
that the service limit on the inside diameter is not
exceeded.
16 kgf•m
Tightening torque for backing
(116 lbf•ft)
plate mounting bolts
[157 N•m] E3000 - EC4000 E4000-E6500
254 + 0.13 0 310 + 0.15 0
Inside
A 0.0051 0)
diameter of (10.0 + (12.2 + 0.0059 0)
Shoes and Linings brake drum
B 256 (10.08) 312 (12.28)
1. Check each shoe and lining for cracks.
Unit: mm (in.)
2. Replace the lining if it is dirty, greasy, burnt,
A = Assembly standard B = Repair or service limit
or glazed.
3. Check the thickness of the lining. Replace
the lining if it exceeds the service limit. Adjusting Screws
Check the wheel teeth for wear. Turn the screw by
hand to ensure its rotating parts turn freely.

203005

200274

E3000 - EC4000 E4000-E6500

4.87 6 Parking Brake Cable
A
Lining (0.19) (0.24)
thickness Replace a cable if it is permanently stretched,
2.5 (0.10) 3 (0.12)
B rusted, or damaged.
maximum maximum
Unit: mm (in.) Other:
A = Assembly standard B = Repair or service limit
1. Check the return springs for cracks or fatigue.
2. Check the adjusting springs for cracks or
fatigue.
3. Check the fitting cables for stretching.

99759-8B110
5.7
BRAKE SYSTEM

Reassembly (E3000 - EC4000)

6 10
A 3
12 1

8 12

13
5
8
4
7
1
11

9
9

14
16
2 Section A-A
15 A

205960

Sequence
1. Backing plate 9. Pin, hold-down spring, and cup
2. Parking brake cable 10. Shoe guide plate
3. Wheel cylinder 11. Fitting cable
4. Parking brake lever 12. Return spring
5. Shoe and primary lining 13. Cable guide
6. Retainer and washer 14. Adjusting lever and adjusting spring
7. Shoe and secondary lining 15. Adjusting screw
8. Strut and anti-rattle spring 16. Return spring

99759-8B110
5.8
 BRAKE SYSTEM

Reassembly (E4000 - E6500)

A
3 11
6 9

13 1

7
4
8

10
10

12

16
14
Section A-A
15
2 A
205961

Sequence
1. Backing plate 9. Strut and anti-rattle spring
2. Parking brake cable 10. Pin, hold-down spring, and cup
3. Wheel cylinder 11. Shoe guide plate
4. Parking brake lever 12. Fitting cable
5. Shoe and primary lining 13. Return spring
6. Retainer and washer 14. Adjusting lever and adjusting spring
7. Pin, sheave, and washer 15. Adjusting screw
8. Shoe and secondary lining 16. Return spring

99759-8B110
5.9
BRAKE SYSTEM

Suggestions
Installing Wheel Cylinder Greasing
Apply 3 Bond to the mounting face of the wheel Apply a thin coat of the specified brake grease to
cylinder before positioning the cylinder in place. each of the following parts.
Secure it by tightening to the specified torque: 1. Shoe ledges (6 places):
The ledges are the portions of the backing
plate in contact with the shoe.
E3000 - EC4000 E4000-E6500 2. Anchor pin surface in contact with the shoe
Tightening 0.8 to 1.2 1.8 to 2.7 ends.
torque for (6 to 9) (13 to 20)
wheel cylinder [8 to 12] [18 to 26] Installing Shoes
Unit: kgf•m (lbf•ft) [N•m] Make sure that each push rod of the wheel cylin-
der is snugly fitted to its shoe web.

Installing Return Springs

Use a special tool to install the return springs to
the backing plate pins

Special Tool Part Number

Spring installer 65309-15413

200275

200276

99759-8B110
5.10
 BRAKE SYSTEM

Installing Automatic Adjusting Device

1. Clean the adjusting screw and associated
parts, then grease the screw threads and
screw socket. Be sure the screw turns freely
when rotated by hand. If the screw is hard to
turn, replace it.
2. The right and left adjusting screws are color-
coded.
• Right-hand adjusting screw and lever (left-
hand thread) is yellow.
• Left-hand adjusting screw and lever (right- 200277
hand thread) is white.

NOTE

After reassembly, bleed air out of the brake

fluid lines. (Refer to INSPECTION AND
ADJUSTMENT, p. 5.15).

99759-8B110
5.11
BRAKE SYSTEM

Wheel Cylinders
Disassembly

10

7
6 12

5 11

9
3
8

2
*

97246-10900B

Sequence
1. Connecting link 8. Spring
2. Boot 9. Cup
3. Piston 10. Piston
4. Piston cup 11. Boot
5. Body 12. Connecting Link
6. Bleeder screw
7. Cap

NOTE

The parts (*) to be changed annually are

included in the repair kit.

99759-8B110
5.12
 BRAKE SYSTEM

Inspection after Disassembly

Cylinder Bodies
1. Check the bore for rusting, corrosion, and
scoring.
2. Check the threads of the bleeder screw and oil
pipe for damage.
Pistons
1. Check the sliding surface for rusting or
scratching. Cylinders with any rust, corrosion
or scoring should be replaced
2. Check the piston clearance in the cylinder
body. Replace the cylinder body and piston if
the clearance exceeds the service limit.
Piston Cups
Check for swelling or other defects. Replace the
cups at the time of overhaul and every year.
Boots
Replace the boots if they are hardened, damaged,
or otherwise deteriorated.
Reassembly
To reassemble, reverse the procedure for disas-
sembly and do the following:
1. Coat the piston cups and the cylinder bore
with brake fluid.
2. Be careful not to damage the lips of the cups.

200280

E3000 - EC4000 E4000-E6500

0.040 to 0.125 0.020 to 0.105
Clearance A (0.00157 to (0.00079 to
between 0.00492) 0.00413)
piston and
cylinder B 0.15 (0.0059)

Unit: mm (in.)
A = Assembly standard B = Repair or service limit

It is recommended that the brake cylinder kit be

replaced any time it is disassembled.

99759-8B110
5.13
BRAKE SYSTEM

Inspection and Adjustment

Automatic Adjusting Device
1. Have the service brake properly set with the
drum-to-lining clearance adjusted to specifi-
cation. Pull the adjusting lever by giving a
push to the cable, as shown, to see if the
lever turns the adjusting screw by one tooth
and, as the push is released, returns to its
original position. If it does, the device is in
satisfactory condition.
3. When the automatic adjusting device is sus-
pected of malfunctioning during normal use of
the machine, check for the following causes:
a. Adjusting spring is not correctly hooked to
the primary shoe.
b. Any one of these parts is in bad condition
and needs replacing:
1) fitting cable
2) adjusting lever
3) adjusting screw

Manual Adjustment
The drum-to-lining clearance can be adjusted by
rotating the adjusting screw with a screwdriver on
to the toothed wheel. The hole through which the
screwdriver tip can be inserted is in the backing
plate.

200281

2. If the lever fails or is sluggish to turn the

adjusting screw in the above test, the likely
cause is that the lever is not properly posi-
tioned relative to the toothed wheel. Be sure
that the lever is positioned so that its actuating
tip touches the toothed wheel at about 9 mm
(0.35 in.) under the center line of the screw, as
shown below. 200283

9 mm
(0.35 inch)

200282

99759-8B110
5.14
 BRAKE SYSTEM

Brake Pedal Adjustment Bleeding Air Out of Brake Fluid Line

Set the dimensions A, B, and C to the specified Whenever any part of the brake fluid line is dis-
values. connected in servicing work, an air bleeding oper-
After the shoe linings have been replaced, turn ation must be performed to complete the job. Air
the adjusting screw as far as it will go (until the trapped in any part of the fluid line will cause the
clearance becomes zero) and back it off by the brake pedal to feel spongy.
amount of rotation shown below. Air Bleeding Operation Procedure:
E3000 - EC4000: 19 clicks 1. Tie a flexible tube, such as a vinyl pipe, to the
E4000 - E6500: 16 clicks bleeder screw on the wheel cylinder. Insert the
free end of the tube into a vessel filled with
Height from floor to brake fluid.
120mm ± 3 mm
pedal (A) 2. Pump the brake pedal and depress it all the
Stroke (to a point where way. While keeping the pedal depressed,
3 to 10 (0.12 to 0.4)
brakes start to apply) (B) loosen the bleeder screw. When air bubbles
Clearance between piston cease to come out, tighten the screw. Repeat
0.5 to 2.7 (0.02 to 0.11)
and push rod (C) this process until nothing but brake fluid flows
Unit: mm (in.) into the vessel.
3. Repeat procedure at each wheel brake, and fill
up the brake fluid reservoir to level.
B

Push rod

200285

C Stop bolt NOTE

8609011 Be sure that the reservoir never becomes
empty of fluid at any time during the
procedure.

Use specified brake fluid. Avoid mixing

different brands of brake fluid before and
after filling up the reservoir.

Brake Test
After completion of necessary adjustments, test
the brake force by operating the truck at a slow
speed of 2.0 km/h (1.2 mph). Test brakes—then
increase speed up to 10 km/h (6.2 mph). Refer to
Manual Adjustment for necessary readjustment.
99759-8B110
5.15
NOTES

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