Chapter 9 BRAKE SYSTEM

1. Structure .................................................................................................. 9-1

1.1 Brake System (Dry type brake) ............................................................................... 9-1
1.2 Wheel Brakes (Dry type brake) ............................................................................... 9-4
1.3 Parking Brake Valve (Dry type brake) ..................................................................... 9-6
2. Disassembly and Reassembly............................................................... 9-7
2.1 Wheel Brakes (Dry type brake) ............................................................................... 9-7
2.2 Wheel Cylinder (Dry type brake) ........................................................................... 9-16
2.3 Parking Brake Valve (Dry type brake) ................................................................... 9-20
3. Inspection and Adjustment .................................................................. 9-22
3.1 Automatic Adjuster Test (Dry type brake).............................................................. 9-22
3.2 Manual Adjustment (Dry type brake) ..................................................................... 9-23
3.3 Brake Pedal Adjustment ........................................................................................ 9-23
3.4 Brake Lines Bleeding (Dry type brake).................................................................. 9-24
3.5 Braking Performance Test (Dry type brake) .......................................................... 9-25
3.6 Oil Pressure Measurement (Dry type brake) ......................................................... 9-26
3.7 Parking Brake Emergency Release....................................................................... 9-27
4. Troubleshooting.................................................................................... 9-29
5. Service Data........................................................................................... 9-30

9
 BRAKE SYSTEM

1. Structure
Chapter 9 BRAKE SYSTEM

1.1 Brake System (Dry type brake)

Hydraulic tank Transmission

Parking brake valve

Brake pedal

Hydraulic gear pump

Stop lamp switch

Brake system gear pump

Wheel brake valve

Pressure switch
Right wheel brake
Parking brake

Front axle

Left wheel brake

215495

The wheel brake has a brake drum set into each side
of the front axle.
The parking brake with a wet multi-disc brakes (nega-
tive brakes) is set in the transmission. A gear pump in
the braking system uses hydraulic oil from the braking
system to generate pressure to activate the wheel
brakes and the parking brake.

DO NOT use brake fluid, use hydraulic oil.

9-1
BRAKE SYSTEM

Brake pedal Parking brake valve

Rear combination T2 Port P Port
lamp
T1 Port
Stop lamp switch

Fuse PKB Port

BR Port
Wheel brake valve
P Port Brake system
T2 Port gear pump

T1 Port

Hydraulic tank
T Port
Main Parking brake valve
Right wheel brake relief
valve
BR Port Reducing valve
A Port P Port PKB Port
Emergency relief port
Parking brake switch
Brake piston Orifice

VCM Parking brake solenoid

Left wheel brake

Pressure switch
Parking brake

Transmission㧕 Instrument panel 217521
When the brake pedal is released, pressure in the release the brake disks so that the parking brake is
hydraulic circuit rises so that the main relief valve in released.
the parking brake valve is activated to return hydraulic When the parking brake switch is pushed or the
oil to the hydraulic tank from the T2 port. engine is stopped, the reducing valve in the parking
When the brake pedal is pressed, the wheel brake brake closes. Disks inside the parking brake in the
valve feeds hydraulic oil to the wheel brake cylinders transmission are pressed by springs while the gear is
in each of the wheel brake, which activates the wheel fixed to the output shaft, which results in stopping the
brakes to stop the lift truck. lift truck.
At this time, the valves in the braking system are acti- When the hydraulic oil pressure in the parking brake
vated in proportion to the foot pressure applied to the circuit becomes low, the pressure switch is activated
brake pedal, which fluctuates the oil pressure to the which causes the parking brake warning lamp to glow
wheel cylinders. The more foot pressure applied to in the instrument panel.
the brake pedal, the more hydraulic pressure
increases, which results in more braking power gener-
ation.
When the parking brake switch on the seat is pulled,
an electric signal is sent to the solenoid of the parking
brake valve, through the VCM. The solenoid valve
opens, and then the decompressed hydraulic oil at the
reducing valve is fed from a PKB port to the parking
brake in the transmission. Inside the parking brake,
the brake piston moves and presses the springs to

9-2
 BRAKE SYSTEM

Wheel brake valve Parking brake valve

Parking brake
Relief Reducing or releasing emergency relief port
valve pressure valve
A P BP
PKB
T
Right wheel brake

T1

T2 P Orifice

Front To hydraulic
axle controller valve
Brake system Hydraulic gear pump
gear pump
PTO

Left wheel brake PB

Pressure switch
Wheel cylinder pressure

Parking brake

Transmission

T Hydraulic tank

Pedal stroke Suction

(Piston stroke) strainer

Wheel brake operation

215497

The schematic chart above shows the oil pressure cir-

cuit for the wheel brakes and the parking brake.
Oil pressure from the wheel brake valve to the wheel
cylinder acts on the brake pedal stroke as shown in
the graph above.

9-3
BRAKE SYSTEM

1.2 Wheel Brakes (Dry type brake)

1.2.1 4.0, 4.5 ton class

7
A 1

9 5

3 10

Drum rotating direction

during forward movement
4
Adjusting screw
13 rotating direction
11 to expand shoes
A
12
Section A-A

215498

1 Wheel cylinder 8 Fitting cable

2 Backing plate assembly 9 Return spring
3 Shoe and lining assembly (primary) 10 Sheave
4 Shoe and lining assembly (secondary) 11 Adjusting lever
5 Return spring 12 Adjusting screw
6 Hold-down spring 13 Return spring
7 Shoe guide plate

Note: The illustration shows a left-hand wheel brake.

9-4
 BRAKE SYSTEM

1.2.2 5.0C, 5.0, 5.5 ton class

A 2
3
5

9
6

10

Drum rotating
direction during 8
forward movement
4
Adjusting screw
13 11 rotating direction
A to expand shoes
12
Section A-A

215499

1 Wheel cylinder 8 Fitting cable

2 Backing plate assembly 9 Return spring
3 Shoe and lining assembly (primary) 10 Toggle lever
4 Shoe and lining assembly (secondary) 11 Adjusting lever
5 Return spring 12 Adjusting screw
6 Link 13 Return spring
7 Hold-down spring

Note: The illustration shows a left-hand wheel brake.

9-5
BRAKE SYSTEM

1.3 Parking Brake Valve (Dry type brake)

T2 Port P Port

A
T1 Port
1

7
BR Port

2
A
PKB Port 4

3 7

4
5

2 Section A-A

215500

1 Parking brake valve block 5 Reducing valve

2 Solenoid valve block 6 Orifice
3 Main relief valve 7 Emergency relief port
4 Solenoid valve assembly

9-6
 BRAKE SYSTEM

2. Disassembly and Reassembly

2.1 Wheel Brakes (Dry type brake)
2.1.1 Disassembly (4.0, 4.5 ton class)

11
9

7
1

5
3

10 6

8
2

215501
Disassembly sequence
1 Return spring 6 Shoe guide plate
2 Fitting cable 7 Shoe and lining assembly (secondary)
3 Hold-down spring, Cup, Pin 8 Shoe and lining assembly (primary)
4 Adjusting lever, Adjusting spring, 9 Wheel cylinder, Breeder, Bolt
Return spring 10 Mounting bolt, Spring washer
5 Sheave, Adjusting screw, Washer 11 Backing plate

Preparation
(1) Remove the front wheels. (Refer to the "Front
Axle and Reduction Differential.")
(2) Remove the wheel hub and the brake drum.
(3) Have a container available to catch any residual
oil when the brake pipe is removed from the wheel
brake assembly.

9-7
BRAKE SYSTEM

2.1.2 Disassembly (5.0C, 5.0, 5.5 ton class)

12 10

10

13

11 8

2 1

7 1

5
4

13 3

4 6
7
215502
Disassembly sequence
1 Return spring 8 Shoe and lining assembly (secondary)
2 Link 9 Shoe and lining assembly (primary)
3 Fitting link 10 Wheel cylinder, Breeder, Bolt, Spring washer
4 Hold-down spring, Cup, Pin 11 Mounting bolt, Spring washer
5 Toggle lever, Split pin, Washer 12 Dust shield
6 Adjusting lever, Adjusting spring, Return spring 13 Backing plate, Bolt
7 Adjusting screw, Cover

Preparation
(1) Remove the front wheels. (Refer to the "Front
Axle and Reduction Differential.")
(2) Remove the wheel hub and the brake drum.
(3) Have a container available to catch any residual
oil when the brake pipe is removed from the wheel
brake assembly.
(4) Remove mounting bolts and then remove the
wheel brake assembly from the front axle hous-
ing.

9-8
 BRAKE SYSTEM

Suggestions for Disassembly

(1) Removing return springs
Use a special tool to remove the return springs
from the shoe guide plates.

Special tool
Spring remover 91K67-00100

Spring
remover
215503

(2) Removing hold-down springs

Use a special tool to remove the hold-down
springs from the backing plate. Spring retainer
Special tool
Spring 4.0, 4.5 ton class 91M67-00100
retainer 5.0C, 5.0, 5.5 ton class 91N67-00100

215504

(3) Removing only shoe and lining

In order to remove the wheel brake assembly,
Turn the wheel hub
remove the wheel hub and drums. In order to
remove only the shoe and lining assembly,
remove only the drums.
(a) Remove the front wheels.
(b) Remove the drums.
(c) Turn the adjusting screw to shorten its length to
the minimum.
Concaved point
Notice: When it is difficult to turn the adjusting
215507
screw, turn it from behind through the backing
plate's adjustment hole. (Refer to the "3.2 Man-
ual adjustments.")
(d) Turn the wheel hub to find the concaved point,
then insert the tool to remove the return spring,
the adjusting spring, and the hold-down spring.

9-9
BRAKE SYSTEM

(e) Remove the adjusting lever, and the fitting

cable or the fitting ring. Return spring
attaching point Hold-down spring
(f) Remove the shoe and the lining assembly (pri-
mary and secondary), and the adjusting screw.

4.0, 4.5 ton class

Hold-down spring 215508

Return spring
attaching point

Hold-down
spring
5.0C, 5.0, 5.5
ton class 215509
Note: For disassembling of wet disc brake, refer to
"Chapter 7 FRONT AXLE AND REDUCTION
DIFFERENTIAL".
Inspections after Disassembly
(1) Backing plate
(a) Check the backing plate for cracks and distor-
tions.
(2) Shoe and lining assembly
(a) Check the shoe and lining for cracks or dam-
age.
(b) Replace the lining with a new one if it is found
grease-stained, burned, or deformed.
(c) Measure the thickness of the lining with a cali-
per to tell whether its thickness is within the
service limit value. Replace the lining with a
new one if the thickness is less than the ser-
vice limit value or it is more likely to exceed the
215505
limit value before the next inspection.

Unit: mm (in.)
Truck model
Item 4.0, 4.5 ton 5.0C, 5.0, 5.5
class ton class
Thickness of A 4.87 (0.19) 10.0 (0.39)
linings B 1.0 (0.04) 4.8 (0.19)
A: Standard value B: Service limit

(d) When the lining is secured to the plate with riv- Lining must not
reach rivet’s head.
ets (5.0C, 5.0, 5.5 ton class), replace the lining 215506
with a new one if the lining thickness is at 1
mm (0.04 in.) from the rivets' heads.
9-10
 BRAKE SYSTEM

(3) Brake drums

Grind the inside of the brake drums if they have
unusual wear or scratches.

Unit: mm (in.)
Truck model
Item 4.0, 4.5 ton 5.0C, 5.0, 5.5
class ton class
Brake drums A 317.5 (12.5) 317.5 (12.5)
Inner diameter B 318.5 (12.54) 318.5 (12.54)
A : Standard value B: Service limit

(4) Adjusting screw

Check the wheel teeth for wear and check that
each part of the adjusting screw turns smoothly.

215510
(5) Other parts
(a) Check the shoe return springs for cracks or
settling.
(b) Check the adjusting springs for cracks or
fatigue.
(c) Check the fitting cable for overstretching, wear
and cuts. (4.0, 4.5 ton class)
Note: For disassembling of wet disc brake, refer to
"Chapter 7 FRONT AXLE AND REDUCTION
DIFFERENTIAL".

9-11
BRAKE SYSTEM

2.1.3 Reassembly (4.0, 4.5 ton class)

6
A 1

8
8

Section A-A
A
10

215511

Reassembly sequence
1 Wheel cylinder 6 Shoe guide plate
2 Backing plate assembly 7 Fitting cable
3 Shoe and lining assembly (primary) 8 Return spring
4 Shoe and lining assembly (secondary) 9 Cable guide, Sheave, Pin, Washer
5 Hold-down spring, Cup, Pin 10 Adjusting lever, Adjusting screw, Adjusting spring

Note: The illustration shows a left-hand wheel brake.

9-12
 BRAKE SYSTEM

2.1.4 Reassembly (5.0C, 5.0, 5.5 ton class)

10
1
A 2
3

8
8

Section A-A
A
9

215512

Reassembly sequence
1 Wheel cylinder 6 Toggle lever, Split pin, Washer
2 Backing plate assembly 7 Fitting link
3 Shoe and lining assembly (primary) 8 Return spring, Link
4 Shoe and lining assembly (secondary) 9 Adjusting lever, Adjusting screw, Adjusting spring
5 Hold-down spring, Cup, Pin 10 Dust shield

Note: The illustration shows a left-hand wheel brake.

9-13
BRAKE SYSTEM

Suggestions for Reassembly

(1) Installing wheel cylinder
Tighten the wheel cylinder to the backing plate
with bolts. Torque to specifications.

Unit: N·m (kgf·m) [lbf·ft]

Weight class
Item 5.0C, 5.0, 5.5 ton
4.0, 4.5 ton class
class
17.65 to 26.48 17.65 to 26.48
Tightening
(1.8 to 2.7) (1.8 to 2.7)
torque
[13.03 to 19.54] [13.03 to 19.54 ]
215513

(2) Greasing
Apply a thin coat of the brake grease (AKB100) to (a) (b)
the following areas. (e)

(a) Shoe ledge (6 locations) (b)

(Contact surface between the backing plate (b) (a)
(d) (a)
and the shoe)
(h)
(b) Contact surface of the shoe web and the (h) (a)
anchor pin of the backing plate. (4.0, 4.5 ton (a)
(a)
class)
(c) Contact surface of the shoe web and the 4.0, 4.5 ton class 215515
groove of the backing plate. (5.0C, 5.0, 5.5 ton
class)
(d) Contact surface of the cup of the hold-down
spring and the shoe.
(e) Contact part of the fitting cable and the sheave,
and the pin. (4.0, 4.5 ton class) Anchor pin surface Groove point
in contact with in contact with
(f) Contact part of the fitting link and the toggle the shoe web the shoe web
lever, and the pin. (5.0C, 5.0, 5.5 ton class)
(g) Contact part of the adjusting lever and the pin.

4.0, 4.5 ton class 5.0C, 5.0, 5.5 ton class

215516

(3) Installing shoe and lining assembly

Ensure that each connector link of the wheel cylin-
der has been correctly inserted into the shoe web.
(4) Installing return spring
Use a special tool to install the return springs to
the backing plate pins. Spring hook
Special tool
Spring installer 65309-15413

215514

9-14
 BRAKE SYSTEM

(5) Installing automatic adjuster

(a) Clean each part of the adjusting screws and
apply grease to the threaded portion and the
screw socket mounting surface. Ensure that
the screws turn easily by hand.
If a screw is hard to turn, replace it with a new
one.
(b) Identification of adjusting screw (mark)
Left side (left-hand thread) = LH
Right side (right-hand thread) = RH
Note: After reassembly, bleed air out of the brake oil
lines. (Refer to "Inspection and Adjustment.")

(6) Installing dust shield

Tighten the mounting bolt to the specified torque.

Unit: N·m (kgf·m) [lbf·ft]

7.85 to 11.77
Tightening torque (0.8 to 1.2)
[5.79 to 8.69]

(7) Installing drum

Pay attention to tightening of the wheel nuts,
because the wheel nuts hold the drums and the
front wheels together. For installing the drums,
refers to the "Front Axle and Reduction Differen-
tial."
Note: For assembling of wet disc brake, refer to
"Chapter 7 FRONT AXLE AND REDUCTION
DIFFERENTIAL".

9-15
BRAKE SYSTEM

2.2 Wheel Cylinder (Dry type brake)

2.2.1 Disassembly (4.0, 4.5 ton class)

6
*4
*5 1

2
*
*4
3

2
1
*

215517

Disassembly sequence
1 Connector link 5 Return spring
2 Boot 6 Bleeder screw, Cap
3 Piston 7 Cylinder body
4 Piston cup
Note: The parts marked * are included in the repair kit, and they should be changed periodically.

9-16
 BRAKE SYSTEM

2.2.2 Disassembly (5.0C, 5.0, 5.5 ton class)

6 3

*4
1

2
*
*4
3

*
2

1 *

215518

Disassembly sequence
1 Connector link 5 Return spring
2 Boot 6 Bleeder screw, Cap
3 Piston 7 Cylinder body
4 Piston cup
Note: The parts marked * are included in the repair kit, and they should be changed periodically.

9-17
BRAKE SYSTEM

2.2.3 Inspection and Repair

(1) Cylinder body
(a) Check the inner surface of the cylinder bore for
rust, erosion or scratches.
(b) Check threads of both the bleeder screw and
oil pipe for damage.
(2) Piston
(a) Check the outer surface of the piston for rust
and scratches.
(b) Install the piston inside the cylinder body and
measure the clearance between the piston and
cylinder body to check whether its clearance is
within the service limit value. Replace the pis-
ton with a new one if its clearance exceeds the
service limit value.

Unit: mm (in.) 213759

Clearance between A 0.020 to 0.105 (0.001 to 0.004)
piston and cylinder B 0.15 (0.006)
A: Standard value B: Service limit

(3) Piston cup

Check the piston cup for swelling and damage.
Replace the cup with a new one even if it is
slightly defective.

Unit: mm (in.)
Tightness between piston cup A 1.85 (0.07)
and cylinder body B 0.65 (0.03)
A: Standard value B: Service limit
Boot NBR mark raised
on the side face
(4) Boot
Replace the boot with a new one if it is damaged
or distorted.
Shape change
Note: Because mineral oils are used as brake oil,
the materials of the boots, the piston cups, and Piston cup
the bleeder cups are different from those of the Bleeder cap
previous model. The illustration on the right shows
215520
how to identify the new ones.

9-18
 BRAKE SYSTEM

2.2.4 Reassembly
For reassembly, follow the disassembly sequence in
reverse. Also follow the instructions below.
(1) Clean metal parts with volatile cleaning oil, and
blow them completely dry with compressed air.
(2) Apply a thin coat of rubber grease or brake oil to
the inner surface of the cylinder body and piston
cups.
(3) Be careful not to damage the lips of the piston
cup.
(4) Make sure that the piston cups face the correct
directions when reassembled.
(5) Tighten the bleeder screw to the specified torque.

Unit: N·m (kgf·m) [lbf·ft]

5.88 to 8.83
Tightening torque (0.6 to 0.9)
[4.33 to 6.51]

9-19
BRAKE SYSTEM

2.3 Parking Brake Valve (Dry type brake)

2.3.1 Disassembly

4
7

217522

Disassembly sequence
1 Solenoid valve assembly, plunger 5 Solenoid valve block
2 Spool, Spring 6 Orifice
3 Main relief valve 7 Parking brake valve block
4 Spool, Slug, Spring

Inspections after Disassembly

1 Inspection of springs
2 Check springs for cracks or overstretch.

9-20
 BRAKE SYSTEM

2.3.2 Reassembly

6.0 to 8.0 N·m

(0.61 to 0.82 kgf·m)
[4.33 to 5.9 lbf·ft]

4.0 N·m
(0.41 kgf·m)
[2.95 lbf·ft]

A 40 ± 5.0 N·m
(4.08 ± 0.51 kgf·m)
[29.5 ± 3.7 lbf·ft]

24.5 ± 2.5 N·m

(2.5 ± 0.25 kgf·m)
[18.1 ± 1.85 lbf·ft]

6.0 to 8.0 N·m

(0.61 to 0.82 kgf·m)
[4.33 to 5.9 lbf·ft]
24.5 ± 2.5 N·m
(2.5 ± 0.25 kgf·m)
[18.1 ± 1.85 lbf·ft]

24.5 ± 2.5 N·m

(2.5 ± 0.25 kgf·m) Section A-A
[18.1 ± 1.85 lbf·ft]
217510

Reassembly sequence
For reassembly, follow the disassembly sequence in
reverse. Also follow the instructions below.
(1) Tighten each part shown in the illustration above
to the specified torques for reassembly.

9-21
BRAKE SYSTEM

3. Inspection and Adjustment

3.1 Automatic Adjuster Test (Dry type brake)
(1) With the clearance between the lining and the
brake drum being set to specification, pull the fit-
ting cable or the fitting link toward you with a fin-
ger. Then the adjusting lever moves the adjusting
screw wheel one notch and returns to the original
position.

Unit: mm (in.)
Truck model
Item 4.0, 4.5 ton 5.0C, 5.0, 5.5
class ton class
215523
Drum inside
317.5 (12.5) 317.5 (12.5)
diameter
Drum-to-lining 0.25 to 0.4 0.45 to 0.65
clearance (0.010 to 0.016) (0.018 to 0.022)

(2) If the adjusting lever does not release the adjust-

ing screw when the fitting cable or the fitting link Adjusting screw wheel
returns, or if the adjusting lever reacts slowly,
check whether the position of the adjusting lever
is correct. The adjusting screw lever is set at
approximately 9 mm (0.35 in.) below the center-
line of the adjusting screw so that the lever con-
tacts the adjusting screw wheel. If the position of
the adjusting screw lever is incorrect, the lever
does not engage with the teeth of the adjusting
wheel, which prevents the wheel from turning cor-
Adjusting lever 215524
rectly.

(3) If the automatic adjuster fails to operate correctly,

take the following steps.
(a) Ensure that the adjusting spring is correctly
hooked to the hole of the primary shoe.
(b) Replace the fitting cable or the fitting link with a
new one.
(c) Replace the adjusting lever with a new one.
(d) Replace the adjusting screw with a new one.

9-22
 BRAKE SYSTEM

3.2 Manual Adjustment (Dry type brake)

(1) Remove the cover attached to the adjusting hole
which is located on the back of the backing plate.
Adjusting screw
(2) Adjust the drum-to-lining clearance to specifica- Wide
tion by turning the adjusting screw wheel with two
screwdrivers through a hole on the back of the
backing plate.
Narrow
(3) Hold the adjusting lever with one screwdriver and
turn the wheel of the adjusting screw with the
other screwdriver.
Note: The adjusting screw wheel can be adjusted by Adjusting lever
215525
the notch of the wheel. One notch equals 0.03
mm (0.001 in.) in diameter.

3.3 Brake Pedal Adjustment

(1) Adjust the stopper bolt to set the brake pedal pad
Free play approx. 5 mm
height at approx. 270 mm (10.63 in.) from the cen-
(0.2 in.)
ter of the shaft, and lock it into place with a lock Stopper bolt
nut.
Lock nut
(2) In order to keep the clearance value to 1 mm
(0.04 in.) between the push rod and the piston Approx.
inside the wheel brake valve, set the distance Approx. 270 mm
from the center of the clevis slot to the edge of the 110 mm (10.63 in.)
body to approx. 110 mm (4.33 in.), adjust the push (4.33 in.)
rod by rotating, and lock the clevis with locking
nut. Make sure the free play of the brake pedal is
approx. 5 mm (0.2 in.) after the adjustment is
completed.

Clevis

215526

9-23
BRAKE SYSTEM

3.4 Brake Lines Bleeding (Dry type brake)

3.4.1 Wheel Brakes
When any part of the brake oil lines has been disas-
sembled for repair, bleed air out of the lines.
(1) Block the rear wheels.
(2) Connect a transparent vinyl tube onto the bleeder
screw of the right-hand wheel cylinder, which is
the farthest wheel cylinder from the wheel brake
valve. Place the other end of the vinyl tube into a
container filled with brake oil so that the tube end
stays below the oil surface level.
Note: Use a vinyl tube whose diameter is around
7 mm (0.28 in.) in the outside and 5 mm (0.2 in.) in
the inside.
(3) Before starting the engine, make sure that the
direction lever is placed to the neutral position and 215527
the parking brake is applied.
(4) Loosen the bleeder screw and press the brake
pedal.
(5) Make sure the brake oil is flowing through the
vinyl tube.
(6) While bubbles are seen in the brake oil, keep
pressing the brake pedal.
(7) After no more air bubbles are seen, tighten the
bleeder screw to the specific torque before the
brake oil stops flowing.

Unit: N·m (kgf·m) [lbf·ft]

5.88 to 8.83
Tightening torque (0.6 to 0.9)
[4.33 to 6.51]

(8) Repeat the same procedures for the left-hand

wheel cylinder.
(9) Stop the engine after the air-bleeding procedure is
finished.

9-24
 BRAKE SYSTEM

3.4.2 Parking brake

(1) Connect a transparent vinyl tube onto the bleeder
screw of the transmission. Place the other end of
the vinyl tube into a container filled with brake oil.
(2) Start the engine and press the brake pedal.
(3) Pull the parking brake switch while pressing the
brake pedal to release the parking brake.
(4) Loosen the bleeder screw and tighten the bleeder
screw while the brake oil is flowing through the
vinyl tube.
(5) Repeat the previous steps until the brake oil in the
vinyl tube is free of air bubbles.
(6) Push the parking brake switch to stop the engine
after the air-bleeding procedure is finished.
Note: Check the hydraulic tank oil level after the
215528
air-bleeding procedure is finished.

3.5 Braking Performance Test (Dry type brake)

After all of the required adjustments on the brake sys-
tem are completed, test the braking force at a speed of
10 km/h (6.2 MPH).
Readjust them if necessary by referring to the "Manual
Adjustment."

9-25
BRAKE SYSTEM

3.6 Oil Pressure Measurement (Dry type brake)

(1) Block the rear wheels.
(2) Connect oil pressure gauges to the oil pressure
taps. Attach an oil pressure gauge to the emer- Oil pressure
gency relief port to measure the reducing valve oil gauge for
pressure. reducing valve
(3) Use the following tools for the oil pressure mea-
surement.
Oil pressure
Main relief valve Rc1/8
gauge for main
Reducing valve G1/8 relief valve

(4) Oil pressure measurement 215529

(a) Main relief valve
Start the engine and place all the control levers
into the neutral position. Then measure the
pressure at which the valve opens using an oil
pressure gauge.

Unit: Mpa (kgf/cm2) [psi]

Engine speed Low idle speed
Oil pressure 9.0 (91.77) [1305.36]

(b) Reducing valve downstream oil pressure

Unit: Mpa (kgf/cm2) [psi]

Engine speed Low idle speed
Oil pressure 6.0 (61.18) [870.32]

(5) If the main relief valve oil pressure value does not
meet the standard value, take the following steps
for adjustment.
(a) Stop the engine.
(b) Remove the cap nut of the main relief valve
and loosen the lock nut.
(c) Turn the screw with screwdriver to adjust oil
pressure.
If the oil pressure is higher than the standard
value, tighten the screw, if the pressure is
lower, loosen the screw.
(d) Restart the engine to measure the oil pressure.
(e) Repeat the above steps until the value meets
the standard.
(f) When the oil pressure value meets the stan-
dard, tighten the lock nut securely and put on
the cap nut.
(6) If the reducing valve oil pressure value does not
meet the standard, disassemble the valve and
replace the spring inside the valve with a new
one.

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 BRAKE SYSTEM

3.7 Parking Brake Emergency Release

(1) If the parking brake can not be released for some
reason, take the following steps.
(2) Before starting operation, be sure to block wheels.

3.7.1 Releasing by turning the bolt

(1) Remove the plug on the transmission housing,
and screw a bolt with nut into the slot.

Bolt F1035-16045
Washer F2500-16000

(2) Screw the bolt into the slot until the bolt and
washer contacts the transmission housing surface Plug
and then tighten the bolt one turn. Do not over-
tighten.
Note: For details, refer to "1.8 Releasing parking 215530
brake with the release bolt" of "Chapter 6 Pow-
ershift Transmission."

Bolt

Washer

215531

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BRAKE SYSTEM

3.7.2 Releasing by external oil pressure

(1) Remove the plug (G1/8) on the emergency relief
port from the parking brake valve.

Plug port for

forced release
215532

(2) Install the emergency relief connector with nut,

washer, and O-ring to the emergency relief port. O ring

Emergency relief connector 91K67-00200

Nut 91K67-00300
Washer F2500-10000
O-ring 05500-24014
Connector for
(3) Screw the emergency relief connector into the forced release
parking brake valve until it completely touches to Nut
the surface of the seal on the block of the parking Seal Washer
215533
brake valve, and then tighten the nut to the speci-
fied torque.

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque 19.6 (2.0) [14.46]

(4) Connect the external oil pressure generator to the

emergency relief connector (G1/4) in order to gen- External oil pressure generator
erate oil pressure to release the parking brake.

Unit: Mpa (kgf/cm2) [psi]

5 to 7
Oil pressure acceptable range (50 to 71.38)
[725.26 to 1015.37]

215534

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 BRAKE SYSTEM

4. Troubleshooting
(Dry type brake)
Item Condition Possible cause Action
Oil leaks from the wheel brake valve. Replace only the piston cup if the cyl-
inder is not worn.
Oil leaks from the wheel cylinder cup.
Oil leaks from oil pipe connection. Retighten the connection, or replace
Lack of braking force
the pipe and the connector.
Shoe lining is worn. Replace.
Shoe lining is dirty with oil or grease. Clean or replace.
Lining or drum with less effective braking Clean with cleaner, replace if the lining
force is dirty with oil or grease. is still dirty.
Uneven braking effect Brake drum is wobbly or its parts are loosely Replace the drum. Readjust and
connected. retighten if it is loosely connected.
Wheel tires are inflated unequally. Re-inflate to specifications.
Lining become hardened from heat. Grind the surface with sand paper.
Wheel Lining is worn. Replace the shoe and lining assembly.
brake
Brake squeaks Backing plate bolts are loosely tightened. Retighten.
Wheel bearings are loosely connected. Readjust and retighten the preload.
Brake drum is dirty. Clean with cleaner.
Shoe anchor end rattles against anchor. Repair or replace.
Brake squeaks
Shoe ledge is worn thin. Replace backing plate.
(clicking)
Piston in the wheel cylinder is worn thin. Replace wheel cylinder.
Clearance between the lining and the drum Adjust.
Unusual sound while is small.
driving
Brake drum is distorted too much. Repair or replace.
Lining is worn out to the service limit. Replace.
Brake will not activate Clearance between the lining and the drum Adjust.
is large.
Parking brake assembly is damaged. Replace.
Oil line is clogged. Disassemble the parking brake valve
Brake will not activate for inspection after bleeding oil out of
the emergency relief port of the park-
ing brake valve.
Parking Oil line pressure is low. Measure and adjust oil pressure of the
brake main relief valve and the reducing
valve.
Brake can not be
released. Solenoid valve spool is defective. Replace.
Parking brake assembly is damaged. Replace.
Electrical wiring is damaged. Check wiring for continuity.

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BRAKE SYSTEM

5. Service Data
Unit: mm (in.)
Truck model
Item
4.0, 4.5 ton class 5.0C, 5.0, 5.5 ton class
A 317.5 (12.5) 317.5 (12.5)
Inside diameter of brake drum 1
B 318.5 (12.54) 318.5 (12.54)
A 4.87 (0.19) 10.0 (0.39)
Thickness of lining 2
B 1.0 (0.04) 4.8 (0.19)
Clearance between drum and lining 3 (Total) A 0.25 to 0.40 (0.010 to 0.016) 0.45 to 0.55 (0.018 to 0.022)
Free length A 124 (4.88) 93 (3.66)
Length under set force A 138 (5.43) 101.2 (3.98)
Return spring 4
N 225 ± 22.6 245
Set force (kgf) A (22.94 ± 2.3) (24.98)
[lbf] [50.58 ± 5.08] [55.08]
Free length A 126 (4.96) 123.2 (4.85)
Length under set force A 145.7 (5.74) 152 (5.98)
Adjusting
spring 5 N 78 78
Set force (kgf) A (7.95) (7.95)
[lbf] [17.53] [17.53]
N·m 214 295
Tightening torque of backing plate
(kgf·m) A (2.18) (30.08)
mounting bolts 6
[lbf·ft] [15.79] [217.71]

4.0, 4.5 ton class

Wheel 2
brake 4
3 4

6
5
5.0C, 5.0, 5.5 ton class
2
1 4

5 6

215535

A: Standard value B: Repair or service limit

Note: For the service date of wet disc brake, refer to "Chapter 7 FRONT AXLE AND REDUCTION DIFFEREN-
TIAL".

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 BRAKE SYSTEM

Unit: mm (in.)
Item All truck model
Free length A 23.5 (0.92)
Length under set force A 20.0 (0.78)
Main relief valve spring 1
107.9 ± 10.0
Set force N (kgf) [lbf] A (11 ± 1.02)
[24.25 ± 2.25]
Free length A 40.0 (1.57)
Length under set force A 36.6 (1.44)
Reducing valve spring 2
207 ± 21
Set force N (kgf) [lbf] A (21.11 ± 2.14)
[46.53 ± 4.72]
Free length A 22.3 (0.88)
Length under set force A 19.5 (0.76)
Solenoid valve spring 3
10.8 ± 1.1
Set force N (kgf) [lbf] A (1.1 ± 2.43)
[1.1 ± 0.25]
39.2 ± 5.0
Tightening torque of main relief valve 4 N·m (kgf·m) [lbf·ft] A (4 ± 0.51)
[28.93 ± 3.69]
Tightening torque of mounting bolts for solenoid 6.0 to 8.0
valve block 5 N·m (kgf·m) [lbf·ft] A (0.61 to 0.82)
[4.43 to 5.90]
Tightening torque of mounting bolts for solenoid
N·m (kgf·m) [lbf·ft] A 4.0 (0.41) [2.95]
valve assembly 6
Tightening torque of plug for emergency relief 6.0 to 8.0
port 7 N·m (kgf·m) [lbf·ft] A (0.61 to 0.82)
Parking [4.43 to 5.90]
brake
valve 24.5 ± 2.5
Tightening torque of each plug 8 N·m (kgf·m) [lbf·ft] A (2.45 ± 0.25)
[18.08 ± 1.85]

4 1

A 2

5
8

3 Section A-A 217511

A: Standard value

9-31