BR 1

SERVICE DATA BRAKE PROPER
SERVICE DATA
SPECIFICATIONS
FRONT WHEEL BRAKE
Unit name BHL41 FB43 BAL41
Brake system Air-over hydraulic brake system Full air brake system
Brake shoe type Leading-trailing shoe type
Brake drum I.D. mm (in) 410 (16.14)
Width 150 (5.91)
Brake lining mm (in)
Thickness 16.0 (0.630) 15.0 (0.591) 16.0 (0.630)
Wheel cylinder type Hydraulic piston type —
Wheel cylinder I.D. mm (in) 50.80 (2.0000) —
Brake cam type — Involute
Brake lining clearance adjusting system — Slack adjuster
REAR WHEEL BRAKE

Unit name BLL41 *BHL41 RB41 BPL41
Brake system Air-over hydraulic brake system Full air brake system
Brake shoe type Leading-trailing shoe type
Brake drum I.D. mm (in) 410 (16.14)
Width 220 (8.66) 150 (5.91) 220 (8.66)
Brake lining mm (in)
Thickness 16.0 (0.630) 15.0 (0.591) 16.0 (0.630)
Wheel cylinder type Hydraulic piston type —
Wheel cylinder I.D. mm (in) 55.56 (2.1874) 44.0 (1.7323) —
Brake cam type — Involute
Brake lining clearance adjusting system — Slack adjuster
NOTE
+ *BHL41 is for rear dead axle. (This also applies to the following pages.)
BR-1-1
UNIT NAME
FB 4 3
WHEEL BRAKE ABBREVIATION BRAKE OPERATING SYSTEM MODEL CLASSIFICATION
FB Front wheel brake 4 Air brake for large-sized vehicles
RB Rear wheel brake
B H L 41
TYPE CLASSIFICATION DRUM SIZE

UNIT CLASSIFICATION IDENTIFICATION OF THE FRONT
(Decimal point rounded up)
AND REAR L Leading-trailing
B Brake 41 41 cm
Front or rear liquid pres-
H
sure
L Rear liquid pressure
A Front air pressure
P Rear air pressure
BR-1-2
SERVICE DATA
Unit: mm (in)
Application
*
Maintenance B B B F B R B
Item Service limit Remarks
standard H L H B A B P
L L L 43 L 41 L
41 41 41 41 41
414
I.D. 410 (16.14) j j j j j j j
Brake (16.30)
drum Less than 0.20 Difference between max.
Out-of-roundness j j j j j j j
0.025 (0.0010) (0.0079) and min. drum diameters
Clearance between brake drum 0.3 - 0.4
— j j j — — — —
and brake lining (0.012 - 0.016)
Brake
lining 16.0 (0.630) j j j — j — j
Brake lining thickness 5.0 (0.197) Remaining thickness
15.0 (0.591) — — — j — j —
29.85
30.0 (1.181) j j j — j — j
(1.1752)
29.80
Anchor pin O.D. 30.0 (1.181) — — — j — — —
(1.1732)
31.80
32.0 (1.260) — — — — — j —
(1.2520)
30.15
30.0 (1.181) j j j — j — j
(1.1870)
30.20
Brake shoe bushing I.D. 30.0 (1.181) — — — j — — —
(1.1890)
32.20
32.0 (1.260) — — — — — j —
(1.2677)
0.07 - 0.20 0.25
j j j — j — j
(0.0028 - 0.0079) (0.0098)
Brake Clearance between anchor pin 0.10 - 0.25 0.35
— — — j — — —
shoe and brake shoe bushing (0.0039 - 0.0098) (0.0138)
0.10 - 0.25 0.50
— — — — — j —
(0.0039 - 0.0098) (0.0197)
26.4
26.0 (1.024) — — — j — j —
(1.039)
Brake shoe roller I.D.
20.7
20.3 (0.799) — — — — j — j
(0.815)
56.6
57.0 (2.244) With oil seal — — — j — j —
(2.228)
Brake shoe roller O.D.
39.9
40.3 (1.587) — — — — j — j
(1.571)
25.6
26.0 (1.024) — — — j — j —
(1.008)
Brake shoe roller pin O.D.
19.6
20.0 (0.787) — — — — j — j
(0.772)
BR-1-3
Unit: mm (in)
Application
*
L L L 43 L 41 L
41 41 41 41 41
0.09 - 0.15 0.40
— — — j — j —
Brake Clearance between brake shoe (0.0035 - 0.0059) (0.0157)
shoe roller and brake shoe roller pin 0.20 - 0.43 0.80
— — — — j — j
(0.0079 - 0.0169) (0.0315)
0.120 - 0.234
j — — — — — —
(0.0047 - 0.0092)
Clearance between wheel cylin- 0.128 - 0.248 0.25
— j — — — — —
der and piston (0.0050 - 0.0098) (0.0098)
0.104 - 0.205
Wheel — — j — — — —
(0.0041 - 0.0081)
cyl-
inder 50.6 - 51.2 Wheel cylinder I.D.
— j — — — — — —
(1.992 - 2.016) 50.80 mm (2.0000 in)
Wheel cylinder piston cup (lip) 55.4 - 56.0 Wheel cylinder I.D.
— — j — — — — —
O.D. (2.181 - 2.205) 55.56 mm (2.1874 in)
43.8 - 44.4 Wheel cylinder I.D.
— — — j — — — —
(1.724 - 1.748) 44.00 mm (1.7323 in)
44.3
44.0 (1.732) — — — j — j —
(1.744)
Camshaft bushing I.D.
40.3
40.0 (1.575) — — — — j — j
(1.587)
43.7
44.0 (1.732) — — — j — j —
(1.720)
Camshaft O.D.
Cam- 39.7
40.0 (1.575) — — — — j — j
shaft (1.563)
0.15 - 0.22
— — — j — — —
(0.0059 - 0.0087)
Clearance between camshaft 0.05 - 0.12 0.60
— — — — j — j
bushing and camshaft (0.0020 - 0.0047) (0.0236)
0.37 - 0.44
— — — — — j —
(0.0146 - 0.0173)
Free length 195.9 (7.71) —
549 - 637 Measure tension when j — — — — — —
Brake Tension N {kgf, lbf} {56.0 - 65.0, — spring is set at 219.0 mm
shoe 123 - 143} (8.62 in) in length
return Free length 192.0 (7.56) —
spring
Outer 462.4 - 527.1 Measure tension when — j — — — — —
Tension N {kgf, lbf} {47.15 - 53.75, — spring is set at 219.0 mm
104.0 - 118.5} (8.62 in) in length
BR-1-4
Unit: mm (in)
Application
*
L L L 43 L 41 L
41 41 41 41 41
Free length 243.9 (9.60) —
Inner 178.9 - 208.3 Measure tension when — j — — — — —

40.2 - 46.8} (10.15 in) in length
Free length 192.0 (7.56) —
462.4 - 527.1 Measure tension when — — j — — — —
104.0 - 118.5} (8.62 in) in length
Free length 184.3 (7.26) —
548 - 646 Measure tension when — — — j — — —
123 - 145} (8.23 in) in length
Free length 195.9 (7.71) —
*1 549 - 637 Measure tension when

123 - 143} (8.62 in) in length
— — — — j — —
Brake Free length 194.3 (7.65) —
shoe 544 - 642 Measure tension when
*2
return Tension N {kgf, lbf} {55.5 - 65.5, — spring is set at 219.0 mm
spring 122 - 144} (8.62 in) in length
Free length 229.8 (9.05) —
Measure tension when — — — — — j —
783.6
Tension N {kgf, lbf} — spring is set at 250.0 mm
{79.9, 176.2}
(9.84 in) in length
Free length 195.9 (7.71) —
Outer 549 - 637 Measure tension when

123 - 143} (8.62 in) in length
*1
Free length 242.6 (9.55) —
Inner 198 - 233 Measure tension when — — — — — — j

45 - 52} (9.94 in) in length
Free length 186.7 (7.35) —
*2 691 - 819 Measure tension when

155 - 184} (8.62 in) in length
165 (6.50) 30 (1.18) 45 (1.77) — — — j j — —
Brake chamber push
*3 125 (4.92) 24 (0.94) 40 (1.57) — — — — — — j
rod stroke
150 (5.91) 30 (1.18) 45 (1.77) — — — — — j j
BR-1-5
TIGHTENING TORQUE
Unit: N·m {kgfzm, ftzlbf}
Application
*
Item Tightening torque Remarks B B B F B R B
H L H B A B P
L L L 43 L 41 L
41 41 41 41 41
490 - 588 {50.0 - 60.0, 362 - 434} Castellated nut
j — — — j — —
216 - 294 {22.0 - 30.0, 159 - 217} Bolt
216 - 294 {22.0 - 30.0, 159 - 217} — j — — — — j
Brake bracket mounting bolt or nut 490 - 588 {50.0 - 60.0, 362 - 434} M22
— — j — — — —
216 - 294 {22.0 - 30.0, 159 - 217} M16
216 - 294 {22.0 - 30.0, 159 - 217} — — — j — — —
216 - 265 {22.0 - 27.0, 159 - 195} — — — — — j —
75 - 91 {7.6 - 9.3, 55 - 67} j — j — — — —
Wheel cylinder mounting bolt
113 - 157 {11.5 - 16.0, 83 - 116} — j — — — — —
Air bleeder screw 10 - 34 {1.0 - 3.5, 7 - 25} j j j — — — —
Anchor pin setscrew 21 - 34 {2.1 - 3.5, 15 - 25} j j j — j — j
Back plate mounting bolt 21 - 34 {2.1 - 3.5, 15 - 25} j j j j j j j
69 - 88 {7.0 - 9.0, 51 - 65} — — — — j — —
137 - 157 {14.0 - 16.0, 101 - 116} — — — — — — j
Brake chamber bracket mounting bolt
108 - 127 {11.0 - 13.0, 80 - 94} — — — j — — —
127 - 147 {13.0 - 15.0, 94 - 108} — — — — — j —
81 - 108 {8.3 - 11.0, 60 - 80} Chamber size No. 20 — — — — j — —
Chamber size No. 24 — — — j j — —
Brake chamber mounting nut Chamber size No. 30 — — — — — j —
167 - 186 {17.0 - 19.0, 123 - 137}
Chamber size 2430 — — — — — — j
Chamber size 3030 — — — — — j j
4.76 (0.1874) 13 - 18 {1.3 - 1.8, 9 - 13}
6.35 (0.2500) 16 - 24 {1.6 - 2.4, 12 - 17}
Tube
Flared O.D. 8.0 (0.315) 29 - 39 {3.0 - 4.0, 22 - 29}
Steel
nut mm 10.0 (0.394) 39 - 49 {4.0 - 5.0, 29 - 36}
brake
(in) j j j j j j j
tube 12.0 (0.472) 59 - 78 {6.0 - 8.0, 43 - 58}
joints
15.0 (0.591) 69 - 93 {7.0 - 9.5, 51 - 69}
Nipple nut 21 - 28 {2.1 - 2.9, 15 - 21}
Eye connector 42 - 57 {4.3 - 5.8, 31 - 42}
BR-1-7
TOOLS BRAKE PROPER
TOOLS
Application
*
Part name and number Description Shape B B B F B R B
H L H B A B P
L L L 43 L 41 L
41 41 41 41 41
Return spring tool Used to remove/install return
99867 Z0000 spring
NOTE
+ For unit names marked with * *
* on the Application col- j j j j j j j
umn, this tool is used only
on the outer side.
CTL1-031
Return spring tool assembly Used to remove/install return

99867 Z0001 spring (inner side)
j1 99868 Z0000 j1 Handle
j2 99868 Z0001 j2 Hanger
— j — — — — —
EBR003A
Return spring tool assembly Used to remove/install return

99867 Z0002 spring (inner side)
j1 99868 Z0000 j1 Handle
j2 99868 Z0002 j2 Hanger
j3 99524 Z0000 j3 Spacer
— — — — — — j
EBR004A
Adjusting cam assembly spring tool Used to remove/install brake

99842 Z0000 shoe clearance adjusting mecha-
nism, and cam spindle pin of the
adjusting cam assembly
j j j — — — —
CTL1-066
Piston cup guide Use as a guide when installing

*1 99866 Z0006 the piston cup into the wheel
*2 99866 Z0008 cylinder
*3 99866 Z0004 Cup guide inside diameter (D):
*1 50.8 mm
(2.000 in)
*1 *2 *3
*2 55.56 mm — — — —
j j j
(2.1874 in)
*3 44.0 mm
(1.732 in)
CTL1032B
BR-2-1
FRONT BRAKE (UNIT NAME BHL41) BHL41, BLL41, *BHL41
= BRAKE PROPER (UNIT NAME BHL41, BLL41, *BHL41) =

FRONT BRAKE (UNIT NAME BHL41)
CONSTRUCTION
<WHEEL BRAKE>
EBR069A
BR-3-1
<WHEEL CYLINDER>
EBR070A
DISASSEMBLY
REMOVAL
1. Chock the rear road wheels at the front and rear.
2. Remove the front road wheels.
(Refer to the ‘‘FRONT AXLE’’ section for procedures.)
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the wheel brake side.
NOTE
+ Brake fluid will run out when the hose is disconnected.
Use a suitable container to catch the fluid.
+ Do not twist the brake hose excessively when disconnect-
ing it.
4. Remove the hub (with drum) assembly.
BR-3-2
DISASSEMBLY
<WHEEL BRAKE>
EBR073A
Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)
>.j
1 Return spring assembly j7 Shoe guide pin j
13 Cover
>j
2 Lock washer j8 Back plate j
14 Adjuster boots
j
3 Lock plate j9 Wheel cylinder cover j
15 Adjuster spring
j
4 Anchor pin j
10 Wheel cylinder assembly j
16 Adjuster washer
>j
5 Brake shoe assembly >.j
11 Cam spindle pin >j
17 Adjuster cam assembly
j
6 Return spring pin j
12 Indicator j
18 Brake bracket
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.
BR-3-3
Key point of disassembly

j
1 Return spring assembly
Remove the return spring using a spring tool (99867 Z0000).
NOTE
+ Attach a band or ring [410 mm (16.14 in) in inside diameter]
to the edge of the brake lining to prevent it from expand-
ing.
CBR1005G
j
11 Cam spindle pin
Remove the cam adjuster spindle pin using adjusting cam assem-
bly spring tool (99842 Z0000), and disassemble the adjuster.
NOTE
+ When removing the spindle pin, do not compress the
spring more than 1 mm (0.04 in) from its installation length.
CBR2151B
BR-3-4
<WHEEL CYLINDER>
EBR074A
j
1 Boot >j
4 Back-up ring j
7 Bleeder screw
j
2 Push rod >.j
5 Piston cup j
8 Body
j
3 Piston j
6 Spring
j5 Piston cup
When removing piston cup from the piston, pay attention so as not
to scratch or damage the piston.
BR-3-5
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
Key point of reassembly
j5 Piston cup
Install the piston cup to the piston using piston cup guide (99866
Z0006).
CBR1-102
j4 Back-up ring
Install the back-up ring so that the side stamped with the red letter
faces the piston cup.
<WHEEL BRAKE>
j
Apply bearing grease sparingly when installing.
CBR1-039
j11 Cam spindle pin

Install the cam adjuster spindle pin using adjusting cam assembly
spring tool (99842 Z0000).
NOTE
+ When installing the spindle pin, do not compress the
spring more than 1 mm (0.04 in) from its installed length.
CBR2151B
j5 Brake shoe assembly

When installing the brake shoe assembly to the brake bracket,
apply bearing grease sparingly to the inner surface (groove) of the
bushing and the two grooves of the anchor pin.
NOTE
+ After installing the brake shoe assembly, attach the band
or ring [410 mm (16.14 in) in inside diameter] to the edge of
the brake lining.
CBR1116F
BR-3-6
j2 Lock washer
After tightening the bolt to specifications, bend the lock washer
sharply against the flat bolt head.
: 21 - 34 N·m {2.1 - 3.5 kgfzm, 15 - 25 ftzlbf}
CBR1006D
j1 Return spring assembly

1. Install the return spring using the spring tool (99867 Z0000).
2. Detach the band or ring.
NOTE
+ Make sure that oil or grease is not applied to the face of the
lining. If oil or grease is applied, clean the lining with a
cloth and dress with an emery cloth.
CBR1005G
INSTALLATION
1. Install the hub (with drum) assembly.
2. Adjust the preload.
3. Install the brake hose on the wheel brake side. Then, install the
brake hose on the bracket side (frame side).
NOTE
+ Do not twist the brake hose excessively when reconnect-
ing it.
4. Bleed the air from the brake line.
(For detailed information on bleeding the air from the brake line,
refer to the ‘‘BRAKE UNITS’’ section.
5. Install the front road wheel.
BR-3-7
REAR BRAKE (UNIT NAME BLL41, *BHL41) BHL41, BLL41, *BHL41
REAR BRAKE (UNIT NAME BLL41, *BHL41)

CONSTRUCTION
<WHEEL BRAKE>
Unit name BLL41
EBR071A
BR-3-8
<WHEEL CYLINDER>
Unit name BLL41
EBR072A
BR-3-10
DISASSEMBLY
<WHEEL BRAKE>
Unit name BLL41
EBR010A
>.j
1 Return spring assembly j9 Shoe guide pin j
16 Indicator
j
17 Cover
j
3 Guide pin j
11 Back plate j
18 Adjuster boots
>.j
4 Return spring assembly j
12 Shield cover (Upper) j
19 Adjuster spring
>j
5 Lock washer j
13 Wheel cylinder cover j
20 Adjuster washer
j
6 Lock plate j
14 Shield cover (lower) >j
j
7 Anchor pin >.j
15 Cam spindle pin
j
22 Brake bracket
>j
8 Brake shoe assembly
BR-3-12

j
1 Return spring assembly (Unit names BLL41 and *BHL41
are explained jointly)
NOTE
+ Attach a band or ring [410 mm (16.14 in) inside diameter] to
the edge of the brake lining to prevent it from expanding.
j
4 Return spring assembly (Unit name BLL41 only)
CBR2-151
j
j
15 Unit name BLL41
11 Unit name *BHL41 } Cam spindle pin
Remove the cam spring pin using adjusting cam assembly spring
tool (99842 Z0000).
NOTE
+ Do not compress the spring more than 1 mm (0.04 in) from
its installation length when removing the pin.
CBR2151B
BR-3-14
Unit name *BHL41
EBR074A
j
1 Boot >j
4 Back-up ring j
7 Bleeder screw
j
2 Push rod >.j
5 Piston cup j
8 Body
j
3 Piston j
6 Spring

j5 Piston cup (Unit names BLL41 and *BHL41 are explained
jointly)
When removing the piston cap from the piston, use care not to
scratch the piston.
BR-3-16
REASSEMBLY
REASSEMBLY
<WHEEL CYLINDER>
j5 Piston cup (Unit names BLL41 and BHL41 are explained
jointly)
Install the piston cup to the piston using piston cup guide.
Unit name Piston cup guide
CBR1-102
BLL41 99866 Z0008
*BHL41 99866 Z0004
j4 Back-up ring (Unit names BLL41 and BHL41 are explained

jointly)
Install the back-up ring so that the side stamped with the red letter
faces the piston cup.
<WHEEL BRAKE>
j
21 Unit name BLL41
j
17 Unit name *BHL41 }Adjuster cam assembly
Apply bearing grease sparingly when installing.
CBR1-039
j
j
15 Unit name BLL41
11 Unit name *BHL41 } Cam spindle pin
Install the cam adjuster spindle pin using adjusting cam assembly
spring tool (99842 Z0000).
NOTE
+ When installing the spindle pin, do not compress the
spring more than 1 mm (0.04 in) from its installed length.
CBR2151B
BR-3-17
j
8 Unit name BLL41
j
5 Unit name *BHL41 } Brake shoe assembly
apply bearing grease sparingly to the inner surface (groove) of the
bushing and the two grooves of the anchor pin.
NOTE
+ After installing the brake shoe assembly, attach a band or
ring [410 mm (16.14 in) in inside diameter] to the edge of
the brake lining.
CBR1116F
j
j
5 Unit name BLL41
2 Unit name *BHL41 } Lock washer
After tightening the bolt to specifications, bend the lock plate
sharply against the flat bolt head.
: 21 - 34 N·m {2.1 - 3.5 kgfzm, 15 - 25 ftzlbf}
CBR1006D
j4 Return spring assembly (Unit name BLL41 only)

Install the return spring using the spring tool (99867 Z0001).
NOTE
CBR2-151
j1 Return spring assembly (Unit names BLL41 and *BHL41

are explained jointly)
1. Install the return spring using the spring tool (99867 Z0000).
NOTE
INSTALLATION
(Refer to the ‘‘REAR AXLE’’ section for procedures.)
3. Install the brake hose or tube onto the rear axle housing. Then,
install the brake hose or tube on the bracket side (frame side).
NOTE
ing it.
4. Bleed the air from the brake line.
BR-3-18
(For detailed information on bleeding the air from the brake line,
refer to the ‘‘BRAKE UNITS’’ section.)
5. Install the rear road wheel.
BR-3-19
INSPECTION BHL41, BLL41, *BHL41
INSPECTION
+ Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
+ If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BRAKE DRUM
Inside diameter
Unit: mm (in)
Maintenance standard Service limit
410 (16.14) 414 (16.30)
Out-of-roundness
To check, measure the inside diameter of the drum at four places.
If the difference between the maximum and minimum values
exceeds the service limit, machine the inner surface of the drum to
correct.
Unit: mm (in)
Less than 0.025 (0.0010) 0.20 (0.0079)
CBR1040B
Checking brake drum inner surface

Check the brake drum for wear (scores, uneven wear and stepped
wear on the inside face of drum), heat cracks, and damage.
NOTE
+ Light heat cracks or stepped wear may be corrected by
re-grinding the drum inner surface within the service limit.
If unable to correct by re-grinding, replace the brake drum
with a new one.
CBR1-132
BRAKE LINING
Brake lining thickness
Unit: mm (in)
Maintenance
Service limit Remarks
standard
16.0 (0.630) 5.0 (0.197) Remaining thickness (H)
CBR1137A
BR-3-20
BRAKE SHOE
Anchor pin outside diameter
Unit: mm (in)
30.0 (1.181) 29.85 (1.1752)
CBR1-139
Brake shoe bushing inside diameter

Unit: mm (in)
30.0 (1.181) 30.15 (1.1870)
EBR076A
Clearance between anchor pin and brake shoe bushing

Unit: mm (in)
0.07 - 0.20
0.25 (0.0098)
(0.0028 - 0.0079)
WHEEL CYLINDER
Clearance between wheel cylinder and piston
Unit: mm (in)
Unit name Maintenance standard Service limit
0.120 - 0.234
BHL41
(0.0047 - 0.0092)
0.128 - 0.248
BLL41 0.25 (0.0098)
(0.0050 - 0.0098)
0.104 - 0.205
*BHL41
(0.0041 - 0.0081)
BR-3-21
Tension
Unit: N {kgf, lbf}
Maintenance Service
Unit name Remarks
standard limit
549 - 637 Measure tension when
BHL41 {56.0 - 65.0, — spring is set at 219.0 mm
123 - 143} (8.62 in) in length
462.4 - 527.1 Measure tension when
Outer {47.15 - 53.75, — spring is set at 219.0 mm
104.0 - 118.5} (8.62 in) in length
BLL41
Inner {18.24 - 21.24, — spring is set at 257.7 mm
40.2 - 46.8} (10.15 in) in length
*BHL41 {47.15 - 53.75, — spring is set at 219.0 mm
104.0 - 118.5} (8.62 in) in length
BR-3-23
REPAIR AND REPLACEMENT BHL41, BLL41, *BHL41
REPAIR AND REPLACEMENT

BRAKE LINING
1. Drill away the rivet heads at the brake shoe, using a drilling
machine. Then remove the rivets and separate the lining.
CBR1-042
2. Align the lining hole with the brake shoe hole, and attach the
lining to the shoe, as shown in the figure. Secure the backing in
a vice.
NOTE
+ Start riveting the lining to the shoe at the center, and work
alternately outward to the ends.
Before riveting the lining, thoroughly remove any
scratches or irregularities from the platform of the shoe.
CBR1-043
BRAKE SHOE BUSHING

1. Drive out the bushing.
2. Remove all dirt and foreign matter from the brake shoe bushing
hole.
3. Tap the bushing into the brake shoe.
After press-fitting the bushing, measure the bushing inside
diameter. If it is over 30.00 to 30.05 mm (1.1811 to 1.1831 in),
ream the bushing so that the inside diameter is within the
standard value.
NOTE
+ Do not coat the shoe bushing with grease or oil. EBR079A
BR-3-24
ADJUSTMENT BHL41, BLL41, *BHL41
ADJUSTMENT
ADJUSTING THE LINING CLEARANCE
1. Jack up the axle and make sure that there is no play at the
wheel bearing.
2. Remove the back plate grommet, and insert a 0.3 to 0.4 mm
(0.012 to 0.016 in) feeler gauge.
3. Rotate the adjuster cam from the ‘‘START’’ position in the
direction of the arrow, until resistance is felt when pulling out
the feeler gauge.
Unit: mm (in)
CBR1115E
0.3 - 0.4 (0.012 - 0.016) —
NOTE
+ Rotate the drum to check the clearance all around the
brake drum, and make adjustments where the clearance is
the smallest.
4. Adjust the clearance of the other lining similarly.

5. Rotate the drum by hand to ensure the lining doesn’t drag.
NOTE
+ If the indicator needle does not point to ‘‘END’’ after
adjustment, replace the lining with a new one.
After the lining has been replaced, return the indicator
needle to the ‘‘START’’ position.
CBR1115F
BR-3-25
FRONT BRAKE (UNIT NAME FB43, BAL41) FB43, BAL41, RB41, BPL41
DISASSEMBLY
REMOVAL
2. Remove the front road wheels.
3. Remove the brake hose from the bracket side (frame side).
Then, remove the brake hose from the wheel brake side.
NOTE
ing it.
BR-4-3
Unit name BAL41
EBR083A
>.j
1 Return spring assembly j8 Roller j
15 Camshaft spacer
>j
2 Lock washer j9 Cotter pin j
16 Felt ring
j
3 Lock plate j
10 Clevis pin j
17 Camshaft
j
4 Anchor pin j
11 Retaining ring j
18 Back plate
>j
5 Brake shoe assembly >j
12 Wear indicator j
19 Brake bracket
j
6 Clip j
13 Camshaft spacer >j
20 Brake chamber assembly
>j
7 Roller pin >.j
14 Slack adjuster assembly
BR-4-5

j1 Return spring assembly (Unit names FB43 and BAL41 are
explained jointly)
Remove the return spring assembly by using a spring tool (99867
Z0000).
NOTE
+ Attach a band or ring [410 mm (16.14 in) in inside diameter]
to the edge of the brake lining to prevent it from expand-
ing.
CBR1005G
j
j
15 Unit name FB43
14 Unit name BAL41 } Slack adjuster assembly
If the slack adjuster assembly is hard to remove, take it off using a
puller.
NOTE
+ To rotate the auto slack adjuster, remove the fitting, gas-
ket, spring and guide pawl. Take care not to lose the
removed parts. (Unit name BAL41 only)
CBR1023E
REASSEMBLY
REASSEMBLY
j
j
22 Unit name FB43
20 Unit name BAL41 } Brake chamber assembly
Before installing the brake chamber assembly, make sure dimen-
sion ‘‘L’’.
Unit: mm (in)
Unit name Dimension ‘‘L’’
WBR005A
FB43 163 (6.42)
BAL41 225 (8.86)
: 81 - 108 N·m {8.3 - 11.0 kgfzm, 60 - 80 ftzlbf}

(Chamber size #20)
167 - 186 N·m {17.0 - 19.0 kgfzm, 123 - 137 ftzlbf}
(Chamber size #24)
j14 Slack adjuster assembly (Unit name BAL41 only)

When rotating the auto slack adjuster to connect it with the brake
chamber assembly, remove the fitting, gasket, spring and guide.
Be careful not to lose the removed parts.
CBR1023E
BR-4-6
j
j
13 Unit name FB43
12 Unit name BAL41 } Wear indicator
Install the wear indicator by aligning it with the arrow mark on the
camshaft.
CBR1023G
j6 Roller pin (Unit name FB43 only)

1. Face the clip in the direction shown in the figure.
2. When installing the roller pin, be careful not to scratch the roller
oil seal.
WBR006A
j7 Roller pin (Unit name BAL41 only)

Pay attention to the direction of the roller pin during installation.
After installation, check the roller for smooth rotation.
NOTE
+ Do not apply grease to any part of the roller and roller pin.
CBR1067D
j
j
4 Unit name FB43
}
5 Unit name BAL41 Brake shoe assembly
apply bearing grease sparingly to the inner groove of the bushing
and anchor pin grooves (two places).
NOTE
+ After installing the brake shoe assembly, attach the band
or ring [410 mm (16.14 in) in inside diameter] to the edge of
the brake lining.
CBR1116F
j2 Lock washer (Unit name BAL41 only)

After tightening the bolt, bend the lock washer sharply against the
bolt head.
: 21 - 34 N·m {2.1 - 3.5 kgfzm, 15 - 25 ftzlbf}
CBR1006D
BR-4-7
j1 Return spring assembly (Unit names FB43 and BAL41 are

explained jointly)
1. Install the return spring assembly using spring tool (99867
Z0000).
NOTE
CBR1005G
INSTALLATION
3. Install the brake hose on the wheel brake side. Then, install the
brake hose on the bracket side (frame side).
NOTE
ing it.
4. Install the front road wheel.
BR-4-8
REAR BRAKE (UNIT NAME RB41, BPL41) FB43, BAL41, RB41, BPL41
REAR BRAKE (UNIT NAME RB41, BPL41)

CONSTRUCTION
Unit name RB41
EBR081A
BR-4-9
DISASSEMBLY
REMOVAL
2. Remove the rear road wheels.
3. Remove the brake hose or tube from the bracket side (frame
side). Then, remove the brake hose or tube from the rear axle
housing side.
NOTE
ing it.
BR-4-12
Unit name BPL41

<Type I>
EBR085A
>.j
1 Return spring assembly >j9 Roller pin j17 Camshaft spacer
>.j
2 Return spring assembly j
10 Roller j18 Felt ring
j
11 Cotter pin j19 Camshaft
>j
4 Lock washer j
12 Clevis pin j20 Ring
j
5 Lock plate j
13 Retaining ring j21 Back plate
j
6 Anchor pin >j
14 Wear indicator >j
22 Brake chamber assembly
>j
7 Brake shoe assembly j
15 Camshaft spacer >j
23 Brake chamber bracket
j
8 Clip >.j16 Slack adjuster assembly j
24 Brake bracket
BR-4-14
INSPECTION FB43, BAL41, RB41, BPL41
INSPECTION
+ Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
+ If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BRAKE DRUM
Inside diameter
Unit: mm (in)
410 (16.14) 414 (16.30)
Out-of-roundness
To check, measure the inside diameter of the drum at four places.
If the difference between the maximum and minimum values
exceeds the service limit, machine the inner surface of the drum to
correct.
Unit: mm (in)
Less than 0.025 (0.0010) 0.20 (0.0079)
CBR1040B
Checking brake drum inner surface

Check the brake drum for wear (scores, uneven wear and stepped
wear on the inside face of drum), heat cracks, and damage.
NOTE
+ Light heat cracks or stepped wear may be corrected by
re-grinding the drum inner surface within the service limit.
If unable to correct by re-grinding, replace the brake drum
with a new one.
CBR1-132
BRAKE LINING
Brake lining thickness
Unit: mm (in)
Maintenance
Unit name Service limit Remarks
standard
FB43, RB41 15.0 (0.591)
5.0 (0.197) Remaining thickness (H)
BAL41, BPL41 16.0 (0.630)
CBR1137A
BR-4-21
INSPECTION FB43, BAL41, RB41, BPL41
Tension
Unit: N {kgf, lbf}
Ser-
Maintenance
Unit name vice Remarks
standard
data
548 - 646 Measure tension when spring
FB43 {55.9 - 65.9, — is set at 209.0 mm (8.23 in)
123 - 145} in length
Inboard type {56.0 - 65.0, — is set at 219.0 mm (8.62 in)
BAL41
Outboard
{55.5 - 65.5, — is set at 219.0 mm (8.62 in)
type
Measure tension when spring
783.6
RB41 — is set at 250.0 mm (9.84 in)
{79.9, 176.2}
in length
Outer {56.0 - 65.0, — is set at 219.0 mm (8.62 in)
In- 123 - 143} in length
board
type 198 - 233 Measure tension when spring
BPL41 Inner {20.2 - 23.8, — is set at 252.5 mm (9.94 in)
45 - 52} in length
Outboard
{70.5 - 83.5, — is set at 219.0 mm (8.62 in)
type
BR-4-26
REPAIR AND REPLACEMENT FB43, BAL41, RB41, BPL41
REPAIR AND REPLACEMENT

BAKE LINING
1. Drill away the rivet heads at the brake shoe, using a drilling
machine. Then remove the rivets and separate the lining.
CBR1-042
2. Align the lining hole with the brake shoe hole, and attach the
lining to the shoe, as shown in the figure. Secure the backing in
a vice.
NOTE
+ Start riveting the lining to the shoe at the center, and work
alternately outward to the ends.
Before riveting the lining, thoroughly remove any
scratches or irregularities from the platform of the shoe.
CBR1-043
BRAKE SHOE BUSHING

<UNIT NAME BAL41 AND BPL41>
hole.
standard value.
EBR079A
NOTE
+ Do not coat the shoe bushing with grease or oil.
<UNIT NAMES FB43 AND RB41>
hole.
NOTE
+ Do not coat the shoe bushing with grease or oil.
BR-4-27
REPAIR AND REPLACEMENT FB43, BAL41, RB41, BPL41
CAMSHAFT BUSHING
<UNIT NAME FB43>
1. Remove the oil seal from the brake bracket.
2. Drive out the camshaft bushing from the brake bracket.
3. Remove all dirt and foreign matter from the brake bracket
bushing hole.
4. Press-fit the new bushing and oil seal onto the brake bracket.
WBR029A
<UNIT NAME BAL41>

bushing hole.
standard value.
CBR1-170
NOTE
+ When press-fitting the rear side bushing, align the bushing
hole with the grease hole in the brake bracket.
<UNIT NAME RB41>

bushing hole.
EBR095A
EBR096A
BR-4-28

BR 1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BR 1

Uploaded by

Copyright:

Available Formats

SERVICE DATA BRAKE PROPER

REAR WHEEL BRAKE

WHEEL BRAKE ABBREVIATION BRAKE OPERATING SYSTEM MODEL CLASSIFICATION

FB Front wheel brake 4 Air brake for large-sized vehicles

RB Rear wheel brake

TYPE CLASSIFICATION DRUM SIZE

Inner 178.9 - 208.3 Measure tension when — j — — — — —

*1 549 - 637 Measure tension when

Outer 549 - 637 Measure tension when

Inner 198 - 233 Measure tension when — — — — — — j

*2 691 - 819 Measure tension when

Return spring tool assembly Used to remove/install return

Return spring tool assembly Used to remove/install return

Adjusting cam assembly spring tool Used to remove/install brake

Piston cup guide Use as a guide when installing

= BRAKE PROPER (UNIT NAME BHL41, BLL41, *BHL41) =

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

Key point of disassembly

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j11 Cam spindle pin

j5 Brake shoe assembly

j1 Return spring assembly

REAR BRAKE (UNIT NAME BLL41, *BHL41)

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

Key point of disassembly

Unit name *BHL41

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

Key point of disassembly

j4 Back-up ring (Unit names BLL41 and BHL41 are explained

j4 Return spring assembly (Unit name BLL41 only)

j1 Return spring assembly (Unit names BLL41 and *BHL41

Checking brake drum inner surface

Brake shoe bushing inside diameter

Clearance between anchor pin and brake shoe bushing

REPAIR AND REPLACEMENT

BRAKE SHOE BUSHING

4. Adjust the clearance of the other lining similarly.

Unit name BAL41

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

Key point of disassembly

: 81 - 108 N·m {8.3 - 11.0 kgfzm, 60 - 80 ftzlbf}

j14 Slack adjuster assembly (Unit name BAL41 only)

j6 Roller pin (Unit name FB43 only)

j7 Roller pin (Unit name BAL41 only)

j2 Lock washer (Unit name BAL41 only)

j1 Return spring assembly (Unit names FB43 and BAL41 are

REAR BRAKE (UNIT NAME RB41, BPL41)

Unit name BPL41

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

Checking brake drum inner surface

REPAIR AND REPLACEMENT

BRAKE SHOE BUSHING

<UNIT NAME BAL41>

<UNIT NAME RB41>

You might also like