SECTION 4 BRAKE SYSTEM

Group 1 Structure and Function -------------------------------------------------------------------------------------- 4-1

Group 2 Operational Checks and Troubleshooting -------------------------------------------------------- 4-9
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-13
Group 4 Disassembly and assembly ------------------------------------------------------------------------------ 4-14
 SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
1) BRAKE VALVE TYPE

1
2

C
A

Inlet
B A

Brake pipe

Outlet Rear axle

D

Port Port name Port size

A To service brake 9/16-18UNF
Transmission
B To parking brake 7/8-14UNF
C To differential lock 7/16-20UNF
Hand operated release for
D -
parking brake

H940S4WS4BS01-1

1 Brake pedal & bracket assembly 2 Reservoir tank assembly

3 Brake master valve

4-1
2. SPECIFICATION
1) SERVICE BRAKES
Item Specification
Type Oil-immersed multi-plate disc, self-adjust
Actuation Hydraulic servo assisted.
Location Inside the rear axle center casing (2 brake packs).

2) BRAKE VALVE
Item Specification
Type Boosted brake master cylinder.
Number of cylinders 2
Piston diameterÝstroke ͚31.75Ý28.58 mm

3) PARKING BRAKE
Item Specification
Type Oil-immersed multi-plate disc.
Actuation Hydraulic
Location Inside the rear axle input casing.

4-2
3.. BRAKE VALVE
1) STRUCTURE

11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22
3 23

2 24

1 26 25

H940CB4SM01

1 Push rod 10 Hydraulic tank plug 19 Seal

2 Check ball 11 Spring 20 Spring
3 Land 12 Brake port, LH 21 Spring
4 Inlet port 13 Spool 22 Inlet port
5 Spring 14 Brake port, RH 23 Land
6 Spring 15 Spring 24 Check ball
7 Seal 16 Hydraulic tank port 25 Push rod
8 Piston 17 Valve assembly 26 Hydraulic system port
9 Valve assembly 18 Piston

4-3
2) OPERATION
(1) Neutral position (brakes released)

11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22
3 23

2 24

1 26 25

Left pedal contact Right pedal contact

Unrestricted Flow
Atmospheric Pressure
H940CB4SM02

Oil from the hydraulic system enters ports (4 & 22) separately. This oil flows through land areas (3
& 23), through the center of pistons (8 & 18) and on to the hydraulic system reservoir port (26).
The two halves of the master cylinder reservoir are open to one another. Hydraulic oil enters the
master cylinder reservoir at port (16). A small flow of oil through the attached connection keeps the
master cylinder reservoir full.
In the neutral position, pistons (8 & 18) are fully retracted and valve assemblies (9 & 17) are open.
The brake system is at reservoir pressure through brake ports (12 & 14).
Pedals are held in the neutral position by springs (5 & 6) and springs (20 & 21).

4-4
(2) Both pedals applied

11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22

3 23

2 24

1 26 25

Left pedal contact Right pedal contact

Modulated Pressure
Unrestricted Flow
Brake System Pressure
Atmospheric Pressure H940CB4SM03

Oil from the hydraulic system enters ports (4 & 22) separately and drains to hydraulic system
reservoir port (26). Both pedals are depressed forcing springs (5 & 21) to compress. Oil flowing
through land areas (3 & 23) becomes restricted. Oil flow moves to close check balls (2 & 24).
Restricted oil flow at lands (3 & 23) causes pressure to act against the large diameter of pistons (8
& 18). Pistons (8 & 18) move to compress springs (6 & 20). As more push rod displacement
occurs, valve assemblies (9 & 17) close, stopping brake system oil from moving to reservoir or
atmosphere pressure. Additional movement of the push rods and pistons (8 & 18) forces brake
system oil to the brakes causing brakes to fill through ports (12 & 14). If the brakes consume
slightly different amounts of oil, spool (13) moves against either spring (11 or 15) to satisfy the
original amount of brake oil of which ever side has the most required.
After the brakes are filled, higher brake pressure is developed by the inlet oil pressure being
modulated at lands (3 & 23), causing piston (8 & 18) to generate a higher pressure at the brake
ports. Brake pedal mod- ulated feel is determined by the hydraulic areas of push rods (1 & 25) and
modulated pressure at lands (3 & 23).
Maximum boosted brake pressure is limited by the inlet oil pressure at ports (4 & 22).
Additional pedal effort can cause higher brake pressure and is dependent only by the amount of
pedal force applied.

4-5
(3) One pedal applied

11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22

3 23

2 24

1 26 25

Right pedal contact

Left pedal contact

Modulated Pressure
Unrestricted Flow
Brake System Pressure
Atmospheric Pressure
H940CB4SM04

When only one pedal is applied, the opposite side brake remains at reservoir pressure. This
system works the same as described in Figure 2 except piston (13) moves full stroke then stops
and brake pressure is developed by the same means as described in both pedals applied. The
effort required on one pedal is one half that of the effort when applying both pedals to obtain the
same brake pressure.

4-6
(4) Both pedals applied (power-off condition)

11 12 13 14 15

10 16

9 17

8 18

7 19
6 20
5 21
4 22
3 23

2 24

1 26 25

Left pedal contact Right pedal contact

Atmospheric Pressure
Brake System Pressure
H940CB4SM05

When the engine in not running (power-off condition) one or both brakes can be actuated manually.
When push rods (1 & 25) are displaced by the pedals, springs (5 & 21) compress until lands (3 &
23) are mechanically closed. Additional push rod displacement forces pistons (8 & 18) to move.
Valve assemblies (9 & 17) close, stopping oil from going to the hydraulic reservoir. More push rod
travel fills the brakes and pressure is developed by providing pedal force. The amount of pressure
to the brake depends on how hard the pedals are pushed. When the pedals return to the neutral
position, valve assemblies (9 & 17) open and return brakes to reservoir pressure.

4-7
4. BLEEDING
1) Low pressure bleeding
① Unscrew the bleeding valve of the brake.
Rear axle
② Push the brake pedal up to the stroke's
Bleeding valve
end. (LH)
③ Screw the bleeding valve.
④ Release the brake pedal.
⑤ Wait for about 10 seconds.
⑥ Repeat point ① to ⑤ until no more air Bleeding valve
(RH)
bubbles come from the bleeding valve.

2) High pressure bleeding H940S4WSBS05

① Push the brake pedal.

② Unscrew the bleeding valve keeping the
pedal applied.
③ When the fluid has been flowed, screw
the bleeding valve.
④ Release the brake pedal.
⑤ Wait for about 10 seconds.
⑥ Repeat point ① to ⑤ until :
- No more air bubbles come from the
bleeding valve
- The applied pedal is not too spongy but
stiff (stroke quite short)

4-8