Service Brake: Model FB (Air Over Hydraulic Brake)

1 page
INDEX1
Model FB SERVICE BRAKE 13-1
13-379E-03
CHAPTER 13
SERVICE BRAKE
Model FB
(AIR OVER HYDRAULIC BRAKE)
1 Model FA (VACUUM SERVO)
TROUBLESHOOTING ............................................................... 13- 2
SPECIAL TOOL ......................................................................... 13- 4
BRAKE PIPING DIAGRAM ....................................................... 13- 5

13
INSPECTION AND ADJUSTMENT ........................................... 13- 6
FRONT AND REAR WHEEL BRAKES ..................................... 13- 11
BRAKE VALVE .......................................................................... 13- 23
BRAKE AIR BOOSTER

(FRONT WHEEL BRAKE) .................................................... 13- 35
(REAR WHEEL BRAKE) ...................................................... 13- 48
QUICK RELEASE VALVE ......................................................... 13- 69
PRESSURE REGULATOR ........................................................ 13- 72
SAFETY VALVE ......................................................................... 13- 78
CHECK VALVE .......................................................................... 13- 82
PROTECTION VALVE ............................................................... 13- 85
FINAL CHECK AND ADJUSTMENT ......................................... 13- 89
AIR DRYER................................................................................ 13- 91

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13-2 SERVICE BRAKE Model FB
TROUBLESHOOTING
Symptom Possible causes Remedy
Not enough Wheel brake and Lining is wet with grease or fluid ............. Replace the lining.
braking drum
Improper contact of drum and lining ....... Correct.
Improper lining material or ...................... Correct.
glazed lining
Deformation or hardening of drum .......... Correct or replace.
Excessively worn lining ........................... Replace.
Improper adjustment of shoe .................. Adjust hold-down nut.
Control system Leakage of brake fluid from .................... Tighten further or replace
brake system gasket.
Leakage of compressed air from ............ Tighten further or replace
Lack of brake fluid . ................................. Supply brake fluid.
Lack of compressed air pressure ............ Use properly.
due to excessive use
Improper operation of air ........................ Repair or replace.
compressor
Improper operation of brake valve .......... Repair or replace.
Improper operation of air booster ........... Repair or replace.
Clogging of brake system . ..................... Replace pipe, hose, etc.
Vapor lock in brake system ..................... Bleed air from brake line.
Brake fluid decreases Leakage of brake fluid from .................... Tighten further or replace
brake piping gasket.
Leakage of brake fluid from cylinder ....... Replace cup.
Leakage of brake fluid from .................... Replace oil seal.
push rod oil seal of air booster
Unequal or unstable braking Lining is wet with grease or fluid ............. Replace lining.
Defective lining material .......................... Replace lining.
(Improper combination)
Nonuniform lining contact ....................... Correct.
Improper adjustment of brake shoe ........ Adjust.
Nonuniform shoe clearance .................... Check the operation of the
automatic adjuster.
Distorted drums ...................................... Correct or replace.
Excessively in abrasion loss of drums .... Correct or replace.
Loose hub bearing .................................. Adjust or replace bearing.
Improper or unequal pneumatic .............. Adjust to proper pneumatic
pressure of tire pressure.
Clogging of brake system ....................... Replace pipe, hose, etc.
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Symptom Possible causes Remedy
Brake drags or Wheel brake Improper adjustment of shoe .................. Check the operation of the
does not release and drum claearance automatic adjuster.
Improper adjustment of brake shoe ........ Adjust hold-down nut.
Defective shoe return spring ................... Replace.
Control system Lack of pedal play. .................................. Adjust.

Improper return of brake pedal ............... Repair or replace.
Improper operation of brake valve .......... Repair or replace.
Defective check valve of air booster ....... Replace.
Improper operation of air booster ........... Repair or replace.
Clogging of brake system ....................... Replace pipe, hose, etc.
Brake squeal Improper lining material or ...................... Replace lining.

glazed lining.
Loose lining rivets ................................... Replace or tighten the rivet
further.
Lining rivet in contact with drum ............. Replace lining and rivet.
Deformation or wear of drum .................. Repair or replace.
Intrusion of foreign matter ....................... Clean the surface of lining
between drum and lining ......................... or replace
Loose hub bearing . ................................ Adjust or replace bearing.
Impossible to bleed air completely Oil hose between air booster and ........... Correct the bend of feed
oil reservoir bends and air trapped. pipe and let air out of the oil
reservoir.
Improper tightness of joint of .................. Tighten further or replace
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SPECIAL TOOL
Prior to starting a service brake overhaul, it is necessary to have these special tools.
Illustration Tool No. Tool name
09665-1130 ADJUSTING TOOL
09606-1040 REMOVER
09657-1400 GUIDE
09603-1430 WRENCH
09674-1040 CLAMP REMOVER
09653-1370 HOOK
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BRAKE PIPING DIAGRAM
6 7 9
3 4 5 19
8 10
11 11
23 16
13 11 15
12 17
14
2 18
20
1
21
22
19
1. Stop lamp switch 13. Air tank (Rear)

2. Brake valve 14. Air tank (Water separator)
3. Air pressure gauge 15. Air dryer (AD – 9)
4. Wheel brake (Front) 16. Protection valve
5. ABS control valve (Front) 17. Magnetic valve
6. Brake air booster (Front) 18. Pressure regulator
7. ABS control valve (Rear, right) 19. Wheel brake (Rear)
8. ABS control valve (Rear, left) 20. Low pressure warning lamp switch
9. Brake air booster (Rear, right) 21. Exhaust brake control cylinder
10. Brake air booster (Rear, left) 22. Air compressor
11. Check valve 23. Quick release valve
12. Air tank (Front)
SPLIT HYDRAULIC AIR BRAKE SYSTEM

Fig. 1 BPD-526
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INSPECTION AND ADJUSTMENT
1. BRAKE SHOE CLEARANCE

1. The brake shoe clearance adjustment of 2. Before starting adjustment of the brake
the vehicle is of an automatic adjustment shoe clearance, make sure that the
type. Though the brake shoe clearance of brake drum has been fully cooled off.
the vehicle will automatically be adjusted, 3. Check the remaining thickness of the
cheek the shoe clearance every 20,000 brake lining every 10,000 km (6,000
km (12,000 miles) or every 3 months and miles) or every 2 months and when
if the clearance is out of assembly stand- performing brake shoe clearance
ard, check the operation of the automatic check.
adjuster and adjust it by the method ex- NOTE:
plained in this section. The adjusting method is identical for all
of front and rear wheels.
WARNING
Failure to properly adjust the brakes can result in
personal injury and/or property damage.
4. Check the bake shoe clearance.

Assembly Standard: 0.25 – 0.6 mm (0.010 – 0.023 in.)
5. Adjust the clearance between the brake lining and
brake drum.
a. Raise the truck until the tires clear the floor.
b. Turn the brake drum in the forward direction and
stabilize the shoe by stepping on the brake pedal, a
couple of times.
Fig. 1 SM13-404
c. Remove the hole plug and turn the adjusting screw
with an adjusting tool in the direction of the arrow
TOP TOP
(The arrows are marked near each hole on the
backing plate) to expand the brake shoe while turn-
REAR REAR
ing the drum (the wheel) slowly by hand, until the
drum rubs the shoe and is difficult to turn.
Special Tool: Adjusting tool (09665 – 1170)
LEFT SIDE WHEEL RIGHT SIDE WHEEL
Adjusting screw turning direction to expand shoes
Fig. 2 SM13-354
d. Then turn the adjusting screw 10 to 14 notches in
the direction opposite the arrow, so the drum rotates
freely without drag.
Front : 10 – 14 notches.
Rear : 10 – 14 notches.
Special Tool: Adjusting tool (09665 – 1170)
NOTE: ● There are two adjusting points for each
wheel.
Fig. 3 SM13-577
● Be sure to adjust both points.
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e. Turn the brake drum in the forward direction and sta-

bilize the shoe by stepping on the brake pedal, a
couple of times.
f. Be sure that the drum rotates freely without drag. If
there is any dragging, repeat the operation from b.
g. Install the hole plug securely.
Fig. 4 SM13-404
2. REMAINING THICKNESS OF LINING
Inspection holes have been drifted in the brake backing
plate. Remove the rubber plug and check the wear of the
brake lining. if the lining has been worn to the indent mark-
ing which indicates the limit of wear or if it is foreseen
that the lining will be worn to the indent marking by the
INSPECTION HOLD
time of the next inspection, replace the lining with a new
one. After the inspection is over, securely install the rub-
ber plug.
Fig. 5 SM13-715
WARNING
If a lining which has become thinner than the limit
BRAKE SHOE marking is left unreplaced, the drum may be dam-
aged by the rivet head and the braking force will be
badly degraded. Be sure to check carefully the worn
INSPECTION states of the brake linings of all wheels.
HOLE
LIMIT
MARKING
BRAKE LINING
Fig. 6 SM13-180
3. FLUID LEAK AND AIR LEAK c) Check that the hoses are not deterio-
1. Check for fluid leaks. rated, deformed, or swollen.
a. Fluid leaks from lines. NOTE:
With the brake pedal depressed, visu- As a general rule, the hoses should be
ally check for leaks of brake fluid from replaced with new ones every year.
the brake hydraulic line including the Whenany defects as above have been
pipes, connection, hoses, etc. If any found, replace immediately with new
leak is found, repair or replace with the ones.
corresponding parts.
b. When checking for leaks, check also
the following items and repair or re-
place with the corresponding parts as
required.
a) Check that the pipes and hoses are not
hitting or rubbing other parts. Check
that the pipe clips are not loose.
b) Check that the pipes have no cracks
and that they have not become rusty.
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c. Fluid leaks from components other than lines. • Check the function of the protection valve, ex-
a) Check the wheel cylinder. plained in Section “PROTECTION VALVE”.
If the trouble cannot be corrected through the e. If both “a” and “b” are abormal, check the
above procedure, rise the air pressure to 8.5 items listed below.
kg/cm2 (120.87 lb/sq.in.), and depress the • Check for air leak from the air tank.
brake pedal fully. In this condition, if the level • Check for air leaks from pipes, hoses, and
of brake fluid in the reservoir gradually goes connections of piping between the air tank
down, it is possible that brake fluid is leaking and the brake valve.
through the rubber cup in the wheel cylinder. • Check the function of the brake valve ex-
Disassemble and inspect the wheel cylinder plained in Section “ BRAKE VALVE “ .
in the wheel brake as explained in Section
f. If “c)” is abnormal, check the items listed
“WHEEL CYLINDER”.
betow.
b) Check the air booster • Check for air leakes from pipes and con-
If no leak is found in the lines or items a) above, nections of piping between the brake valve
it is possible that brake fluid is leaking through and the air booster.
the booster hydraulic cylinder cup or push rod • Check the function of the brake valve, ex-
oil seal. Disassemble and inspect the parts plained in Section “BRAKE VALVE”.
as explained in Section “BRAKE AIR • Check the function of the air booster,
BOOSTER” and replace them as required. explainecl in Section “AIR BOOSTER”.
2. Check for air leaks NOTE: When checking for air leaks, use soapy
a. Confirming that the air pressure gauge fully water.
indicates zero, start the engine and let it idle, g. When checking for leaks, also check the
and measure the time it takes for the air pres- folowing items and repair or replace with the
sure gauge to reach an indication of 8.5 corresponding parts as required.
kg/cm2 (120.87 lb/sq.in.). a) Check that the pipes and hoses are not hitting
Charging time: other parts. Check that the pipe clips are not
Within 14 minutes loose.
b) Check that the pipes have no cracks and that
b. Rise the air pressure until the air pressure they have not become rusty.
gauge reaches an indication of 8.5 kg/cm2
c) Check that the hoses are not deteriorated,
(120.87 Ib/sq.in.); if there is no drop in air pres-
deformed, or swollen.
sure for a period of one minute, it is normal.
NOTE: As a general ruse, the hoses should
c. Next, depress the brake pedal fully, if there is be replaced with new ones every two
no drop in air pressure for a period of one year.
minute, it is normal. When any such defects as above have
d. If “a)” is abnormal but “b)” is normal, check been found, replace immediately with
the items listed below. new ones.
• Check the idling speed of engine.
• Check the function of the air compressor,
explained in CHAPTER 23, AIR COM-
PRESSOR.
• Check for air leakes from pipes and connec-
tion of piping between the air compres-sor
and air tank.
• Check the function of the pressure regula-
tor, explained in Section “PRESSURE
REGULATOR”.
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4. BRAKE FLUID
The brake fluid reservoir is located on the primary
and secondary brake lines, mounted on the right side
MAX
frame.
MIN
When the brake fluid is used for a long time, water
may get into the brake fluid and its boiling point may
become low, thereby causing a possibility of vapor
lock which is very dangerous. Replace old brake fluid
with fresh brake fluid (Use DOT3 or DOT4 brake
Fig. 7 SM13-619 fluid) every year.
1. Hydraulic brake fluid color check 2. Brake filuid level check
● Check the color of the brake fluid in NOTE:
the brake fluid reservoir. ● Check the fluid level of the brake fluid res-
● Check that the color is as specified by ervoir which is located at the right side
FMVSS116 (transparent or amber). frame. If the fluid level has fallen below the
● Replace the brake fluid if it has become MIN line of the reservoir, replenish the
discolored. brake fluid to the MAX line. For replenish-
● Probable causes of discoloration are as fol- ment, USE DOT3 OR DOT4 BRAKE FLUID.
lows:
● Thermal Carl
● Aging
● Oxidation
● Contaminated with mineral oil
● Be sure to use clean brake fluid. Note that if • Brake fluid is highly hygroscopic and ab-
a foreign substance is mixed with the brake sorbs moisture. Be sure to securely tighten
fluid,components of the brake line may be the caps of the containers to prevent en-
damaged and their functions may be try of moisture.
degraded,thereby causing insufficient brak- • Do not leave the reservoir cap removed
ing force. for a long time.
• Before removing the brake fluid reservoir • When replenishing or replacing brake fluid
cap, clean the vicinity of the cap. outdoors on a rainy day, exercise care so
• If foreign matter has settled on the bottom that no water gets into the brake fluid.
of the reservoir, clean the reservoir. • Pay attention that no mineral fluid is mixed
• Check that the container and tools used for into brake fluid. Mineral oil will cause
brake fluid replenishment are clean. If they swelIing of the rubber parts of the brake
are dusty or dirty, clean them.
line,causing insufficient braking force.
• Be sure to clean the strainer of the reser-
• Do not mix different types of brake fluid.
voir when replacing the brake fluid.
5. BRAKE WARNING LAMPS
AIR PRESSURE PARKING BRAKE
WARNING LAMP WARNING LAMP
1. Check for brake warning lamp failure
Turn the starter switch to the “H” position.
BRAKE
If the lamps do not turn on, they have failed. Replace
BRAKE any failed lamp with a new one.
FLUID If the “BRAKE” lamp does not turn on when the starter
switch is turned to the ON position with the parking
BRAKE FLUID LEVEL AND
brake applied, the “BRAKE” lamp has failed. Replace
STROKE WARNING LAMP
it with a new one.
Fig. 8 SM13-620
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CAP
2. Check the brake fluid level warning switch.
STRAINER A fluid level switch is provided for the brake fluid res-
INSPECTION HOLE ervoir. When the fluid level has fallen, the float falls,
LEAD SWITCH the magnet of the float is brought closer to the lead
FLOAT switch, a magnetic flux passes through the lead
RESERVOIR
switch, the lead switch turns on, and the “BRAKE
STOPPER
FLUID” warning lamp on the meter panel turns on
and the buzzer sounds.
NOTE: The buzzer does not sound as long as the
Fig. 9 KMT-C012 parking brake is applied.
a. Even when the reservoir is filled with brake 3. Check the air pressure warning lamp
fluid, the trip point of the level warning switch a. The air tank has an air pressure warning lamp
can be checked by removing the reservoir cap switch. When the air pressure in the tank has
and strainer, and inserting a bar through the fatten below 5.0 kg/cm2 (71.10 lb/sq.in.), the
hole to submerge the float. switch activates the warning lamp and the
buzzer.
b. Notes for inspection b. Inspection procedure
a) Since the contact rating of the switch is small, a) Run the engine until the air pressure gauge
it must be tested in combination with the nor- indicates 8.5 kg/cm2 (120.87 lb/sq.in.).Stop
mal circuit and normal parts. Note that the the engine and leave the starter switch in
switch contact may be damaged if the lamp the “ON” position.
alone is used for testing. Also note that, even
when the normal circuit is used, the switch or b) Observing the air pressure gauge on the in-
the diode in the controller may be damaged strument panel, press the brake pedal re-
if the rating of the lamp is large. peated fly.
b) The lead switch (alarm switch) will turn ON
at any position of the float so far as it is lower c) Check that the warning lamp turns on when
than the set fluid level. By moving the float the air pressure gauge reading has become
when inspecting the trip point of the switch, lower than 5.0 kg/cm2 (71.10 Ib/sq.in.). In this
cheek that the alarm operation continuously state, release the parking brake and check
covers the full range from the starting point that the buzzer sounds.
of alarm to the point where the float hits the NOTE: The buzzer does not sound as long
stopper. If any discontinuity is found, replace as the parking brake is applied.
the reservoir assembly. d) If neither the warning lamp nor the buzzer op-
erates, check the wiring. If the wiring is all
right, replace the switch.
4. Piston stroke detector and warning switch.

Depress the brake pedal and then loosen the bleeder
of the brake air booster hydraulic cylinder.
NOTE: Insert a vinyl tube to the bleeder plug, and
take care not to splatter brake fluid.
Under this condition, check that the warning lamp
lights up and buzzer sounds.
parking brake is applied.
Fig. 10 SM13-398
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FRONT AND REAR WHEEL BRAKES
1 6 7 8 9
10
5
2 11
2
12
21
4 13
20 14
3 15
19
16
18
4 17
14
14
35
33 34
31 32
30
29
28
27
26
36
25 37
24
23
22
SM13-655 SM13-1242
FRONT WHEEL BRAKE

1. Oil pipe joint 14. Wheel cylinder assembly 27. Backup ring
2. Grommet 15. Retracting spring 28. Piston cup
3. Oil pipe 16. Spring cover 29. Cone spring
4. Hole plug 17. Brake drum 30. Drive ring
5. Backing plate 18. Bracket 31. Adjuster shaft assembly
6. Adjuster lock spring 19. Sleeve 32. O-ring
7. Adjusting nut 20. Sensor 33. Locater spring
8. Rivet 21. Clip 34. Locater
9. Brake lining 22. Piston head 35. Cylinder
10. Brake shoe 23. Piston head retainer 36. Air bleeder screw
11. Hold down washer 24. Adjuster wheel 37. Bleeder cap
12. Hold down nut 25. Boot
13. Cotter pin 26. Piston
Fig. 1
1 page 1
1
1 19
2
18
16 6 8
7 9
10
17
5
11 12
3 6
4 13
14
5
27
34
26 23 15
25
24
24
23 25
22 26
31
21
20
29
28
30 32
33
SM13-1243
SM 13-657
REAR WHEEL BRAKE

1. Grommet 13. Retracting spring 25. Backup ring
2. Oil pipe 14. Spring cover 26. Piston cup
3. Hole plug 15. Brake drum 27. Adjuster shaft assembly
4. Backing plate 16. Holder 28. Locater spring
5. Wheel cylinder assembly 17. Sleeve 29. Locater
6. Cotter pin 18. Sensor 30. O-ring
7. Adjusting nut 19. Clip 31. Cylinder
8. Rivet 20. Piston head 32. Air bleeder screw
9. Brake Iining 21. Piston head retainer 33. Bleeder cap
10. Brake shoe 22. Adjuster wheel 34. Drive ring
11. Hold down washer 23. Boot
12. Hold down nut 24. Piston
Fig. 2
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REMOVAL
1. REMOVAL OF FRONT AND REAR WHEEL BRAKES
1. Remove the wheel.

NOTE: Refer to CHAPTER 16, WHEEL AND TIRE.
2. Remove the brake drum, wheel hub assembly, wheel

hub bearing and ABS wheel sensor.
NOTE: Refer to CHAPTER 10, REAR AXLE and
CHAPTER 11, FRONT AXLE.
3. Remove the shoe retracting spring by using the spe-

cial tool. Be sure to engage the spring remover by
inserting it in the rivet holes of the lining.
Special Tool: Remover (09606-1040)
NOTE: Brake shoe assembly and wheel cylinder can
be replaced with the wheel hub remaining in-
stalled.
Fig. 3 SM13-661
4. Remove the cotter pin, shoe hold down nut, and shoe
hold down washer.
Fig. 4 SM13-662
5. Remove the brake shoes.
Fig. 5 SM13-663
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6. Disconnect the hose and oil pipe from the wheel cyl-
inder, remove the fixing-bolts of the wheel cylinder,
and remove the wheel cylinder.
Fig. 6 SM13-664
7. Remove the piston, cup, boot and other parts from
– FRONT – – REAR – the wheel cylinder.
NOTE: If removing of the backing plate is necessary,
then remove the wheel hub and related parts.
Refer to CHAPTER 10, REAR AXLE and CHAP-
TER 11, FRONT AXLE.
Fig. 7 SM13-658 SM13-657

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INSPECTION
1. INSPECT THE DRUM.
1. Inspect the drum for cracks or any other damage.
Minor scratches can be eliminated by polishing with
emery paper. To repair large flaws or rough surface,
grind the drum using a lathe. Check the drum for dis-
coloration and cracks. If any cracks are found, re-
place the drum with a new one.
Fig. 8 SM13-890
2. Measure the inside diameter.
If the inside diameter of the drum has become larger
than the service limit, replace the drum with a new
one. The service limit of the drum is indicated on the
drum.
NOTE: If the inside diameter of the drum exceeds the
repair limit, use an oversized lining.
Assembly Standard : 320 mm (12.60 in.)

Fig. 9 SM13-891 Repair Limit : 321 mm (12.64 in.)
Service Limit : 322 mm (12.68 in.)
3. Brake drum maximum braking surface diameter
marking location.
Fig. 10 SM13-892
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4. Measure the runout.

a. If runout of the drum is 0.2 mm (0.008 in.) or over,
repair it by grinding it using a lathe.
TURN THE DRUM
Standard : 0 – 0.1 mm (0 – 0.004 in.)
THIS WAY Service Limit : 0.2 mm (0.008 in.)
a) If the dimension of the ground drum exceeds the re-
pair limit shown in the table, replace the drum with a
SURFACE PLATE
new one.
b) Before installing a new drum, be sure to thoroughly
Fig. 13 SM13-173
remove the rustproof coating on the machined sur-
face.
2. INSPECT THE BRAKE SHOE ASSEMBLY FOR CRACKS

OR ANY OTHER ABNORMALITY.
1. If the lining indicates any signs of abnormality, be sure
to replace it with a new one.
2. Check the brake shoes for wear, cracks, deforma-
tion and other abnormalities. Replace them as re-
quired.
SM13-893
Fig. 14
3. MEASURE THE THICKNESS OF THE LINING.
If the lining has been worn to the limit or if it is fore-
seen that it may be worn to the limit before the next
inspection time, replace it with a new one. For brake
shoe relining, proceed as follows.
Assembly Standard : 13.0 mm (0.512 in.)
Service Limit : 4.0 mm (0.157 in.)
Fig. 15 SM13-894
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a. Removal of lining
DRILL a) Use drill smaller than the rivet diameter.
PRESS OR TAP
b) Drill the rivet caulking section of the brake shoe as-
sembly with the rivet caulking section upward.
BRAKE BRAKE
SHOE c) At this time, be careful not to damage the inner sur-
RIVET SHOE
face of the brake shoe.
d) After drilling, remove the remaining rivet head with a
LINING RIVET HEAD LINING fine chisel or rivetting machine.
Fig. 16 SM13-270
Unit: mm b. Brake shoe re-lining

Before re-lining the shoe, make sure that the surface
to be lined is free of rust or any foreign matter. Clean
φ 15 the surface with emery paper. Be sure to insert the
φ 8.5
+0.5 rivets from the lining side, so that you swage them
–0
on the shoe side.
φ 6.5
60° NOTE: ● Do not use shoes with elongated rivet
holes or bent or worn shoe web or rim.
• Insert the rivets into all the holes so
that the positions of the lining and shoe
2
are in alignment.
45°
(Attach the rivets to the lining side with
0.75
R1
R 0.2
adhesive tape to prevent losing them.)

• Stake slowly to avoid cracking the lin-
ing.
• Stake gradually while observing the
staking state, find the ideal pressure and
stake the other rivets by exerting a uni-
form pressure.
Fig. 17 Recommended configuralation of punch
SM13-171 • Staking in diagonal order is recom-
mended.
● Do not let brake fluid, oil, or grease touch
the brake lining.
• Riveting should be done sequentially
from the center of the lining. Pay atten-
tion so that the clearance between the
shoe and the lining is not greater than
0.3 mm (0.012 in.).
• Staking force of rivet: 2.4 tons
1 page 1
4. INSPECT THE SPRING FOR CRACKS OR ANY OTHER

ABNORMALITY.
1. Check the claws of the front spring cover for dam-
age or other abnormalities, and replace them as re-
quired.
2. Check the set load of the spring and replace the
spring if its set load is not within the tolerance shown
in the following table.
- FRONT - - REAR - Setting Length: Front 179.6 mm (7.071 in.)
Fig. 18 SM13-895 SM13-896A
Rear 220.6 mm (8.685 in.)
Setting Load: Front 29.7 – 36.3 kg
(65.477 – 80.027 lb)
Rear 36.9 – 45.1 kg
(81.350 – 99.427 lb)
5. INSPECT THE WHEEL CYLINDER

– FRONT – – REAR – NOTE: ● Before inspecting the parts, clean them
with isopropyl alcohol.
● Do not clean the components with mineral
oil. Mineral oil will cause swelling of the
rubber parts, thereby causing insufficient
braking force.
1. Check the parts for wear or damage.
2. Check the adjusting bolt for warp, damage or other
Fig. 19 SM13-658 abnormalities. (Check that the bolt can be lightly
turned with your fingers when it is threaded into the
piston.)
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A B
6. MEASURE THE INNER CLEARANCE OF THE WHEEL
CYLINDER.
Measure clearance between the inner surface of the
cylinder bore and the piston. If the clearance is not
within the service limit, replace the parts as required.
Clearance A–B
Standard: 0.03 – 0.13 mm (0.0012 – 0.0051 in.)
Service Limit: 0.25 mm (0.0098 in.)
Fig. 20 SM13-403 SM13-392

7. INSPECT THE BACKING PLATE
Check the backing plate and stud pins for deforma-
tion, damage and any other abnormality, and replace
them as require.
Fig. 21 SM13-308
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ASSEMBLY
– FRONT – – REAR – 1. ASSEMBLE THE WHEEL BRAKES.
1. Assemble the wheel cylinder.
NOTE: ● The rubber parts must be replaced every
year. The replacement spare parts are
available as repair kits.
● When installing the cup, exercise care not
to damage the cup.
Fig. 22 SM13-658
BACK UP RING
PISTON CUP
Fig. 23 SM13-1206
When assembling, apply rustproof oil to the cylinder
bore and apply rubber grease sparingly to the exter-
nal surface of the piston, piston grooves cylinder boot
grooves and adjusting bolts.
NOTE: ● Rubber grease and rustproof oil are avail-
able as a service parts under the following
parts
– FRONT –
No.
Rustproof oil (CCl No. 20): 04156-1010
Rubber grease (Rx-2): 04133-1080.
● The parts where the rubber grease should

be applied are shown in Fig.24 with dots.
Tightening Torque:
Bleeder screw: 70 – 120 kg·cm (5.1 – 8.6 Ib·ft)
– REAR –
Fig. 24 SM13-665
1 page 1
2. Install the wheel cylinder

Securely tighten the mounting bolts with the tighten-
ing torques shown in the table.
Bolt diameter Tightening torque
mm (in.) kg·cm (Ib·ft)
8.0 (0.315) 170 – 250 (13 – 18)
10.0 (0.394) 380 – 500 (28 – 36)
12.0 (0.472) 600 – 880 (44 – 63)
Fig. 25 SM13-666 14.0 (0.551) 1,500 – 2,000 (109 – 144)
3. Install the brake shoe assembly.

a. Apply heat-resistance grease.
Heat resistance grease:
Refer to RECOMMENDED LUBRICANTS LIST.
b. Apply grease to both ends of the shoe web contact-
ing with the piston, and to both sides of the shoe web
contacting the shoe hold washer and adjusting nut.
c. Exercise care so that the lining surface is not stained
with grease.
Fig. 26 SM13-667
4. Install the retracting spring using the special tool or
screwdriver.
After assembling the spring, check that the end of
HOOK OR the shoe web is securely set in the groove of the
BRAKE SHOE
SCREWDRIVER wheel cylinder piston. Also check that the hook of the
SHOE RETRACTING spring is securely hooked in the hole of the shoe.
SPRING
NOTE: When installing the spring, do not extend it
excessively, lest the compression force of the
spring should become weak.
Fig. 27 SM13-181 Special Tool: Hook (09653 - 1370)
5. Adjust the clearance between the hold down washer
and the shoe.
a. When assembling, apply grease amply to both sur-
faces of the washer.
b. Tighten the slotted nut and back off the nut by 1/3
turn. Then secure the nut with the cotter pin.
c. If the cotter pin cannot be inserted into the hole, turn
the slotted nut counterclockwise within 1/6 turn from
state b. to align it with the bolt hole. Be sure to use a
Fig. 28 SM13-668 new cotter pin.
6. Connect the hose (front brakes) and oil pipe (rear
brakes) to the wheel cylinder.
Tightening torque:
Hose: 450 – 600 kg·cm (33 – 43 Ib·ft)
Oil pipe: 4.76 Dia. 130–180 kg·cm
(0.187 in.) (9.4–13.0 Ib·ft)
6.35 Dia. 200 – 220 kg·cm
(0.25 in.) (14.5 – 15.9 Ib·ft)
Fig. 29 SM13-662
1 page 1
7. Install the ABS wheel sensor, wheel hub bearing,

wheel hub assembly and brake drum.
NOTE: Refer to CHAPTER 10, REAR AXLE and
CHAPTER 11, FRONT AXLE.
8. Install the wheel.

NOTE: Refer to CHAPTER 16, WHEEL AND TIRE.
ADJUSTMENT
Finally adjust the brake shoe clearance, explained
in Section “INSPECTION AND ADJUSTMENT”. (See
page 13-6)
WARNING
The specified torque should be observed for tight-
ening wheel nuts. Improperly torqued wheel nuts
can cause the wheel to come off while driving. This
can result in personal injury and/or property dam-
age due to toss of vehicle control.
When the vehicle, wheels or wheel nuts are new the
wheel nuts should be checked and tightened to
specified torque at 100, 500 and 1,000 miles since
they are not well seated. The tightening torque
should be checked with a proper torque wrench.
1 page 1
BRAKE VALVE
9
11
5
3
16 29
12
1 17
2 5
18 35
3 6
4 31
19
5 13
20 28
6 9 27
21 32
6 26
14 6
7 21
6 30 36
8 22 36
27 33
9 15
23
10 25
6
34
24
ASM13-010
1. Secondary valve body 13. Primary feed valve retainer 25. Collar
2. Secondary feed vaIve 14. Secondary piston 26. Roller
3. Retainer 15. Secondary piston return spring 27. Pivot pin
4. Secondary feed valve return spring 16. Sub spring 28. Brake pedal cover
5. Spring seat 17. Shim 29. Brake pedal
6. O-ring 18. Stem 30. Adjusting screw
7. Secondary feed valve retainer 19. Main spring (inner) 31. Boot
8. VaIve seat 20. Main spring (outer) 32. Plunger
9. Retainer ring 21. Spring retainer 33. Brake valve cover
10. Check valve 22. Primary piston 34. Piston supporter
11. Primary feed valve 23. Primary piston return spring 35. Cover
12. Primary feed valve return spring 24. Primary valve body 36. Bushing
Fig. 1
1 page 1
REMOVAL
1. BRAKE VALVE
1. Remove the 3 bolts joining the brake valve cover and
brake valve body, and the 3 bolts fixing the brake
valve to the floor.
Fig. 2 SM13-903
2. Disconnect the electrical wires, remove the air pipes
and valve body from under side of floor, and remove
the pedal assembly from inside the cab.
Fig. 3 SM13-904
DISASSEMBLY
1. Remove the cotter pin and disassemble the brake
pedal assembly and cover.
Fig. 4
2. Remove the piston supporter and disassemble the
brake valve assembly.
Fig. 5 SM13-825
3. Remove the primary piston assembly, return spring
and O-ring.
Fig. 6 SM13-826
1 page 1
4. Remove the retainer ring and then remove the sub

spring assembly.
WARNING
The retainer ring is spring steel and may pop out,
wear safety glasses to protect your eyes.
Fig. 7 SM13-827
5. Remove the lock nut and then disassemble the sub
spring assembly.
Fig. 8 ASM13-011
6. Remove the bolts and then remove the secondary
valve body.
NOTE: Before removing the secondary valve body,
apply an aligning mark to primary valve body
and secondary valve body.
Fig. 9 SM13-830
7. Remove the return spring and secondary piston as-
sembly.
Fig. 10 SM13-831
8. Disassemble the secondary piston assembly.
Fig. 11 SM13-832
1 page 1
9. Remove the retainer ring, then remove the primary

feed valve retainer and primary feed valve assem-
bly.
WARNING
Fig. 12 SM13-833
10. Remove the check valve and retainer ring, then re-
move the valve seat, secondary feed valve retainer
and secondary feed valve assembly.
WARNING
Fig. 13 SM13-834
11. Disassemble the primary and secondary feed valve
assembly.
A
A : Primary
B : Secondary
Fig. 14 SM13-835
1 page 1
INSPECTION
NOTE: Before inspecting the parts, clean them with
isopropyl alcohol.
1. BRAKE PEDAL
Inspect the pivot pin for wear and L-shaped lock pin
for damage.
Fig. 15 SM13-905
2. ROLLER, PLUNGER AND RUBBER BOOT
Inspect the roller, plunger and plunger guide for wear,
and rubber boot for damage.
Fig. 16 SM13-906
3. MAIN SPRING AND SUB SPRING
Inspect the main spring and sub spring for rust and
damage, and measure the free length, setting length
and setting load.
A : MAIN SPRING
B : SUB SPRING
Assembly standard
Free length 29 mm (1.142 in.)
Fig. 17 ASM13-012 SM13-837

A Setting length 27.2 mm (1.071 in.)
Setting load 20.8 – 24.8 kg (45.86 – 54.68 lb)
Free length 23.6 mm (0.929 in.)
B Setting length 19.8 mm (0.780 in.)
Setting load 22.9 kg (54.49 lb)
4. PRIMARY PISTON AND SECONDARY PISTON

Inspect the piston slide and valve contact surface for
wear or any other damage.
Fig. 18 ASM13-013
1 page 1
5. PRIMARY AND SECONDARY PISTON RETURN

SPRING
A Inspect the return spring for rust and damage, and
measure the free length, setting length and setting
load.
A : PRIMARY PISTON RETURN SPRING
B B : SECONDARY PISTON RETURN SPRING
Assembly standard
Fig. 19 SM13-839 SM13-837 Free length 43.2 mm (1.701 in.)
B Setting length 12 mm (0.472 in.)
6. PRIMARY AND SECONDARY FEED VALVE

Inspect the rubber seat surface of each feed valve
and sideway for damage.
NOTE: Valves should be replaced once every year.
A : PRIMARY FEED VALVE
B : SECONDARY FEED VALVE
A B
Fig. 20 SM13-840
1 page 1
7. PRIMARY AND SECONDARY FEED VALVE RETURN

SPRING
A Inspect each return spring for rust and damage, and
measure the free length, setting length and setting
load.
A : PRIMARY FEED VALVE RETURN SPRING
B B : SECONDARY FEED VALVE RETURN SPRING
Assembly standard
Fig. 21 SM13-841 SM13-837 Free length 21.4 mm (0.846 in.)
B Setting length 13 mm (0.512 in.)
8. SECONDARY VALVE BODY

Inspect the secondary feed valve contact surface for
damage and wear.
Fig. 22 SM13-842
9. PRIMARY VALVE BODY
Inspect the primary and secondary piston slide sur-
face, and primary feed valve contact surface for dam-
age and wear.
Fig. 23 ASM13-014
1 page 1
ASSEMBLY
NOTE: ● When assembling the brake valve, be sure
8 to use new O-ring and valves.
1
● Apply silicone grease to the each sliding
2 surface of the assembly parts.
● The O-ring and valves of brake valve are
items to be replaced periodically.
9
Replace them every year.
3 Replacement spares are available in repair
10 kits.
4
11
12
5 6
Fig. 24 ASM13-015
1. Pivot pin, roller and collar 7. Secondary feed valve retainer O-ring
2. Plunger 8. Pivot pin
3. Primary piston 9. Brake valve cover
4. Primary feed valve 10. Primary piston O-ring
5. Secondary piston 11. Primary valve body O-ring
6. Primary feed valve retainer O-ring 12. Secondary piston O-ring
1. BRAKE VALVE
A 1. Assemble the primary and secondary feed valve as-
sembly.
A : Primary
B : Secondary
Fig. 25 SM13-835
2. Install the primary feed valve assembly and primary
feed valve retainer assembly, then fix the retainer ring.
WARNING
Fig. 26 SM13-833
1 page 1
3. Install the secondary feed valve assembly, feed valve

retainer assembly and valve seat, then fix the retainer
ring.
Install the check valve.
WARNING
Fig. 27 SM13-834
4. Assemble the secondary piston assembly.
Install three O-rings in the ring grooves of secondary
piston.
Fig. 28 SM13-845
5. Install the secondary piston assembly, piston return
spring and secondary valve body.
NOTE: Align the aligning mark on the primary body
and secondary body which was applied at dis-
assembly.
Tightening Torque: 60 – 75 kg·cm (4.4 – 5.4 lb·ft)
Fig. 29 SM13-846
1
6. Assemble the primary piston spring.
5 At this point, adjust the spring tension with the shim
keeping the dimension “A”, and tighten the lock nut.
A : 28.5 – 28.9 mm (1.122 – 1.138 in.)
2
P : Spring tension 0 – 1 kg (0 – 2.205 lb)
3 A
Tightening Torque: 30 – 50 kg·cm (2.2 – 3.6 lb·ft)
NOTE: In adjusting the spring tension, the axial play
4
of the spring must be removed.
P
Fig. 30 ASM13-1529
1. Lock nut
2. Stem
3. Sub spring
4. Shim
5. Spring seat
1 page 1
7. Install the O-ring on the primary piston.
Fig. 31 ASM13-016
8. Assemble the primary piston assembly.
Place the main springs (outer, inner) and sub-spring
assembly in the primary piston, and fix the retainer
ring.
WARNING
Fig. 32 SM13-849
9. Install the O-ring on the primary valve body.
Fig. 33 SM13-850
10. Install the primary piston assembly and return spring
together with the piston supporter.
Fig. 34 SM13-825
11. Assemble the brake pedal assembly.
NOTE: Be sure to use new cotter pin.
Fig. 35 SM13-907
1 page 1
ADJUSTMENT
1. BRAKE PEDAL
1. Fully return the adjusting screw of the brake pedal.
Fig. 36 SM13-908
2. Adjust the pedal installation height and angle with the
adjusting screw then tighten the lock nut.
1 : Brake pedal
1 2 : Adjusting screw
A A : Installation height 194–204 mm (7.64–8.03 in.)
B
B : Installation angle 36°–40°
2
Tightening Torque: 30 – 50 kg·cm (2.2 – 3.6 lb.ft)
Fig. 37 SM13-151
2. SECONDARY FEED VALVE
Measure the position of secondary feed valve with
the pedal released and at full stroke by means of a
depth gauge.
A : Secondary feed valve movement 0.8 mm
at primary fail. (0.0315 in.)
A
Fig. 38 SM13-095
3. BRAKE VALVE FUNCTION
1. Confirm that the pedal depression angle at full stroke
of the pedal is in standard value.
A
A : Pedal depression angle (Full stroke)
23° – 27°
Fig. 39 SM13-151
2. Mount the brake valve and gauges as shown and
set the pressure to the air tank for 8.5 kg/cm2 (120.8
lb/sq.in.).
4 1. Air pressure gauge (Primary line)
2. Air pressure gauge (Secondary line)
1 3. Brake valve
2 3
5 4. Air pressure gauge (Air tank)
5. Air tank
Fig. 40 SM13-151
1 page 1
3. Gradually depress the pedal to check for the point

8.5
Discharge pressure (kg/cm2)
where the pressure gauge shows the first rise.

6.2 When these valves are not fulfilled, adjust the pres-
5.4
sure with the main spring shim.
2.0
Discharge pressure:
1.4
Primary 0.1 – 0.3 kg/cm2
0.3
0.1
0
(1.422 – 4.267 lb/sq.in.)
3 5 8 11 17 20 23 27
Pedal depression angle (°)
Pedal depression angle 3° – 5°
Fig. 41 Primary line SM13-537
4. Depress the pedal still further and confirm the pres-

sures are within the specified values, while the de-
pression angle ranges from 8°–11°.
Discharge pressure:
(19.908 – 28.440 lb/sq.in.)
5. Confirm that the pressure is reached, when the pedal

is depressed at an angle of 17°–20°.
Discharge pressure:
(76.788 – 88.164 lb/sq.in.)
INSTALLATION
1. BRAKE VALVE
1. Mount the brake valve and connect the air pipes.
Fig. 42 SM13-904
2. From inside the cab, assemble the pedal assembly
to the valve body, and fix it to the floor with the bolts.
Tightening Torque:
Pedal assembly to valve body
100–200 kg·cm (8–14 lb·ft)
Pedal assembly to floor
380–500 kg·cm (28–36 lb·ft)
Fig. 43 SM13-903
1 page 1
BRAKE AIR BOOSTER

(FRONT WHEEL BRAKE)
13
11
10
9
8
7
6
5
36
13
2 18 14
12
1 37
35
17
3
34 4
16 15
18 20
21
25
22
19
23
28
26
31
27
29
30
32
33
SM13-1399
1. Nut 14. Bolt 27. Washer

2. Holder 15. Power cylinder shell 28. Backup ring
3. Exhaust cover 16. Nut 29. Retainer
4. Warning switch 17. Lock washer 30. Valve seal
5. Retainer ring 18. O-ring 31. Pin
6. Pipe joint 19. Retainer ring 32. Hydraulic cylinder
7. Retainer ring set 20. O-ring 33. Piston cup
8. Spring seat 21. Piston seal 34. Bolt
9. Spring 22. Piston 35. Hydraulic cylinder
10. O-ring 23. Compression spring 36. O-ring
11. Check valve 24. Hydraulic piston sub-assembly 37. Plate
12. Bleeder screw 25. Pin
13. Nut 26. Push rod
Fig. 1
1 page 1
REMOVAL
Disconnect the air pipes and oil pipes from the air booster.
NOTE: ● Cover the air pipe openings with tape, etc.
in order to prevent the entry of alien sub-
stances.
● Prepare a tray when removing the oil pipe
to prevent brake fluid spillage. Moreover,
cover the openings in order to prevent the
entry the alien substances.
● Be careful that the brake fluid does not
Fig. 2 SM13-1318 stain painted surfaces.
1. Remove the warning lamp switch harness connec-
tor.
Fig. 3 SM13-1318
2. Pull out the reservoir tank side oil hose.
NOTE: ● Prepare a tray to prevent brake fluid spill-
age from the hose. Moreover, cover the
openings in order to prevent the entry of
alien substances.
● Be careful that the brake fluid not stain
painted surfaces.
Fig. 4 SM13-1318
3. Remove the three nuts which attach the air booster

to the bracket and remove the air booster from the
bracket.
Fig. 5 SM13-1319
1 page 1
DISASSEMBLY
EXHAUST COVER Drain the brake fluid completely by supplying com-
HOLDER pressed air through the fluid filler opening.
1. Remove the nut and then the clamp, holder, and ex-
haust cover.
Fig. 6 SM13-1324
2. Remove the warning switch.
WARNING SWITCH
Fig. 7 SM13-1325
3. Remove the retainer ring, connector assembly,
spring, and check valve.
Fig. 8 SM13-1326
4. Remove the cap and the bleeder screw.
BLEEDER SCREW
Fig. 9 SM13-1330
5. Secure the brake booster, using the special tool pro-
vided for that purpose.
Fig. 10 SM13-1331
1 page 1
6. Remove the nut and the cylinder seal.

7. Secure the piston plate, using a holder provided for
that purpose, and remove the nut.
Special Tool: Wrench (09603-1430)
NOTE: ● Keep the power piston pushed far enough
toward the hydraulic cylinder side while
removing the nut.
● If the power piston is not adequately
pushed toward the hydraulic cylinder side,
Fig. 11 SM13-1332
the push rod pin will turn together with the
nut.
● When removing the locknut, take precau-
tions, for there is a spring that will jump
out when the locknut is removed.
● Some models have different springs for the
front and rear boosters, so the front and
rear boosters must be distinguished and
stored separately.
8. Remove the retainer ring, using a snap ring pliers,
Fig. 12 SM13-1333
and then remove the push rod assembly.
HYDRAULIC PISTON ASSEMBLY Special Tool: Clamp remover (09674-1040)
9. Press and hold down the hydraulic piston spring and
remove the pin, and then remove the hydraulic pis-
ton assembly.
PUSH ROD
Fig. 13 SM13-1334
10. Remove the retainer assembly, pulling it in the di-
rection away from the push rod threaded part.
Fig. 14 SM13-1401
1 page 1
INSPECTION
isopropyl alcohol.
Do not clean the components with nimeral oil.
Mineral oil will cause swelling of the rubber
parts, thereby causing insufficient braking
force.
1. POWER CYLINDER SHELL

Inspect the power cylinder shell for rust and dam-
age.
Fig. 15 SM13-1327
2. PUSH ROD
1. Check the push rod sliding surfaces for damage and
replace the push rod if damage is found.
2. Check the straightness of the push rod and replace
the push rod if it is bent.
Fig. 16 SM13-1328
3. COMPRESSION SPRING
Inspect the spring for rust and damage, also meas-
ure the free length, setting length and setting load.
STANDARD LIMIT
Free length mm (in.) 161 (6.34) 154 (6.06)
Setting length mm (in.) 132 (5.20) —
Setting load kg (lb) 8 (17.633) 6 (13.226)
Fig. 17 SM13-1329
4. POWER PISTON
Inspect the power piston for wear.
Fig. 18 SM13-924
1 page 1
5. HYDRAULIC CYLINDER AND PISTON

1. Inspect the hydraulic cylinder for rust and damage.
2. Inspect the hydraulic piston for rust and damage.
Fig. 19 SM13-921
A B 6. MEASURE THE CREARANCE BETWEEN HYDRAULIC
PISTON AND CYLINDER.
Standard Clearance (A-B): 0.07 - 0.14 mm
(0.0028 - 0.0055 in.)
Service Limit: 0.16 mm (0.0062 in.)
Fig. 20 SM13-389 SM13-390

1 page 1
ASSEMBLY
PUSH ROD 1. Coat the end plate oil filler part and the oil seal with
silicon grease. Then pressure-fit the oil seal on the
end plate, using a bar provided for that purpose.
NOTE: Make sure the oil seal is correctly oriented
when you install it.
2. Soak the washers in brake fluid and then install the
end plate.
3. Coat the push rod surfaces with silicon grease, and
Fig. 21 SM13-1336
install the push rod on the end plate.
4. Secure the cylinder assembly with the work stand pro-
vided for that purpose.
5. Install the spring on the piston.
NOTE: ● Do not remove the spring from the piston
unless it is damaged.
Fig. 22 SM13-1337
6. Soak the piston cap and backup ring in brake fluid
HYDRAULIC PISTON and install them on the piston.
PISTON CUP
NOTE: ● Install the backup ring and piston cap in
the correct order and orientation.
BACKUP RING
● Make sure the backup ring is not biting into
the piston.
Fig. 23 SM13-1338
7. Line up the push rod end pin, the valve seal assem-
HYDRAULIC PISTON ASSEMBLY bly hole, and the hydraulic piston assembly hole, and
then insert the pin.
PUSH ROD
Fig. 24 SM13-1339
8. Coat the hydraulic piston assembly exterior surfaces,
HYDRAULIC CYLINDER
the hydraulic cylinder inner surfaces, and the O-ring
with brake fluid, and then assemble the O-ring on the
hydraulic cylinder and install the hydraulic cylinder
on the end plate.
Tightening Torque: 200 - 300 kg·cm (15 - 21 lb·ft)
END PLATE
Fig. 25 SM13-1340
1 page 1
9. Install the pin in the push rod threaded part hole.
PIN
Fig. 26 SM13-1341
10. Install the return spring on the end plate.
RETURN SPRING
END PLATE
Fig. 27 SM13-1342
11. Coat the piston plate cap groove and piston cap with
mineral grease, and then install the piston cap.
NOTE: Make sure the cap is correctly oriented when
you install it.
Fig. 28 SM13-1343
12. While pressing and holding down the compression
spring, install the O-ring and washer in that order,
and then secure the hydraulic piston and push rod in
place with the nuts.
NOTE: ● Supply compressed air (about 0.1 MPa)
through the hydraulic cylinder discharge
opening.
● After fastening the nut, caulk the nut and
Fig. 29 SM13-1344
the push rod threaded parts with a punch.
1 page 1
13. Remove the hydraulic cylinder assembly from the

stand and install the power cylinder shell on the stand.
Fig. 30 SM13-1345
14. Coat the power cylinder shell inner surfaces with
mineral grease, and then install the hydraulic cylin-
der assembly.
Fig. 31 SM13-1346
15. Install the bleeder screw and cap.
BLEEDER SCREW Tightening Torque: 70 - 130 kg·cm (5.1 - 9.3 lb·ft)
Fig. 32 SM13-1347
16. Install the retainer ring, connector assembly, spring,
and check valve.
Fig. 33 SM13-1348
17. Install the warning switch.
Tightening Torque: 80 - 120 kg·cm (5.8 - 8.6 lb·ft)
WARNING SWITCH
Fig. 34 SM13-1349
1 page 1
18. Coat the exhaust cover holder insertion part and the
EXHAUST COVER
end plate insertion part with silicon grease, and as-
semble the exhaust cover on the holder and install
the clamp.
HOLDER
Fig. 35 SM13-399
INSPECTION
1. MOUNT AIR BOOSTER ASSEMBLY.
Fix the air booster with bracket.
Tightening Torque: 190 - 260 kg.cm (14 - 18 lb.ft)
Fig. 36 SM13-1319
1 page 1
2. CONNECT THE PIPES AND ELECTRICAL WIRES.

1. Connect the oil pipes to the air booster.
Tightening Torque: 200–220 kg·cm (14.5–15.9 lb·ft)
Fig. 37 SM13-1318
2. Connect the air pipes to the air booster.
Tightening Torque: 400–500 kg·cm (2.36 lb·ft)
3. Connect the other disconnected pipes, hoses and
electrical wires.
Pipe diameter Air pipe tightening torque
mm (in.) kg·cm (lb·ft)
6.35 (0.25) 200–220 (14.5–15.9)
10.0 (0.394) 400–500 (29–36)
12.0 (0.472) 600–700 (44–50)
3. CHECK THE FUNCTION OF THE AIR BOOSTER.

A
1. Remove the hydraulic cylinder’s air bleeder, and at-
B tach an oil pressure gauge.
2. Remove the quick release valve’s plug, and attach
an air pressure gauge.
A: Air pressure gauge
B: Oil pressure gauge
Fig. 38 SM13-1259
QUICK RELEASE
VALVE
Fig. 39 SM13-1319
3. Operation starting pressure test. 4. Full load operation test.

Make sure that the pressure in the air tank Continue to raise the air pressure, and once
is zero, and then depress the brake pedal the pressure reaches 6.0 kg/cm 2 (85.32
held in this position, start the engine and lb/sq.in.) stop the engine. If the oil pressure
raise the air pressure. If the oil pressure gauge at this time shows a pressure in the
begins to show an increase of pressure be- range of 122–142 kg/cm 2 (1,735–2,019
fore the air pressure reaches 0.7 kg/cm2 lb/sq.in.), it is normal.
(10.0 lb/sq.in.) it is normal.
1 page 1
5. Full load air-tightness test. 6. Residual pressure test (Check valve test)
Under the conditions shown in step 3, if (1) Replace the oil pressure gauge range to
there is no drop in air pressure for a period 0-7 kg/cm2 (0-99 lb/sq.in.).
of one minute, it is normal. (2) Depress the brake pedal until the air
pressure reaches 1.5 -2.0 kg/cm2 (21.4-
28.4 lb/sq.in.) and then release it. Check
that the oil pressure at this time is 0.6-
1.6 kg/cm2 (8.6-22.7 lb/sq.in.).

of the hydraulic cylinder.
Under these conditions, check that the warning lamp
Fig. 40 SM13-398
parking brake is operating.
BRAKE
BRAKE
FLUID
Fig. 41
1 page 1
PERIODIC INSPECTION
1. INSPECTION BEFORE DRIVING

Inspect the fluid quantity in the oil reservoir. Confirm that the fluid surface is within the specified range and
that the fluid surface has not deteriorated abnormally.
At the same time, inspect for fluid leaks around the hydraulic cylinder and for air leaks from the power
cylinder.
2. YEARLY INSPECTION
Disassemble every two years, inspect each component and replace the components listed in the following
table.
Refer to “INSPECTION OF COMPONENTS AND INSPECTION AFTER ASSEMBLY” for the inspection
and maintenance items and the functional checks to perform after assembly.
COMPONENTS TO BE REPLACED EVERY DISASSEMBLY

COMPONENT NAME QUANTITY COMPONENT NAME QUANTITY
O-ring 1 O-ring 1
O-ring 1 Retainer ring 1
Retainer ring O-ring
1 1
(Plug) (Power cylinder shell)
COMPONENTS TO BE PERIODICALLY REPLACED EVERY TWO YEARS

Repair kit parts No. 44069-5340
Hydraulic piston assy 1 Piston seal 1
O-ring 1 Dust cover 1
O-ring 1 Oil seal 1
Valve 1 Retainer ring 1
O-ring 1 Check valve assembly 1
Band 1 O-ring 1
Oil seal 1
1 page 1
BRAKE AIR BOOSTER

(REAR WHEEL BRAKE)
32
38 33
39
34
43 35
31 36
37
40 3 1
20 24 41
12 13 14 42
15 16 17 44 5
4
2
22 21 7
18
23
19
11
6
29 8
30
10 22
9 25
26 SM13-1400
27
28
1. Bolt 16. Spring seat 31. Return spring

2. Washer 17. Check valve 32. Washer
3. ABS control valve 18. Cap 33. Push rod
4. Spring 19. Bleeder screw 34. Ring
5. Pipe 20. Nut 35. Oil seal holder
6. Nut 21. Bolt 36. Plug
7. Washer 22. Power cylinder assembly 37. O-ring
8. Housing 23. Pipe 38. Valve
9. Warning switch 24. Hydraulic cylinder 39. Pin
10. Bracket 25. Nut 40. Hydraulic cylinder
11. End cap 26. Spring 41. Back up ring
12. Pipe joint 27. Plate 42. Piston cup
13. O-ring 28. O-ring 43. Band
14. Washer 29. Piston seal 44. Washer
15. Spring 30. Piston
Fig. 1
NOTE: Refer to CHAPTER 77, ANTI LOCK BRAKE SYSTEM for the principles of operation.
1 page 1
REMOVAL
1. Remove the front booster.
(Please refer to the front booster chapter for removal
instructions.)
2. Disconnect the air pipes and oil pipes from the air
booster.
NOTE: ● Cover the openings of the air pipes
with tape, etc. in order to prevent the
entry of alien substances.
● Prepare a tray when removing the oil
pipe to prevent brake fluid spillage.
Moreover, cover the openings in order
to prevent the entry of alien sub-
Fig. 2 SM13-1320 stances.
● Be careful that the brake fluid does not
stain painted surfaces.
3. Remove the air booster sub harness connector.

Then, remove the nuts attaching the air booster
bracket to the frame and remove the air booster and
related components from the frame along with the
bracket.
WARNING
Because the booster assembly is heavy, its removal
should be done by more than two persons and be
Fig. 3 SM13-1321 careful not to drop it on your feet.
4. Remove the air pipes at the two points shown in the

diagram.
NOTE: Cover the openings of the air pipes with tape,
etc. in order to prevent the entry of alien sub-
stances.
Fig. 4 SM13-1321
5. Remove the two ABS control valve harness connec-
tors.
Fig. 5 SM13-1321
1 page 1
6. Remove the two warning lamp harness connectors.
Fig. 6 SM13-1321
7. Remove the two air booster bracket attachment nuts.
Fig. 7 SM13-1322
8. Remove the six nuts which attaches the air booster
to the bracket and remove the air booster from the
bracket.
Fig. 8 SM13-1321`
1 page 1
DISASSEMBLY
1. Remove the four bolts, nuts, and lock washers which
join the bodies and disassemble the hydraulic cylin-
der with piston assembly, the power cylinder shell,
LOCKWASHER ABS CONTROL VALVE and the ABS control valve.
NUT BOLT
NOTE: ● Never disassemble the ABS control valve.
● Do not apply air pressure grease onto oil
pressure components. Conversely, do not
apply oil pressure grease (brake fluid) onto
air pressure components.
POWER CYLIN-
DER SHELL
HYDRAULIC CYLINDER WITH
PISTON ASSEMBLY
Fig. 9 SM13-1208
CONNECTOR
2. Remove the bolt that holds the ABS control valve
connector bracket in place.
BRACKET
Fig. 10 SM13-1352
ABS CONTROL VALVE 3. Remove the ABS control valve and the return valve
assembly.
NOTE: Never disassemble the ABS control valve.
RETURN VALVE
ASSEMBLY
Fig. 11 SM13-1353
1 page 1
4. Remove the O-ring from the housing.
HOUSING
O-RING
Fig. 12 SM13-1354
5. Remove the ring and then disconnect the hose from
ABS CONTROL
VALVE the ABS control valve.
HOSE
RING
Fig. 13 SM13-1355
6. Remove the screw and take the holder, valve, and
ABS CONTROL cover off the ABS control valve.
VALVE
HOLDER
VALVE
COVER
Fig. 14 SM13-1356
7. Remove the housing and then the power cylinder
O-RING
shell and the O-ring.
HOUSING
Fig. 15 SM13-1357
8. Loosen the nut and remove the power cylinder shell.
POWER CYLINDER Then remove the hydraulic cylinder assembly, pipe,
SHELL
and seal.
NOTE: Make sure the parts do not come in contact
with oil or grease that is not their designated
HYDRAULIC
CYLINDER type.
Fig.16 SM13-1358
1 page 1
9. Remove the retainer ring from the hydraulic cylin-

der.
NOTE: Make sure the parts inside the power cylin-
der do not come in contact with the grease
on the power cylinder side.
Fig. 17 SM13-1359
10. Remove the power piston assembly from the hydrau-
lic cylinder.
NOTE: Do not apply excessive force when removing
the plug.
Fig. 18 SM13-1360
11. Remove the O-ring from the hydraulic cylinder.
Fig. 19 SM13-1361
12. Remove the warning switch connector from the con-
nector bracket.
Fig. 20 SM13-1362
13. Pry open the bent part of the clip.
Fig. 21 SM13-1363
1 page 1
14. Remove the warning switch from the hydraulic cylin-

der, and then remove the clip, bracket, and O-ring.
WARNING
SWITCH
Fig. 22 SM13-1364
15. Remove and turn the turning prevention clamp of the
band from the hydraulic piston hole to pull out the
pin, and remove the hydraulic piston assembly.
Fig. 23 SM13-1217
16. Remove the hydraulic seal holder and the plug sub
assembly from the power piston assembly.
Fig. 24 SM13-1218
17. Remove the nuts holding the power piston assem-
SPRING PLATE PISTON bly in place, and disassemble the push rod, power
PUSH ROD
piston, piston seal, O-ring, plate, and coned disc
spring.
NOTE: Do not remove the push rod plate.
O-RING
PISTON SEAL
Fig. 25 SM13-1365
18. Loosen the end cap and remove it from the hydrau-
lic cylinder together with the O-ring.
Fig. 26 SM13-1366
1 page 1
19. Remove the air bleeder screw from the hydraulic cyl-
inder.
Fig. 27 SM13-1367
20. Remove the pipe joint retainer ring from the hydrau-
lic cylinder.
Special Tool: Clamp remover (09674-1040)
Fig. 28 SM13-1368
21. Remove the pipe joint and O-ring from the hydraulic
cylinder.
Fig. 29 SM13-1369
CHECK VALVE 22. Remove the check valve assembly from the hydrau-
ASSEMBLY lic cylinder.
Fig. 30 SM13-1370
1 page 1
INSPECTION
NOTE: Inspect all disassembled components and
replace them in the following cases. In addi-
tion, even in the absence of abnormalities,
replace all rubber components ONCE EVERY
YEAR.
1. POWER CYLINDER SHELL
Nicks or scratches on the power piston motion part
or worn to the point that its internal surface black
plating has peeled off.
Fig. 31 SM13-1255
2. POWER PISTON ASSEMBLY
Nicks or scratches on the push rod. Harmful scratch
on the piston seal groove.
Fig. 32 SM13-1256
3. HYDRAULIC CYLINDER
Nicks, scratches, or rust on the inner surface of the
cylinder. Harmful nicks or scratches on the bushing.
Scratches on the oil seal, dust seal insertion part and
O-ring, or O-ring seal of the pipe joint.
Fig. 33 SM13-1254
4. HYDRAULIC PISTON
BACKUP
VALVE
PISTON PIN
RING
HYDRAULIC
Scars or scratches on the outer surface and on the
PISTON valve seat. Scratches on the piston cup insertion part.
5. VALVE
Scratches on the valve (rubber) or worn out. Surface
harmfully worn. (Even in the absence of abnormali-
ties, replace ONCE EVERY YEAR.)
6. BACKUP RING
Fig. 34 SM13-1257 Scars or scratches.
1 page 1
CHECK VALVE ASSEMBLY END CAP 7. PISTON PIN

Scratches, abrasion or deformation.
8. END CAP
SM13-1258
SEAL CUP
Scratches on the shim seal or check valve assem-
PISTON CUP
bly seat.
Fig. 35 SM13-1257
O-RING 9. PISTON SEAL, SEAL CUP, PISTON CUP, CHECK

VALVE ASSEMBLY AND O-RINGS
Scratches or abrasion, or appears harmful externally.
(Even in the absence of abnormalities, replace ONCE
EVERY YEAR.)
PISTON SEAL
Fig. 36 SM13-1261
10. SPRINGS
Rust, cracks, or bent. In the case of the compres-
sion spring, if its relaxed length exceeds the usage
limit.
STANDARD LIMIT
Free length mm (in.) 168.9 (6.65) 161 (6.34)
Setting length mm (in.) 107.4 (4.23) —
Setting load kg (lb) 7.2 - 8.4 (15.874 - 18.518) 6.8 (14.991)
Fig. 37 SM13-1203
11. BAND
Replace the band if there are hammer marks or
scratches on it.
Fig. 38 SM13-1371
12. HOUSING
Check all the housing O-ring seat parts and return
valve seat parts for scratches and rust, and replace
any part found damaged.
Fig. 39 SM13-1403
1 page 1
13. RETURN VALVE

Check the return valve outer rim sliding parts, end
rubber seat parts, and rubber parts for scratches,
wear, and rust, and replace any part found damaged.
Fig. 40 SM13-1404
14. RETURN SPRING
Check the return spring for rust and cracks and re-
place it if it is damaged.
Fig. 41 SM13-1405
15. OTHER PARTS
Check the plug assembly, clips, valves, hoses, rings,
snap rings, and O-rings for scratches and wear, and
replace any part found damaged.
NOTE: Replace these parts once every year, even if
they are not damaged.
1 page 1
ASSEMBLY
1. Install the clip, bracket, and O-ring on the warning
WARNING switch. Coat the O-ring with grease .
SWITCH
NOTE: Make sure the clip is correctly oriented when
you install it.
2. Install the warning switch on the hydraulic cylinder.
Fig. 42 SM13-1372
3. Install the warning switch connector on the bracket.
Fig. 43 SM13-1373
4. Install clips on the bracket and warning switch and
bend the clips to secure them in place.
Fig. 44 SM13-1374
5. Install the air bleeder screw on the hydraulic cylin-
der.
Fig. 45 SM13-1375
CHECK VALVE 6. Install the check valve assembly on the hydraulic cyl-
ASSEMBLY
inder. Coat the check valve assembly with brake
fluid.
NOTE: Install the check valve assembly so that the
rubber side is in contact with the hydraulic
cylinder.
Fig. 46 SM13-1376
1 page 1
7. Install the end cap using a new shim.

Fig. 47 SM13-1226
8. Coat the pipe joint O-ring with brake fluid and install
the O-ring on the pipe joint.
9. Install the pipe joint on the hydraulic cylinder.
Fig. 48 SM13-1377
10. Install the retainer ring.
Fig. 49 SM13-1378
PLATE 11. Install the power piston, O-ring, plate, and coned disc
PISTON SEAL
SPRING spring on the push rod.
PUSH ROD Tightening Torque: 200 - 300 kg·cm (15 - 21 lb·ft)
NOTE: After tightening the nuts, caulk the push rod
threaded parts with a punch to keep them
from turning.
O-RING
PISTON
Fig. 50 SM13-1379
PISTON ROD 12. Coat the plug assembly inner surfaces and the push
O-RING
rod sliding parts with silicon grease, and temporarily
PLUG ASSEMBLY RETAINER RING assemble the retainer ring, oil seal holder, and plug
OIL SEAL HOLDER assembly on the push rod.
OIL SEAL ASSEMBLING POWER PISTON

PLUG
Fig. 51 SM13-1227
1 page 1
CUP INSERTION TOOL

13. Soak the piston cap and backup ring in brake fluid
PISTON CUP
and then install them on the hydraulic piston.
NOTE: ● Make sure the piston cap is correctly ori-
ented and the backup ring is correctly po-
sitioned when you install them.
● Use only brake fluid for assembly of these
parts.
HYDRAULIC PISTON
Fig. 52 SM13-1228
14. Line up the hydraulic piston pin insertion hole and
the band opening and temporarily assemble the
band.
BAND
Fig. 53 SM13-1229
15. Line up the pin insertion holes and install the hydrau-
lic piston and the valve on the push rod.
NOTE: Do not use a band whose opening has been
stretched too wide and deformed.
Fig. 54 SM13-1383
16. Insert the piston pin and assemble the parts.
Fig. 55 SM13-1384
17. Insert the pin in the band detent hydraulic piston hole.
BAND TURNING
PREVENTION
CLAMP
Fig. 56 SM13-1385
1 page 1
18. Coat the O-ring with the grease provided in the re-
pair kit, and install it on the hydraulic cylinder.
NOTE: Make sure the grease does not contact the
parts inside the hydraulic cylinder. If grease
does contact the parts, replace the hydraulic
cylinder with a new one.
Fig. 57 SM13-1386
19. Install the return spring and piston assembly on the
hydraulic cylinder and secure them with the snap ring.
Fig. 58 SM13-1387
Fig. 59 SM13-1388
20. Coat the front face of the power piston seal with the
grease provided in the repair kit, and then install the
seal on the power piston assembly.
NOTE: Make sure the power piston seal is correctly
oriented when you install it.
Fig. 60 SM13-1389
21. Coat the seal with grease and install it on the pipe.
SEAL
SEAL
PIPE
Fig. 61 SM13-1390
1 page 1
22. Install the power cylinder seal and pipe on the hy-
draulic cylinder assembly. At this time, coat the
power cylinder air piston sliding surfaces with
grease.
POWER CYLINDER 23. Install the power cylinder shell on the hydraulic cyl-
SHELL inder.
HYDRAULIC
CYLINDER
Fig. 62 SM13-1392
24. Install the O-ring on the housing.
HOUSING
Fig. 63 SM13-1393
25. Install the housing on the power cylinder shell.
POWER Tightening Torque: 70 - 120 kg·cm (5.1 - 8.6 lb·ft)
CYLINDER
SHELL
HOUSING
Fig. 64 SM13-1394
26. Install the holder, valve, and cover on the ABS con-
ABS CONTROL trol valve.
VALVE Tightening Torque: 10 - 20 kg·cm (0.8 - 1.4 lb·ft)
NOTE: Make sure the cover locks into the valve hole
and does not bite into the valve.
HOLDER
VALVE
COVER
Fig. 65 SM13-1395
1 page 1
27. Install the hose on the ABS control valve and secure
ABS CONTROL it with a ring.
VALVE
NOTE: Make sure the hose is correctly oriented when
you install it.
HOSE
RING
Fig. 66 SM13-1396
ABS CONTROL VALVE

28. Coat the return valve assembly sliding parts with
grease and install the valve assembly on the ABS
control valve and then in the housing.
NOTE: ● Make sure the return valve assembly is
correctly oriented when you install it.
RETURN VALVE ● Do not apply grease to the return valve
ASSEMBLY assembly rubber seat.
● Do not remove the return valve assembly
Fig. 67 SM13-1397
end rubber.
● Make sure the pipe is correctly connected.
29. Install the bracket on the ABS control valve connec-
tor.
CONNECTOR
BRACKET
Fig. 68 SM13-1398
1 page 1
INSPECTION
1. MOUNT AIR BOOSTER ASSEMBLY.
For assembly, follow the disassembly sequence
backward, observing in particular the following steps
in doing the work.
1. Fix the air booster with bracket.

Fig. 69 SM13-1321
2. Connect the oil pipes to the air booster.
3. Connect the air pipes to the air booster.

Fig. 70 SM13-1320
4. Attach the bracket to the frame.
Fig. 71 SM13-1322
5. Attach the air booster bracket.
Fig. 72 SM13-1323
1 page 1
2. CHECK THE FUNCTION OF THE AIR BOOSTER.

C 1. Remove the hydraulic cylinder’s air bleeder, and at-
tach an oil pressure gauge.
D 2. Remove the brake valve stop lamp switch and install
A
an air pressure gauge.
FOR RIGHT
E Air pressure Oil pressure
Measurement
gauge gauge
B
A C D
FOR LEFT
B C E
Fig. 73 SM13-1259
Fig. 74 SM13-1320
3. Operation starting pressure test. 4. Full load operation test.

Make sure that the pressure in the air tank Continue to raise the air pressure, and once
is zero, and then depress the brake pedal the pressure reaches 8.5 kg/cm2 (120.89
held in this position, start the engine and lb/sq.in.) stop the engine. If the oil pressure
raise the air pressure. If the oil pressure gauge at this time shows a pressure in the
begins to show an increase of pressure be- range of 207–227 kg/cm 2 (2,944–3,228
fore the air pressure reaches 0.7 kg/cm2 lb/sq.in.), it is normal.
(10.0 lb/sq.in.) it is normal.
5. Full load air-tightness test. 6. Residual pressure test (Check valve test)
Under the conditions shown in step 3, if (1) Replace the oil pressure gauge range to
there is no drop in air pressure for a period 0–7 kg/cm2 (0–99 lb/sq.in.).
of one minute, it is normal. (2) Depress the brake pedal until the air
pressure reaches 1.5–2.0 kg/cm2 (21.4–
28.4 lb/sq.in.) and then release it. Check
that the oil pressure at this time is 0.6–
1.6 kg/cm2 (8.6–22.7 lb/sq.in.).
1 page 1

of the hydraulic cylinder.
Under these conditions, check that the warning lamp
Fig. 75 SM13-398
parking brake is operating.
BRAKE
BRAKE
FLUID
Fig. 76
1 page 1
PERIODIC INSPECTION
1. INSPECTION BEFORE DRIVING

Inspect the fluid quantity in the oil reservoir. Confirm that the fluid surface is within the specified range and
that the fluid surface has not deteriorated abnormally.
At the same time, inspect for fluid leaks around the hydraulic cylinder and for air leaks from the power
cylinder and the ABS control valve.
2. YEARLY INSPECTION
Disassemble every two years, inspect each component and replace the components listed in the following
table.
Refer to “INSPECTION OF COMPONENTS AND INSPECTION AFTER ASSEMBLY” for the inspection
and maintenance items and the functional checks to perform after assembly.
COMPONENTS TO BE REPLACED EVERY DISASSEMBLY
Shim O-ring
1 1
(Warning switch) (Pipe joint)
Retainer ring Retainer ring
1 1
(Warning switch) (Pipe joint)
O-ring O-ring
1 2
(Plug) (Power cylinder shell)
Retainer ring
1
(Plug)

Piston cup 1 Plug subassembly 1
Backup ring 1 O-ring 1
Valve 1 Retainer ring 1
O-ring 1 Check valve assembly 1
Band 1 Retainer ring 1

O-ring 1 O-ring 1
O-ring 1 Piston seal 1
O-ring 1 O-ring 1
O-ring 2 Check valve 1
Clip 1
1 page 1
QUICK RELEASE VALVE
5 4 3 2 1
1. Cover
2. Gasket
3. Filter
4. Diaphragm
5. VaIve body
6. Bolt
Fig. 1
1 page 1
REMOVAL
DISMOUNT THE QUICK RELEASE VALVE ASSEMBLY.
Disconnect the pipes and remove the valve from the
front end cross member.
Fig. 2 SM13-851
DISASSEMBLY
1. BEFORE DISASSEMBLING THE QUICK RELEASE
VALVE, APPLY THE ALIGNING MARK “A” FOR THE
A
COVER AND VALVE BODY.
Fig. 3
2. LOOSEN THE BOLTS AND REMOVE THE COVER AND
THEN DISASSEMBLE THE QUICK RELEASE VALVE.
Fig. 4 SM13-852
INSPECTION
NOTE: Before starting inspection, clean the parts
VALVE BODY AND COVER.
Inspect the body and cover for wear or any other
damage.
Fig. 5 SM13-853
ASSEMBLY
NOTE: ● When assembling the quick release valve,
be sure to use new rubber parts.
A ● The diaphragm and O-ring, must be re-
B placed every year.
A : Gasket
B : Diaphragm
Fig. 6
1 page 1
1. ASSEMBLE THE QUICK RELEASE VALVE ASSEMBLY.

NOTE: Align the aligning mark which was applied at
disassembly.
Fig. 7
2. TIGHTEN THE BOLTS FOR COVER.
Fig. 8 SM13-854
INSTALLATION
MOUNT THE QUICK RELEASE VALVE ASSEMBLY.
Install the valve to the front end cross member and
connect the pipes.
Tightening Torque: 190–260 kg·cm (14–18 lb·ft)
Fig. 9 SM13-851
1 page 1
PRESSURE REGULATOR
2
9
3
10
4 10
5
11
6
10
7
12
7
8
13
7
14
14
1. Dust cover 8. Push rod

2. Protector 9. Back up ring
3. Adjusting screw 10. O-ring
4. Adjusting screw lock nut 11. Piston
5. Retainer ring 12. Valve
6. Spring seat 13. Body
7. Spring 14. Filter
Fig. 10
1 page 1
REMOVAL
DISCONNECT THE PIPES AND THEN REMOVE THE
PRESSURE REGULATOR.
Fig. 11 SM13-622
DISASSEMBLY
1. REMOVE THE DUST COVER AND PROTECTOR.
Fig. 12 SM13-579
2. REMOVE THE RETAINER RING.
1. Using a socket wrench and a vise, compress the
spring.
2. Remove the retainer ring and loosen the vise to re-
lease the spring so that the spring seat (upper), ad-
justing screw and lock nut assembly, and springs can
be removed.
Fig. 13 SM13-580 SM13-590

3. REMOVE THE PISTON ASSEMBLY.
1. Turn the body upside down to take the push rod,
spring, spring seat and back up ring off.
2. Hold the body upside down and then tap on a soft
pad to remove the piston, O-rings, valve and spring
assembly.
Fig. 14 SM13-581
4. REMOVE THE FILTERS.
Use an allen wrench (width across flats: 6.0 mm
{ 0.236 in.}), loosen and remove the filters.
Fig. 15 SM13-583
1 page 1
5. DISASSEMBLE THE PISTON ASSEMBLY.

1. Remove the two outer and one inner O-rings from
piston.
2. Remove the spring and valve.
NOTE: Be careful not to distort the spring.
Fig. 16 SM13-585 SM13-582

6. DISASSEMBLED PRESSURE REGULATOR.
Fig. 17 SM13-584
INSPECTION
isopropyl alcohol.
1. PISTON, PUSH ROD, SPRING SEATS, VALVE AND O-
RING
Inspect the respective parts for wear or any other
damage and replace where necessary.
Fig. 18 SM13-585
Inspect the springs for rust and damage, and meas-
A ure the free length, setting length and setting load.
A B
Free length 26.0 mm (1.024 in.) 41.0 mm (1.614 in.)
Setting length 17.4 mm (0.685 in.) 35.9 mm (1.413 in.)
B
Setting load 0.7 – 0.9 kg 31.6 – 49.0 kg
(1.55 – 1.98 lb) (69.67 – 108.03 lb)
Fig. 19 SM13-586 SM 23-024

1 page 1
ASSEMBLY
NOTE: ● When assembling the pressure regulator,
apply silicone grease to each sliding sur-
face of the assembly parts.
● When assembling the pressure regulator,
be sure to use new rubber parts.
● The valve and O-rings are to be replaced
1 once a year.
1 ● Replacement spares are available as repair
kits.
2
1. O-ring
2. Piston
3. Valve
Fig. 20 SM13-553
1. ASSEMBLE THE PISTON ASSEMBLY
1. Fit the valve and spring into the piston bore.
NOTE: Be careful not to distort the spring.
2. Fit the two outer and one inner O-rings into the
grooves of the piston .
Fig. 21 SM13-582 SM13-587

2. INSTALL THE FILTERS
Using an allen wrench (width across flat: 6.0 mm –
0.236 in.), screw the filters in.
Tightening torque: 5 – 10 kg·cm (0.36 – 0.72 lb.ft.)
Fig. 22 SM13-583
3. INSTALL THE PISTON, SPRING SEAT, SPRING AND
PUSH ROD.
1. Insert the piston into the body.
NOTE: Face the valve in the piston toward the bot-
tom.
2. Place the backup ring on the O-ring fitted in the pis-
ton bore.
3. Assemble the spring seat (lower), spring and push
rod then insert the assembly into the piston bore.
Fig. 23 SM13-588 SM13-589
1 page 1
4. INSTALL THE RETAINER RING

1. Set the spring on the spring seat in the body.
2. Place the spring seat (upper) with adjusting screw
and lock nut.
3. Using a socket wrench and a vise, compress the
spring.
Fig. 24 SM13-590 SM13-580

INSTALLATION
MOUNT THE PRESSURE REGULATOR, AND CONNECT
THE AIR PIPE.
Tightening torque for bolts: 190–260 kg·cm
(14–18 lb·ft)
Tightening torque for pipes: 200–220 kg·cm
(14.5–15.9 lb·ft)
Fig. 25 SM13-623
ADJUSTMENT
1. ADJUST THE PRESSURE REGULATOR
1. Turn the adjusting screw clockwise until it is tight, then
start up the engine and idle.
Fig. 26 SM13-624 SM13-107D

2. Stop the engine when the gauge indicates 8.5±0.2
kg/cm2 (121±2.84 lb/sq.in.).
Fig. 27 SM13-202
3. Turn the adjusting screw counter clockwise gradu-
ally until air starts to leak from the port to the unloader
valve side.
Fig. 28 SM13-624 SM13-202

1 page 1
4. Tighten the adjusting screw lock nut.

Fig. 29 SM13-625
5. Confirm the pressure gauge pointer and see that it
stops at the pressure of 7.5 kg/cm2 (107 lb/sq.in.).
Fig. 30 SM13-107F SM13-623

6. Connect the pipe and pressure regulator.
7. Install the protector and dust cover.
Fig. 31 SM13-626 SM13-622

1 page 1
SAFETY VALVE
10
1. Valve body 6. Spring seat

2. Valve seat 7. Compression spring
3. Shim 8. Adjusting screw
4. Valve cap 9. Lock nut
5. Release pin 10. Cover
Fig. 1
1 page 1
REMOVAL
DISMOUNT THE SAFETY VALVE ASSEMBLY.
Fig. 2 SM13-627
DISASSEMBLY
1. REMOVE THE LOCK NUT AND ADJUSTING SCREW.
Fig. 3 SM13-860
2. DISASSEMBLE THE SAFETY VALVE.
Fig. 4 SM13-861
INSPECTION
isopropyl alcohol.
1. VALVE AND VALVE SEAT
Inspect the valve seat for wear or any other damage.
Fig. 5 SM13-862
Inspect the spring for rust and damage, and meas-
Setting length 24.0 mm (0.945 in.)
Fig. 6 SM13-863 SM13-837

1 page 1
ASSEMBLY
1
NOTE: ● When assembling the safety valve, apply
the silicone grease to each sliding surface
of the assembly parts.
● When assembling the safety valve, be sure
to use new rubber parts.
● The valve seat must be replaced every
2 3 year.
1. Valve
Fig. 7
2. Release pin
3. Valve seat
Assembly the safety valve assembly.
Fig. 8 SM13-861
ADJUSTMENT
1. FULLY TURN THE ADJUSTING SCREW CLOCKWISE, AND
1 MOUNT THE SAFETY VALVES AS SHOWN IN Fig. 9.
2
NOTE: The pressure in the air tank should be 9.7
kg/cm2 (137.934 lb/sq.in.)
1. Safety valve
3 2. Pressure gauge
3. Air tank
Fig. 9 SM13-107G
2. TURN THE ADJUSTING SCREW COUNTER CLOCK-
1 WISE DIRECTION GRADUALLY TILL AIR STARTS TO
LEAK FROM THE EXHAUST PORT.
A A
1. Adjusting screw
A. Exhaust
B. From air tank
B
Fig. 10 SM13-107C
3. TIGHTEN THE ADJUSTING SCREW LOCK NUT.
Tightening Torque: 200–300 kg·cm (15–21lb·ft)
Fig. 11 SM13-864
1 page 1
INSTALLATION
MOUNT THE SAFETY VALVE ASSEMBLY.
Fig. 12 SM13-627
1 page 1
CHECK VALVE
5
4
3
2
1
2
3
4
1. Valve body
2. Conical spring
3. Valve sub assembly
4. O-ring
5. Body cap
Fig. 1
1 page 1
REMOVAL
DISMOUNT THE CHECK VALVE ASSEMBLY.
Fig. 2 SM13-628
DISASSEMBLY
1. REMOVE THE BODY CAP.
Fig. 3 SM13-855
2. DISASSEMBLE THE CHECK VALVE ASSEMBLY.
Fig. 4 SM13-856
INSPECTION
NOTE: Before starting inspection, clean the parts
1. VALVE AND BODY CAP
Inspect the valve and body cap for wear or any other
damage.
Fig. 5 SM13-857
2. CONICAL SPRING
Assembly standard Service limit

Free length 17.6 mm (0.693 in.) 16.5 mm (0.649 in.)
Setting length 15.4 mm (0.606 in.) —
Setting load 0.08 kg (0.176 lb) —
Fig. 6 SM13-858 SM13-837

1 page 1
ASSEMBLY
1. ASSEMBLE THE CHECK VALVE ASSEMBLY.
NOTE: ● When assembling the check valve, be sure
to use new rubber parts.
● The valve sub assembly and O-ring, must
be replaced every year.
Fig. 7 SM13-856
2. TIGHTEN THE BODY CAP.
Fig. 8 SM13-859
INSTALLATION
MOUNT THE CHECK VALVE ASSEMBLY.
Tightening Torque:
400 – 500 kg·cm

10.0 mm (0.394 in.)
(29 – 36 lb·ft)
Pipe diameter
600 – 700 kg·cm
12.0 mm (0.472 in.)
(44 – 50 lb·ft)
Fig. 9 SM13-628
1 page 1
PROTECTION VALVE
5
1
1. Compression spring
2. Adjusting screw
3. Lock nut
4. Body cap
5. O-ring
6. Valve sub assembly
7. Valve body
Fig. 1
1 page 1
DISASSEMBLY
1. REMOVE THE ADJUSTING SCREW.
Fig. 2 SM13-865
2. REMOVE THE BODY CAP.
Fig. 3 SM13-866
3. DISASSEMBLE THE PROTECTION VALVE ASSEMBLY.
Fig. 4 SM13-867
INSPECTION
isopropyl alcohol.
1. VALVE AND BODY CAP.

Inspect the valve and body cap for wear or any other
damage.
Fig. 5 SM13-868
2. COMPRESSION SPRING.
ure the free length, setting length, and setting load.
Setting length 49.0 mm (1.929 in.)
Fig. 6 SM13-869 SM13-837

1 page 1
ASSEMBLY
NOTE: ● When assembling the protection valve,
apply the silicone grease to the each slid-
ing surface of assembling parts.
● When assembling the protection valve, be
sure to use new rubber parts.
● The valve sub-assembly and O-ring must
be replaced every year.
1. O-ring
2. Valve sub-assembly
Fig. 7 SM13-099
1. ASSEMBLE THE PROTECTION VALVE ASSEMBLY.
Fig. 8 SM13-867
2. TIGHTEN THE BODY CAP.
Fig. 9 SM13-870
3. TEMPORARILY INSTALL THE ADJUSTING SCREW
WITH LOCK NUT.
Fig. 10 SM13-865
1 page 1
ADJUSTMENT
1 1. FULLY TURN THE ADJUSTING SCREW CLOCKWISE,
3
AND MOUNT THE PROTECTION VALVE AS SHOWN IN
Fig. 11.
NOTE: The pressure in the air tank should be 5.7
kg/cm2 (81.054 lb/sq.in.).
4
2 1. Protection valve
2. Adjusting screw
Fig. 11 SM13-107H 3. Pressure gauge
4. Air tank
2. TURN THE ADJUSTING SCREW COUNTER CLOCK-

B WISE GRADUALLY TILL AIR STARTS TO LEAK FROM
THE OUTLET OF PROTECTION VALVE.
A 1. Adjusting screw
A. Exhaust
B. From air tank
1
Fig. 12
3. TIGHTEN THE ADJUSTING SCREW LOCK NUT.
Fig. 13 SM13-871
4. CONFIRM THE PROTECTION VALVE FEELER AND SEE
THAT IT STOPS AT THE PRESSURE OF 5.0 kg·cm2
(71.10 lb·ft).
Fig. 4 SM13-107K
1 page 1
FINAL CHECK AND ADJUSTMENT
AIR BLEEDING There are two methods of air bleecling, manual air
When disassembling any part of the hydraulic brake bleeding and pressure air bleeding. If a pressure air
line or in a situation where air may be caught in the bleeding equipment is on hand, the use of pressure
hydraulic brake line, always bleed the air from the air bleeding is recommended.
brake line. Air bleeding for the primary brake line Be careful not to spill brake fluid from the reservoir
and the secondary brake line should be performed and the air bleeder during air bleeding. The brake
separately. fluid can damage the paint finish on the body or floor.
1. MANUAL AIR BLEEDING
1. Air bleeding (Brake fluid reservoir – Air booster)
1) Fill the brake fluid reservoir with brake fluid.
(DOT 3 or DOT 4).
Fig. 1 SM13-1247
2)Operate the engine and obtain an air pressue
of 7.5 – 8.5 kg·cm2 (106.65 – 120.87 lb/sq.in.) in
the air tank, and connect vinyl pipe to the air
bleeder on the hydraulic cylinder.
NOTE: Be sure that the end of vinyl tube is inserted
into container of brake fluid.
Fig. 2 SM13-106B SM13-398

3)
Slowly depress the brake pedal, and slowly
loosen the air bleeder. Air in the system will be
expelled with the brake fluid.
4) After tightening the air bleeder, release the brake
pedal. Repeat step 3) as many times as neces-
sary to discharge all bubbles from the brake fluid.
NOTE: The brake fluid in the reservoir should be
continuousty replenished while air bleeding
so that the reservoir never becomes empty.
Fig. 3 SM13-398
2. Air bleeding (Air booster – Wheel cylincler)
1) Bleed air from the wheel cylincler’s air bleeder
using the same procedures as for the air booster.
Begin with the wheel cylinder nearest the air
booster.
Fig. 4 SM13-397
1 page 1
3. The Other Line

1) When the air bleeding of the primary line has
been completed, perform air bleeding of the
secondary line.
The procedure is exactly the same as that
for the primary line.
4. At the Completion of Air Bleeding.

1) Check that there are no fluid leaks from the 2) Make sure that the rubber cap for the air
air bleeders or any other parts loosened in bleeder is properly placed.
this servicing. Make sure there are no leaks 3) Fill the reservoir with brake fluid up to the
from the piping system as well. MAX. level.
2. PRESSURE AIR BLEEDING.

Perform pressure air bleeding according to
the instruction manual for the pressure air
bleeding unit. Adhere to the general proce-
dures found in above notes.
ADJUSTMENT TESTING
1. DISASSEMBLE AND INSPECT THE BRAKE Measure the braking effect of each wheel
PARTS AND AFTER PERFORMING AIR on the brake tester after completing item
BLEEDING, MAKE SURE OF THE FOLLOW- above. If no brake tester is on hand, per-
ING ADJUSTMENT. form the brake test from low speed 5 –10
Shoe clearance adjustment km/h (3.1 – 6.2 miles/h) and cheek the
Adjust the shoe clearance of each front braking performance that there are no
and rear wheels according to the method irregluarities in general.
shown in SECTION FOR ADJUSTMENT
OF BRAKE SHOE CLEARANCE.
1 page 1
AIR DRYER
(NABCO DR-31)
CONSTRUCTION
27
25
24
20
14
26
29
23
28
22
21
37 1
12
16 36 35
15
13 30
17
18
19
6
8 34
5
4
7 3
33
9 2 32 31 ASM13-029
11
10
Fig. 1
1. Body 14. Filter plate (2) 27. Purge tank

2. Valve body 15. Filter 28. Bolt
3. O-ring 16. Desiccant 29. Nut & washer
4. O-ring 17. Filter gasket 30. Heater
5. Piston 18. Oil filter comp 31. Thermostat comp
6. O-ring 19. Gasket ring 32. Screw
7. Purge valve 20. Set spring 33. Clamp
8. Valve spring 21. Case giude 34. Screw
9. Bolt & washer 22. Sealing ring 35. Bracket
10. Exhaust cover 23. O-ring 36. Bolt
11. Retaining ring 24. Cover 37. Oil filter
12. Case 25. Check valve
13. Filter plate (1) 26. O-ring
1 page 1
13
17
30 16
17 25
31
5 13
24
12
2 37 22
17
7 21
18
10
19
ASM13-030
1. Body 18. Oil filter comp

2. Valve body 19. Gasket ring
5. Piston 21. Case giude
7. Purge valve 22. Sealing ring
10. Drain pipe 24. Cover
12. Desiccant case 25. Check valve
13. Plate 30. Heater
16. Desiccant 31. Thermostat comp
17. Filter gasket 37. Oil filter
Fig. 2
1 page 1
REMOVAL AND DISASSEMBLY

IMPORTANT POINT – DISMOUNTING
INSPECTION PRIOR TO DISMOUNTING
1. Check to see that there is no air leakage from the
purge valve when the compressor is functioning.
2. Check to see that the air is discharged from the purge
valve at the moment of the compressor stops func-
tioning.
3. Check the drain water from the purge valve, and if
there is an abnormal amount of oil, inspect the com-
pressor.
(See chapter for AIR COMPRESSOR)
4. Open the drain valve of the main tank and check to
see that no water is drained. On normal operation, if
water is drained, disassemble the dryer and check
the desiccant. If more than 1/5 of the desiccant is
stained, change it with new one.
ASSEMBLY
IMPORTANT POINTS – ASSEMBLY
A C
1. When assembling the air dryer use new O-ring, gas-
ket and seal.
2. Apply grease (lithium base) to each sliding surface
of the component parts O-ring groove.
A: O-ring
A
B: Sliding surface
BEFORE TIGHTEN THE LOCK NUT WITH SPECIFIED

TIGHTENING TORQUE, TAP ALL OVER THE OUTER
SURFACE OF THE CASE WITH A PLASTIC HAMMER.
C: Lock nut
B A
Fig. 3 ASM13-1079
1 page 1
IMPORTANT POINT – DISMOUNTING

INSPECTION
1. Operate the engine and raise the air pressure until
the air compressor stops functioning.
(The pressure reaches the valve opening pressure
of the air pressure regulator).
a. Check to see that there is no air leakage from the
purge valve while the compressor is functioning.
b. When the compressor stops functioning, check to see
that the air is discharged from the purge valve for a
period of approx. 50 seconds.
MAINTENANCE AND INSPECTION OF AIR

DRYER
Carry out inspection and maintenance according to the
following interval or vehicle milage.
1. Every three months or 20,000 km (12,400 miles)
a. To check that the air dryer operates correctly, open
the drain cock of the air tank and see if any drainage
comes out.
Fig. 4 ASM13-032 b. If a little drainage comes out, check if desiccant 1 is
discolored. If more than one fifth of the desiccant
has changed color from white to brown, renew des-
iccant.
Limit: Discolored, more than 1/5 of the guantity
NOTE: In an operational environment where the de-
crease of the ambient temperature in the air
tank is higher than 17°C a little moisture might
collect.
c. Pour desiccant 1 into container 2, tap around the

container lightly to settle the desiccant.
Fig. 5 ASM13-033
d. Carefully inspect the drainage from the exhaust port
of the air dryer body. Inspect the air compressor and
take appropriate action for abnormal oil consumption.
2. Every year or every 100,000 km (62,000 miles)

Disassemble the air dryer body. Replace the oil filter, fil-
ter and all the rubber parts together with a repair kit.
1 page 1
INSPECTION
(1) After starting the engine and when the
pressure reaches the maximum pressure
or the cut-off pressure of the governor
and the air compressor changes from the
loaded to the unloaded condition, air
should be exhausted from the exhaust
port of the air dryer.
Then, the air be exhausted is great in the
beginning, but it should reduce in 3 sec-
onds or so to such a level that almost no
noise would be heard.
(2) After the pressure descended to the mini-
mum pressure or the cut-in pressure and
the air compressor changed to the
loaded condition, air leakage from the
exhaust port of the air dryer should be
20 cc/min (a ø15 bubble in 6 sec) or less.
(3) Each connecting portion of the piping
should have no leakage.
1 page 1
TROUBLE AND DISPOSAL

If day-to-day and periodical maintenance and inspection are made satisfactorily, no failure due to Air
Dryer itself would occur.
Periodical maintenance should be made strictly in accordance with this manual.
❋ When such out-of-order condition or failure as enumerated below occurs, conduct inspection
and take corrective actions as mentioned in the following instructions. When you failed to make
good of the defect, consult the nearest service station for inspection and repair.
Out-of-order Cause Corrective Action
Drain in main tank 1. When dryer is added newly, it 1. Until air becomes dry completely,
takes some time to become dry continue draining through closinghour
from the state of saturated inspection, etc..
humidity
2. Under peculiar using conditions, 2. Either make compressor repeat load-

air consumption is great and no unload cycles or recheck installation
load-unload cycles of air com- of dryer.
pressor is repeated.
3. Cut-off pressure of governor 3. Adjust cut-off pressure of governor to

(pressure regulator) is low and 5 kgf/cm2 or more
drain valve does not open.
4. No replacement of desiccant 4. Replace then every 1 year or 100,000

and oil filter are made for a long km run (in case of construction rig,
period. every 1 year or 2,000 hrs operation).
5. Sufficient purging is not made. 5. In case of the system where purging

is made by a relief valve, if difference
between cut-off pressure of governor
and closing pressure of relief valve
are not large, the purging time be-
comes shorter and makes regenera-
tion difficult.
No drain exhausted 1. Heater fails to function and air 1. In case of heater defect, replace
from drain valve dryer is freezing. heater.
In case of defect of thermostat,
replace thermostat.
2. Cut-off pressure of governor is 2. Adjust cut-off pressure of governor to

low and drain valve dose not 5 kgf/cm2 or more
open
3. Drain valve does not function as 3. Disassemble and inspect drain valve
foreign materials are caught. portion and replace the parts if nec-
essary.
1 page 1
Out-of-order Cause Corrective Action
Inside of air dryer is 1. Installation of dryer body is not 1. Either alter the installing position or
frozen proper and temperature of dryer install a hood to prevent wind.
will reduce to -30°C or less
during cold run.
2. Because of defect of heater, it 2. Whether heater fails or not, deter-

dose not function. mine it through checking the conduc-
tion with a testar. If so, replace it.
3. Because of defect of thermostat, 3. Confirmation should be made:

heater dose not function. (a) Leave it in temp. of less than -0°C
and see the conduction with a
tester;
(b) Surround the thermostat with
palm and confirm OFF.
If so, replace the thrmostat.
4. Ice/snow sticks on air dryer 4. Carefully remove ice/snow so as not

body and this reduces tempera- to hurt air dryer body and wiring
ture extraordinarily.
5. Because of disconnection of 5. Reconnection of wiring to heater and

wiring to heater and thermostat, thermostat should be made properly.
heater does not function.
Air leaks from drain 1. Because foreign materials were 1. Disassemble and inspect the valve
valve caught in the valve, the valve is body portion;
not seated correctly. either replace the valve or, when the
rubbing suface of valve body is hurt,
replace valve body comp.
Pressure in main tank 1. When air compressor is at 1. Disassemble and inspect the check
reduces extraordinarily unloaded condition, if the check valve and replace it, if necessary.
valve between main tank and
purge chamber does not per-
form its original role, dry air in
the main tank will counterflow
and be exhausted from air dryer.

Service Brake: Model FB (Air Over Hydraulic Brake)

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Service Brake: Model FB (Air Over Hydraulic Brake)

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1 page

SPECIAL TOOL ......................................................................... 13- 4

BRAKE PIPING DIAGRAM ....................................................... 13- 5

FRONT AND REAR WHEEL BRAKES ..................................... 13- 11

BRAKE VALVE .......................................................................... 13- 23

BRAKE AIR BOOSTER

QUICK RELEASE VALVE ......................................................... 13- 69

PRESSURE REGULATOR ........................................................ 13- 72

SAFETY VALVE ......................................................................... 13- 78

CHECK VALVE .......................................................................... 13- 82

PROTECTION VALVE ............................................................... 13- 85

FINAL CHECK AND ADJUSTMENT ......................................... 13- 89

AIR DRYER................................................................................ 13- 91

Symptom Possible causes Remedy

Symptom Possible causes Remedy

Control system Lack of pedal play. .................................. Adjust.

Brake squeal Improper lining material or ...................... Replace lining.

Illustration Tool No. Tool name

09665-1130 ADJUSTING TOOL

09674-1040 CLAMP REMOVER

BRAKE PIPING DIAGRAM

1. Stop lamp switch 13. Air tank (Rear)

SPLIT HYDRAULIC AIR BRAKE SYSTEM

INSPECTION AND ADJUSTMENT

1. BRAKE SHOE CLEARANCE

4. Check the bake shoe clearance.

e. Turn the brake drum in the forward direction and sta-

4. Piston stroke detector and warning switch.

FRONT AND REAR WHEEL BRAKES

FRONT WHEEL BRAKE

REAR WHEEL BRAKE

1. Remove the wheel.

2. Remove the brake drum, wheel hub assembly, wheel

3. Remove the shoe retracting spring by using the spe-

Fig. 7 SM13-658 SM13-657

Assembly Standard : 320 mm (12.60 in.)

4. Measure the runout.

2. INSPECT THE BRAKE SHOE ASSEMBLY FOR CRACKS

Unit: mm b. Brake shoe re-lining

adhesive tape to prevent losing them.)

4. INSPECT THE SPRING FOR CRACKS OR ANY OTHER

5. INSPECT THE WHEEL CYLINDER

Fig. 20 SM13-403 SM13-392

● The parts where the rubber grease should

2. Install the wheel cylinder

Fig. 25 SM13-666 14.0 (0.551) 1,500 – 2,000 (109 – 144)

3. Install the brake shoe assembly.

7. Install the ABS wheel sensor, wheel hub bearing,

8. Install the wheel.

4. Remove the retainer ring and then remove the sub

9. Remove the retainer ring, then remove the primary

Fig. 17 ASM13-012 SM13-837

4. PRIMARY PISTON AND SECONDARY PISTON

5. PRIMARY AND SECONDARY PISTON RETURN

6. PRIMARY AND SECONDARY FEED VALVE

7. PRIMARY AND SECONDARY FEED VALVE RETURN

8. SECONDARY VALVE BODY

3. Install the secondary feed valve assembly, feed valve

7. Install the O-ring on the primary piston.

3. Gradually depress the pedal to check for the point

where the pressure gauge shows the first rise.

Fig. 41 Primary line SM13-537