PARKING BRAKE

CONTENTS
SYSTEM OVERVIEW....................................................................................PB-1
OVERVIEW ...............................................................................................PB-1
PARKING BRAKE VALVE..............................................................................PB-2
CONSTRUCTION .....................................................................................PB-2
DISASSEMBLY AND REASSEMBLY........................................................PB-3
INSPECTION .......................................................................................... PB-11
RELAY VALVE .............................................................................................PB-13
CONSTRUCTION ...................................................................................PB-13
DISASSEMBLY AND REASSEMBLY......................................................PB-14
PERFORMANCE TESTING....................................................................PB-14
SERVICE DATA ...........................................................................................PB-15
TIGHTENING TORQUE ..........................................................................PB-15

PB
 SYSTEM OVERVIEW PARKING BRAKE

SYSTEM OVERVIEW
OVERVIEW
Operation diagrams (BAL41, BPL41 models)

Pneumatically controlled spring brake is utilized as parking brake

equipment and secondary braking equipment. Their construction
consists of a brake chamber fixed to the brake bracket that is cou-
pled with an expander inside the brake.
Operation is carried out using the parking brake valve located in the
driver's cab. When the spring brake is being used, the air in the
brake chamber is expelled, and when the brake is not being used,
the chamber is filled with air.
When the brake is being used, the tensile force of the extended
spring presses the wedge assembly in the expander to move the
plunger in the brake operating direction. This causes the brake
shoe to expand, creating the braking power.

PB-1
 PARKING BRAKE VALVE PARKING BRAKE

PARKING BRAKE VALVE

CONSTRUCTION
2-port type

3-port type

PB-2
 PARKING BRAKE VALVE PARKING BRAKE

DISASSEMBLY AND REASSEMBLY

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

1 Grip 2 Hold spring 3 Pin (3 mm)
4 Grip holder 5 Lever lock assembly 6 Cover
7 Slide cover B 8 Slide cover A 9 Hexagon socket bolt
10 Lock washer 11 Lever & spring assembly 12 Pin (4 mm)
13 Mounting plate 14 O-ring 15 Upper body
16 Seal ring 17 Piston A 18 Parallel pin
19 Piston & plunger assembly 20 Piston B 21 Exhaust stem
22 Shim 23 Main spring 24 O-ring
25 Piston C 26 O-ring 27 Guide bushing
28 O-ring 29 Lower body 30 Screw
31 Nipple holder 32 Exhaust nipple

PB-3
 PARKING BRAKE VALVE PARKING BRAKE

Key point of disassembly

<2-port and 3-port type>
1. Pull out the grip while holding down the grip holder.

2. Insert a hexagon wrench (1.5 mm) into the pin hole to push out
the pin ( 3 mm) and pull out the lock assembly.

3. Press inward the two hooks on the cover simultaneously with

fingers, then pull the cover upward to remove it from the
mounting plate.
Then remove the slide cover A and B.

4. Slightly loosen hexagon socket bolt at two locations with a

hexagon wrench (4 mm).
Loosen the hexagon bolts further and remove them with the
lock washers, then remove the lever & spring assembly.

PB-4
 PARKING BRAKE VALVE PARKING BRAKE

5. Use a hexagon wrench (1.5 mm) to push out the pin (4 mm)
and remove the mounting plate and O-ring.

6. Remove the upper body and seal ring while holding the
plunger and the head of piston C.

7. Remove the parallel pin and remove the piston & plunger
assembly, shim and main spring.

PB-5
 PARKING BRAKE VALVE PARKING BRAKE

<3-port type only>

1. Pull out the piston C, then remove the O-rings from the piston
C.

2. Remove the guide bushing, and then remove the O-ring from
the guide bushing.

Key point of reassembly

<3-port type only>
1. Install the O-ring to the guide bushing, and then install the
guide bushing to the lower body.

NOTE
 Apply approx. 1 gram of grease evenly to the inner diam-
eter sliding surface (large diameter side) of the lower
body.
 Apply approx. 0.1 grams of grease evenly to the O-ring.

2. Install O-rings to piston C, then install piston C to the guide

bushing.

NOTE
 Apply approx. 0.1 grams of grease evenly to the O-rings.

PB-6
 PARKING BRAKE VALVE PARKING BRAKE

<2-port and 3-port type>

1. Assemble the main spring into the round groove at the bottom
of the lower body, then place the shim on the main spring.

2. Hold piston A of the piston & plunger assembly with fingers.

Assemble by facing the cutout side of plunger towards piston
C (or the hole for piston C) and aligning the octagon at the bot-
tom end of exhaust stem with the octagon at the bottom of the
lower body.

NOTE
 If the new piston & plunger assembly is not greased,
remove the O-rings and apply approx. 0.1 grams of
grease evenly before assembling.
 When the piston & plunger assembly is assembled to the
lower body, the height of piston A end surface from the
lower body end surface should be within 16 mm. If the
height is approx. 20 mm, the octagonal fitting is not
engaged. Reassemble the parts.
3. Fit the seal ring into the seal ring groove in the upper body.
Insert the two parallel pins into the holes in the lower body, and
then put the upper body onto the lower body.

NOTE
 Apply approx. 0.1 grams of grease evenly to the seal
ring.
 Apply approx. 1 gram of grease to the sliding surfaces in
the upper body for piston A, plunger and piston C.
 Make sure that the seal ring is not protruding from its
groove and trapped between the upper body and lower
body.

4. Fit the O-ring into the O-ring groove in the upper body, then
install the mounting plate.

NOTE
 The O-rings are for fixing and require no grease.

PB-7
 PARKING BRAKE VALVE PARKING BRAKE

5. Make fine adjustment so that the two flats of the plunger

becomes parallel with the edges of the upper body (error
should be within ± 2 degrees), then insert the pin (4 mm).

NOTE
 Apply approx. 0.2 grams of grease to the sliding surface
(rounded surface) for the lever & spring assembly in the
upper body.
 The ends of the pin (4 mm) must be equally protruding
from the two flats of the plunger at both sides.
 Apply approx. 0.2 grams of grease to the cam sliding sur-
face of the pin (4 mm).

6. Put the lever & spring assembly in position on the mounting

plate while facing the lever of the lever & spring assembly in
the direction away from piston C.

7. Set the lock washer and hexagon socket bolt in the through
hole in the lever & spring assembly.
Tighten the hexagon socket bolt with a hexagon wrench (4
mm) until the bolt head contacts the lock washer.

8. Tilt the lever of the lever & spring assembly in the direction
towards piston C, then tighten the hexagon socket bolt until it
seats.

Tightening torque [N•m {kgf•m}]: 2.0 - 4.0 {0.2 - 0.4}

PB-8
 PARKING BRAKE VALVE PARKING BRAKE

NOTE
 Apply approx. 0.2 grams of grease to the entire surface
of the lever of the lever & spring assembly.

 Apply approx. 0.3 grams of grease to the sliding surfaces

between the lever & spring assembly and lever lock
assembly as shown as a shaded area in the figure.

9. Place slide cover A over the lever and along the upper guide of
the lever & spring assembly so that the corner cutout comes to
the top.
Likewise, place slide cover B over slide cover A.
Place the cover over the lever & spring assembly with the lever
going through the cover.

10. Press the cover until the hooks at the bottom snap into the
mounting plate holes. Make sure the cover does not come off.

CAUTION
 Incorrect assembly of the covers may prevent smooth
operation of the lever, consequently degrading the per-
formance.

PB-9
 PARKING BRAKE VALVE PARKING BRAKE

11. Since the lever lock assembly hooks are asymmetrical in

shape (hook sizes not same), it must be assembled to the
lever & spring assembly while the lever going through the
cross opening in slide cover A and by following the procedures
shown below.
a) Press down the grip holder, then insert pin ( 3 mm) until its
end becomes flush with the hole.

b) Install the hold spring to the lever (3-port type only).

c) Grip is pushed on.

NOTE
 If it is difficult to insert the lever lock assembly into slide
cover A, make sure that slide cover A is facing the cor-
rect direction.

CAUTION
 If forcibly assembled in a wrong way, the lever may not
be able to operate smoothly and consequently the per-
formance will be degraded.

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 PARKING BRAKE VALVE PARKING BRAKE

INSPECTION
OPERATION TESTING
Piping diagram for inspection

INSPECTION ITEM
1. Air leakage inspection (Driving position)

Lever position : Driving position

Inspection pressure : 0.93 MPa and 0.05 MPa (To supply side)
Inspection method : Supply inspection pressure, maintain a stable pressure for a certain period, and then shut
the cut valve
Inspection standard : Pressure drop at supply port (or port 21) in 15 seconds should be 0.003 MPa or less
2. Air leakage inspection (Parking position)

Lever position : Parking position

Inspection pressure : 0.93 MPa and 0.05 MPa (To supply side)
Inspection method : Supply inspection pressure, maintain a stable pressure for a certain period, and then shut
the cut valve
Inspection standard : Pressure drop at supply port in 15 seconds should be 0.003 MPa or less
3. Air leakage inspection (Test position) 3-port type only

Lever position : Test position

Inspection pressure : 0.93 MPa (To supply side)
Inspection method : Supply inspection pressure, maintain a stable pressure for a certain period, and then shut
the cut valve
Inspection standard : Pressure drop at supply port (or port 22) in 15 seconds should be 0.003 MPa or less
4. Air leakage inspection (Exhaust leakage inspection)

Lever position : Driving position parking position

Inspection pressure : 0.93 MPa (To supply side)

PB-11
 PARKING BRAKE VALVE PARKING BRAKE

Inspection method : Connect a hose longer than 450 mm to the exhaust nipple. Supply inspection pressure,
maintain a stable pressure for a certain period, then move the lever from driving position to
parking position
Inspection standard : Make sure that there is no leakage at the contact surfaces between the exhaust nipple and
lower body
5. Operation characteristic inspection

a) Make sure that the outlet pressure varies as shown in the dia-
gram according to the lever angle.

b) Maker sure that the lever moves smoothly in both directions.

6. Lever operation torque inspection

Inspection item : 1. Operating torque at operating angle 10º

Inspection pressure
Operation range for inspection
Inspection method
2. Maximum torque within the operating range
: 0.93 MPa
: From driving position to parking position
: Check for the force needed to move the parking brake valve lever by deriving the
torque acting on the lever pivot

Maintenance standard Remarks

Inspection item
N•m kgf•m
Operation angle 10º Less than 1.6 Less than 0.16
Maximum torque Less than 6.3 Less than 0.64

PB-12
 RELAY VALVE PARKING BRAKE

RELAY VALVE
CONSTRUCTION

PB-13
 RELAY VALVE PARKING BRAKE

DISASSEMBLY AND REASSEMBLY

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

1 Bolt 2 Cover 3 O-ring
4 Relay valve complete 5 Return spring 6 Seal ring
7 Body 8 Screw 9 Lock washer
10 Inlet exhaust valve 11 Valve retainer 12 Valve spring
13 O-ring 14 Valve guide 15 O-ring
16 Retaining ring 17 Exhaust cover 18 Exhaust check valve
19 Plug

PERFORMANCE TESTING
Confirm that when air is pressurized from the inlet side, the differ-
ence between the inlet pressure and outlet pressure is less than
39kPa {0.4kgf/cm2}.

PB-14
 SERVICE DATA PARKING BRAKE

SERVICE DATA
TIGHTENING TORQUE
Tightening torque
Item
N•m kgf•m
Parking brake valve Hexagon socket bolt 2.0 - 4.0 0.2 - 0.4
Cover mounting bolt 4.0 - 6.8 0.4 - 0.7
Relay Valve
Exhaust cover mounting screw 3.0 - 4.9 0.3 - 0.5

PB-15