Group 35 Brake

GROUP 35 BRAKE
SPECIFICATIONS ................................ 35-2 HANDLING OF NYLON TUBE FOR

AIR LINE
STRUCTURE AND OPERATION <PUSH-IN TYPE> ................................. 35-48
1. Brake System ................................ 35-4
<COMPRESSION TYPE> .................... 35-51
2. Air Compressor ........................... 35-14
<TUBE IDENTIFICATION COLORS>... 35-54
3. Air Dryer ...................................... 35-15
HANDLING OF CONNECTOR ........... 35-55
4. Dual Brake Valve .......................... 35-18
5. Wheel Brake ................................ 35-22 AIR COMPRESSOR ........................... 35-56
6. 4-Way Protection Valve ................ 35-27
AIR DRYER ....................................... 35-60
7. Relay Valve .................................. 35-28
8. Quick Release Valve .................... 35-30 BRAKE PEDAL .................................. 35-64
9. Hand Control Valve FRONT WHEEL BRAKE .................... 35-72
<Trailer Brake> ............................. 35-31
10.Trailer Control Valve REAR WHEEL BRAKE ...................... 35-80
<Trailer Brake> ................................ 35-32 BRAKE CHAMBER ............................ 35-88
11.Quick Release Valve
<Trailer Brake> ................................ 35-36
EXPANDER ........................................ 35-92
4-WAY PROTECTION VALVE ............ 35-98
TROUBLESHOOTING ....................... 35-38
RELAY VALVE .................................. 35-104
ON-VEHICLE INSPECTION AND
ADJUSTMENT QUICK RELEASE VALVE ................ 35-108
1. Exhaust Noise from
CHECK VALVE ..................................... 35-110
Brake Valve .................................. 35-40
2. Air Pressure Build-up .................. 35-40 SAFETY VALVE .................................... 35-111
3. Inspection and Adjustment of
HAND CONTROL VALVE
Brake Pedal Free Play .................... 35-41 <TRAILER BRAKE> ........................ 35-112
4. Inspection of Brake
Lining Thickness ......................... 35-41 TRAILER CONTROL VALVE
5. Initial Adjustment of Clearance <TRAILER BRAKE> ........................ 35-116
between Brake Drum and Shoe..... 35-42 QUICK RELEASE VALVE
6. Maintenance and Inspection of <TRAILER BRAKE> ........................ 35-120
Air Dryer ...................................... 35-43
DOUBLE CHECK VALVE
7. Inspection and Adjustment of Air <TRAILER BRAKE> ........................ 35-122
Dryer’s Air Pressure Governor ..... 35-44
8. Inspection of the 4-way Protection AIR SERVICE VALVE
Valve ................................................ 35-47 <TRAILER BRAKE> ............................ 35-123
35-1
SPECIFICATIONS
Air compressor
Item Specifications
Type Water-cooled 1 cylinder
Cylinder bore × stroke mm φ85 × 60
3
Cylinder displacement cm {mL} 340 {340}
Manufacturer Sanwa Seiki
Air dryer
Item Specifications
Model DU-5
Purge chamber capacity dm3 {L} 2.7 {2.7}
Required time for recycling desiccant sec. 50
Upper threshold
Threshold pressure of Air 800 +29 +0.3
–20 {8.2 –0.2 }
pressure
pressure governor
kPa {kgf/cm2} Lower threshold 690 ± 15 {7.0 ± 0.15}
pressure
Manufacturer Nabtesco
Air tank
Specifications
Item
FP-R FS, FV
30, 33, 33 (18 + 15) 30, 33, 33 (18 + 15), 23
Capacity dm3 {L}
{30, 33, 33 (18 + 15)} {30, 33, 33 (18 + 15), 23}
Wheel brake
Item Specifications
Type Wedge type
Brake type Leading trailing type
Brake drum inside diameter mm 410
Brake lining width × thick- Front axle 150 × 16
ness mm Rear axle 200 × 16
Brake chamber type ( O - Front axle No. 20
O shown for wheel park-
ing brake-equipped type) Rear axle No. 24-24
Brake shoe clearance adjustment Automatic adjusting type
35-2
35
M E M O
35-3
STRUCTURE AND OPERATION
1. Brake System
<FP-R>
35-4
35
1 Front brake chamber 20 Stop lamp switch <Service brake>
2 Air dryer 21 Low air pressure switch
3 4-way protection valve 22 Air pressure gauge
4 Air tank 23 Synchro-valve
5 Safety valve 24 Air service valve
6 Air take-off valve 25 Trailer control valve
7 Rear brake chamber 26 Air coupling <Control>
8 Relay valve 27 Air coupling <Supply>
9 Relay valve (with double check valve)
10 Check valve A: Air line
11 Air compressor B: Hose
12 Air cleaner C: To auxiliaries
13 Quick release valve G: Green tape
14 Double check valve L: Blue tape
15 Stop lamp switch <Trailer brake> O: Orange tape
16 Hand control valve <Trailer brake> R: Red tape
17 Hand control valve <Wheel parking brake> W: White tape
18 Parking brake switch Y: Yellow tape
19 Dual brake valve
• The service brake is a full air acting-on-all wheels brake with two completely independent circuits. If one of the cir-
cuits is damaged and leaks air, the other circuit is kept working.
• The 4-way protection valve shuts off a leaking air circuit to keep other air circuits working.
• The trailer control valve controls the brake air pressure supplied to the trailer.
35-5
<FS>
35-6
35
1 Front brake chamber 20 Low air pressure switch
2 Air dryer 21 Air pressure gauge
3 4-way protection valve 22 Synchro-valve
4 Air tank 23 Air service valve
5 Safety valve 24 Trailer control valve
6 Air take-off valve 25 Quick release valve
13 Double check valve G: Green tape
14 Stop lamp switch <Trailer brake> L: Blue tape
15 Hand control valve <Trailer brake> O: Orange tape
16 Hand control valve <Wheel parking brake> R: Red tape
17 Parking brake switch W: White tape
18 Dual brake valve Y: Yellow tape
19 Stop lamp switch <Service brake>
35-7
<FV51JKM2>
35-8
35
1 Front brake chamber 15 Parking brake switch
2 Air dryer 16 Dual brake valve
3 4-way protection valve 17 Low air pressure switch
4 Air tank 18 Air pressure gauge
5 Safety valve
6 Air take-off valve A: Air line
7 Rear brake chamber B: Hose
8 Relay valve C: To auxiliaries
9 Relay valve (with double check valve) G: Green tape
10 Air compressor L: Blue tape
11 Air cleaner O: Orange tape
12 Quick release valve R: Red tape
13 Stop lamp switch W: White tape
14 Hand control valve Y: Yellow tape
35-9
<FV (except FV51JKM2)>
35-10
35
1 Front brake chamber 20 Stop lamp switch <Service brake>
2 Air dryer 21 Low air pressure switch
3 4-way protection valve 22 Air pressure gauge
4 Air tank 23 Synchro-valve
5 Safety valve 24 Air service valve
6 Air take-off valve 25 Trailer control valve
13 Quick release valve D: To air suspension (See Gr34B.)
14 Double check valve G: Green tape
15 Stop lamp switch <Trailer brake> L: Blue tape
16 Hand control valve <Trailer brake> O: Orange tape
17 Hand control valve <Wheel parking brake> R: Red tape
18 Parking brake switch W: White tape
19 Dual brake valve Y: Yellow tape
35-11
Auxiliaries
1 Connector
*b:
a: FP-R
2
3
Clutch booster
Clutch master cylinder
*A: FP-R, FV54JT
Air line
4 Reducing valve B: Hose
5 Magnetic valve C: Fluid line
6 Power cylinder D: To 4-way protection valve
E: To exhaust gas recirculation magnetic valve
(See Gr17.)
F: To turbocharger magnetic valve (See Gr15.)
G: To air suspension (See Gr34B.)
H: To differential lock
I: To air horn
J: To cab air suspension
L: Blue tape
R: Red tape
35-12
35
M E M O
35-13
2. Air Compressor
2.1 During suction

• When the piston goes down during the suction stroke cycle, the
vacuum causes the suction valve to open, allowing air to be
drawn into the cylinder.
2.2 During compression and delivery

• When the piston goes up during the compression and delivery
stroke cycle, the suction valve is closed by air pressure.
• Air pressure compressed by the piston forces open the delivery
valve and makes its way to the air dryer and air tank.
35-14
35
3. Air Dryer
• The air dryer protects brake compo-
nents by removing moisture and oil
from air that has been compressed by
the air compressor.
• The air dryer incorporates an air pres-
sure governor, which keeps the pres-
sure in the air tank constant by
releasing air compressed by the air
compressor to the atmosphere when
the pressure in the air tank makes
such operation necessary.
35-15
3.1 Drying action
• While the air tank is being charged, air
from the air compressor enters the air
dryer’s supply side. Moisture and oil
are separated from the air inside the
body and collect in the bottom. The air
then passes through the oil filter,
which removes smaller oil droplets
and particles of dust. The air then
flows into the case, where the desic-
cant removes any remaining moisture.
• As the air flows upward in the case, it
makes contact with increasingly dry
desiccant and thus contains less and
less moisture. When the air reaches
the top of the case, it is dry. It flows
through the check valve A, purge
chamber, and check valve B, and it is
then supplied from the delivery side to
the air tank. Air pressure also acts
upon the piston in the air pressure
governor.
3.2 Regeneration of desiccant

• When the air pressure in the air tank
reaches the upper threshold level, sig-
nal pressure from the air pressure
governor causes the valve in the air
dryer’s control port to open. As a re-
sult, the pressure in the case cleans
the oil filter and pushes the water and
oil out into the atmosphere.
• Following the rapid drop in pressure,
dry air in the purge chamber flows
through the orifice, expands, and be-
comes super-dry. As this super-dry air
flows backward through the case, it
carries moisture from the desiccant
out into the atmosphere, thereby com-
pleting the desiccant’s regeneration.
• During the regeneration process, the
check valve is closed. Thus, the signal
pressure from the air pressure gover-
nor continues to act upon the control
port and the valve remains open. Air
from the air compressor thus flows
through the valve, through the silenc-
er, and out into the atmosphere.
• The regeneration process continues
until air consumption causes the pres-
sure in the air tank to decrease to the
governor lower threshold level.
35-16
35
3.3 Operation when tank pres-
sure reaches upper threshold
level
• Air pressure from the air tank continu-
ously acts upon the piston.
• When the tank pressure increases to
such a level that it overcomes the
spring, it pushes the piston upward
such that the valve closes.
• When the tank pressure increases fur-
ther and exceeds the upper threshold
level, the piston is pushed upward fur-
ther such that the exhaust stem opens
the intake valve. Air pressure from the
air tank thus flows out of the air pres-
sure governor as signal pressure,
causing the valve to open. Regenera-
tion of the air dryer’s desiccant thus
begins.
3.4 Operation when tank pres-

sure reaches lower threshold
level
• When the air pressure A from the air
tank drops below the lower threshold
level, the piston is pushed downward
by the spring such that the intake
valve closes and the exhaust valve
opens. As a result, air pressure flows
through the exhaust stem and es-
capes to the atmosphere.
35-17
4. Dual Brake Valve
• The dual brake valve controls the
braking force of the vehicle by feeding
pressurized air to the brake chamber
in accordance with the pressed angle
of brake pedal.
4.1 When brake not operating

• The spring forces of spring A and
spring B seat primary intake valve at
primary side and secondary intake
valve at secondary side on their re-
spective seats. This shuts off air from
the air tank to maintain air tightness.
The spring force of spring C raises pis-
ton to its upper position. Exhaust valve
seat A opens and chamber A is open
to atmosphere via chamber B.
• Since the spring forces of spring E is
stronger than the spring force of spring
D, relay piston is raised to its upper
position and exhaust valve seat B is
opened. This opens chamber C to at-
mosphere via chamber B. Chamber A
at the primary side and chamber D at
the upper part of relay piston at the
secondary side are connected via pas-
sage port of the body.
35-18
35
4.2 When pressing brake pedal
(before braking pressure is
generated)
• Pressing the brake pedal (illustrated
as brake pedal action) forces down
piston via plunger.
• Forcing down piston changes the bal-
ance between the spring forces of
spring F and spring G, and the spring
force of spring D, forcing down relay
piston. This seats the piston on sec-
ondary intake valve and closes ex-
haust valve seat B.
• This closes the secondary side ex-
haust passage; however, primary side
exhaust valve seat A remains open.
No braking pressure is generated at
either primary or secondary sides.
4.3 When pressing brake pedal

(braking pressure is generat-
ed)
(1) Primary side
• As the brake pedal is pressed further
(illustrated as brake pedal action), pis-
ton is forced down until it is seated on
primary intake valve, closing exhaust
valve seat A.
• Primary intake valve is forced down,
compressing spring A, and supply
valve seat A of body separates from
the primary intake valve. The air in
supply port chamber E flows into
chamber A and is fed to rear brake
system via discharge port as braking
pressure.
(2) Secondary side

• The air at the primary side flows into
chamber D via passage port of the
body.
• The air fed into chamber D acts on the
upper part of relay piston to force
down the piston and compress spring
B, forcing up secondary intake valve.
• This separates cover, supply valve
seat B and secondary intake valve.
• The air in supply port chamber F flows
into chamber C and is fed to front
brake system via discharge port as
braking pressure.
35-19
4.4 Stabilization of braking pressure
• When the brake pedal remains pressed at the specified depression angle, the braking air pressure stabilizes at
the pressure corresponding to the pressed angle of brake pedal.
(1) Primary side

• The braking air pressure fed under the
bottom of piston raises the piston and
primary intake valve together in tan-
dem.
• Primary intake valve makes contact
with supply valve seat A, then the sup-
ply of air from the air tank ceases and
the increase in the braking air pres-
sure stops. This stabilizes braking
pressure for the rear brake system.
(2) Secondary side

• As the braking pressure (pressure in
chamber C) for the front brake system
balances the pressures in chambers A
and D, the force pushing down the re-
lay piston disappears, and the relay
piston rises in tandem with secondary
intake valve.
• Secondary intake valve makes contact
with supply valve seat B of cover, then
the supply of air from chamber F to
chamber C ceases and the increase in
the braking air pressure stops. This
stabilizes brake pressure for the front
system.
4.5 Release of brake pressure

(1) Primary side
• When the brake pedal is released (il-
lustrated as brake pedal action),
spring C and air pressure at discharge
port (pressure in chamber A) raise the
plunger and the piston. Then, exhaust
valve seat A at the lower end of the
piston separates from primary intake
valve.
• The air pressure of the rear brake sys-
tem flows through chamber A to be
discharged from exhaust passage
chamber B into atmosphere.
35-20
35
(2) Secondary side
• As the air pressure in the rear brake
system drops, the air pressure in
chamber D is discharged via passage
port of the body, and chambers A, B
into atmosphere.
• This changes the air pressure balance
between chambers D and C. The air
pressure in chamber C raises relay
piston, and exhaust valve seat B at the
lower end of the relay piston separates
from secondary intake valve. Air pres-
sure in the front brake system is dis-
charged from exhaust passage
chamber B into atmosphere.
4.6 When abnormality occurs

(1) Operation when the air pipe of the
front brake system fails
• The primary side operates the same
as normal, generating braking pres-
sure in rear brake system.
• At the secondary side, even if the pri-
mary side generates air pressure in
chamber D, braking pressure is not
generated in front brake system since
no air pressure is generated in supply
port F.
(2) Operation when the air pipe of the

rear brake system fails
• In the rear brake system, air pressure
is not generated up to supply port
chamber E. Therefore, even if the
brake pedal is pressed (causing the
piston to force down the primary intake
valve), braking pressure is not gener-
ated.
• If the brake pedal is pressed further (il-
lustrated as brake pedal action), the
piston makes contact with the relay
piston and they force down the sec-
ondary intake valve.
• This action separates supply valve
seat B of the cover from the secondary
intake valve. The air pressure flows
into chamber C from chamber F and is
fed to the front brake system via the
discharge port as braking pressure.
35-21
5. Wheel Brake
• The wheel brake is a leading-trailing
shoe type brake.
• The double-acting expander ensures
that, in both the forward- and rear-
ward-travel braking, one of the brake
shoes operates as a leading shoe
which, through self-boosting effect,
generates a great stopping power.
5.1 Wedge mechanism

• When air pressure is applied to the
brake chamber, the push rod is
pushed into the wedge.
• This causes the wedge to push open
the sleeves of the expander through
rollers, expanding the brake shoes.
35-22
35
5.2 Brake chamber
<Without Spring Chamber>
• When air pressure is applied to the brake chamber, the push rod and wedge are pushed by the medium of the di-
aphragm.
• When air pressure is released from the brake chamber, the wedge and push rod are forced back to their original
positions by the spring.
<With Spring Chamber>
• In addition to the service brake, the brake chamber incorporates a spring brake mechanism.
• The washer, release nut and release bolt are used for mechanical release of the spring brake.
35-23
(1) Service brake
(1.1) Operation
service brake port, the push rod and
wedge are pushed forward by the me-
dium of the diaphragm.
(1.2) Release
• When air pressure at the service brake
port is released, the wedge and push
rod are forced back to their original po-
sitions by the spring.
(2) Spring brake (wheel parking brake)

(2.1) Operation
• When air pressure at the spring brake
port is released, the piston, push rods
A and B and wedge are pushed for-
ward by the spring in the piggyback.
(2.2) Release
spring brake port, the piston is pushed
back by the medium of the diaphragm
to compress the spring A.
• The push rod A is forced back to its
original position by the spring B.
• The wedge and push rod B are forced
back to their original positions by the
spring C.
35-24
35
5.3 Expander
• As the wedge is pushed in, the rollers are increasingly open along the tapered portion of the wedge.
• The rollers roll along the tapered surfaces of the sleeves to push the sleeves and adjusting screws outward.
• The body of the expander incorporates an automatic adjuster mechanism for brake shoe clearance.
(1) Automatic adjuster mechanism

• Each adjusting screw is locked by the
clip not to move in the turning direc-
tion.
• Each clip is locked by the brake shoe
not to move in the turning direction.
(1.1) When brake shoe clearance is as

specified
• The bottom of the sleeve is in contact
with the body before braking.
• The drive ring is held in contact with
the body by the spring.
35-25
• When the brake is operated, the
sleeve moves within the limits of back-
lash.
(1.2) When brake shoe clearance is

larger than specified
• When the brake is operated, the
sleeve moves beyond the limits of
backlash, and the drive ring is pushed
by the spring to rotate along the thread
lead surface of the sleeve.
• The drive ring is held in contact with
the body by the spring.
• When the brake is released, the

sleeve is moved until its bottom con-
tacts the body.
Although the sleeve moves without ro-
tating as much as backlash, rotates
thereafter along the thread lead sur-
face of the drive ring. The adjusting
screw is pushed out by the effect of its
thread and the brake shoe clearance
is thereby adjusted to the specified
value.
35-26
35
6. 4-Way Protection Valve
• Should air leak from one air line, the 4-way protection valve shuts off the faulty air circuit and protects other air
lines.
Even if air leaks from any port in the air system, other ports maintain tank pressure at the valve closing level. Also,
when air is refilled by the air compressor, it is filled up to the valve opening pressure for the leaking port.
• The circuits of the output ports (21) and (22) are provided with bypass circuits to ensure that air pressure is deliv-
ered from the output ports (21) and (22) before the output ports (23) and (24).
35-27
7. Relay Valve
• The relay valve supplies air in the air
tank to the brake chamber in accor-
dance with a command pressure from
the dual brake valve.
7.1 When operated

• When command pressure A flows in,
the piston is moved downward to rest
on the intake valve. The exhaust valve
seat is closed to prevent air flow into
the exhaust passage chamber G.
• The intake valve is pushed down while
compressing the spring, and the sup-
ply air valve seat of the body and the
intake valve are opened apart be-
tween them.
• Air pressure B from the air tank flows
out from the chamber C into the cham-
ber D and is delivered to the discharge
port E.
7.2 Stabilization of air pressure

• When command pressure A is main-
tained at a constant level, air pressure
from the discharge port E is stabilized
as well in accordance with the com-
mand pressure.
• Air pressure in the chamber D passes
through the passage F to act on the
bottom of the piston. The piston and
intake valve are pushed upward to-
gether in close contact with each oth-
er.
• When the intake valve comes into con-
tact with the supply air valve seat of
the body, supply of air pressure B from
the air tank is stopped. The air pres-
sure stops rising and stabilizes.
35-28
35
7.3 Release of air pressure
• Upon loss of command pressure A,
the piston is pushed up by the spring
and air pressure at the discharge port
E side (air pressure in the chamber D)
and the exhaust valve seat at the bot-
tom of the piston leaves the intake
valve.
• Discharge-side air pressure E is re-
leased into the atmosphere from the
exhaust passage chamber G in the
middle.
35-29
8. Quick Release Valve
8.1 When operated
• Air pressure from the supply port
pushes down the diaphragm and ring
into close contact with the body, shut-
ting off the chambers A and B. The air
pressure further pushes down the
spring. The diaphragm and ring leaves
the housing and the air pressure flows
into the chamber B.
8.2 When released

• Air pressure from the supply port is re-
leased, and the diaphragm and ring is
allowed to leave the body by the ten-
sion of the spring. Simultaneously, air
pressure from the brake chamber is
discharged from the exhaust port into
the atmosphere.
35-30
35
9. Hand Control Valve <Trailer Brake>
• The hand control valve allows the
brake to be manually operated on the
trailer side only.
9.1 When operated

• When the trailer brake lever is operat-
ed in the brake activating direction, the
exhaust valve is pushed by means of
the cam into close contact with the
feed valve. The exhaust port is closed
as a result. When the trailer brake le-
ver is further operated, the feed valve
leaves the valve seat of the piston to
open the supply valve seat.
Air pressure at the supply port thus
flows to the discharge port.
9.2 When released

• When the trailer brake lever is placed
into the Release position (automatical-
ly returned to the Release position
when released), the feed valve is
moved by the valve spring into close
contact with the valve seat of the pis-
ton and the supply valve seat is closed
as a result. The exhaust valve is
moved by the return spring and the ex-
haust port of the exhaust valve opens.
Thus, air pressure at the supply and
discharge ports is released through
the exhaust port of the exhaust valve
and the exhaust port of the hand con-
trol valve into the atmosphere.
35-31
10.Trailer Control Valve <Trailer Brake>
• The trailer control valve regulates the brake air pressure supplied to the trailer side.
35-32
35
10.1 When normally operated
• When the wheel parking hand control
valve is in the Release position, air
pressure from the port No. 43 flows
into the chamber R to push down the
piston C.
• Air pressure from the port No.11 flows
into the chamber H and joins the
spring in pushing up the piston E.
• The air pressure from the port No. 11
further flows into the chamber J to
supply air pressure to the port No. 12.
10.2 When service brake is operat-

ed
• When the brake pedal is pressed, a
quantity of air pressure proportional to
the leg power is supplied from the port
No. 41 and 42.
• Also, when the trailer brake lever is
operated, a quantity of air pressure
proportional to the operating angle is
supplied from the port No. 41.
• Air pressure at the port No. 41 flows
into the chambers K and L to act on
the piston B.
• Air pressure in the chamber K pushes
down the piston B to rest on the valve,
closing the exhaust valve.
• Air pressure flowing into the chamber
L acts on the upper side of the piston
E, but not to an extent that the piston
is moved.
• The valve is further pushed down to

open the supply valve between the
valve and piston C.
• Air pressure in the chamber J passes
through the supply valve into the
chamber P. Air pressure is supplied to
the port No. 22 to activate the trailer
service brake.
35-33
• The piston A and valve are pushed up
to a position at which air pressure
(chamber K) from the port No. 41 and
air pressure (chamber P) from the port
No. 11 are balanced in the respective
force acting on the piston A.
• The supply valve is closed, air pres-
sure at the port No. 22 is maintained
constant and the braking force is stabi-
lized.
10.3 When dual brake valve (rear

system) is faulty
• Air pressure (rear system) from the
port No. 41 is not supplied and only air
pressure (front system) is supplied.
Therefore, the piston B does not
move.
• Air pressure in the chamber R forces
the piston A down to rest on the valve.
• The exhaust valve is closed, the sup-
ply valve is opened to supply air pres-
sure to the port No. 22.
• The supply valve is closed when air
pressure in the chamber P corre-
sponds with air pressure in the cham-
ber R, maintaining air pressure at the
port No. 22.
10.4 When dual brake valve (front

system) faulty and trailer
brake is operated
• Air pressure (front system) from the
port No. 42 is not supplied, and only
air pressure (rear system) from the
port No. 41 is supplied.
• Air pressure is supplied to the port No.
22 by air pressure in the chamber K as
in the normal condition.
35-34
35
10.5 When trailer brake control
system is faulty
• When the brake pedal is pressed, air
pressure in the chamber K is supplied
to the port No. 22 as in the normal
condition.
• Since air pressure at the port No. 22 is
released into the atmosphere, the air
pressure in the chamber Q is lowered.
This allows the piston E to be pushed
down by air pressure in the chamber L
to restrict the hole, and the air flowing
into the chamber J is reduced as a re-
sult.
• Air pressure at the port No. 12 passes
through the supply valve to be re-
leased from the faulty part of the trailer
brake control system, causing the trail-
er emergency brake to be activated.
10.6 When brake pedal is released

• When the brake pedal is released, air
pressure is discharged from the port
No. 41 and 42. The pistons A and B
and valve are returned to their original
positions, and the supply valve is
closed and the exhaust valve is
opened.
• Air pressure at the port No. 22 passes
through the exhaust valve to be dis-
charged from the exhaust port into the
atmosphere. The trailer service brake
is released as a result.
10.7 When wheel parking brake is

operated
• When the hand control valve for wheel
parking brake is placed into the Park-
ing position, air is discharged from the
port No. 43.
• The piston C is moved upward by the
pressure acting on the piston C in the
chamber J.
• The supply valve is opened as when
the front system is faulty, allowing air
pressure to be supplied to the port No.
22.
35-35
11. Quick Release Valve <Trailer Brake>
11.1 When operated

• Air pressure A from the supply port
pushes down the diaphragm and ring
into close contact with the body, shut-
ting off the chambers A and B. The air
pressure further pushes down the
spring. The diaphragm and ring leaves
the housing and the air pressure A
flows into the chamber A.
• Air pressure B that has been expelled
from the chamber spring chamber is
expelled from the exhaust port.
11.2 When released

• Air pressure A from the supply port is
released, and the diaphragm and ring
is allowed to leave the body by the
tension of the spring. At the same
time, air pressure C from the brake
chamber is expelled from the exhaust
port to the atmosphere and air pres-
sure B is fed to the chamber spring
chamber.
35-36
35
M E M O
35-37
TROUBLESHOOTING
Wheel Brake
Symptoms Brake
Wheel brake
drum over-
not effective
heating
Noise generated when brake pedal is pressed down

Brake shoe return slow when brake pedal is re-
Brake not quite effective though no air leakage
Air leaks when brake pedal is pressed down
Air leaks when brake pedal is released
Wheel brake application one sided

Reference
Gr
Wheel brake works suddenly

leased (brake drum drags)
Warning lamp illuminates

Air pressure too low
Possible causes
Too much brake shoe clearance O O O
Brake lining surface greasy or oily O O
Brake lining surface hardened with degrada-
O O
tion
Brake lining worn O
Brake lining worn and rivet head is exposed O
Uneven wear of brake drum inner surface O
Improper fitness of brake shoe and brake lin-
O
ing
Brake drum mounting loose O O
Uneven material of brake lining O
Wheel brake
Incorrect contact of brake lining O
Deflection of brake drum O
Wheel parking brake activated O
Too little brake shoe clearance O O O
Brake shoe return spring worn-out or broken O O
Expander sleeve return insufficient O O
Wedge or anchor pin rusty O O
Anchor pin loose O
Air pressure not released from brake chamber O
Air pressure delivered into brake chambers
O
uneven
O-ring damaged O
Air tightness of primary or secondary valve in-
O O
Dual brake valve complete
Inefficient return of primary or secondary valve
O
or clogged by foreign matters at exhaust port
Connector loose O O
Air leakage O
Brake air system Improper adjustment of air pressure governor
O
in the air dryer
Air compressor malfunction O
Tires Tire pressure uneven between left and right O Gr31
Gr33,
Suspension Leaf spring U-bolt loose O
34A, B
35-38
35
Air Dryer
Symptoms
Freezing takes place within air dry-

Deposits come out of drain cock of
Engine oil leaks from exhaust port

Air pressure in air tank decreases
No deposits come out of exhaust
Reference
Gr
markedly
air tank
port
Possible causes
er
Deterioration of desiccating agent O
Malfunctioning of valve due to adherence of
O
foreign particles
Extreme lowering of temperature of air dryer
O
Air dryer main body due to adherence of snow/ice
Dry air in air tank flows out in reverse when
check valve of air dryer fails to function as a O
non-return valve
Rising of oil level in air compressor O
35-39
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Exhaust Noise from Brake Valve
• When the brake pedal is pressed and released, exhaust noise
should be heard from the dual brake valve. Check if the pedal
fully returns to its original position without hitching.
2. Air Pressure Build-up

• Fully discharge compressed air by opening the drain cock on the
air tank.
• With the engine started and set at idle, measure the time it takes
for the air pressure indicated on the gauge to rise from 0 kPa {0
kgf/cm2} to 685 kPa {7 kgf/cm2}. The time taken should be up to
11 min.
35-40
35
3. Inspection and Adjustment of Brake Pedal Free Play
Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Depression angle 3.5° +1.0°
–0.5°
– Pedal free play – Adjust
Pedal toe 12 +3.0
–1.5
Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Lock nut 4.9 to 7.8 {0.5 to 0.8} –
[Inspection]
• Measure the free play of the brake pedal by pressing the pedal
toe by hand.
• If the measurement deviates from the standard values, make an
adjustment.
[Adjustment]
• Loosen the lock nut and adjust the free play by turning the set
screw.
• After adjustment, tighten the lock nut to the specified torque.
4. Inspection of Brake Lining Thickness
CAUTION
• Be sure to inspect both shoes on each wheel to avoid malfunction of brakes.

6
(side shoul-
– Thickness of brake lining 16 Replace
der means
wear limit)
• Remove the inspection hole plug from the inspection hole in the
backing plate. Through the inspection hole, measure the thick-
ness of the brake lining.
• If any lining is worn down to the step on the side face, replace all
linings on that axle.
• After the inspection, be sure to install the plug onto the inspec-
tion hole.
35-41
5. Initial Adjustment of Clearance between Brake Drum and Shoe
CAUTION
• To ensure correct operation of the brakes, be sure to inspect both shoes on each wheel.

– Brake shoe clearance 0.3 to 0.8 – Adjust or inspect
– Difference between right and left brake shoe clearances 0 to 0.3 – Adjust or inspect
[Inspection]
• Apply chocks and release the parking brake.
• Press the brake pedal several times to seat the brake shoe for
proper inspection condition.
• Then perform the following inspection. If the measured value de-
viates from the standard value, adjust the clearance.
(1) Brake shoe clearance
• Remove the check hole plug from the dust cover. Insert the feel-
er gauge into the check hole to measure the brake shoe clear-
ance. Take the value when the gauge can be slide in and out
with slight resistance as the brake shoe clearance.
(2) Difference between right and left brake shoe clearances
• Check that the difference between the right and left brake shoe
clearances is within the standard value.
• After inspection, be sure to install the inspection hole plug.
[Adjustment]
• Apply chocks and release the parking brake.
• Jack up the wheel to be adjusted, then check if there is no loose-
ness in the wheel hub bearing.
• Remove the dust cover.
• Insert a 0.4-mm feeler gauge into the check hole at the dust cov-
er. Adjust the clearance by turning the adjust screw of the ex-
pander to the extent that you feel slight resistance when sliding
in and out the feeler gauge. Perform this at two check holes of
the wheel.
• If the proper clearance cannot be obtained, disassemble and in-
spect the expander.
• After adjustment, be sure to install the dust cover.
CAUTION
• When inserting the flat-blade screwdriver, do not damage
the boot of the expander.
35-42
35
6. Maintenance and Inspection of Air Dryer
Perform maintenance and inspections at each of the indicated in-
tervals or distances.
6.1 Every 3 months or 15,000 km
• Check whether the air dryer is functioning properly by opening
the drain cock on the air tank and checking whether water flows
out.
• If a small amount of water flows out, check whether the desic-
cant has changed color. If one fifth or more of the desiccant has
changed in color from white to brown, replace the desiccant with
the desiccant kit. (See “AIR DRYER”.)
• A small amount of moisture may collect whenever the tempera-
ture in the vicinity of the air tank drops by more than 16°C.
• Place the desiccant in the case, then settle the desiccant by tap-
ping gently and evenly around the case with a plastic hammer.
• Place the soft layer side of the filter on the desiccant, and place
the filter plate on the case, then tap the desiccant down.
<Tapping>
• Before tapping the case against the work surface, lay two or
three layers of shop towel on the work surface to protect the bot-
tom of the case from scratches.
• Holding down the filter plate with both hands, lift the case to a
height of about 100 mm and tap it gently against the work sur-
face.
• Tap the case about 30 more times. Make sure the filter plate
drops by 4 to 6 mm from its original position.
WARNING
• Unless the tapping procedure is performed, particles of
desiccant may escape and create blockages in brake lines,
thus preventing normal brake operation.
• Look carefully at the water that flows out of the air dryer’s ex-
haust port. If the water is contaminated with oil, inspect the air
compressor. (See “AIR COMPRESSOR”.)
6.2 Every year or 100,000 km

• Disassemble the air dryer and replace the desiccant, oil filter, fil-
ter, and all rubber parts with the air dryer kit. (See “AIR DRY-
ER”.)
35-43
7. Inspection and Adjustment of Air Dryer’s Air Pressure Governor
Service standards
Upper threshold 800 +29
–20 kPa
– Adjust
Threshold pressure of air pres- pressure {8.2 +0.3
–0.2 kgf/cm2}
–
sure governor
Lower threshold 690 ± 15 kPa
– Replace
pressure {7.0 ± 0.15 kgf/cm2}

– Plug 14.7 to 24.5 {1.5 to 2.5} –
– Cap nut (seat and plate mounting) 4.9 to 5.9 {0.5 to 0.6} –
– Nut (for retention of adjusting screw) 6.9 to 7.8 {0.7 to 0.8} –
Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
– Plug thread ThreeBond 1110B As required
35-44
35
[Inspection]
(1) Air leak
• Install the air pressure gauge A between the air dryer and air
tank (wet tank side).
• Remove the plug from the air dryer at the location shown in the
drawing. Connect air pressure gauge B at that point.
• Start the engine to activate the air compressor such that the air
pressure in the air tank gradually increases. Check that the pres-
sures indicated by the pressure gauges A, B do not decrease
when air is expelled from the silencer.
• If the pressure indicated by either of the pressure gauges A, B
decreases, air is leaking from the check valve and air pressure
governor in the air dryer causing continuous charging and purg-
ing. Carry out the disassembly and inspection of the air dryer.
(2) The upper threshold pressure of air pressure governor

• Start the engine and gradually increase the air pressure in the
air tank.
• When air is expelled from the silencer, check whether the pres-
sure indicated by air pressure gauge A is the standard value (the
upper threshold pressure). If the indicated pressure deviates
from the standard value, make adjustments.
(3) The lower threshold pressure of air pressure governor

• With the upper threshold pressure indicated, open the drain
cock to gradually reduce the air pressure. When air stops being
expelled from the silencer, check whether the pressure indicated
by air pressure gauge B is the standard value (the lower thresh-
old pressure). If the indicated pressure deviates from the stan-
dard value, replace relevant parts of the air pressure governor
as an assembly.
35-45
[Adjustment]
Threshold pressure of air pressure governor
• Remove the cap nut, plate, and seat.
• Start the engine and gradually increase the air pressure in the
air tank.
• Turn the adjusting screw until the pressure indicated by air pres-
sure gauge A when air is expelled from the silencer is the stan-
dard value (the upper threshold pressure).
• Reduce the air pressure to the low threshold pressure or lower,
then gradually increase it again. Check whether the pressure in-
dicated by the air pressure gauge A is the standard value (the
upper threshold pressure). If the indicated pressure deviates
from the standard value, make further adjustments.
35-46
35
8. Inspection of the 4-way Protection Valve
Service standards
460 ± 20 kPa
– Closing valve pressure – Adjust or replace
{4.7 ± 0.2 kgf/cm2}
• Perform the following inspections. If the measured value is out of

the standard value, repair or replace the valve. (See “4-WAY
PROTECTION VALVE”.)
• Before each inspection, run the engine until the air gauge (2-
pointer type) in the meter cluster indicates the maximum pres-
sure. The inspections should be performed with the engine
stopped, and read the air gauge in the meter cluster when its in-
dication becomes stable.
8.1 Valve closing pressure on discharge port No. 21

• Open the discharge port (21) to atmosphere. When one air
gauge lowers to 0 kPa {0 kgf/cm2}, read the other air gauge.

• Open the discharge port (22) to atmosphere. When one air
gauge lowers to 0 kPa {0 kgf/cm2}, read the other air gauge.

• Open the discharge port (23) to atmosphere and confirm that the
indications of two pointers are both within the standard value.

• Open the discharge port (24) to atmosphere and confirm that the
indications of two pointers are both within the standard value.
35-47
HANDLING OF NYLON TUBE FOR AIR LINE <PUSH-IN TYPE>
Special tools
Mark Tool name and shape Part No. Application
Release tool kit (a set of

MC085288 Removal of tube
6 pieces)
Tube cutter MC083532 Cutting of tube
• The nylon tube for air line (hereafter referred to as “tube”) can be
connected to the push-in connector (hereafter referred to as
“connector”) by simply “pushing in” the tube into the connector.
• Air tightness is achieved by the rubber seal. If the rubber seal is
damaged, dirty or otherwise defective, air can leak through the
seal.
• The collet is used to retain the tube in position, preventing it from
coming off.
• Push the collet to remove the tube.
• For information on removal and installation of the tube, see the
procedure. (See later section.)
(1) Precautions for handling the tube

• The tube can sustain damage or break when exposed to heat, acid, or when scored. Always replace the tube with
a new part when the tube appears defective.
• Do not expose the tube or connector to heat of 100°C or above.
• Whenever welding is performed, protect the tube from related heat and spark.
• Do not allow the tube to come into contact with battery electrolyte.
• Do not stamp on, fold, or press sharp edges against the tube.
• When pressure washing the vehicle, do not place the nozzle too close to the tube.
(2) Precautions for routing the tube

• Observe the minimum bending radius for the various types of tubes listed in the table below.
• Wherever the tube and connector are located near the engine or other hot spots, provide heat protection plates or
other similar means to keep the temperatures of the tube and connector below 100°C.
• Wherever the tube is likely to sustain damage or wear, protect them using corrugated tube, grommet or similar.
• Temperature change can cause the tube to lengthen or shrink. When routing the tube, provide an extra tube
length of approx. +1 %.
• Use those clamps that are designed to not cause damage to the tube. The tube should be clamped at intervals of
approx. 500 mm.
• Wherever possible, refrain from using relay connectors. If they need to be used, be sure to clamp them to prevent
deflecting while taking care that the mounting area for the relay connector is also protected from damage.
• After several months following production, the tubes will likely start becoming stiffer, making them less easy to
route. Wherever possible, use new tubes.
• After the tube has been routed, check it for air leakage, deflection or interference.
35-48
35
(3) Specifications and dimensions
• Always use those tubes that bear the following identification codes on the surface.
(example) DIN 74324 10 × 1.25 PA11 9803
Standard No. Outer diameter Material Company name Year/month of
× thickness production
Tube type (Unit: mm)

Tube insertion Minimum bending
Outer diameter × thickness Material Manufacturer
dimension radius (inner diameter)
6×1 20 30
8×1 21 40
10 × 1.25 22 60 PA12-PHL
Nitta Moor
or
12 × 1.5 22 60 or
PA11-PHL
Usui Kokusai
15 × 1.5 24 90 (based on DIN73378)
16 × 2 29 95
16 × 2 (with cover) 32 95
DIN: Deutsche Industrie-Norm
(4) Removal and installation of tube

CAUTION
• The tube can sustain damage during installation or removal. Do not remove and re-install them more of-
ten than necessary.
• A connector which is dirty inside must be replaced with a new part.
• Replace the tube with a new part when it is damaged or it has been cut too short.
[Removal]
• Completely release air pressure from the tube.
• Before removing the tube from the connector, clean the periph-
ery of the connector and tube. A connector which is contaminat-
ed inside must not be reused.
• Pull off the tube by hand while pressing the collet using .
CAUTION
• To prevent possible damage to the tube and collet, do not
pull the tube too strong. Never use tools except when
pulling off the tube.
[Installation]
• Check the portion of the tube that is to be inserted into the con-
nector for damage or contamination.
• Cut away any damage or curl in the tube insertion portion using
.
35-49
HANDLING OF NYLON TUBE FOR AIR LINE <PUSH-IN TYPE>
• Make a mark on the tube 0 to 2 mm away from the outer end of
the tube insertion dimension. The mark is useful as a reference
when inserting the tube.
• Insert the tube straight into the connector until it bottoms out.
CAUTION
• Do not insert the tube at an angle, or the tube may be dam-
aged.
• After installation, pull the tube by hand to ensure that it is firmly

retained in position.
• When under air pressure or being pulled, the collet and tube will
move together away from the connector by approx. 2 mm.
• After installation, check the connector for air leakage.
35-50
HANDLING OF NYLON TUBE FOR AIR LINE <COMPRESSION TYPE> 35
• The nylon tube (hereafter referred as “tube”), on which an insert
has been installed, is retained in the connector by tightening the
nut onto the connector, which causes the sleeve to bite into the
tube and thereby air tightness is achieved. Therefore, once the
nut is tightened, the tube, insert and sleeve are all deformed and
cannot be reused. (See later section.)
• For information on removal and installation of the tube, see the
procedure. (See later section.)
Special tools
Tube cutter MC083532 Cutting of tube
(1) Precautions for handling the tube

• The tube can sustain damage or break when exposed to heat, acid, or when scored. Always replace the tube with
a new part when the tube appears defective.
• Do not expose the tube or connector to heat of 100°C or above.
• Whenever welding is performed, protect the tube from related heat and spark.
• Do not allow the tube to come into contact with battery electrolyte.
• Do not stamp on, fold, or press sharp edges against the tube.
• When pressure washing the vehicle, do not place the nozzle too close to the tube.
(2) Precautions for routing the tube

• Observe the minimum bending radius for the various types of tubes listed in the table below.
• Wherever the tube and connector are located near the engine or other hot spots, provide heat protection plates or
other similar means to keep the temperatures of the tube and connector below 100°C.
• Wherever the tube is likely to sustain damage or wear, protect them using corrugated tube, grommet or similar.
• Temperature change can cause the tube to lengthen or shrink. When routing the tube, provide an extra tube
length of approx. +1 %.
• Use those clamps that are designed to not cause damage to the tube. The tube should be clamped at intervals of
approx. 500 mm.
• Wherever possible, refrain from using relay connectors. If they need to be used, be sure to clamp them to prevent
deflecting while taking care that the mounting area for the relay connector is also protected from damage.
• After several months following production, the tubes will likely start becoming stiffer, making them less easy to
route. Wherever possible, use new tubes.
• After the tube has been routed, check it for air leakage, deflection or interference.
35-51
HANDLING OF NYLON TUBE FOR AIR LINE <COMPRESSION TYPE>
(3) Specifications and dimensions
• Always use those tubes that bear the following identification codes on the surface.
(example) DIN 74324 10 × 1.25 PA11 9803
Standard No. Outer diameter Material Company name Year/month of
× thickness production
Tube type (Unit: mm)

Tube insertion Minimum bending
Outer diameter × thickness Material Manufacturer
dimension radius (inner diameter)
6×1 20 30
8×1 21 40
10 × 1.25 22 60 PA12-PHL
Nitta Moor
or
12 × 1.5 22 60 or
PA11-PHL
Usui Kokusai
15 × 1.5 24 90 (based on DIN73378)
16 × 2 29 95
16 × 2 (with cover) 32 95
DIN: Deutsche Industrie-Norm
(4) Connector component part No. and tightening torque

Part Part No.
Outer Relay connector Tightening torque
diameter of Insert Sleeve Nut part No. N·m {kgf·m}
tube mm
φ6 MH038022 MH038014 MH037911 MH038148 20 {2.0}
φ10 MH038023 MH038015 MH037912 MH038149 34 {3.5}
φ12 MH038027 MH038019 MH037931 MH039082 49 {5.0}
φ15 MH038028 MH038029 MH037935 – 54 {5.5}
(5) Removal and installation of tube

CAUTION
• The tube can sustain damage during installation or removal. Do not remove and re-install them more of-
ten than necessary.
• A connector which is dirty inside must be replaced with a new part.
• Replace the tube with a new part when it is damaged or it has been cut too short.
[Removal]
• Completely release air pressure from the tube.
• Before removing the tube from the connector, clean the periph-
ery of the connector, nut and tube. A connector which is contam-
inated inside must not be reused.
35-52
35
[Installation]
• Check the portion of the tube that is to be inserted into the con-
nector for damage or contamination.
• Cut away any damage or curl in the tube insertion portion using
.
• Ensure that the insert, sleeve, nut and tube are arranged as
shown in the illustration.
• Insert the tube into the connector until it reaches the end of the
connector. Press the sleeve into the connector and temporarily
tighten the nut by hand.
• Tighten the nut to the specified torque.
Then, pull the tube to ensure that it will not come off and there is
no air leakage.
35-53
HANDLING OF NYLON TUBE FOR AIR LINE <TUBE INDENTIFICATION COLORS>
1. Air Line Lower Clip
• Tubes for connection to the cab are routed under the front of the
cab and connected to the cab through the lower clip.
• When passing the tubes through the lower clip for installation,
match the identification colors of the tube-end tape with the em-
bossed identification symbols on the lower clip.
CAUTION
• Be sure that the tubes pass right places through the lower
clip. If not, the tubes could be crushed or jerked to make
brake air insufficient or leak brake air, causing the brake to
malfunction.
35-54
HANDLING OF CONNECTOR 35
– Taper screw area of connector ThreeBond 1110B As required
• When installing once removed connector of air system for

brakes, remove remainder of sealant, oil, and water sufficiently.
• Apply sealant to threads leaving 1 or 2 threads on top blank.
CAUTION
• Be careful not to apply sealant to the parallel screw area of
the connector.
• Where alignment is required, stop at aligning point in additional

tightening process.
35-55
AIR COMPRESSOR
35-56
35
Disassembly sequence
1 Lock washer 10 1st compression ring 19 Bearing holder
2 Compressor gear 11 2nd compression ring 20 O-ring
3 Key 12 3rd compression ring 21 Bearing
4 Cylinder head 13 Oil ring 22 Bearing
5 Gasket 14 Snap ring 23 Crankshaft
6 Valve seat 15 Piston pin 24 Crankcase
7 O-ring 16 Piston
8 O-ring 17 Connecting rod : Non-reusable parts
9 Cylinder liner 18 Connecting rod cap
• For removal and installation procedures, see Gr11.
Assembly sequence
Follow the disassembly sequence in reverse.

Clearance between cylinder and pis- Top 0.168 to 0.233 0.335
9, 16 Replace
ton Skirt 0.084 to 0.149 0.189
1st, 2nd, 3rd
Piston ring end gap (measured with compression 0.15 to 0.30 1.0
10 to 13 ring Replace
ring placed in cylinder)
Oil ring 0.20 to 0.40 1.5
1st, 2nd, 3rd
10 to 13, Clearance between piston ring and compression 0.01 to 0.045 0.10
ring Replace
16 piston groove
Oil ring 0.02 to 0.06 0.10
15, 16 Clearance between piston pin and piston 0 to 0.028 0.07 Replace
Clearance between piston pin and connecting rod small
15, 17 0.016 to 0.044 0.07 Replace
end
17 End play of connecting rod 0.2 to 0.4 0.5 Replace
23 Crankshaft end play 0.03 to 0.75 1.0 Replace

Nut (compressor gear mounting) 215 to 245 {22 to 25} –
Bolt (cylinder head mounting) 29 to 34 {3.0 to 3.5} –
Bolt (cylinder liner mounting)
25 to 29 {2.5 to 3.0} –
Bolt (bearing holder mounting)
Nut (connecting rod mounting) 23 to 25 {2.3 to 2.6} –
35-57
AIR COMPRESSOR
Special tools (Unit: mm)
Drive gear puller
A B C MH062276 Removal of compressor gear

70 M14 × 1.5 M10 × 1.25
Removal and installation of piston

Piston ring tool MH060014
ring
Removal procedure
Removal: Compressor gear
Removal: Piston rings
Installation procedure
Installation: Connecting rod
• Assemble the connecting rod and cap while noting their align-
ment marks.
• Install bolts in such a way that the notches in the bolt heads are
directed toward the inside of the connecting rod cap.
35-58
35
Installation: Piston rings
• Install the piston rings, ensuring that their end gaps are located
as shown in the illustration.
• Install the piston rings by following the removal sequence in re-
verse. (See “ Removal: Piston rings”.)
Installation: Lock washer

• Fit the nut with its marking outside.
• Fit the lock washer its projection aligned with the hole in the
compressor gear.
• Tighten the nut to the specified torque, and then bend the oppo-
site side of the projection of the lock washer over the nut to lock
it.
35-59
AIR DRYER
35-60
35
1 Purge chamber 20 Retaining ring 39 Silencer
2 O-ring 21 Upper spring seat 40 Silencer plate
3 Check valve 22 Spring 41 Silencer case
4 Case cover 23 Lower spring seat 42 Air pipe
5 O-ring 24 Adjusting screw 43 Retaining ring
6 Set spring 25 Exhaust stem 44 Exhaust body
7 Filter plate 26 Exhaust stem spring 45 O-ring
8 Filter 27 O-ring 46 O-ring
9 Desiccant 28 O-ring 47 Piston
10 Filter 29 Piston 48 Valve spring
11 Filter plate 30 Valve 49 Valve body
12 Case 31 Valve spring 50 O-ring
13 Oil filter 32 Retaining ring 51 Valve
14 O-ring 33 O-ring 52 Plug
15 Cover 34 Check valve guide 53 Body
16 Gasket ring 35 Check valve spring
17 Gasket ring 36 Check valve : Non-reusable parts
18 Plate 37 Retaining ring
19 Seat 38 Silencer plate
Assembly sequence
• Check and adjust the air pressure governor after assembly. (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)
Repair kit: Air dryer kit, Desiccant kit

Bolt (purge chamber, cover and body mounting) 17.7 to 27.5 {1.8 to 2.8} –
Bolt (case mounting)
Screw (case cover mounting) 3.9 to 6.9 {0.4 to 0.7} –
Bolt (valve, piston and valve body mounting)
Cap nut (seat and plate mounting) 4.9 to 5.9 {0.5 to 0.6} –
Nut (adjusting screw retaining) 6.9 to 7.8 {0.7 to 0.8} –
Plug
14.7 to 24.5 {1.5 to 2.5} –
Silencer

O-ring
Adjusting screw (entire surface except thread) Multipurpose grease
As required
Outer periphery of piston and O-ring groove [NLGI No.2 (Li soap)]
Body (inside surface)
Plug thread ThreeBond 1110B As required
35-61
AIR DRYER
Adjustment: Adjusting screw
• Turn the adjusting screw to achieve the indicated dimension
from the top of the upper spring seat to the bottom of the lower
spring seat. Doing so will facilitate the threshold pressure adjust-
ment to the specified value.
Installation: Filters, desiccant, and filter plate

• Install the filters with their soft layers facing the desiccant.
• Place the desiccant in the case, then settle the desiccant by tap-
ping gently and evenly around the case with a plastic hammer.
• Place the soft layer side of the filter on the desiccant, and place
the filter plate on the case, then tap the desiccant down following
the procedure below.
• Before tapping the case against the work surface, lay two or
three layers of shop towel on the work surface to protect the
bottom of the case from scratches.
• Holding down the filter plate with both hands, lift the case to a
height of about 100 mm and tap it gently against the work sur-
face.
• Tap the case about 30 more times. Make sure the filter plate
drops by 4 to 6 mm from its original position.
CAUTION
• Unless the tapping procedure is performed, particles of
desiccant may escape and create blockages in brake lines,
thus preventing normal brake operation.
35-62
35
Inspection after installation
Inspection: Air leakage
• Completely plug the delivery side of the air dryer, then apply air
pressure of 49 kPa {0.5 kgf/cm2} or 780 kPa {8 kgf/cm2} to the
supply side and check that no air leaks from any joint.
Leakage from the valve assembly must not exceed 10 cm3 {10
mL} per minute.
• If air leakage is found, replace the defective part.
35-63
BRAKE PEDAL
Removal sequence
1 Nylon tube 5 Plug
2 Dual brake valve (See later section.) 6 Connector
3 Connector
4 Connector
*a: Steering support
Installation sequence
Follow the removal sequence in reverse.

Connector 29.4 to 117.6 {3 to 12} –
Connector
29.4 to 39.2 {3 to 4} –
Plug

Thread of connector As required
ThreeBond 1110B or Loctite 575
Thread of plug
35-64
35
Work before removal
Removal: Dual brake valve
(1) Disconnecting the wiring and piping under the cab
• Disconnect the harness connectors of the air pressure sensor
and stop lamp switch.
• Disconnect the nylon tube.
(2) Work in the cab

• Remove the scuff plate, heel pad, foot rest and then the floor
mat.
• Remove the steering support.
(3) Removal of the dual brake valve

• Remove the valve board mounting bolts.
• Take out the dual brake valve while avoiding the steering shaft.
Installation: Connector
• After tightening each connector to a torque just beyond the lower
limit of the specified torque, adjust its direction by turning it with-
in one turn. The installed angles of the connectors must be as
shown in the illustration.
Installation: Dual brake valve

• To install the dual brake valve, follow the removal procedure in
reverse. (See “ Removal: Dual brake valve”.)
35-65
BRAKE PEDAL
Dual Brake Valve
35-66
35
1 Silencer 14 Spring 27 Intake valve
2 Valve board 15 Plate guide 28 Boby
3 Straight pin 16 O-ring 29 O-ring
4 Roller 17 Relay piston 30 Retaining ring
5 Pedal cover 18 O-ring 31 Valve seat
6 Set screw 19 Relay piston spring 32 O-ring
7 Pedal 20 Retaining ring 33 Intake valve
8 Boot 21 Retainer 34 O-ring
9 Plunger 22 O-ring 35 Valve retainer
10 Plate 23 O-ring 36 Valve spring
11 Piston 24 Washer 37 Cover
12 O-ring 25 Valve spring
13 Spring 26 Washer : Non-reusable parts
Assembly sequence
Repair kit: Dual brake valve kit

Outer diameter of straight Roller mounting 12 –0.05
–0.10 11.85
3 Replace
pin Pedal mounting 9.5 9.45
Inner diameter 12 12.1
4 Roller Replace
Outer diameter 18.3 18.15
9 Outer diameter of plunger 19.9 19.8 Replace
Inner diameter of straight
9.5 9.68
10 Plate pin hole Replace
Inner diameter of bushing 20 20.1
112.8 ± 5.9 N
13 Spring load (installed length 19.6) – Replace
{11.5 ± 0.6 kgf}
67.6 ± 6.8 N
14 Spring load (installed length 29.6) – Replace
{6.9 ± 0.69 kgf}
51 ± 2.9 N
19 Relay piston spring load (installed length 13.6) – Replace
{5.2 ± 0.3 kgf}
40.2 ± 2.0 N
33 Valve spring load (installed length 13.5) – Replace
{4.1 ± 0.2 kgf}
50 ± 2.9 N
36 Valve spring load (installed length 13) – Replace
{5.1 ± 0.3 kgf}

Lock nut (set screw mounting)
Bolt (valve assembly primary and secondary sides assem- 5.0 to 7.8 {0.5 to 0.8} –
bling)
Screw 2.9 to 5.0 {0.3 to 0.5} –
Silencer 7 to 9 {0.7 to 0.9} –
Bolt (pedal and valve mounting) 11.8 to 18.6 {1.2 to 1.9} –
35-67
BRAKE PEDAL
Sliding surfaces and groove of O-ring, sliding surfaces of Multipurpose grease
As required
metals [NLGI No.2 (Li soap)]
Outside periphery of straight pin
High pressure-resistant, high As required
Sliding surfaces of plunger and other parts abrasion-resistant grease
[NLGI No.2 (Li soap)]
Pack between boot and plunger 1 cm3 {1 mL}
Special tools
Insert tool
*910-24463 Installation of O-ring
Retainer
*910-24592 Holding of piston
Silencer holder MK529837 Removal and installation of silencer
*: Knorr-Bremse part No.

Work before removal
Alignment mark: Dual brake valve
Removal procedure
Removal: Silencer
35-68
35
Removal: Relay piston
• Hold a socket wrench (10 mm between the flats) on vise.
• Insert the head of self-locking bolt into socket wrench to tighten
body.
WARNING
• You must be careful when you loosen screw, because the
spring in body can forcibly eject relay piston. To avoid this
hazard, press down on the relay piston with your hand
when you carry out the above work.
• Using a hexagon wrench, slowly loosen the screw and remove

the relay piston.
Hexagon wrench: HEX4
Installation: O-ring
Installation: Piston
• Install to prevent the piston from jumping out.
• After installing the body and cover, remove .
Installation: Packing grease between boot and plunger
35-69
BRAKE PEDAL
Installation: Silencer
• Install the silencer by following the removal sequence in reverse.
(See “ Removal: Silencer”.)

Inspection: Pedal play
• Using the set screw, adjust the brake pedal play, which is ob-
tained when the pedal toe is pressed by hand, to the following
value.
Brake pedal play: 3.5° +1.0° +3
–0.5° (12 –1.5 mm: reference value)
• Reference value is the stroke at the pedal toe.
• Secure the set screw in the correct position by tightening the
lock nut to the specified torque.
Inspection: Air leakage and performance inspection

• Install a pressure gauge capable of measuring a minimum of
0.98 MPa {10 kgf/cm2} to the primary output port.
• Install a pedal force gauge to the brake pedal.
• While applying an air pressure of 0.7 MPa {7 kgf/cm2} to the pri-
mary input port, check for air leakage.
• If air leakage is found, proceed as follows.
• Retighten the connectors.
• Disassemble the dual brake valve and check if the O-rings of
each part are correctly installed.
• Apply an air pressure of 0.7 MPa {7 kgf/cm2} to the primary input

port, and check that the primary output pressure and leg power
with respect to the pressed angle of brake pedal are as shown in
the input-output characteristics diagram in the next page.
• If the output pressure is lower than the standard values, replace
the piston.
35-70
35
Input / Output Characteristic Curve Diagram
35-71
FRONT WHEEL BRAKE
1 Inspection hole plug 7 Lock plate 14 Bushing
2 Dust cover 8 Anchor pin 15 Brake shoe
3 Brake chamber 9 O-ring 16 Expander (See later section.)
(See later section.) 10 Rivet 17 Anchor bracket
4 O-ring 11 Brake lining
5 Return spring 12 Snap ring
*a:: Brake drum
Non-reusable parts
6 Lock washer 13 Pin
• For removal and installation of the front drum brake and brake drum, see Gr26.
Assembly sequence
Repair kit: Brake lining kit
CAUTION
• To prevent poor working of the brake, do not smear the surface of the brake lining with grease or oil.
• After mounting the brake on the vehicle, adjust the brake shoe clearance (See “ON-VEHICLE INSPECTION AND
ADJUSTMENT”. )
35-72
35
Clearance
Return spring load 292 ± 29 N between
5 Replace
(installed length 258) {29.8 ± 2.5 kgf} coils or coil
and cover
8, 14 Clearance between anchor pin and bushing 0.05 to 0.14 0.3 Replace
6
(side step
11 Brake lining thickness 16 Replace
shows wear
limit)
Inside diameter 410 414 (*412) Correct or
*a Brake drum
Cylindricity 0.05 0.2 replace
*: Brake drum resurfacing limit

Bolt (dust cover mounting)
19.6 ± 3.9 {2 ± 0.4} –
Bolt (lock plate mounting)
Bolt (brake chamber mounting) 44.1 ± 8.8 {4.5 ± 0.8} –
Screw (expander mounting) 18.6 ± 4.9 {1.9 ± 0.5} –

Grease grooves of anchor pin
O-ring
Wheel bearing grease
Contact areas between brake shoe and wheel cylinder As required
Inner surface of bushing
Tip of expander wedge
Shell Darina Grease 2
Expander wedge insertion hole 8 g or above
[NLGI No.2 (Non soap)]

Return spring setter
A Removal and installation of return

MC809749
spring
500
Anchor pin puller
A B C 03727-60000 Removal of anchor pin

φ60 M16 × 1.5 173
35-73
FRONT WHEEL BRAKE
Removal procedure
Removal: Return spring
• Hook on the return spring and pry the return spring off.
CAUTION
• When attaching , avoid the oil seal sliding contact area
of the rear axle.
Removal: Anchor pin
Removal: Brake lining

• Using a drilling machine, break the flattened rivet heads on the
brake shoe side to release the brake lining.
Inspection procedure
Inspection: Brake lining thickness
• If the brake lining is worn down to the side step, replace all brake
Inspection: Clearance between anchor pin and bushing

• If the measured clearance exceeds the specified limit, replace
the bushing.
35-74
35
[Installation]
• After installing the bushing in the brake shoe, measure its inner
diameter.
• If the measurement deviates from the illustrated dimension,
ream the bushing the specified standard value.
Inspection: Brake drum

(1) Visual inspection
• If an abnormal wear or damage is found on the inside of the
brake drum, regrind the brake drum inner surface with a wheel
hub as a set within the correction limit or replace the drum.
(2) Inner diameter

• If the measured value exceeds the limit, replace the brake drum.
(3) Cylindricity
• If the measured value exceeds the limit, regrind the brake drum
inner surface within the correction limit or replace the drum.
Installation: Expander
• Pack a specified quantity of grease in the illustrated space of the
expander.
• Install the expander to the anchor bracket facing in the illustrated

direction.
35-75
FRONT WHEEL BRAKE
Installation: Brake lining
• Using cleaning fluid, clean the brake shoe surface to which the
brake lining is to be mounted. Then, dry the shoe surface.
• Insert rivets from the brake lining to the shoe. Stake them, start-
ing from the center of the shoe towards the ends.
• The staking load for the rivets should be 19.61 ± 0.98 kN {2000 ±
100 kgf}.
CAUTION
• New replacement brake linings that are to be installed on
the same axle should all be in the same size and have the
same identification mark. Otherwise, braking performance
can be different from left to right.
• After assembly, check the brake drum-to-lining clearance. Cor-

rect as required.
Installation: Brake shoe

• Make sure that the adjusting screw contact surface of each boot
is greased.
CAUTION
• If the adjusting screw surface is not greased, the boot could
be broken or the automatic adjusting mechanism could
malfunction.
• Fully tighten each adjusting screw by hand to such an extent

that the sleeve in the expander is not rotated. Tighten the adjust-
ing screw slowly so that the boot is not caught in the screw.
• Make sure that each clip has its open side facing in the direction
of arrow. If not, turn the adjusting screw further clockwise to ro-
tate the sleeve in the expander so that the open side of the clip
faces in the direction of arrow.
• Make sure that the clip has its raised part between teeth of the
adjust screw.
• Watching the clip for a slip out of position, back up the adjusting
screw two turn counterclockwise and make sure that the clip has
its open side facing in the direction of arrow.
35-76
35
• Position the clips of the expander to face in the illustrated direc-
tions.
• Install each brake shoe so that it fits properly in the width across
flat part of the clip.
CAUTION
• When installing the brake shoes, use care not to damage
the clips and O-rings.
• Apply grease in the grease groove of each anchor pin.

• Install the anchor pins in the illustrated direction.
CAUTION
• If the anchor pin is installed in the wrong direction, O-ring
could be damaged.

• Tighten the lock plate attaching bolt to the specified torque, then
bend one portion of the lock washer to lock the bolt as shown.
Installation: Return spring

• Hook one end of the return spring on the pin of the brake shoe.
• Attach to the other end of the return spring, then install the
return spring in place with the spring end hooked on the pin by
levering the tool.
CAUTION
• When attaching , avoid the oil seal sliding contact sur-
face of the rear axle.
35-77
FRONT WHEEL BRAKE
Work after installation
Inspection: Operation
• The installed dimension of the expander should be 82 mm. If
not, disassemble the expander and correct its installed dimen-
sion with the adjusting screws reinstalled. (See later section.)
• Reinstall the expander and brake shoes.
• Press the push rod for a full stroke to open the brake shoes wid-
er.
• Return the push rod. The expander should return to 82 mm.
• If not, reinspect the return spring for intensity, the brake shoes
for drag and the expander.
CAUTION
• Unless operation inspection is properly carried out after as-
sembly, the automatic adjusting mechanism may not work
as it should.
• When the brake chamber is disassembled, perform the following

checks.
• Pull the brake shoe with a force of 20 to 30 N {2 to 3 kgf}. The
brake shoes should not move with the expander adjusting screw.
• If the brake shoe moves, the push rod and push plate of the
brake chamber is angled. Without the brake drum installed, put
the push rod and push plate into the correct position by pressing
the brake pedal 2 or 3 times.
35-78
35
M E M O
35-79
REAR WHEEL BRAKE
1 Seal 8 Lock plate 16 Brake shoe
2 Inspection hole plug 9 Anchor pin 17 Stopper plate
3 Dust cover 10 O-ring 18 Expander (See later section.)
4 Brake chamber 11 Snap ring 19 Anchor bracket
(See later section.) 12 Pin
5 O-ring 13
14
Rivet
Brake lining
*a:: Brake drum
Non-reusable parts
6 Return spring
7 Lock washer 15 Bushing
• For removal and installation of the rear drum brake and brake drum, see Gr27.
Assembly sequence
Repair kit: Brake lining kit
CAUTION
• To prevent poor working of the brake, do not smear the surface of the brake lining with grease or oil.
• After mounting the brake on the vehicle, adjust the brake shoe clearance (See “ON-VEHICLE INSPECTION AND
ADJUSTMENT”. )
35-80
35
Clearance
363 ± 29 N between
6 Return spring load (installed length 262.6) Replace
{37.0 ± 3.0 kgf} coils or coil
and cover
9, 15 Clearance between anchor pin and bushing 0.05 to 0.14 0.3 Replace
6
(side step
14 Brake lining thickness 16 Replace
shows wear
limit)
Inside diameter 410 414 (*412) Correct or
*a Brake drum
Cylindricity 0.05 0.2 replace
*: Brake drum resurfacing limit

Bolt (dust cover mounting)
19.6 ± 3.9 {2 ± 0.4} –
Bolt (lock plate mounting)
Bolt (brake chamber mounting) 44.1 ± 7.8 {4.5 ± 0.8} –
Screw (expander mounting) 18.6 ± 4.9 {1.9 ± 0.5} –

Grease grooves of anchor pin
O-ring
Contact areas between brake shoe and wheel cylinder As required
Inner surface of bushing
Tip of expander wedge
Expander wedge insertion hole 8 g or above

Return spring setter
A Removal and installation of return

03727-15001
spring
500
Anchor pin puller
A B C 03727-60000 Removal of anchor pin

φ60 M16 × 1.5 173
35-81
REAR WHEEL BRAKE
Work before removal
Mechanical release of parking brake
• Release the spring brake by mechanical means.
• Remove release bolt, washer and release nut from the brake
chamber.
• Remove the end cap without failling to pull up its knob by hand
or using a plier or other tools.
CAUTION
• Never remove the end cap by inserting a screwdriver or oth-
er tools into the brake chamber and prying it to open the
chamber. Failure to observe the above can cause the brake
chamber to be damaged, allowing water to intrude into the
brake chamber. The water can cause rust on spring, leading
to breakage in the spring.
• Insert the release bolt all the way and give it a 1/4 turn.
• Pull the release bolt to make sure that it does not come out.
• If the release bolt comes out, insert it all the way and give it a 1/4
turn again.
• Install the washer and release nut.

• To make it easy to turn the release nut, let out the thread of the
release bolt 82 mm long by turning the nut while applying an air
pressure of 640 kPa {6.5 kgf/cm2} to the spring brake port.
CAUTION
• To prevent the brake chamber from being damaged, do not
turn the release nut to an excessive torque (greater than
68.6 N·m {7 kgf·m}).
Removal procedure
Removal: Return spring
• Hook on the return spring and pry the return spring off.
CAUTION
• When attaching , avoid the oil seal sliding contact area
of the rear axle.
35-82
35
Removal: Anchor pin
Removal: Brake lining

• Using a drilling machine, break the flattened rivet heads on the
brake shoe side to release the brake lining.
Inspection: Brake lining thickness
• If the brake lining is worn down to the side step, replace all brake
Inspection: Clearance between anchor pin and bushing

• If the measured clearance exceeds the specified limit, replace
the bushing.
[Installation]
• After installing the bushing in the brake shoe, measure its inner
diameter.
• If the measurement deviates from the illustrated dimension,
ream the bushing the specified standard value.
35-83
REAR WHEEL BRAKE
Inspection: Brake drum
(1) Visual inspection
• If an abnormal wear or damage is found on the inside of the
brake drum, regrind the brake drum inner surface with a wheel
hub as a set within the correction limit or replace the drum.
(2) Inner diameter

• If the measured value exceeds the limit, replace the brake drum.
(3) Cylindricity
• If the measured value exceeds the limit, regrind the brake drum
inner surface within the correction limit or replace the drum.
Installation: Expander
• Pack a specified quantity of grease in the illustrated space of the
expander.
• Install the expander to the anchor bracket facing in the illustrated

direction.
Installation: Brake lining

• Using cleaning fluid, clean the brake shoe surface to which the
brake lining is to be mounted. Then, dry the shoe surface.
• Insert rivets from the brake lining to the shoe. Stake them, start-
ing from the center of the shoe towards the ends.
• The staking load for the rivets should be 19.61 ± 0.98 kN {2000 ±
100 kgf}.
CAUTION
• New replacement brake linings that are to be installed on
the same axle should all be in the same size and have the
same identification mark. Otherwise, braking performance
can be different from left to right.
• After assembly, check the brake drum-to-lining clearance. Cor-

rect as required.
35-84
35
Installation: Brake shoe
• Make sure that the adjusting screw contact surface of each boot
is greased.
CAUTION
• If the adjusting screw surface is not greased, the boot could
be broken or the automatic adjusting mechanism could
malfunction.
• Fully tighten each adjusting screw by hand to such an extent

that the sleeve in the expander is not rotated. Tighten the adjust-
ing screw slowly so that the boot is not caught in the screw.
• Make sure that each clip has its open side facing in the direction
of arrow. If not, turn the adjusting screw further clockwise to ro-
tate the sleeve in the expander so that the open side of the clip
faces in the direction of arrow.
• Make sure that the clip has its raised part between teeth of the
adjust screw.
• Watching the clip for a slip out of position, back up the adjusting
screw two turn counterclockwise and make sure that the clip has
its open side facing in the direction of arrow.
• Position the clips of the expander to face in the illustrated direc-

tions.
• Install each brake shoe so that it fits properly in the width across
flat part of the clip.
CAUTION
• When installing the brake shoes, use care not to damage
the clips and O-rings.
• Apply grease in the grease groove of each anchor pin.

• Install the anchor pins in the illustrated direction.
CAUTION
• If the anchor pin is installed in the wrong direction, O-ring
could be damaged.
35-85
REAR WHEEL BRAKE
• Tighten the lock plate attaching bolt to the specified torque, then
bend one portion of the lock washer to lock the bolt as shown.
Installation: Return spring

• Hook one end of the return spring on the pin of the brake shoe.
• Attach to the other end of the return spring, then install the
return spring in place with the spring end hooked on the pin by
levering the tool.
CAUTION
• When attaching , avoid the oil seal sliding contact sur-
face of the rear axle.
Work after installation

Inspection: Operation
• The installed dimension of the expander should be 82 mm. If
not, disassemble the expander and correct its installed dimen-
sion with the adjusting screws reinstalled. (See later section.)
• Reinstall the expander and brake shoes.
• Press the push rod for a full stroke to open the brake shoes wid-
er.
• Return the push rod. The expander should return to 82 mm.
• If not, reinspect the return spring for intensity, the brake shoes
for drag and the expander.
CAUTION
• Unless operation inspection is properly carried out after as-
sembly, the automatic adjusting mechanism may not work
as it should.
• When the brake chamber is disassembled, perform the following

checks.
• Pull the brake shoe with a force of 20 to 30 N {2 to 3 kgf}. The
brake shoes should not move with the expander adjusting screw.
35-86
35
• If the brake shoe moves, the push rod and push plate of the
brake chamber is angled. Without the brake drum installed, put
the push rod and push plate into the correct position by pressing
the brake pedal 2 or 3 times.
Cancellation of mechanical release of parking brake

• To cancel the mechanical release of parking brake, perform the
mechanical release procedure in reverse while confirming the
following items.
(See “ Mechanical release of parking brake”.)
• Clean the end cap mounting position and confirm that there is no
water or dust in that position.
• Confirm that an O-ring is attached to the end cap.
• Using a φ15 mm or thinner rod with a dull end such as a release
bolt, push in the concave section at the center of the end cap
squarely into the piggy back. A click is heard when the section A
is securely seated into the piggy back.
• When seating the end cap, be careful not to bend or twist the
section B.
• Confirm that there is no damage on the tube and the tube is in-
stalled securely.
35-87
BRAKE CHAMBER
<Without Spring Chamber>
1 Clamp ring 5 Bushing 9 Push rod and push plate
2 Pressure plate 6 Push rod guide 10 Base
3 Diaphragm 7 Ring
4 Pin 8 Dust cover : Non-reusable parts
Assembly sequence
Repair kit: Chamber kit
CAUTION
• Keep the diaphragm clear of oil or grease. If it is smeared, it could be slipped out of place.

Nut (clamp ring mounting) 14.7 to 20.0 {1.5 to 2.0} –

Multipurpose grease
Part contact surfaces As required
35-88
35
Work before removal
Alignment mark: Brake chamber
• Before disassembling the brake chamber, provide alignment
marks on the clamp ring, pressure plate and base.
35-89
BRAKE CHAMBER
<With Spring Chamber>
1 Clamp ring 6 Push rod guide 11 Elbow
2 Piggyback 7 Ring 12 Base
3 Diaphragm 8 Dust cover
4 Pin 9 Push rod and push plate : Non-reusable parts
5 Bushing 10 Elbow
35-90
35
WARNING
• Never attempt to disassemble the piggyback. It contains a very strong spring and is very dangerous.
Assembly sequence
Repair kit: Spring chamber kit
CAUTION
• Keep the diaphragm clear of oil or grease. If it is smeared, it could be slipped out of place.

Nut (clamp ring mounting) 14.7 to 20.0 {1.5 to 2.0} –

Tube connecting surface of elbow Loctite 414 As required
Multipurpose grease
Part contact surfaces As required
Work before removal

Alignment mark: Brake chamber
• Before disassembling the brake chamber, provide alignment
marks on the clamp ring, piggyback and base.
35-91
EXPANDER
1 Clip 7 Sleeve 13 Cap
2 Adjusting screw 8 Snap ring 14 Wedge and roller
3 Boot 9 Retainer 15 Body
4 Spring cage 10 Spring
5 Spring 11 Snap ring : Non-reusable parts
6 Drive ring 12 Boot
Assembly sequence
35-92
35
Automatic adjusting mechanism operating force of ex-
– 147 N {15 kgf} or less – Replace
pander (push-back force of sleeve)
1.5 to 5.0 N·m
1 Clip holding torque – Replace
{0.15 to 0.5 kgf·m}
73.6 N
5 Spring load (installed length 11.3) 83.4 N {8.5 kgf} Replace
{7.5 kgf}
6, 7 Backlash between drive ring and sleeve 2.9 to 3.4 – Replace
Depression on rolling contact surfaces of sleeve and
7, 14 – 0.010 Replace
wedge and roller
132.3 N
10 Spring load (installed length 105.8) 147 N {15 kgf} Replace
{13.5 kgf}
15 Inner diameter of body φ38.1 to 38.2 φ38.23 Replace

Screw 15 ± 3 {1.5 ± 0.3} –

Thread of adjusting screw
Adjusting screw contact area of boot As required
Periphery of sleeve, thread and roller contact area
Roller of wedge and roller 2g
Wedge and roller contact surface of boot
As required
Coating
Body (inside surface)
Filling 8g
Thread of screw Loctite 202 or ThreeBond 2415 As required

Clip adaptor
A B C MC889860 Measurement of clip holding torque

18 20 40
Boot setter MC889862 Installation of boot
Spring holder MC889861 Removal and installation of spring
35-93
EXPANDER
Removal procedure
Removal: Adjusting screw and boot
• Using a flat-blade screwdriver, separate the boot and body at the
joint.
• Turning the adjusting screw counterclockwise, remove the ad-
justing screw and boot as an assembly.
• Remove the boot from the adjusting screw.
Removal: Spring cage

• Remove the spring cage holding it by hand not to let the spring
leap out.
WARNING
• Use care not to let the spring leap out.
Removal: Spring
• Secure with bolts and compress the spring.
• Remove the snap ring.
• Remove the bolts and .
WARNING
• When removing the bolts, use care not to let the spring leap
out.
• Remove the retainer and spring.
35-94
35
Inspection: Clip
• Hold the adjusting screws with a vise.
CAUTION
• Use cushion, such as rubber sheet or the like, to protect the
adjusting screw from damage. If the thread of adjusting
screw is damaged, the automatic adjusting mechanism will
not properly work.
• Attach .
• Measure the clip holding torque (torque at the point of clip begin-
ning to turn).
• If the measurement deviates from the specified standard value
range, replace the clip.
Inspection: Damage on clips, boots and caps

• If any damage such as deformation, break, crack or wear is
found, replace the faulty part.
Inspection: Wear of roller sliding surface on sleeve and

wedge and roller
• If a stepped wear is found on the roller sliding surface, measure
the amount of wear.
• If the measurement exceeds the service limit, replace the
sleeve.
Installation: Body
• Apply grease to the inner surface of the body.
• Fill grease in the hatched space.
Installation: Spring
• To install the spring, follow the removal procedure in reverse.
(See “ Removal: Spring”.)
Installation: Sleeve
• Apply grease to the peripheral surface, thread and roller contact
surface of the sleeve.
• Install the sleeve aligning its groove with the screw hole in the
body.
• Install the screw in the screw hole with sealant applied to its
thread, and tighten it to the specified torque.
NOTE
• Unless the screw is driven as deep as shown, it does not go
into the groove of the sleeve.
• Make sure that the sleeve does not come out.
35-95
EXPANDER
Installation: Spring cage
• Fit one end of the spring cage in the mating groove of the body.
• Press-fit the other end of the spring cage into place with a flat-
blade screwdriver.
• To check that the spring cage has its end firmly fitted in the
groove of the body, rotate the spring cage while pushing to see if
it smoothly turns.
Installation: Adjusting screw and boot

• Apply grease to the adjusting screw contact area of the boot and
the thread of the adjusting screw.
• Fit the boot in the groove of the adjusting screw.
• Drive the adjusting screw in until the end faces of the adjusting
screw and body are approximately 20 mm apart from each other.
Make sure that the adjusting screw smoothly turns.
• Lightly pulling the adjusting screw, make sure that the sleeve
slides.
• Using , press-fit the boot into place.
Installation: Clip
• To facilitate installation of the clip to the adjusting screw, turn the
adjusting screw to draw it out to such an extent that it does not
contact the boot.
• Install the clip to the adjusting screw.
CAUTION
• When installing the clip, use care not to damage the boot.
35-96
35
Inspection: Backlash between drive ring and sleeve
• Move the adjusting screw in the direction of arrow with a dial
gauge applied to it and measure backlash between the drive ring
and sleeve.
• If the measurement deviates from the specified standard value
range, replace the drive ring and sleeve.
NOTE
• When measuring backlash, use care so that the drive ring is
pushed by the sleeve to leave the body.
Inspection: Automatic adjusting mechanism operating

force of expander
• Draw out the adjusting screw by hand as much as practically
possible.
• Push in the adjusting screw until the change of resistance is felt.
• Push the adjusting screw with a push-pull gauge in the direction
of arrow to measure the maximum force.
• If the measurement deviates from the standard value, replace
the sleeve.
35-97
4-WAY PROTECTION VALVE
35-98
35
1 Dust cover 18 Shim B 35 Spacer
2 Dust seal rubber 19 Spacer 36 Piston A
3 C-ring 20 Piston B 37 O-ring
4 Dust seal plate 21 O-ring 38 Valve
5 Main spring 22 Valve spring 39 Dust seal rubber
6 Shim A 23 Valve 40 C-ring
7 Shim B 24 Plug 41 Dust seal plate
8 Spacer 25 Body 42 Main spring
9 Piston B 26 O-ring 43 Shim A
10 O-ring 27 Check valve 44 Shim B
11 Valve spring 28 Dust cover 45 Spacer
12 Valve 29 Dust seal rubber 46 Piston A
13 Dust seal rubber 30 C-ring 47 O-ring
14 C-ring 31 Dust seal plate 48 Valve
15 Dust seal plate 32 Main spring 49 Body
16 Main spring 33 Shim A
17 Shim A 34 Shim B : Non-reusable parts
Assembly sequence
Repair kit: 4-way protection valve kit
Service standards
590 ± 20 kPa
Opening valve pressure – Adjust or replace
{6.0 ± 0.2 kgf/cm2}
–
460 ± 20 kPa
Closing valve pressure – Adjust or replace
{4.7 ± 0.2 kgf/cm2}

Nut (body mounting) 15.0 ± 4.9 {1.5 ± 0.5} –
Plug 25.0 ± 4.9 {2.5 ± 0.5} –

Each sliding area and O-ring As required
35-99
Installation: Piston A, Piston B
• Install each piston A into the body, ensuring that the bypass hole
in the piston is located correctly.

Inspection: 4-way protection valve
(1) Inspection of outlet ports No. 21 and No. 22
[Inspection]
(1.1) Operation check
• Apply the air pressure of 930 kPa {9.5 kgf/cm2} into the inlet port
to evacuate the air from the outlet ports (No. 21, No. 22) three or
four times. If no air is evacuated, replace the faulty parts.
(1.2) Valve opening pressure

• Plug the other outlet port as illustrated and open the stop valve
on the outlet side.
by opening the stop valve on inlet side gradually with the follow-
ing condition.
Condition: The air pressure should rise from 295 to 490 kPa
{3 to 5 kgf/cm2} in 3 to 7 seconds.
• Measure the inlet pressure when the indication of the air pres-
sure gauge on the inlet side becomes stable.
• If the measured pressure deviates from the standard value, per-
form the following adjustment.
• Perform this inspection to both outlet ports (No. 21 and No. 22).
35-100
35
(1.3) Valve closing pressure
• Plug the other outlet port as illustrated and close the stop valve
on the outlet side.
• Apply the air pressure of 930 kPa {9.5 kgf/cm2} into the inlet
port. (outlet pipe capacity: approximately 0.5L)
• After checking air pressure of 930 kPa {9.5 kgf/cm2} on the
gauges of inlet and outlet, stop applying the air pressure and
evacuate the air pressure from inlet port by opening the stop
valve on inlet side gradually with the following condition
Condition: The air pressure should decrease from 590 to 295
kPa {6 to 3 kgf/cm2} in 3 seconds or less
• Measure the outlet pressure when the indication of the outlet
pressure gauge becomes stable.
• Perform this inspection to both outlet ports (No. 21 and No. 22).
[Adjustment]
• If the valve opening and/or closing pressure deviate from the
standard value, adjust by shims A, B and spacers.
Thickness: Shim A (t=0.4 mm)
Shim B (t=0.2 mm)
Spacer (t=1.0 mm)
• If the standard value cannot be obtained by the adjustment, re-
place the faulty parts.
(2) Inspection of outlet ports No. 23 and No. 24

[Inspection]
(2.1) Operation check
• Plug the outlet ports (No. 21 and No. 22) as illustrated and apply
the air pressure of 930 kPa {9.5 kgf/cm2} into the inlet port to
evacuate air from the outlet ports (No. 23, No. 24) three or four
times. If no air is evacuated, replace the defective part.
• Perform the following inspections with plugging the outlet ports
(No. 21 and No. 22).
35-101
(2.2) Valve opening pressure
on outlet side.
by opening the stop valve on the inlet side gradually with the fol-
lowing condition.
Condition: The air pressure should rise from 295 to 490 kPa
{3 to 5 kgf/cm2} in 8 to 22 seconds.
• Measure the pressure on the pressure gauge connected to the
inspection port when the indication of the outlet pressure gauge
starts to move.
• Perform this inspection both outlet ports (No. 23 and No. 24).
(2.3) Valve closing pressure
on outlet side.
• Apply air pressure of 930 kPa {9.5 kgf/cm2} into the inlet port
(outlet pipe capacity: approximately 0.5L)
• After checking air pressure of 930 kPa {9.5 kgf/cm2} on the
gauges of inlet and outlet, close the inlet stop valve and open
the outlet stop valve to evacuate the air pressure from outlet port
by opening the stop valve on the outlet side gradually with the
following condition.
Condition: The air pressure should decrease from 590 to 295
kPa {6 to 3 kgf/cm2} in 3 seconds or less
• Measure the pressure on the pressure gauge connected to the
inspection port when the indication of the pressure gauge con-
nected to the inspection port becomes stable.
• Perform this inspection both outlet ports (No. 23 and No. 24).
[Adjustment]
• If the valve opening and/or closing pressure deviate from the
standard value, adjust by shims A, B and spacers.
Thickness: Shim A (t=0.4 mm)
Shim B (t=0.2 mm)
Spacer (t=1.0 mm)
• If the standard value cannot be obtained by the adjustment, re-
place the faulty parts.
35-102
35
M E M O
35-103
RELAY VALVE
1 Cover
2 O-ring
3 O-ring
4 O-ring
5 Piston
6 Spring
7 Silencer
8 Retaining ring
9 Valve seat
10 O-ring
11 O-ring
12 Retaining ring
13 Valve guide
14 O-ring
15 Spring
16 Valve retainer
17 Intake valve
18 Body
: Non-reusable parts
Assembly sequence
Follow the disassembly sequence in re-
verse.
Repair kit: Relay valve kit

13 N
6 Spring load (installed length 10.3) 16 N {1.65 kgf} Replace
{1.35 kgf}
24 N
15 Spring load (installed length 15.7) 29 N {3.0 kgf} Replace
{2.4 kgf}

Bolt (cover mounting) 12 to 19 {1.2 to 1.9} –
Silencer 7 to 9 {0.7 to 0.9} –
35-104
35
Sliding contact surface of cover with piston
O-ring Multipurpose grease
As required
Sliding contact surface of intake valve with valve guide [NLGI No.2 (Li soap)]
Sliding contact surface of body with piston

Silencer holder MK529837
Removal and installation of silencer
Spanner
A MK529838
27
Removal procedure
Removal: Silencer

Inspection: Relay valve
• With an air pressure of 685 kPa {7 kgf/cm2} applied to the air
supply port, supply air to the command pressure port. The com-
mand-discharge pressure relationship should be as shown in the
characteristics diagram.
• If there is any abnormality, replace the spring.
35-105
RELAY VALVE
Characteristics Diagram
35-106
35
M E M O
35-107
QUICK RELEASE VALVE
1 Silencer
2 Body
3 O-ring
4 Spring
5 Retainer
6 Ring
7 Diaphragm
8 Housing
Assembly sequence
verse.
Repair kit: Quick release valve kit
Service standards
9.8 ± 4.9 kPa
– Starting pressure – Replace
{0.1 ± 0.05 kgf/cm2}

Body 17 to 22.5 {1.7 to 2.3} –
Silencer 8 ± 1 {0.8 ± 0.1} –
Special tools
35-108
35
Removal procedure
Removal: Silencer

Inspection: Quick release valve
• With the air lines connected as shown, gradually apply air pres-
sure from the supply port. Confirm that the relation between the
supply pressure and the discharge pressure is as shown by the
35-109
CHECK VALVE
Check Valve <Disassembled Type>
1 Connector
2 Cap
3 O-ring
4 Valve
5 Spring
6 Valve body
Assembly sequence
verse.
Service standards
29 kPa
– Pressure difference between supply and discharge port – Replace
{0.3 kgf/cm2} or less

Cap 44 to 55 {4.5 to 5.5} –

Thread of connector ThreeBond 1110B or Loctite 575 As required
Check Valve <Unit Type>
CAUTION
• Do not disassemble the check valve
because it is a unit type.
Service standards
29 kPa {0.3 kgf/cm2}
– Pressure difference between inlet and outlet – Replace
or less

Thread of check valve ThreeBond 1110B or Loctite 575 As required
35-110
SAFETY VALVE 35
Service standards
950 +600 kPa
– Release pressure – Replace
{9.7 +0.6
0 kgf/cm2
}

Thread of safety valve ThreeBond 1110B or Loctite 575 As required
35-111
HAND CONTROL VALVE <TRAILER BRAKE>
1 Snap ring 13 Cam holder 25 Snap ring
2 Washer 14 Steel ball 26 Valve seat
3 Spring cover 15 Shim A 27 O-ring
4 Lever spring 16 Snap ring 28 Snap ring
5 Spring seat 17 Spring support 29 Valve
6 Spring guide 18 Return spring 30 O-ring
7 Steel ball 19 Exhaust valve 31 Piston
8 Plug 20 Cover 32 O-ring
9 Spring pin 21 Shim B 33 Body
10 Camshaft 22 Main spring
11 Pin 23 Valve spring : Non-reusable parts
12 Cam 24 O-ring
Assembly sequence
Repair kit: Hand control valve kit

4 Free length of lever spring 21.7 20.5 Replace
18 Free length of return spring 38 36.6 Replace
22 Free length of main spring 31.3 29.5 Replace
23 Free length of valve spring 28.5 27.5 Replace
35-112
35
Bolt (cam holder mounting) 9.8 to 20 {1 to 2} –
Screw (cover mounting) 5.4 to 7.4 {0.55 to 0.75} –

Steel ball
Valve seat, piston and O-ring groove of body Multipurpose grease
As required
O-ring [NLGI No.3 (Li soap)]
Spring guide contact surfaces
Adjustment: Installed height of exhaust valve
• Temporarily install the cam holder. Adjust by changing the num-
ber of shims A placed under the steel ball so that the dimension
between the bottom surface of the exhaust valve and the bottom
surface of the body measures 38.5 ± 0.2 mm.
Installation: Spring guide

• Install spring guide with notch facing in the direction shown (to-
ward the opposite side to body).
35-113
HAND CONTROL VALVE <TRAILER BRAKE>
Inspection: Hand control valve
• Apply an air pressure of 685 kPa {7 kgf/cm2} from the air supply
port and, while measuring the camshaft turning angle, check that
the output air pressure from the discharge port comes within the
specified range shown in the characteristics diagram.
• If the camshaft turning angle deviates from the specified range,
change the number of shims A under the steel ball or replace the
hand control valve.
• If the output air pressure deviates from the specified range, cor-
rect by changing the number of shims B.
35-114
35
M E M O
35-115
TRAILER CONTROL VALVE <TRAILER BRAKE>
1 Connector
2 Packing
3 Silencer
4 O-ring
5 Trailer control valve
Shown in ( ) is a port number.
Assembly sequence
verse.
Service standards
Output air pressure from port 22 when air pressure of
1 to 30 kPa
850 kPa {8.7 kgf/cm2} is applied to port 11, 850 kPa {8.7 – Replace
{0.01 to 0.3 kgf/cm2}
kgf/cm2} to port 43 and 50 kPa {0.5 kgf/cm2} to port 41
–
Output air pressure from port 22 when air pressure of
1 to 30 kPa
850 kPa {8.7 kgf/cm2} is applied to port 11, 850 kPa {8.7 – Replace
{0.01 to 0.3 kgf/cm2}
kgf/cm2} to port 43 and 60 kPa {0.6 kgf/cm2} to port 42

Connector 29 to 39 {3 to 4} –
Clamp 1 to 2 {0.1 to 0.2} –

Entire packing ThreeBond 1101 As required
O-ring Silicone Grease As required
35-116
35
Inspection: Trailer control valve
• Apply air pressure of 850 kPa {8.5 kgf/cm2} to the port 11 and
specified levels of air pressure to other ports. Output air pres-
sure from the port 22 should be within the specified standard
range.
• When air pressure of 850 kPa {8.5 kgf/cm2} is applied to the port
11 and the levels of air pressure at the port 41, 42 and 43 are
changed, the output air pressure at the port 22 should be as
shown in the characteristics diagram.
• If there is any abnormality, replace the trailer control valve.
<Port 41>
35-117
TRAILER CONTROL VALVE <TRAILER BRAKE>
<Port 42>
<Port 43>
35-118
35
M E M O
35-119
QUICK RELEASE VALVE <TRAILER BRAKE>
1 Silencer
2 Retaining ring
3 Valve seat
4 Body
5 O-ring
6 Spring
7 Retainer
8 Ring
9 Diaphragm and ring
10 Housing
Assembly sequence
verse.
Repair kit: Quick release valve kit
Service standards
9.8 ± 4.9 kPa
– Starting pressure – Replace
{0.1 ± 0.05 kgf/cm2}

Body 17 to 22.5 {1.7 to 2.3} –
Silencer 8 ± 1 {0.8 ± 0.1} –
Special tools
35-120
35
Removal procedure
Removal: Silencer

Inspection: Quick release valve
• With the air lines connected as shown, gradually apply air pres-
sure from the supply port. Confirm that the relation between the
supply pressure and the discharge pressure is as shown by the
35-121
DOUBLE CHECK VALVE <TRAILER BRAKE>
1 Joint
2 Packing
3 Check valve
4 Sleeve
5 Body
Assembly sequence
verse.
Repair kit: Double check valve kit
Service standards
Air leakage
– 0 cm3 {0 mL} – Replace
(check pressure: 49 to 835 kPa {0.5 to 8.5 kgf/cm2})

Joint 34 to 44 {3.5 to 4.5} –

Both sides of packing ThreeBond 1101 As required

Inspection: Double check valve
• Apply the specified air pressure into the air supply port A. Air
should come out the air discharge port and no air should come
out from the air supply port B.
• Repeat this by applying air pressure into the air supply port B.
35-122
AIR SERVICE VALVE <TRAILER BRAKE> 35
1 Bracket
2 Air service switch
3 Valve
Assembly sequence
verse.
35-123

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GROUP 35 BRAKE

SPECIFICATIONS ................................ 35-2 HANDLING OF NYLON TUBE FOR

2.1 During suction

2.2 During compression and delivery

3.2 Regeneration of desiccant

3.4 Operation when tank pres-

4.1 When brake not operating

4.3 When pressing brake pedal

(2) Secondary side

(1) Primary side

(2) Secondary side

4.5 Release of brake pressure

4.6 When abnormality occurs

(2) Operation when the air pipe of the

5.1 Wedge mechanism

<With Spring Chamber>

(2) Spring brake (wheel parking brake)

(1) Automatic adjuster mechanism

(1.1) When brake shoe clearance is as

(1.2) When brake shoe clearance is

• When the brake is released, the

7.1 When operated

7.2 Stabilization of air pressure

8.2 When released

9.1 When operated

9.2 When released

10.2 When service brake is operat-

• The valve is further pushed down to

10.3 When dual brake valve (rear

10.4 When dual brake valve (front

10.6 When brake pedal is released

10.7 When wheel parking brake is

11.1 When operated

11.2 When released

Noise generated when brake pedal is pressed down

Wheel brake application one sided

Wheel brake works suddenly

Warning lamp illuminates

Freezing takes place within air dry-

Engine oil leaks from exhaust port

2. Air Pressure Build-up

Service standards (Unit: mm)

Tightening torque (Unit: N·m {kgf·m})

4. Inspection of Brake Lining Thickness

Service standards (Unit: mm)

Service standards (Unit: mm)

6.2 Every year or 100,000 km

Tightening torque (Unit: N·m {kgf·m})

Lubricant and/or sealant

(2) The upper threshold pressure of air pressure governor

(3) The lower threshold pressure of air pressure governor

• Perform the following inspections. If the measured value is out of

8.1 Valve closing pressure on discharge port No. 21

8.2 Valve closing pressure on discharge port No. 22

8.3 Valve closing pressure on discharge port No. 23

8.4 Valve closing pressure on discharge port No. 24

Release tool kit (a set of