BRAKE SYSTEM

Specifications .......................................................................................... 9 – 1
Structure and Functions ....................................................................... 9 – 2
Caliper Assembly ...................................................................................... 9 – 3
Brake Pedal Assembly .............................................................................. 9 – 4
Master Cylinder ........................................................................................ 9 – 5
Parking Brake Lever .................................................................................. 9 – 6
Procedures and Suggestions for Disassembly and
Reassembly ............................................................................................. 9 – 7
Master Cylinder ........................................................................................ 9 – 7
Inspection and Adjustment ................................................................. 9 – 9
Pad Clearance Adjustment ....................................................................... 9 – 9
Brake Pedal Adjustment ............................................................................ 9 – 9
Brake Switch Installation ........................................................................... 9 – 10
Brake Fluid Line Bleeding ......................................................................... 9 – 10
Parking Brake Adjustment ......................................................................... 9 – 10 9
Troubleshooting ....................................................................................... 9 – 11
Service Data ............................................................................................ 9 – 12
 BRAKE SYSTEM

Specifications
Truck Model
1 ton class 2 ton class
Item
Type Hydraulic (mechanical) motor disc brake system
Brake disc effective
162 (6.378)
diameter mm (in.)
Disc outside diameter
200 (7.874)
mm (in.)
Disc thickness
10 (0.39)
mm (in.)
Disc effective thickness
9 (0.35)
mm (in.)
Brake Main brake and Pad area
28.8 × 2 (4.46 × 2)
system parking brake cm2 (in2.)
Pad thickness
5 (0.2)
mm (in.)
Pad effective thickness
4 (0.16)
mm (in.)
The minimum clearance of
0.4 (0.016)
disc and pads mm (in.)
Pad material NS 179
Wheel cylinder inside
19.05 (0.75)
diameter mm (in.)
Wheel cylinder area
2.85 (0.44)
cm2 (in2.)

9-1
BRAKE SYSTEM

Structure and Functions

8 1

4
206824

1 Caliper assembly 5 Reservoir tank

2 Brake disc 6 Parking lever assembly
3 Traction motor 7 Equalizer bracket
4 Brake pedal assembly 8 Lever D

The brake pads clamp the brake disc, mounted on the The brake pedal assembly is mounted on the left side of
traction motor, to provide stopping force. the frame.
The caliper assemblies are installed on the rib section The cable linked to the parking lever pulls lever D of
of the drive motor. the caliper to provide stopping force.

9-2
 BRAKE SYSTEM

Caliper Assembly

8 7 15 1
3
B 17

9
10
4 2 11

8 5 14 13
1

7 16

8
10

6
11

13 12
A 4

206825

1 Body assembly 8 Pin 15 Spring

2 Lever A 9 Spring 16 Bleeder screw
3 Lever B 10 Pad assembly 17 Brake disc
4 Pin, Split pin 11 Bolt, Washer A: Brake fluid inlet
5 Lever C 12 Adjustment bolt B: Parking brake cable
6 Lever D 13 Adjustment bolt
mounting hole
7 Pin, Split pin 14 Lock nut, Washer

The brake pads clamp the brake disc, mounted on the
traction motor, to provide stopping force.
The caliper assemblies are installed on the traction
motor. Pressurized brake fluid entering from section A
pushes the piston into the cylinder of the body
assembly. The piston then presses pin 7, which then
pushes levers C and D to an open position. Levers A
and B move with pin 4 as the fulcrum and open their
link sides, causing the pad assembly to clamp the brake
disc. When the parking brake cable connected to
section B pulls the lever in the direction of the arrow,
the pad assembly operates mechanically. Adjustment
bolts 12, 13 and spring 15 maintain proper clearances
between the brake disc and pads. The caliper assembly
installed on the opposite side of the vehicle is
symmetrically constructed.

9-3
BRAKE SYSTEM

Brake Pedal Assembly

Brake fluid 6

5
3 7

1
4

211053

1 Pedal bracket 5 Master cylinder

2 Brake pedal 6 Adjustment bolt
3 Brake link 7 Brake switch
4 Return spring

The brake pedal assembly is mounted on the left side of Brake fluid is supplied to the master cylinder from the
the frame. reservoir tank located under the left side of the
The adjustment bolt is used to set the brake pedal dashboard.
height.
The installation length of the brake switch is pre-
adjusted. When the pedal is pressed, the switch
activates and controls the operating speed of the
traction motor.

9-4
 BRAKE SYSTEM

Master Cylinder

12
13
1 7
8
2 4 3
10 11 9

14

15
16 5 6 17 18

211054

1 Cylinder body 10 Clevis

2 Safety ring 11 Nut
3 Piston 12 Filler
4 Secondary cup 13 Gasket
5 Primary cup 14 Clevis pin
6 Spring pad 15 Snap pin
7 Spring 16 Valve
8 Dust cover 17 Valve body
9 Push rod 18 Valve seal

The inside diameter of the cylinder is 19.05 mm (3/4

in.), and the maximum stroke is 30 mm (1.2 in.).

9-5
BRAKE SYSTEM

Parking Brake Lever

Maximum stroke: 50°

8
3
2

211055

1 Lever body 5 Stopper

2 Gear 6 Spring
3 Notch 7 Hook
4 Grip 8 Pin

The parking brake lever is mounted on the left side of The maximum lever stroke is 50 degrees. There are a
the dashboard. total of 14 gear teeth. Adjust the parking brake so that
When the grip is pulled, the parking brake cable moves the brake activates and applies force when the third or
fourth tooth of gear 2 engages with the notch.
the pad assembly of the caliper to clamp the brake disc
and apply stopping force.
Notch 3 engages with gear 2 to retain the lever in
Grip operating effort 343 N (35 kgf) [77 lbf]
position. To release the parking brake, pull the grip and
press stopper 5. This disengages the gear from the
notch, and the lever returns to the original position.

9-6
 BRAKE SYSTEM

Procedures and Suggestions for Disassembly and Reassembly

Master Cylinder
Disassembly

8
6
5 7

4
3
2

213017

Sequence
1 Clevis, Nut, Push rod 5 Cup spacer, Primary cup, Spring seat
2 Boot 6 Return spring
3 Stopper ring 7 Cylinder body
4 Secondary cup, Piston 8 Filler, Clamp

NOTE
Parts marked with (❋) are included in the repair kit.

9-7
BRAKE SYSTEM

Inspection after Disassembly

1. Cylinder body
(1) Check the inner surface of the cylinder for rust,
corrosion and scuffing.
(2) Check the inlet port and relief port for clogging.
And check the joint bolts and boot for damage.
A : Standard value
2. Piston
B : Service or repair limit
Check the piston for damage, and replace if damaged.
If the clearance between the piston and cylinder 0.020 to 0.105 mm
A
Clearance between (0.0008 to 0.0041 in.)
exceeds the limit, replace both cylinder and piston.
cylinder and piston 0.2 mm
3. Return spring B
(0.0078 in.)
Replace the return spring once a year.

4. Primary cup, Secondary cup and Spring seat

Inspect rubber parts for damage and swelling. Replace
the primary cup, secondary cup and spring seat once a
year.

Reassembly
Follow the disassembly sequence in reverse. Also
follow the instructions below.
(1) Clean metal parts with a volatile cleaning solution,
and thoroughly dry using compressed air.
(2) Apply a thin coat of brake rubber grease (Metal
Rubber #20) or brake fluid on the inner surface of
the cylinder and the piston cup.

9-8
 BRAKE SYSTEM

Inspection and Adjustment

Pad Clearance Adjustment

Pad B
Loosen the lock nut and turn adjustment bolt A to adjust
pad A clearance. Pad B moves as adjustment bolt A is
turned.
Therefore, use adjustment bolt B to adjust pad B clearance.
One rotation of adjustment bolt A moves pads A and B Clearance
approximately 1 mm (0.04 in.) to the right or left according
Lock nut Pad A
to the direction of the bolt rotation. One rotation of
Adjustment bolt 206825A
adjustment bolt B moves pad B approximately 1 mm (0.04
in.) to the right or left according to the direction of the bolt
rotation.
Adjust the clearance to a range of 0.4 to 1.1 mm (0.0157 to Adjustment bolt A
0.0433 in.) at the tip on each side.
After adjustment, tighten the lock nut.

2.94 to 5.88 N·m

Lock nut tightening torque (30 to 60 kgf·cm)
[2.17 to 4.34 lbf·ft]

Adjustment bolt B
206825B

Brake Pedal Adjustment

(1) Use the stopper bolt to adjust pedal height A (distance
C
between frame and the top of pedal pad). D
(2) Set push rod length B to the specified dimension, and
install the push rod into the master cylinder. The
A’ A
clearance between the push rod and piston should be Stopper bolt
0.5 to 1.5 mm (0.02 to 0.06 in.). The pedal play C
should be 3 to 9 mm (0.12 to 0.35 in.).
(3) After adjustment, check to make sure that pedal stroke
D (brake activating point) is as specified.
Unit : mm (in.)
Truck Model
1 ton class 2 ton class
Item
B 206830
Pedal height A 192.6
from floor plate (7.58)
Pedal height A’ 198.6
from frame (7.82)
Push rod length B 118.6 (4.67)
Free play C 3 to 9 (0.12 to 0.35)
Pedal stroke D 21 to 32
(brake activating point) (0.8 to 1.3)

9-9
BRAKE SYSTEM

Brake Switch Installation

(ON/OFF point)
(1) Use the adjustment bolt to adjust the brake pedal Brake switch
0.7 to 1.3 mm
height, then tighten the lock nut. (0.027 to 0.05 in.)
(2) By rotating the push rod of the brake master cylinder,
adjust the clearance between the push rod and piston to
a range of 0.5 to 1.5 mm (0.019 to 0.059 in.).
When properly adjusted, the pedal should travel a
distance of 3 to 9 mm (0.12 to 0.35 in.) when pressed.
Lock nut
(3) Install the brake switch, and adjust so that the switch
205753
activates when the brake pedal is pressed 7 to 13 mm
(0.27 to 0.51 in.). Then, tighten the lock nut.
The brake switch should turn ON and OFF with pedal
movement of 0.7 to 1.3 mm (0.027 to 0.051 in.).
Brake Fluid Line Bleeding
When any part of the brake fluid system is disassembled for
repair or when brake pedal movement is spongy, bleed the
brake fluid line as follows:
(1) Attach a clear vinyl tube to the bleeder screw of the
right caliper assembly, which is located furthest from
the master cylinder.
(2) Check the brake fluid level in the reserve tank. Add if
the level is low.
(3) Pump the brake pedal several times, and then keep the
pedal pressed. While holding the pedal pressed, loosen
the bleeder screw. While brake fluid is flowing into the
vinyl tube, tighten the bleeder screw.
(4) Repeat the above procedure until no air bubbles are in
the brake fluid.
Repeat the same procedure to bleed the left caliper
assembly.
After air bleeding is completed, add brake fluid in the
tank to the specified level.
Parking Brake Adjustment
When the pad clearances are adjusted to approximately 1.1
mm (0.043 in.), the notch should engage with the third or
fourth tooth of the gear when the parking brake lever is
pulled.
If the pads are worn, tighten the adjustment bolts of the
calipers to adjust the clearances. To adjust the cable length,
use the cable adjustment bolt.

206833

9-10

Troubleshooting
Oil leak from master cylinder
primary cup
Oil leak from caliper cylinder
cup
Inadequate braking force
Oil leak from oil pipe joint
Worn lining
Oil adhesion on lining
Air in hydraulic system
Faulty master cylinder or
piston cup
Excessive pedal stroke
Low oil level in master cylinder
Foot Excessive clearance of master
brake cylinder push rod
Brake fluid leak
Oil or grease adhesion on
Imbalance in braking lining or disc
power
Brake disc wobbling or loose
mounting
Lining surface too smooth
Worn lining
Brake squealing
Loose caliper tightening bolt
Dirty disc
Inadequate clearance
Parking brake stroke too
between disc and lining
short
Parking brake cable too short
Abnormal noise from Inadequate clearance between
Parking hand brake during brake pad and disc
brake driving Warped brake disc
Parking brake cable too long
Parking brake not
producing stopping force Brake lining worn beyond
limit
Excessive clearance between
brake pad and disc
9-11
BRAKE SYSTEM
*
Inspect cylinder. If no abnormality
is found, replace piston cup.
If piston cup is deformed, replace
cup and brake fluid (use genuine
brake fluid).
Re-tighten, or replace pipe
and joint.
Replace.
Clean with brake component
cleaner and repair or replace.
Bleed master cylinder and
caliper cylinder.
Replace piston cup.
Add brake fluid.
Adjust.
Refer to above section marked
with *.
Clean with brake component cleaner
and repair. If oil and grease cannot be
removed from lining, replace lining.
Replace disc. If problem is caused
by loose mounting, re-adjust and
re-tighten.
Replace brake pad.
Re-tighten.
Clean with brake component cleaner.
Adjust to standard clearance
value.
Adjust cable length using
adjustment bolt.
Adjust to standard clearance
value.
Repair brake disc according to
repair standard, or replace.
Adjust cable length using
adjustment bolt.
Replace brake pad.
Adjust clearance between
brake pad and disc.
BRAKE SYSTEM
Service Data A: Standard value
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
Item
Pedal height 1
A 192.6 (7.58)
(between upper pedal edge and floor)
Pedal stroke 2 (brake activating point) A 21 to 32 (0.8 to 1.3)
Free play 3 A 3 to 9 (0.12 to 0.35)
Push rod length 4
A 118.6 (4.67)
(standard assembly dimension)
Clearance between piston and push rod 5 A 0.5 to 1.5 (0.019 to 0.059)
Brake switch activating pedal stroke 6 A 7 to 13 (0.27 to 0.51)
Brake switch activating dimension 7 A 0.7 to 1.3 (0.027 to 0.05)

Brake 2
6
pedal 3

5
4
206831

9-12
 BRAKE SYSTEM
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
Item
+0.052 +0.00205
Cylinder body inside diameter 1 A 19.05 0 (0.7500 0 )
-0.020 -0.00079
Piston outside diameter 2 A 19.05 -0.053 (0.7500 -0.00209 )
A 0.020 to 0.105 (0.00079 to 0.00413 )
Clearance between cylinder and piston
B 0.2 (0.08)
0 0
A 20 -0.3 (0.79 -0.012)
Primary cup lip-side outside diameter 3
B (Replace once a year.)
A 20.2 ± 0.2 (0.795 ± 0.008 )
Secondary cup lip-side outside diameter 4
Master B (Replace once a year.)
cylinder A 46.8 (1.843 )
Return spring free-movement length 5
B (Replace once a year.)

4 2

1 3 5

208380A

9-13
BRAKE SYSTEM
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model
1 ton class 2 ton class
Item
Tightening Pad assembly tightening
A 17.65 to 26.48 (180 to 270) [13.02 to 19.53]
torque bolt 1
N·m
(kgf·cm) Adjustment bolt lock nut 2 A 2.94 to 5.88 (30 to 60) [2.17 to 4.34]
[lbf·ft] Bleeder screw 3 A 6.86 to 11.77 (70 to 120) [5.06 to 8.68]
A 5 (0.2)
Pad lining thickness 4
B 1 (0.039)
Lever D pin hole stroke with 1.1 mm
(0.043 in.) of clearance between brake A 5 (0.197)
disc and pad 5
Lever D pin hole stroke with 4 mm
A 20 (0.787)
(0.157 in.) of pad thickness wear 6
Brake disc thickness 7 A 10 (0.394)

Caliper

2 1

206832

9-14