Hino 700 Brake Direccion Suspension PDF

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1 MENU
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
Applicable for FR1E, FS1E, FY1E, SH1E, SS1E and ZS1E series, equipped with E13C engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
This manual is divided into 9 sections with a thumb index for each section at the edge of the pages.
Please note that the publications below have also been prepared as relevant service manuals for the components and sys-
tems in this vehicles.
Manual Name Pub. No.

Chassis Workshop Manual S1-YFSE16A 1/3
Chassis Workshop Manual S1-YFSE16A 3/3
E13C Engine Workshop Manual S5-YE13E01A
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S1-YFSE16A 2/3

CHAPTER
MODELS FR1E, FS1E, FY1E, SH1E, SS1E, ZS1E
GENERAL INTRODUCTION GN02-001
CLUTCH MAIN UNIT CL02-001 CL02-002 CL02-003 CL02-004
CLUTCH CONTROL CL03-001 CL03-002 CL03-003 CL03-004
TRANSMISSION MAIN UNIT TR02-001 TR02-002 TR02-003 TR02-004
P.T.O. (POWER TAKE-OFF) TR05-001 TR05-002 TR05-003
TRANSMISSION/TRANSFER CONTROL TR06-001
PROPELLER SHAFT PP02-001 PP02-002 PP02-003
DIFFERENTIAL EQUIPMENT DF01-001
DIFFERENTIAL CARRIER DF02-001 DF02-002 DF02-003 DF02-004 DF02-005
BRAKE EQUIPMENT BR01-001
SERVICE BRAKE BR02-001
ABS (ANTI-LOCK BRAKE SYSTEM) BR03-001
ES START (EASY & SMOOTH START) SYSTEM BR04-001
STEERING EQUIPMENT SR01-001
STEERING UNIT SR02-001
POWER STEERING SR03-001
FRONT AXLE AX02-001 AX02-002
REAR AXLE AX03-001 AX03-002
WHEEL & TIRE AX04-001
SUSPENSION SU02-001 SU02-002 SU02-003 SU02-004
CHASSIS FRAME FC02-001
COUPLER (5TH WHEEL) FC03-001
PINTLE HOOK FC04-001
CAB CA02-001
ELECTRICAL EQUIPMENT EL01-001
ELECTRIC WIRE EL02-001
BRAKE CONTROL DN03-001 DN03-002
SUSPENSION CONTROL DN04-001
OTHERS DN06-001
This manual does not contain items on half-tone dot meshing.

INDEX: CHASSIS GROUP 1/4
GENERAL INTRODUCTION
CLUTCH EQUIPMENT
CLUTCH MAIN UNIT
WORKSHOP CLUTCH CONTROL
MANUAL TRANSMISSION EQUIPMENT
TRANSMISSION MAIN UNIT
TRANSFER MAIN UNIT
AUTOMATIC TRANSMISSION
P.T.O. (POWER TAKE-OFF)
TRANSMISSION / TRANSFER CONTROL
PROPELLER SHAFT EQUIPMENT
PROPELLER SHAFT
DIFFERENTIAL EQUIPMENT
DIFFERENTIAL CARRIER
BRAKE EQUIPMENT
SERVICE BRAKE
ABS (ANTI-LOCK BRAKE SYSTEM)
ES START (EASY & SMOOTH START) SYSTEM

All rights reserved. This manual may not be
reproduced or copied in whole in part, with- This manual does not contain items on half-tone dot meshing.
out the written consent of Hino Motors, Ltd.
EXHAUST BRAKE
RETARDER BRAKE
PARKING BRAKE
STEERING EQUIPMENT
STEERING UNIT
POWER STEERING
AXLE EQUIPMENT
FRONT AXLE
REAR AXLE
WHEEL & TIRE
SUSPENSION EQUIPMENT
SUSPENSION
CHASSIS EQUIPMENT
CHASSIS FRAME
COUPLER (5TH WHEEL)
PINTLE HOOK
CAB EQUIPMENT
CAB
ELECTRICAL EQUIPMENT
ELECTRIC WIRE
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
BRAKE EQUIPMENT BR01–1
BRAKE EQUIPMENT
BR01
BR01-001
SERVICE BRAKE ASSEMBLY.................BR01-2

DESCRIPTION ................................................ BR01-2
DIAGRAM ........................................................ BR01-3
TROUBLESHOOTING................................... BR01-41
BR01–2 BRAKE EQUIPMENT
SERVICE BRAKE ASSEMBLY

DESCRIPTION
EN0680201C100001
Type of service brake Drum-shoe type wheel brake activated by compressed air.
Air charging system Air charging is from piston type air compressor and air flow is directed and con-
trolled by a pressure regulator, the necessary valves, and lines as required.
Pressure sensor and air pressure warning switch are used for indicating the
pressure level in the system.
Service brake control system Two independent lines for front and rear wheels with air flow controlled by a
brake valve, and each line comprises a group of valve and brake chambers
(one/ wheel).
Stop lamp switch is used to operate the stop lamps.
Spring brake control system Single line for all spring brake chambers.
The line comprises a control valve which controls air flow, the other necessary
valve and spring brake chambers.
A stop lamp switch is used to turn on the stop lamps.
A parking brake switch is used to turn off the warning buzzer and to turn on the
parking brake warning lamp.
Wheel brake Drum brake with internally expanding, leading-trailing shoes are operated by
slack adjuster and cam shaft or expander in all wheels.
NOTICE
See "DIAGRAM" of the following page the component parts
(Valves, Switches, etc.) used in easy system.
DIAGRAM
EN0680201J100001
MODELS: FS (DUMP, MIXER AND CARGO TRUCK), ZS (DUMP AND CARGO TRUCK)
(For GENERAL COUNTRIES, CHILE, CHINA, G.C.C. COUNTRIES, HONG KONG, IRELAND,
SOUTH AFRICA, TAIWAN)
Q1
2 3 19 H3
A/D A4 A5
CAB CHASSIS A3 26L H2
H1 20
A6
4 20
8 11 F R
A7 6 14 15
B1
D3
P15
32 26L 26L
7 R
D40 C0
F
C1 5 E5
E1
C2
E2 P6 P3 F11
P1
P2
E4 13
P14
17 32
E3 F21
S1
H20 E6
A2 F51
27 B2 D1 E7 32
C3
21
9
24 1 P3
P13
P4
P9
P5
Q3 Q4
18
L1 P8 P6 F16
21 H41 H4
H22 H21
28 14 15
D60 D6
P18
D8 32
11
RUBBER HOSE
STEEL PIPE
NYLON TUBE
H7
16 12
TRANSMISSION CHASSIS 22 H6
X4
23 H5
16
19 L1 X3
X5 21
23 H12 H11 H5
H7 X2
12 21 25 25 X1
25 22 H41
21
WITH MZ12 TRANSMISSION WITH ZF TRANSMISSION

(IF SO EQUIPPED) (IF SO EQUIPPED)
12 H9
H5
H7 21 21 26
25 W3 W31 W4
22
21 W1 W2
WITH HX07 TRANSMISSION WITH INER-AXLE DIFFERENTIAL LOCK

SHTS068020100001
E3
B1 A4
29 E31
10
E4
A3
3
13
WITHOUT AIR DRYER WITH LOAD SENSING VALVE

H5
H5
21 21
J5
J2 J4
J2 J4
30 30
25 25
21
21
J1
J1
WITH TRANSMISSION P.T.O. WITH TRANSMISSION P.T.O.

(WITH HX07 AND MZ12 TRANSMISSION) (WITH ZF TRANSMISSION)
B1 A4
21 10 31
H50
A3 2 A/D A4
E2 E50 E3
3 A3
B1
33 31 3
WITH ES START WITH TIRE INFLATOR WITH TIRE INFLATOR

(IF SO EQUIPPED) (WITHOUT AIR DRYER) (WITH AIR DRYER)
SHTS068020100002
1 Air compressor 18 Relay valve-Spring brake

2 Air dryer (If so equipped) 19 Reducing valve
3 Air tank-Water separator 20 Protection valve
4 Air tank-Front brake 21 Multi joint
5 Air tank-Rear brake 22 Clutch booster
6 Protection valve 23 Range valve
7 Brake valve 24 Air suspension seat
8 Stop lamp switch 25 Magnetic valve
9 Relay valve-Front brake 26 Inter-axle differential lock control cylinder
10 Pressure regulator 27 Cab suspension-Front
11 Spring brake chamber-Front 28 Cab suspension-Rear
12 Power shift 29 Load sensing valve (If so equipped)
13 Release valve-Rear brake 30 Transmission P.T.O. (If so equipped)
14 Spring brake chamber-Rear 31 Tire inflator (If so equipped)
15 Brake chamber 32 ABS control valve (If so equipped)
16 Splitter valve 33 ES start control valve (If so equipped)
17 Spring brake control valve
MODEL: FS (For AUSTRALIA)

19
CAB CHASSIS Z8
33
Z6 EMERGENCY
Z3
P22
3
Z2
B1 10 A9 R 26L Z4
26L
A5
34 SERVICE
A3
A4 5 Z9
A8
19
A6 H2 H3
8 11 H11
P0 A7
D3 F R 14 15
32 5 6 20
7 P15
D20 16 26L 26L 26L
R
C1
D40 4 E5
F E1 E12 13 F3
C2 12 F1 F20
32
E2 E3 F11
E5 F21
P1 E15
P2
1 E13 13 32
17 2 C3 P6
D1 E16 E14
H20 F6
35 27 P4 18
P51
A2 C7
P5
B2
21 Q1
P9
F16
1 22 9 Q4
E7
S1
23 P8
H7
24 H5 H10
W2 W3 W4
L1 H41 H4 W1
H22 H21
26
21 25 14 15
28
P17
R1
D60 D6
20
P18 D30
R13
32
D8 R7 R1 R2
11 R5 31 31
R6
25 R2
26L 29
R3
R4
R10
30
RUBBER HOSE
STEEL PIPE
NYLON TUBE R20 R17
R1 R2
31 31
2 A/D A4
A3
B1
3
WITH AIR DRYER
10
B1 A4 36
A3
2 A/D A4
3 A3
B1
36 3
WITH TIRE INFLATOR WITH TIRE INFLATOR

(WITHOUT AIR DRYER) (WITH AIR DRYER)
SHTS068020100003
1 Air compressor 19 Reducing valve

2 Air dryer (If so equipped) 20 Protection valve
3 Air tank-Water separator 21 Multi joint
4 Air tank-Front brake 22 Clutch booster
5 Air tank-Rear brake 23 Range valve
6 Protection valve 24 Air suspension seat
7 Brake valve 25 Magnetic valve
8 Stop lamp switch 26 Inter-axle differential lock control cylinder
9 Relay valve-Front brake 27 Cab suspension-Front
10 Pressure regulator 28 Cab suspension-Rear
11 Spring brake chamber-Front 29 Air tank-Air suspension
12 Quick release valve 30 Leveling valve
13 Release valve-Rear brake 31 Air spring
14 Spring brake chamber-Rear 32 ABS control valve
15 Brake chamber 33 Cut valve
16 Air tank-Spring brake and trailer brake 34 Trailer control valve
17 Spring brake control valve 35 Trailer hand brake valve
18 Relay valve-Spring brake 36 Tire inflator (If so equipped)
MODEL: FS (CARGO TRUCK) (For HONG KONG, IRELAND, TAIWAN)

Q1
CAB CHASSIS 3 20
B1 A4 A5
19 H3
10 26L
11 H1
D3 4 A6
H2
8 12 f 6 14 15
R
A7
D40
A3 26L
26L
20
7 C0
R
F
C1 5 P11
E1
C2
E2 P6 F3 F11
P1
P2
D1 9
E3 E4
13
F4 F1
C3 12 F2 F21
17 S1
E6
F7 F8
H20
F12 F13
A2
E5 F5 F51
27 B2 E7 12
21
24 1 P3 P4
P10 P9 P51
P5
Q3
Q4 18
P8 F6 F16
L1
P12
21 H41 H4
H22 H21
28 D6 14 15
R1
D60
11 20
12 R13
D8
R5
R9 R1 R2
31 31
R16 R4
RUBBER HOSE 25 29
29
STEEL PIPE R2
NYLON TUBE 26L 26L
R3
R10
R20 R17
R1 R2
H7
31 31
31 32
22 H6
TRANSMISSION CHASSIS
X4
23 H5
L1 X3
31
19
X5 21
23 H12 H11 H5
X2
H7
21 25 25 X1
H41
32 25 22
21
WITH ZF TRANSMISSION WITH MZ12 TRANSMISSION
H9
H5
2 A/D A4
H7 21 A3
B1
21 22 3
WITH HX07 TRANSMISSION WITH AIR DRYER

(IF SO EQUIPPED)
SHTS068020100004
H5
21 H5
21
J5
J2 J4
J2 J4
30 30
25 25
21 21
J1
J1

(WITH ZF TRANSMISSION) (WITH HX07, MZ12 TRANSMISSION)
E3
33 E31
21
H50
E4
E2 E50 E3
13 16
WITH LOADSENSING VALVE WITH ES START

10 B1 A4
34
A3 2 A/D A4
3 A3
B1
34 3
(WITHOUT AIR DRYER) (WITHOUT AIR DRYER)
21 25 26
W3 W31 W4
W1 W2
WITH INTER-AXLE DIFFERENTIAL LOCK

(MODEL: FS)
SHTS068020100005

11 Brake chamber 28 Cab suspension-Rear
12 ABS control valve (If so equipped) 29 Air tank-Air suspension
13 Relay valve-Rear 30 Transmission P.T.O.
14 Spring brake chamber-Rear, Frontward 31 Splitter valve
15 Spring brake chamber-Rear, Rearward 32 Power shift
16 ES start control valve (If so equipped) 33 Load sensing valve
17 Spring brake control valve 34 Tire inflator (If so equipped)
MODEL: FS (For NEW ZEALAND)
19
Z3
CAB CHASSIS 5
A9
R 26L
16 Z8
SERVICE
10 F Z4
3 19
Z6
H3
A4 A5 EMERGENCY
26L H1 26L 33
11 H2
A8
A3 A6
8 D3 B1
32 6 Q3 14 15
P15
D20 F
R 20 Z2
D40 4 5 C7
P22
26L
26L
7 R
C0
C1
F
E1
C2
E2 E3 P6 F3 F11
P1
P21 P2
D1 9
E4
13
㩯1 C3 F1 F2 F21
17 㩯2 32 F7 F8
F4
S1 H20 E6
A2 F12 F13
12 27 E5 F5 F51
B2
21 E7 32
P3 P4
24 1 22 P10 P9 P51
P5
23 Q4
18
H5 H10
P8 F6 F16
L1
21
H41 H4
28 H22 H21
14 15
P17
D40
D30 R1
P18 20
11 D8 32
R13
R1 R2
R2
31 31
RUBBER HOSE
STEEL PIPE
26L
29
NYLON TUBE
R3
30 R10
R20 R17
R1 R2
31 31
21 25 26
W3 W31 W4 2 A/D A4
W1 W2 A3
B1
3
WITH INTER-AXLE DIFFERENTIAL LOCK WITH AIR DRYER
(IF SO EQUIPPED)
B1 A4
10 34
A3 2 A/D A4
3 A3
B1
34 3
SHTS068020100006

12 Trailer hand brake valve 29 Air tank-Air suspension
13 Release valve-Rear brake 30 Leveling valve
14 Spring brake chamber-Rear 31 Air spring
15 Brake chamber 32 ABS control valve
16 Air tank-Spring brake and trailer brake 33 Trailer control valve
MODEL: FS (FULL TRACTOR) (For GENERAL COUNTRIES, CHILE, G.C.C. COUNTRIES)
16
CAB CHASSIS 3 19 H3
B1 A4 A5
10 26L H2
11 H1
26L
D3 4 A6
A8
8 D20 F 5 6 14 15
P15 R Q3
A7
A3 26L 20
26L
C0
7 R P14
C1
F
E1
C2
E2
P1
P2 E3 E4
D1 9 F21 F3
F11
C3
17 13
E6
H20
A2 F51
E5
27 B2 E7
S1
21
P3 P4
1
24 P10 P9
P5
P6
P8
Q4 18
L1 F16
21
H41 H4 F6
H22 H21
28
D6 14 15
P17
D60
D30
P18
D8
11 RUBBER HOSE
STEEL PIPE
NYLON TUBE
19
Z8 H7
CAB CHASSIS
29 30
22 H6
33 Z6
EMERGENCY
Z3
X4
23 H5
16 5 P22
Z4 L1 X3
R
SERVICE
35 Z9 X2
26L 26L
21 25 25 X1
>1 P4 H41
Z2
34 >2 C7
18
WITH TRAILER CONTROL WITH ZF TRANSMISSION

(IF SO EQUIPPED)
SHTS068020100007
H5 TRANSMISSION CHASSIS
21
J2 J4
29
31 19
X5 21
25 23 H12 H11 H5
21 H7
30 25 22
J1
21
WITH TRANSMISSION P.T.O. WITH MZ12 TRANSMISSION
(WITH ZF TRANSMISSION)
(IF SO EQUIPPED)
12
H5 E3
21
J5 E31
J2 J4
E4
31
25 13
21
J1
WITH TRANSMISSION P.T.O.

WITH LOAD SENSING VALVE
(WITH MZ12 TRANSMISSION)
(IF SO EQUIPPED)
(IF SO EQUIPPED)
10
B1 A4 32
2 A/D A4 A3
2 A/D A4
A3 3 A3
B1 B1
3 32 3
WITH AIR DRYER WITH TIRE INFLATOR WITH TIRE INFLATOR

21 25 26
W3 W31 W4
W1 W2
WITH INTER-AXLE DIFFERENTIAL LOCK

SHTS068020100008

2 Air dryer (If so equipped) 20 Protection valve
6 Protection valve 24 Air suspension seat
7 Brake valve 25 Magnetic valve
8 Stop lamp switch 26 Inter-axle differential lock control cylinder
10 Pressure regulator 28 Cab suspension-Rear
11 Spring brake chamber-Front 29 Splitter valve
12 Load sensing valve (If so equipped) 30 Power shift
13 Release valve-Rear brake 31 Transmission P.T.O. (If so equipped)
15 Brake chamber 33 Cut valve (If so equipped)
16 Air tank-Spring brake and trailer brake 34 Trailer hand brake valve (If so equipped)
17 Spring brake control valve 35 Trailer control valve (If so equipped)
18 Relay valve-Spring brake
MODEL: FS (FULL TRACTOR) (For SOUTH AFRICA)

19
Z3
A15 16 Z8
Z4 SERVICE
CAB CHASSIS
2 3 19
F
Z6
H3
A/D A4 A5 EMERGENCY
A3 26L H1 H2
26L
12
8
A6
A8 20 Q3
11 B1 F R
A7
6 14 15
Z2
D3 C7
P22
26L 26L
7 C0 4 5 P11
R D40 E5
C1
F
E1
C2
E2 P6 F3 F11
P1 E4
P2 13
P21
17 E3 F1 F21
F8
E6
H20 F13
A2 F4
F51
27 B2 D1
C3 21 F6 F16
1 9 P3 P4
24 30 P10 P9 P51
H7 P5
29 Q4
22 H6 18
P8
X4
23 H5
L1 X3
X2
X1 14 15
25 25
H41 H4
21 28
H22 H21
D60 D6
11
RUBBER HOSE
STEEL PIPE
NYLON TUBE
B1 A4
10
21 25 26
W3 W31 W4
A3
3 W1 W2
WITHOUT AIR DRYER WITH INTER-AXLE DIFFERENTIAL LOCK

SHTS068020100009
H5
21
E3
J2 J4
31 E31
32
E4
25
13 21
J1
WITH LOAD SENSING VALVE WITH TRANSMISSION P.T.O.

B1 A4
10 33
A3 2 A/D A4
3 A3
B1
33 3

SHTS068020100010

11 Brake chamber-Front 28 Cab suspension-Rear
12 Trailer control valve 29 Splitter valve
13 Release valve-Rear brake 30 Power shift
14 Spring brake chamber-Rear 31 Load sensing valve
15 Spring brake chamber-Rearward 32 Transmission P.T.O.
16 Air tank-Spring brake and trailer brake 33 Tire inflator
MODEL: FY (For GENERAL COUNTRIES, NEW ZEALAND)
18
Z3
CAB CHASSIS 5
A9
R 26L 25 Z8
SERVICE
34 F Z4
3 Z6
A4 A5
18 H3 EMERGENCY
26L H1 26L
H2
11 12 A3 A8 26 21
D3 A6
B1
8 D5
5
4 Q3
14 15
F
R 6 26 Z2
P15 C7
P22
26L
P14 26L
7 R
D2 C0
C1
F
E1
C2
E2 E3 F3 F11
P1
E4 10
16 P21 P2
13
㩯1 C3
㩯2 9 F1 F21
F23
35 S1 H20 E6
A2 F4 F51
27 E7
F53
B2
22 19
31 10 P3 P4
P6
1 P10 P9
P5
P51
P8
H5 H10 Q4
17
L1
F6 F16
19 H41 H4
H22 H21
28
D7 14 15
P17
D9
26
P18
11 12
R13
D8 D10
R1 R2
R2
RUBBER HOSE 32 32
STEEL PIPE
NYLON TUBE 23
26L
R3
24 R10
R20 R17
19 20 29 R1 R2
W3 W31 W4
W1 W2
32 32
3
A/D A4
WITH INTER-AXLE DIFFERENTIAL LOCK A3
B1
2
WITH AIR DRYER
(IF SO EQUIPPED)
33
E3
3
B1 A4
34 30
E31
A3
3
A/D A4
A3
E4
B1
30 2
13
WITH LOAD SENSING VALVE (IF SO EQUIPPED) (IF SO EQUIPPED)
SHTS068020100011
1 Air compressor 19 Multi joint

2 Air dryer (If so equipped) 20 Magnetic valve
3 Air tank-Water separator 21 Trailer control valve (If so equipped)
5 Air tank-Rear brake 23 Air tank-Air suspension (If so equipped)
6 Protection valve 24 Leveling valve (If so equipped)
7 Brake valve 25 Air tank-Spring brake and trailer brake
(If so equipped)
8 Stop lamp switch 26 Protection valve
10 ABS control valve 28 Cab suspension-Rear
11 Brake chamber-Front 29 Inter-axle differential lock control cylinder
12 Spring brake chamber-Front 30 Tire inflator (If so equipped)
13 Relay valve-Rear brake 31 Air suspension seat (If so equipped)
14 Spring brake chamber-Rear 32 Air spring (If so equipped)
15 Brake chamber-Rear 33 Load sensing valve (If so equipped)
16 Spring brake control valve 34 Pressure regulator
17 Relay valve-Spring brake 35 Trailer hand brake valve (If so equipped)
18 Reducing valve
MODEL: FY (For CHINA, HONG KONG)

Q1
25 5
CAB CHASSIS 2 3 A9
R 26L
A/D A4 A5
A3R 26L
H3
A6 H1
4 5 18 H2
8 11 6 26 14 15
D3
12 B1 F R
Q3
D5 A7
C0 26L 26L
7 R
P15 P14
C1
F
E1
C2
E2 F3 F11
P1
16 P2
D4
E3 E4
13
D2
A3 F23
F1 F21
F4
C3
H20
A2
9 E6
F51
27 E5 F53
B2 E7
31
P3 P4
1 19 P13 P9 P51 P6
P5 P8
Q4
24 17
H9
L1
H5
H7 F6 F16
22 19
H41 H4 14 15
19
28 H22 H21
D7
P17
P18
D9
11 12
D8 D10
RUBBER HOSE
STEEL PIPE
NYLON TUBE
23
18
29 X5 19
19 20 W3 W31 W4
21 H12 H11 H5
H7
W1 W2
24 20 22
WITH INTER-AXLE DIFFERENTIAL LOCK WITH MZ12 TRANSMISSION

SHTS068020100012
3 30
10 B1 A4 3
19
A/D A4
H50 A3
A3 E2 E50 E3 B1
2
34
WITHOUT AIR DRYER WITH ES START WITH TIRE INFLATOR

(WITH AIR DRYER)
(IF SO EQUIPPED)
33 3
E3
19 10 B1 A4
H5
E31
J5 A3
E4 J2 J4
32 30
19
13
20
J1
WITH LOAD SENSING VALVE WITH TRANSMISSION P.T.O. WITH TIRE INFLATOR
(IF SO EQUIPPED) (IF SO EQUIPPED) (WITHOUT AIR DRYER)
(IF SO EQUIPPED)
SHTS068020100013

2 Air dryer (If so equipped) 19 Multi joint
3 Air tank-Water separator 20 Magnetic valve
4 Air tank-Front brake 21 Range valve (If so equipped)
6 Protection valve 23 Splitter valve (If so equipped)
7 Brake valve 24 Power shift
8 Stop lamp switch 25 Protection valve
9 Relay valve-Front brake 26 Protection valve
10 Pressure regulator (If so equipped) 27 Cab suspension-Front
12 Spring brake chamber-Front 29 Inter-axle differential lock control cylinder
13 Relay valve-Rear brake 30 Tire inflator (If so equipped)
14 Spring brake chamber-Rear 31 Air suspension seat (If so equipped)
15 Brake chamber-Rear 32 Transmission P.T.O. (If so equipped)
16 Spring brake control valve 33 Load sensing valve (If so equipped)
17 Relay valve-Spring brake 34 ES start control valve (If so equipped)
MODEL: FY (For IRELAND)
Q1
4 25
F 5
CAB CHASSIS 2 3 A9
R 26L
26L A/D A4 A5
A3R 26L
H3
A10 A6 H1
4 18 H2
8 11 5 6 26 14 15
D3
12 B1 F R
A7
Q3
D5
C0 26L 26L
7 R
P15 P14
C1
F
E1
C2
E2 F3 F11
P1
P2 E3 E4
16 D2
D4 13 10
9 F1 F21
F23
F4
H20 C3 E6
A2 F51
E5 F53
27 B2
10 E7
31 22 24 P3 P4
1 H7
23 19 P13 P9 P51 P6
P5 P8
H6
Q4
21 17
H5
X4
L1 X3
F6 F16
X2
X1
20 20
H41 H4 14 15
19
28 H22 H21
D7
P17
P18
D9
11 12
D8 D10
RUBBER HOSE
H5
STEEL PIPE
NYLON TUBE
J2 J4
30
19 32
19 20 29 A3
A/D A4
20
W3 W31 W4 B1
W1 W2
3
2 J1
WITH INTER-AXLE DIFFERENTIAL LOCK WITH TIRE INFLATOR WITH TRANSMISSION P.T.O.
SHTS068020100014

2 Air dryer 18 Reducing valve
4 Air tank-Front brake 20 Magnetic valve
6 Protection valve 22 Clutch booster
7 Brake valve 23 Splitter valve
8 Stop lamp switch 24 Power shift
10 ABS control valve 26 Protection valve
11 Brake chamber-Front 27 Cab suspension-Front
13 Relay valve-Rear brake 29 Inter-axle differential lock control cylinder
15 Brake chamber-Rear 31 Air suspension seat (If so equipped)
16 Spring bake control valve 32 Transmission P.T.O. (If so equipped)
MODEL: SH (For CHILE, G.C.C. COUNTRIES)
CAB CHASSIS
Z8 17
EMERGENCY Z6 32
3
Z4 10 A4 A5
SERVICE A3 26L
Z10 28 B1
A8
17 H3
Z3
A6
8 4 H1
H2
A7
F R
18
D3
5 6 13
7 11 14 26L 26L 26L
R D40 E5
C1 P6 F3
F E3
E1
C2
E2 E4
Z2 12 F1 F21
D2
P1 E6
P2
1 F4 F51
15 2 C3
C21 C4
H20
D1
C5
9
A2
19 B2 E71 E7
21
S1 P3 P4
1 P5 P51
22 16
Q4 P8
Q1
F5
L1
13
21 H41 H4
H22 H21
20
D60 D6
11 R1
D8
18
R5
RUBBER HOSE
STEEL PIPE R7 31
NYLON TUBE R4
23
R2
26L
30
R3
R6
R10
29
R17
31
25
H7 27
H6
26 TRANSMISSION CHASSIS
24
X4
H5 26
L1 X3 24 17
X5 21
H12 H11 H5
X2 27 H7
X1
23 21 25
21 23 23 H41
WITH ZF TRANSMISSION WITH MZ12 TRANSMISSION

SHTS068020100015
21
H5 H5
21 J5
J2 J4 J2 J4
35 35
23 23
21 21
J1 J1

(WITH ZF TRANSMISSION) (WITH MZ12 TRANSMISSION)
R52
E3
34 E32
E3
E4
12 34 E31
E4
R10 12
R3
29
R17
WITH LOAD SENSING VALVE WITH LOAD SENSING VALVE

(WITH AIR SUSPENSION) (WITH LEAF SUSPENSION)
33
B1 A4
2 A/D A4 2 A/D A4 10
A3 A3 A3
B1 B1 3
3 3
33
(IF SO EQUIPPED) (WITH AIR DRYER) (WITHOUT AIR DRYER)
SHTS068020100016
1 Air compressor 19 Cab suspension-Front

2 Air dryer 20 Cab suspension-Rear (If so equipped)
4 Air tank-Front brake 22 Air suspension seat (If so equipped)
5 Air tank-Rear brake 23 Magnetic valve
7 Brake valve 25 Clutch booster
8 Stop lamp switch 26 Splitter valve
9 Relay valve-Front brake 27 Power shift
10 Pressure regulator 28 Trailer control valve
11 Brake chamber-Front 29 Leveling valve
12 Relay valve-Rear brake 30 Air tank-Air suspension
14 Air tank-Spring brake and trailer brake 32 Cut valve
16 Relay valve-Spring brake 34 Load sensing valve (If so equipped)
17 Reducing valve 35 Transmission P.T.O. (If so equipped)
18 Protection valve
MODEL: SH (For CHINA)

5
17
Z3 A9
CAB CHASSIS R 26L
2 3
Z8 A4 A5
A/D
SERVICE A3 26L
Z5 Z4 B1
A8
17 H3
Z7 Z6
A6 H2
EMERGENCY
28 4 H1
8 D3 F R
A7
13
11P15 D20 6 18
7 14 26L 26L 26L 5
R D40
C1 E5
F
E1 P14 P6 F3
C2
E2 E3
Z2 12
P1 F1 F21
P2
P21 \1 F4 F51
15 \2
E6
H20 E7
A2
29 19 E4
P5 P51
B2
21
C7 9 Q1 P4
D2 P9
1 16 P8 F6
C3 Q4
S1
27 H9 Q1
22 H4
H5
21 P9
H7
13
L1
25
H22 H21
21 20
H41
P17
D60 D6
P18 D30
D8
11
RUBBER HOSE 21
H5
STEEL PIPE E3
NYLON TUBE J5
10 E31
J2 J4
E4 21 24
23
12
J1

(IF SO EQUIPPED)
26
2 A/D A4
A3
B1
3
WITH TIRE INFLATOR

(IF SO EQUIPPED)
SHTS068020100017

2 Air dryer 17 Reducing valve
4 Air tank-Front brake 19 Cab suspension-Front
5 Air tank-Rear brake 20 Cab suspension-Rear (If so equipped)
6 Protection valve 21 Multi joint
7 Brake valve 22 Air suspension seat (If so equipped)
9 Relay valve-Front brake 24 Transmission P.T.O. (If so equipped)
10 Load sensing valve 25 Clutch booster
11 Brake chamber-Front 26 Tire inflator (If so equipped)
12 Relay valve-Rear brake 27 Power shift
13 Spring brake chamber-Rear 28 Trailer control valve
14 Air tank-Spring brake and trailer brake 29 Trailer hand brake valve
MODEL: SH (For HONG KONG, TAIWAN)

17
Z3
CAB CHASSIS
3
Z8 10 A4 A5
A3 26L
SERVICE Z5 Z4 B1 17 H3
Z7 Z6 A8
A6 H2
EMERGENCY
8 A7
H1
D3 28 F R
18 13
14 5 6
7 11 26L 26L 26L
R
C1 32 D40 4 E5 r52
34
F E31
E1
C2 E3
Z2
12 E4
32
F1 F20 F2
P1 E6
P2
P21 1 F4 F21 F5
15 2 C3
C4
C21
D1 32
H20
C5
9
A2
19 B2 E71 E7
21 16
S1 P2 P4
P6
22 1 P5 P51
P8
Q4
Q1
H21
L1 21 H4 13
H22
H41
20
D60 D6
R1
32
11
D8 18 29
R10
R3
RUBBER HOSE
STEEL PIPE
31
R4 R5
NYLON TUBE
R2
26L R6 R7
23
30
R17
31
26
X5 21
24 H12 H11 H5 2 A/D A4
H7
A3
27 23 25 B1
3
21
WITH MZ12 TRANSMISSION WITH AIR DRYER

(IF SO EQUIPPED)
SHTS068020100018
21
H5
E3 J5
J2 J4
E31
34
21 35
E4
23
12
J1

B1 A4
33
2 A/D A4
A3
A3
3 B1
3
33

(WITH AIR SUSPENSION ) (WITH LEAF SUSPENSION)
SHTS068020100019

14 Air tank-Spring brake and trailer brake 32 ABS control valve (If so equipped)
18 Protection valve
MODEL: SH (For IRELAND, SOUTH AFRICA)

17
CAB CHASSIS Z3
2 3
Z8 A4 A5
A/D
A3 26L
SERVICE Z5
Z7
Z4
Z6
B1
A8
17 H3
A6 H2
8
EMERGENCY
4 H1 18
D3 28 F R
A7
5 6
7 11 14 26L 26L 26L
13
R
C1 32 D40 E5
F E31
E1
C2
E4
Z2
12 32
F1 F20 F2
P1 E6
P2
P21 F4 F21 F5
E3
15 C4
D1 32
H20
A2 C5 9
19 B2 E71 E7
S1
25 27 D2 21 Q1
P2 P4
22 H7
26 P6
P5 P51
1 H6 16
24 Q4
P8
H5
X4 Q1
L1 X3 H21
13
X2 H4
X1 H22
23 23
H41
20
21 D60 D6
R1 P3
11
32
D8 18 29
R10
RUBBER HOSE
STEEL PIPE
31
R4 R5
NYLON TUBE
R2
26L R6 R7 23
30
R17
31
SHTS068020100020
R52
E3
34 E32
E4
12
3
B1 A4
10
R10
R3
A3
29
R17
WITHOUT AIR DRYER WITH LOAD SENSING VALVE

H5
21 3
B1
33 3 10 A4
A3
J2 J4
35 A3
A/D A4
21 B1
33
23
J1

WITH TRANSMISSION P.T.O. (WITH AIR DRYER) (WITHOUT AIR DRYER)
(IF SO EQUIPPED) (IF SO EQUIPPED) (IF SO EQUIPPED)
SHTS068020100021

14 Air tank-Spring brake and trailer brake 32 ABS control valve (If so equipped)
18 Protection valve
MODEL: SS (For GENERAL COUNTRIES, CHILE, G.C.C. COUNTRIES)
CAB CHASSIS
18
Z8
EMERGENCY Z6
39 5 RUBBER HOSE
25 P3 Z3 3 A9
SERVICE Z4
2 A4 A5
R 26L STEEL PIPE
P2 A/D
A3 NYLON TUBE
26L
B1 A8
18 H3
Z10
8 4
A6 H2
C7 H1
A7
D3 F R 14 15
11P15 D20 37 6 26
7 26L 26L 26L
5
R D40
C1 E5
F
E1 P14
C2 P6 F3 F11
E3
Z2
13
P1 F1 F21
P2
16 1
2 F4 F51
E6 P6
H20 E7
38 A2
27 B2 C7 9 E4
P5 P51
D2 H4 19 P8 F6 F16
1 C3 P4
P9
H21
H22 H21 Q4
17
L1
28 Q1
19 H41 14 15
S1 P17
R13
31
D80 D6 R1 35
D30 R7 R1 R2
P18
R5 R6 36 36
D8
11 R2
20 26L 33
34 R3
R4
R10
R20 R17
R1 R2
36 36
22 24
H7
23
H6
21
H5
X4
L1 X3
19 20 29
W3 W31 W4
X2
W1 W2
20 20 X1
H41
19
WITH INTER-AXLE DIFFERENTIAL LOCK WITH ZF TRANSMISSION
22
H7
21 23
20
H5 H10 X5 19
21 H12 H11 H5
H7
19 24 20 22
19
WITH FULLER TRANSMISSION WITH MZ12 TRANSMISSION
SHTS068020100022
R52
E3
E3
12 E32
12 E31 E4
13
E4
13
R10
R3
34
R17

(WITH LEAF SUSPENSION) (WITH AIR SUSPENSION)
H5 H5
19 19
J5
3
J2 J4 J2 J4
B1 A4
10 32 32
A3
20 20
19 19
J1 J1
WITHOUT AIR DRYER WITH TRANSMISSION P.T.O. WITH TRANSMISSION P.T.O.

(ZF TRANSMISSION) (MZ12 TRANSMISSION)
3
B1 A4 30
10 3
A3 2 A/D A4
A3
B1
30
SHTS068020100023
1 Air compressor 21 Range valve

2 Air dryer 22 Clutch booster
3 Air tank-Water separator 23 Splitter valve
4 Air tank-Front brake 24 Power shift
5 Air tank-Rear brake 25 Trailer control valve
6 Protection valve 26 Protection valve
7 Brake valve 27 Cab suspension-Front
8 Stop lamp switch 28 Cab suspension-Rear
10 Pressure regulator 30 Tire inflator (If so equipped)
11 Brake chamber-Front 31 Air suspension seat (If so equipped)
12 Load sensing valve 32 Transmission P.T.O. (If so equipped)
13 Relay valve-Rear brake 33 Air tank-Air suspension (If so equipped)
14 Spring brake chamber-Rear 34 Leveling valve (If so equipped)
15 Brake chamber-Rear 35 Protection valve (If so equipped)
16 Spring brake control valve 36 Air spring (If so equipped)
17 Relay valve-Spring brake 37 Air tank-Trailer brake
18 Reducing valve 38 Trailer hand brake valve
19 Multi joint 39 Cut valve
20 Magnetic valve
MODEL: SS (For AUSTRALIA)
CAB CHASSIS
Z8
EMERGENCY Z6
3 5
B1 10 A9
R 26L
26L
Z4 A5
A3
SERVICE A4
8 25 A8
18
Z10 Z3 H2 H3
A6
11 4 H1
P0 A7
D3 F R
26 14 15
33 5 6
P15 P14
7 R
D20 26L 26L 26L
C1 D40 E5
F
E1 E12 13 F3
C2 12 F1 F20 F2
E3 F11
E2
Z2
E6 F2 F5
P1 E15
P2 P3
16 E13 13 F4
1
2 C3
P6
34 H20 E16 E14
F6
19 P4 17
27 A2 C7 9 P51
P5
D2 Q1 P9
B2
22 F16
1 21
Q4
E7 P8
H7
H5 H10
31 S1
W2 W3 W4
H41 H4 W1
L1
H22 H21 29
19 28 20
P17 14 15
R1
D60 D6 R7
26
D30 R5
P18 R6
23
D8 20 R2
R13
11 26L
R1 R2
R4
R3 32 32
R10
24
R20 R17
R1 R2
32 32
RUBBER HOSE
STEEL PIPE
NYLON TUBE 3
2 A/D A4
A3
B1
WITH AIR DRYER

(IF SO EQUIPPED)
3
B1 A4
10 30
A3 3
2 A/D A4
A3
30 B1

SHTS068020100024

2 Air dryer 19 Multi joint
4 Air tank-Front brake 21 Range valve
6 Protection valve 23 Air tank-Air suspension
7 Brake valve 24 Leveling valve
8 Stop lamp switch 25 Trailer control valve
12 Quick release valve 29 Inter-axle differential lock control cylinder
15 Brake chamber-Rear 32 Air spring
16 Spring brake control valve 33 Air tank-Trailer brake
17 Relay valve-Spring brake 34 Trailer hand brake valve
MODEL: SS (For CHINA)

5 RUBBER HOSE
18 Z3
3
CAB CHASSIS 2 A9
R 26L STEEL PIPE
A/D A4 A5
Z8 NYLON TUBE
A3
SERVICE Z5 Z4 B1
26L
18 H3
Z7 Z6 A8
A6
8 EMERGENCY
25 4 H1
H2
D3 A7
F R 14 15
11 D20 6 26
7 P15 33 26L 26L 26L
5
R D40
C1 E5
F
E1 P14
C2 P6 F3 F11
E3
Z2
13
P1 F1 F21
P2
P21 >1
F4 F51
16 >2
P6
E6
H20 E7
A2
34 27 P5 P51
C7 E4
B2
D2
9 H4 19 P8 F6 F16
1 C3 P4
P9
H21
H22 H21 Q4
17
S1 L1
28 Q1
14 15
19 H41
P17
D80 D6
31
P18 D30
D8
11
22 24
H7
H6
23
E3
21
H5 12 E31
X4
L1 X3 E4
13
X2
19 20 20 X1
H41
WITH ZF TRANSMISSION WITH LOAD SENSING VALVE
H5
19
J2 J4
19 19 32
20 29
W3 W31 W4 20
W1 W2
J1
WITH INTER-AXLE DIFFERENTIAL LOCK WITH TRANSMISSION P.T.O.

(IF SO EQUIPPED)
SHTS068020100025
3 30
B1 A4 3
2
A3 A/D A4
A3
B1
30
3
B1 A4
10
A3
WITHOUT AIR DRYER
SHTS068020100026

2 Air dryer 19 Multi joint
4 Air tank-Front brake 21 Range valve
6 Protection valve 23 Splitter valve
7 Brake valve 24 Power shift
8 Stop lamp switch 25 Trailer control valve
12 Load sensing valve 29 Inter-axle differential lock control cylinder
15 Brake chamber-Rear 32 Transmission P.T.O. (If so equipped)
16 Spring brake control valve 33 Air tank-Trailer brake
17 Relay valve-Spring brake 34 Trailer hand brake valve
MODEL: SS (For HONG KONG, SOUTH AFRICA)

Z3
A9
R 26L 37
18 3 5 F
A5
18 H3
CAB CHASSIS
10 26L H1 H2
26L
Z8
SERVICE Z5 A3 A6
Z4
4 A8 26 Q1
Z7 Z6 5 A7
8 EMERGENCY B1
A4
F R
6 14 15
25
D3
11 26L 26L
7 R D40
C7
P11
C1 Z2 E5
F
E1
C2
E2 P6 F3 F11
P1
P2
E4 13
16 P21
F1
E3 F21
F8
S1
E6
H20 F4
38 A2
F13
F51
27 B2 D2 D6
E7
C3 9 19
1 P3 P4
F6 F16
P9
31 S1
22 24 P5
P51
H7 P10
23 Q4
17
H6
P8
21
H5
X4
P12
L1 X3
X2
X1
14 15
20 20
H41 H4
19 28
H22 H21
D60
11 35
D8
R13
R7 R1 R2
RUBBER HOSE
STEEL PIPE
36 36
R5
R6
NYLON TUBE
R2
20
26L 33
R3
R4
R10
34
R20 R17
R1 R2
36 36
23
20
X5 19
21 H5
29
H12 H11
H7
19 20 W3 W31 W4
24 20 W1 W2
22
19
WITH MZ12 TRANSMISSION WITH INTER-AXLE DIFFERENTIAL LOCK

SHTS068020100027
H5
19 19
H5
J5
J2 J4 J2 J4
32 32
19 19
20 20
J1 J1

(WITH ZF TRANSMISSION) (WITH MZ12 TRANSMISSION)
R52
E3
E3
12 E32
12 E31
E4
E4 13
13
R10
R3
34 R17

(WITH LEAF SUSPENSION) (WITH AIR SUSPENSION)
3
10 B1 A4
30 A3
3 3
2 A4
2 A4
A/D A/D
A3 A3
B1 B1
30
(IF SO EQUIPPED) (WITH AIR DRYER) (WITHOUT AIR DRYER)
SHTS068020100028
1 Air compressor 20 Magnetic valve

2 Air dryer 21 Range valve
3 Air tank-Water separator 22 Clutch booster
4 Air tank-Front brake 23 Splitter valve
5 Air tank-Rear brake 24 Power shift
6 Protection valve 25 Trailer control valve
7 Brake valve 26 Protection valve
8 Stop lamp switch 27 Cab suspension-Front
9 Relay valve-Front brake 28 Cab suspension-Rear
10 Pressure regulator 29 Inter-axle differential lock control cylinder
11 Brake chamber-Front 30 Tire inflator (If so equipped)
12 Load sensing valve 31 Air suspension seat (If so equipped)
13 Relay valve-Rear brake 32 Transmission P.T.O. (If so equipped)
14 Spring brake chamber-Rear 33 Air tank-Air suspension (If so equipped)
15 Brake chamber-Rear 34 Leveling valve (If so equipped)
16 Spring brake control valve 35 Protection valve (If so equipped)
17 Relay valve-Spring brake 36 Air spring (If so equipped)
18 Reducing valve 37 Air tank-Trailer brake
19 Multi joint 38 Trailer hand brake valve
TROUBLESHOOTING
EN0680201F300001
Symptom Possible cause Remedy/Prevention

Not enough braking Lining is wet with grease or fluid Replace the lining.
(Wheel brake and drum) Improper contact of drum and lining Correct.
Improper lining material or glazed lin- Correct.
ing
Deformation or hardening of drum Correct or replace.
Excessively worn lining Replace.
Not enough braking Leakage of compressed air from brake Tighten further or replace gasket.
(Control system) system
Lack of compressed air pressure due Use properly.
to excessive use.
Improper operation of air compressor Repair or replace.
Improper operation of brake valve Repair or replace.
Improper operation of relay valve and Repair or replace.
quick release valve
Clogging of brake system Replace pipe, hose, etc.
Unequal or unstable braking Lining is wet with grease or fluid Replace lining.
Defective lining material (Improper Replace lining.
combination)
Non-uniform lining contact Correct.
Improper adjustment of brake shoe Adjust.
Non-uniform shoe clearance Adjust the clearance.
Distorted drums Correct or replace.
Excessive abrasion of drums Correct or replace.
Loose hub bearing Adjust or replace bearing.
Improper or unequal pneumatic pres- Adjust to proper pneumatic pressure.
sure of tire
Brake drags or does not release Improper adjustment of shoe clear- Adjust the clearance.
(Wheel brake and drum) ance
Defective shoe return spring Replace.
Brake drags or does not release Lack of pedal play Adjust.
(Control system) Improper return of brake pedal Repair or replace.
Improper operation of brake valve Repair or replace.
Improper operation of relay valve and Repair or replace.
quick release valve
Brake squeal Improper lining material or glazed lin- Replace lining.
ing
Loose lining rivets Replace or tighten the rivet further.
Lining rivet in contact with drum Replace lining and rivet.
Deformation or wear of drum Repair or replace.
Intrusion of foreign matter between Clean the surface of lining or replace
drum and lining
Loose hub bearing Adjust or replace bearing.
SERVICE BRAKE BR02–1
SERVICE BRAKE
BR02
BR02-001
AIR DRYER ...............................................BR02-3 PROTECTION VALVE (WITH 4-WAY

DATA AND SPECIFICATIONS........................ BR02-3 PROTECTION VALVE) ............................BR02-31
DESCRIPTION ................................................ BR02-3 DATA AND SPECIFICATIONS...................... BR02-31
COMPONENT LOCATOR ............................... BR02-4 DESCRIPTION .............................................. BR02-31
OVERHAUL ..................................................... BR02-5 COMPONENT LOCATOR ............................. BR02-32
INSPECTION AND REPAIR ............................ BR02-7 OVERHAUL ................................................... BR02-33
ADJUSTMENT............................................... BR02-33
CHECK VALVE..........................................BR02-8 INSPECTION AND REPAIR .......................... BR02-35
DATA AND SPECIFICATIONS........................ BR02-8
DESCRIPTION ................................................ BR02-8 QUICK RELEASE VALVE .......................BR02-36
COMPONENT LOCATOR ............................... BR02-9 DATA AND SPECIFICATION ........................ BR02-36
INSPECTION AND REPAIR ............................ BR02-9 DESCRIPTION .............................................. BR02-36
COMPONENT LOCATOR ............................. BR02-37
DOUBLE CHECK VALVE .......................BR02-10 OVERHAUL ................................................... BR02-38
DATA AND SPECIFICATION ........................ BR02-10 INSPECTION AND REPAIR .......................... BR02-38
DESCRIPTION .............................................. BR02-10
COMPONENT LOCATOR ............................. BR02-11 LOAD SENSING VALVE .........................BR02-39
OVERHAUL ................................................... BR02-12 DATA AND SPECIFICATION ........................ BR02-39
INSPECTION AND REPAIR .......................... BR02-12 DESCRIPTION .............................................. BR02-40
SAFETY VALVE ......................................BR02-13 OVERHAUL ................................................... BR02-44
DATA AND SPECIFICATIONS...................... BR02-13 ADJUSTMENT............................................... BR02-47
DESCRIPTION .............................................. BR02-13 INSPECTION AND REPAIR .......................... BR02-48
INSPECTION AND REPAIR .......................... BR02-13
SPRING BRAKE CONTROL VALVE
BRAKE VALVE........................................BR02-14 (TYPE-A) .................................................BR02-50
DATA AND SPECIFICATION ........................ BR02-14 DATA AND SPECIFICATIONS...................... BR02-50
DESCRIPTION .............................................. BR02-14 DESCRIPTION .............................................. BR02-50
COMPONENT LOCATOR ............................. BR02-15 COMPONENT LOCATOR ............................. BR02-51
OVERHAUL ................................................... BR02-17 OVERHAUL ................................................... BR02-52
INSPECTION AND REPAIR .......................... BR02-23 INSPECTION AND REPAIR .......................... BR02-54
PROTECTION VALVE (TYPE-A) ............BR02-25 SPRING BRAKE CONTROL VALVE

DATA AND SPECIFICATIONS...................... BR02-25 (TYPE-B) .................................................BR02-55
DESCRIPTION .............................................. BR02-25 DATA AND SPECIFICATIONS...................... BR02-55
COMPONENT LOCATOR ............................. BR02-26 DESCRIPTION .............................................. BR02-55
OVERHAUL ................................................... BR02-27 COMPONENT LOCATOR ............................. BR02-56
INSPECTION AND REPAIR .......................... BR02-27 OVERHAUL ................................................... BR02-57
PROTECTION VALVE (TYPE-B) ............BR02-28
DATA AND SPECIFICATIONS...................... BR02-28 RELAY VALVE (TYPE-A) ........................BR02-60
DESCRIPTION .............................................. BR02-28 DATA AND SPECIFICATIONS...................... BR02-60
COMPONENT LOCATOR ............................. BR02-29 DESCRIPTION .............................................. BR02-60
OVERHAUL ................................................... BR02-30 COMPONENT LOCATOR ............................. BR02-61
INSPECTION AND REPAIR .......................... BR02-30 OVERHAUL ................................................... BR02-62
BR02–2 SERVICE BRAKE
RELAY VALVE (TYPE-B)........................ BR02-64 DESCRIPTION ...............................................BR02-95

DATA AND SPECIFICATIONS ......................BR02-64 COMPONENT LOCATOR..............................BR02-96
DESCRIPTION...............................................BR02-64
BR 02
OVERHAUL....................................................BR02-97
COMPONENT LOCATOR..............................BR02-65 INSPECTION AND REPAIR ..........................BR02-98
OVERHAUL....................................................BR02-66
INSPECTION AND REPAIR ..........................BR02-66 SPRING BRAKE CHAMBER
(MAKER: WABCO) ................................. BR02-99
CUT VALVE............................................. BR02-67 DATA AND SPECIFICATION.........................BR02-99
DATA AND SPECIFICATION.........................BR02-67 DESCRIPTION ...............................................BR02-99
DESCRIPTION...............................................BR02-67 COMPONENT LOCATOR............................BR02-100
COMPONENT LOCATOR..............................BR02-68 SPECIAL TOOL ...........................................BR02-100
OVERHAUL....................................................BR02-68 OVERHAUL..................................................BR02-101
INSPECTION AND REPAIR ..........................BR02-69 INSPECTION AND REPAIR ........................BR02-107
REDUCING VALVE (TYPE-A) ................ BR02-70 TRAILER HAND BRAKE

DATA AND SPECIFICATIONS ......................BR02-70 CONTROL VALVE.................................BR02-108
DESCRIPTION...............................................BR02-70 DATA AND SPECIFICATION.......................BR02-108
COMPONENT LOCATOR..............................BR02-71 DESCRIPTION .............................................BR02-108
OVERHAUL....................................................BR02-72 COMPONENT LOCATOR............................BR02-109
INSPECTION AND REPAIR ..........................BR02-72 OVERHAUL..................................................BR02-110
INSPECTION AND REPAIR ........................BR02-112
REDUCING VALVE (TYPE-B) ................ BR02-73
DATA AND SPECIFICATIONS ......................BR02-73 WHEEL BRAKE
DESCRIPTION...............................................BR02-73 (TYPE: S-CAM BRAKE) .......................BR02-114
COMPONENT LOCATOR..............................BR02-74
DATA AND SPECIFICATIONS ....................BR02-114
OVERHAUL....................................................BR02-75
DESCRIPTION .............................................BR02-115
INSPECTION AND REPAIR ..........................BR02-75
SPECIAL TOOL ...........................................BR02-121
COMPONENT LOCATOR............................BR02-122
BRAKE CHAMBER ................................ BR02-76 OVERHAUL..................................................BR02-132
DATA AND SPECIFICATION.........................BR02-76 ADJUSTMENT .............................................BR02-141
DESCRIPTION...............................................BR02-76 INSPECTION AND REPAIR ........................BR02-143
OVERHAUL....................................................BR02-78 WHEEL BRAKE
(TYPE: WEDGE BRAKE) .....................BR02-145
BRAKE CHAMBER DESCRIPTION .............................................BR02-145
(MAKER: WABCO) ................................. BR02-80 SPECIAL TOOL ...........................................BR02-147
DATA AND SPECIFICATION.........................BR02-80 COMPONENT LOCATOR............................BR02-148
DESCRIPTION...............................................BR02-80 OVERHAUL..................................................BR02-150
COMPONENT LOCATOR..............................BR02-81 ADJUSTMENT .............................................BR02-156
SPECIAL TOOL .............................................BR02-81 INSPECTION AND REPAIR ........................BR02-158
OVERHAUL....................................................BR02-82
INSPECTION AND REPAIR ..........................BR02-86 EXPANDER ...........................................BR02-159
DESCRIPTION .............................................BR02-159
SPRING BRAKE CHAMBER ................. BR02-87 SPECIAL TOOL ...........................................BR02-160
DATA AND SPECIFICATION.........................BR02-87 COMPONENT LOCATOR............................BR02-161
DESCRIPTION...............................................BR02-88 OVERHAUL..................................................BR02-162
SPECIAL TOOL .............................................BR02-89 INSPECTION AND REPAIR ........................BR02-165
OVERHAUL....................................................BR02-90 PRESSURE REGULATOR ...................BR02-167
DESCRIPTION .............................................BR02-167
SPRING BRAKE CHAMBER COMPONENT LOCATOR............................BR02-168
(MAKER: NABCO) ................................. BR02-95 OVERHAUL..................................................BR02-169
DATA AND SPECIFICATION.........................BR02-95 INSPECTION AND REPAIR ........................BR02-170
AIR DRYER
DATA AND SPECIFICATIONS
EN0680202I200001
Type Purge tank, desiccant, auto-purge valve.

Air and Water discharging time (Reclamation cycle) Approx. 50 sec.
DESCRIPTION
EN0680202C100001
SHTS068020200001
1 Chamber (Purge tank) 14 Plug

2 Case cover 15 Pressure regulator
3 Check valve 16 Adjusting screw
4 Spring 17 Piston
5 Body 18 Piston spring
6 Desiccant case 19 Heater (If so equipped)
7 Filter A Inlet (From air compressor)
8 Desiccant B Orifice
9 Oil separator filter C Outlet (Dried air to air tank)
10 Valve body D Purged air
11 Valve spring E Dehumidification
12 Piston F Reclamation
13 Purge valve
COMPONENT LOCATOR
EN0680202D100001
SHTS068020200002
1 O-ring 18 Desiccant
2 Cover 19 Desiccant case
3 Piston 20 Oil separator filter
4 Valve spring 21 Body
5 Valve body 22 Valve stopper
6 Purge valve 23 Governor valve
7 Silencer case 24 Piston assembly
8 Silencer plate 25 Exhaust stem spring
9 Silencer 26 Exhaust stem
10 Retainer ring 27 Pressure regulator assembly
11 Exhaust cover 28 Valve seat
12 Chamber 29 Plate
13 Check valve 30 Heater
14 Case cover 31 Thermostat
15 Set spring 32 Plug
16 Filter plate 33 Elbow connector
17 Filter 34 Tube
Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 3.9-6.9 {40-70, 2.9-5.0} D 6.9-7.8 {71-79, 5.1-5.7}
B 3.9-6.9 {40-70, 2.9-5.0} E 17.7-27.5 {181-280, 14-20}
C 4.9-5.9 {50-60, 3.7-4.3}
OVERHAUL
EN0680202H200001
IMPORTANT POINTS - ASSEMBLY
1. LUBRICATION
C (1) When assembling the air dryer, use new O-ring, gasket and seal.
(2) Apply grease (lithium base) to each sliding surface of the compo-
nent parts and O-ring groove.
A • A: O-ring
• B: Sliding surface
2. ASSEMBLY
A NOTICE
Before tighten the bolt with specified tightening torque, tap all
over the outer surface of the desiccant case with a plastic ham-
mer.
• C: Bolt
A
A
SHTS068020200003
IMPORTANT POINTS - MOUNTING
1. INSPECTION
(1) Operate the engine and raise the air pressure until the air dis-
charge from the purge valve, then stop the engine.
(The pressure reaches the valve opening pressure of the air pres-
sure regulator).
a. Check to see that there is no air leakage from the purge valve.
2. ADJUSTMENT
(1) Loosen the adjusting screw until the rod spring tension is
released, and start and idle the engine to charge the air for the air
tank.
SHTS068020200004
(2) Tighten the adjusting screw gradually till the air pressure gauge
indicate valve opening pressure shown below and the air starts to
discharge from purge valve.
Governor valve opening pressure:
960-1,000 kPa {9.8-10.2 kgf/cm2, 139.2-145.0 lbf/in.2}
(3) Tighten the adjusting screw lock nut.
SHTS068020200005
(4) Watch the air pressure gauge needle and see that it stops at the
valve closing pressure shown below.
Governor valve closing pressure:
860-900 kPa {8.8-9.2 kgf/cm2, 124.7-130.5 lbf/in.2}
SHTS068020200006
INSPECTION AND REPAIR

EN0680202H300001
Inspection Item Standard Limit Remedy Inspection Procedure
Check valve and valve — — Replace, Visual check

seat surface: if necessary.
Wear and damage
Valve body sliding surface — — Replace, Visual check

and purge valve seat sur- if necessary.
face:
Wear and damage
Piston sliding surface: — — Replace, Visual check

Wear and damage if necessary.
Purge valve seat surface: — — Replace, Visual check

Desiccant: — Discolored, Replace. Visual check

Contamination and deteri- more than 1/5
oration of the quantity.
CHECK VALVE
EN0680202I200002
Type Spring type

Valve opening pressure Outlet side pressure 14.7 kPa {0.15 kgf/cm2, 2.13 lbf/in.2}
DESCRIPTION
EN0680202C100002
SHTS068020200012
1 Valve body 5 Body cap

2 Conical spring A OUT
3 Valve seat B IN
4 O-ring
COMPONENT LOCATOR
EN0680202D100002
SHTS068020200013
1 Valve body 4 O-ring

2 Conical spring 5 Body cap
3 Valve seat

A 44.1-53.9 {450-550, 33-39}

EN0680202H300002
Unit: mm {in.}
Body cap: — — Replace, Visual check

Wear and any other dam- if necessary.
age
Conical spring: 17.5 {0.69} 16.5 {0.65} Replace. Measure and Visual check
Rust, damage and free
length
DOUBLE CHECK VALVE

DATA AND SPECIFICATION
EN0680202I200003
Type Piston type
DESCRIPTION
EN0680202C100003
SHTS068020200016
1 Valve body 5 Plug

2 Valve A Outlet
3 Guide B Inlet
4 Gasket
COMPONENT LOCATOR
EN0680202D100003
SHTS068020200017
1 Valve body 4 Gasket

2 Valve 5 Plug
3 Guide

A 34.3-44.1 {350-450, 25.3-32.5}
OVERHAUL
EN0680202H200002
IMPORTANT POINT - ASSEMBLY
1. LUBRICATION
(1) When assembling the double check valve, apply the ThreeBond:
TB-1101 or equivalent to the gasket.
NOTICE
Check to see that there is no air leakage from "A", when air is
charged from "B", and no air leakage from "B", when air is
charged from "A".
SHTS068020200018

EN0680202H300003
Valve and guide: — — Clean or replace, Visual check

Rust, wear and damage if necessary.
Valve body and plug: — — Clean or replace, Visual check

SAFETY VALVE
EN06802022600001
Type Spring type

Valve opening pressure 1,029-1,068 kPa {10.5-10.9 kgf/cm2, 149.2-154.9 lbf/in.2}
DESCRIPTION
EN0680202C100004
SHTS068020200021
1 Valve 5 Compression spring

2 Body A Exhaust
3 Nut B From air tank (Pressure air)
4 Bolt

EN0680202H300004
Unit: kPa {kgf/cm2, lbf/in.2}
Valve opening pressure 1,029-1,068 — Replace. Measure

{10.5-10.9,
149.2-154.9}
BRAKE VALVE
EN0680202I200004
Type Dual pistons and valves with a plunger type pedal
DESCRIPTION
EN0680202C100005
SHTS068020200022
1 Boot 16 Primary piston return spring

2 Plunger 17 Primary valve body
3 Brake valve cover 18 Primary feed valve
4 Retainer ring 19 Retainer
5 Guide ring 20 Primary feed valve return spring
6 Spring seat 21 Primary feed valve retainer
7 Sub spring 22 Secondary piston
8 Shim 23 Secondary piston return spring
9 Stem 24 Secondary valve body
10 Main spring 25 Secondary feed valve
11 Shim 26 Retainer
12 Guide ring 27 Secondary feed valve return spring
13 O-ring 28 Secondary feed valve retainer
14 Primary piston 29 C-ring
15 Guide 30 Exhaust port
COMPONENT LOCATOR
EN0680202D100004
SHTS068020200023
1 Stop lamp switch 10 Push rod

2 Bushing 11 Seal
3 Bracket 12 Clip
4 Buffer 13 Shaft
5 Pin 14 Pedal bracket
6 R-pin 15 Brake valve
7 Pedal pad 16 Connector
8 Brake pedal 17 Clutch master cylinder
9 Return spring

A 9.5-18.5 {97-188, 7.1-13.6} C 24.4-34.5 {249-351, 18-25}
B 18-31 {184-316, 14-22}
SHTS068020200024
1 Boot 16 Primary piston return spring

2 Plunger 17 Primary valve body
3 Brake valve cover 18 Primary feed valve
4 Retainer ring 19 Retainer
5 Guide ring 20 Primary feed valve return spring
6 Spring seat 21 Primary feed valve retainer
7 Sub spring 22 Secondary piston
8 Shim 23 Secondary piston return spring
9 Stem 24 Secondary valve body
10 Main spring 25 Secondary feed valve
11 Shim 26 Retainer
12 Guide ring 27 Secondary feed valve return spring
13 O-ring 28 Secondary feed valve retainer
14 Primary piston 29 C-ring
15 Guide 30 Exhaust port

A 2.9-4.9 {30-50, 2.2-3.6} B 5.9-7.4 {60-75, 4.3-5.4}
NOTICE
The parts in 4 and 13 are not the ones to be reusable.
OVERHAUL
EN0680202H200003
IMPORTANT POINTS - DISMOUNTING
1. REMOVE THE CLUTCH MASTER CYLINDER.

HINT
Even if without removing the clutch master cylinder, pedal bracket
can be removed only to the length of the clutch hose.
2. DISCONNECT THE NYLON TUBE.

NOTICE
Before disconnecting, apply aligning marks on the brake valve
SHTS068020200025
assembly and nylon tube.
3. REMOVE THE PEDAL BRACKET ASSEMBLY.

(1) Loosen the bolt and nut to remove the pedal bracket assembly.
NOTICE
WIPER LINK Before removing the pedal bracket, put the wiper link upward.
SHTS068020200026
4. REMOVE THE BRAKE PEDAL.

(1) Tap the shaft lightly using a brass rod and a hammer, remove the
brake pedal from the pedal bracket assembly.
NOTICE
Do not pull out the shaft because the brake pedal and the clutch
pedal are installed by one shaft.
SHTS068020200027
5. REMOVE THE BRAKE VALVE ASSEMBLY.

ALIGNING MARK (1) Apply aligning marks on the brake valve assembly and pedal
bracket assembly.
SHTS068020200028
IMPORTANT POINTS - DISASSEMBLY

ALIGNING NOTICE
MARK
Before disassembling the brake valve, apply aligning marks on
the brake valve cover, primary valve body and secondary valve
body.
SHTS068020200029
ALIGNING MARK
SHTS068020200030
1. REMOVE THE PRIMARY PISTON ASSEMBLY.
2. REMOVE THE SECONDARY VALVE BODY.
3. REMOVE THE SECONDARY PISTON.

NOTICE
Pull out with hands to prevent the seat part of the secondary pis-
ton from being damaged by using a pryer etc. If not with hands,
secondary piston should not be reused.
4. REMOVE THE PRIMARY FEED VALVE.

SHTS068020200031
5. REMOVE THE EXHAUST PORT.
6. REMOVE THE SECONDARY FEED VALVE.

NOTICE
In order to prevent from incorrect assembling, keep in stock
respectively primary feed valve assembly and secondary feed
valve assembly.
1. LUBRICATION
(1) When reassembling the brake valve, replace the O-rings and
retainer rings with new ones.
(2) Apply adequate amount of silicone grease on the grooves for the
O-ring and to the sliding surfaces of the component parts.
1. Secondary feed valve retainer O-ring
2. Secondary feed valve retainer
3. Secondary feed valve
4. Exhaust port O-ring
5. Primary feed valve retainer O-ring
6. Primary feed valve retainer
7. Secondary piston O-ring
8. Secondary piston
9. Primary valve body
10. Primary piston
11. Primary piston O-ring
12. Plunger
SHTS068020200032
2. ASSEMBLE THE STEM, SPRING, SPRING SEAT AND SHIM.

LOCK NUT
(1) Assemble the sub spring. At this time, adjust dimension "A" and
NUT "B" the spring compression "P" by means of the nut "B" and the shim.
Tightening Torque (Lock nut):
2.9-4.9 N⋅m {30-50 kgf⋅cm, 2.2-3.6 lbf⋅ft}
Dimension "A": 27.55-27.95 mm {1.0847-1.1003 in.}
Setting load "P": 0-9.8 N {0-1 kgf, 0-2.2 lbf}
DIMENSION
"A" NOTICE
In adjusting the spring compression, the axial play of the spring
must be removed.
SHTS068020200033
3. ALIGN THE VALVE COVER AND VALVE BODIES.

ALIGNING (1) When assemble the brake valve cover, primary body and second-
MARK ary body, align the marks which were applied at disassembly.
SHTS068020200029
ALIGNING MARK
SHTS068020200030
4. INSPECTION AND ADJUSTMENT

(1) Brake valve
a. Measure the secondary feed valve stroke (Dimension "A"
from starting to release the plunger to completing to fully
release the plunger).
A dimension: 0.6 mm {0.0236 in.} or above
DIMENSION "A"
SHTS068020200034
b. Connect the brake valve, nylon tube, air pressure gauge, and
air tank as shown in the figure.
c. Set the air tank pressure at 830 kPa {8.5 kgf/cm2, 120.87 lbf/
in.2}.
PRIMARY d. Apply soap water to the exhaust port and check to see there
is no air leakage.
AIR TANK
SECONDARY
SHTS068020200035
e. Drive in slowly the plunger. Measure the plunger stroke and

supply pressure at the point where the primary and second-
PLUNGER
ary air pressure gauges start to rise. If the measurements do
not match with the standard values, adjust by the shim of the
main spring.
PRIMARY
SUPPLY
PRESSURE Measurement item Standard value
AIR TANK
Plunger stroke 0.8-1.6 mm {0.0315-0.0630 in.}
19-41 kPa
Supply pressure
SECONDARY
{0.20-0.41 kgf/cm2, 2.76-5.94 lbf/in.2}
SHTS068020200036
f. Drive in further the plunger. Measure the plunger stroke and

supply pressure at the point immediately before that the pri-
PLUNGER
mary and secondary pressure increases rapidly (bending
point). If the measurements do not match with the standard
values, replace each spring.
PRIMARY
SUPPLY
PLUNGER Measurement item Standard value
AIR TANK
Supply pressure 196 kPa {2.00 kgf/cm2, 28.42 lbf/in.2}
SECONDARY
SHTS068020200037
g. Drive in further the plunger. Measure the plunger stroke and

supply pressure at the point where the primary and second-
PLUNGER
ary pressures increase rapidly. If the measurements do not
match with the standard values, replace each spring.
PRIMARY
SUPPLY Measurement item Standard value
PLUNGER
AIR TANK
Supply pressure 624 kPa {6.36 kgf/cm2, 90.50 lbf/in.2}
SECONDARY
SHTS068020200038
h. Drive in further the plunger. Measure the pedal stepping down

angle and supply pressure at the point where the primary and
PLUNGER
secondary pressure are maximum. If the measurements do
not match with the standard values, replace each spring.
PRIMARY
SUPPLY Measurement item Standard value
PLUNGER Plunger stroke 8.34-9.76 mm {0.3284-0.3842 in.}
AIR TANK
980 kPa
Supply pressure
{9.99 kgf/cm2, 142.14 lbf/in.2}
SECONDARY
SHTS068020200039
(2) Brake pedal

a. Make sure that the installing height of the brake pedal "C" and
the pedal play "B".
"B": 2-5 mm {0.0788-0.1968 in.}
"C": 147.7-157.7 mm {5.815-6.208 in.}
C
B
SHTS068020200040
b. If the pedal play is out of the standard value, loosen the lock
nut and turn the push rod to adjust the pedal play to the stan-
dard value.
Tightening Torque (Lock nut):
LOCK NUT 14-26 N⋅m {143-265 kgf⋅cm, 11-19 lbf⋅ft}
PUSH ROD
BOOT
PLUNGER
SHTS068020200041
(3) Check the clearance between stop lamp switch and buffer.
"D": 0.5-1.5 mm {0.0197-0.0590 in.}
STOP LAMP SWITCH
BUSHING
BUFFER
SHTS068020200042

EN0680202H300005
Main and sub spring: Main: 28.5 mm Replace, Measure and visual check
Free length/ 29.3 mm {1.15 in.}/ {1.12 in.} if necessary.
setting length/ 27.5 mm {1.08 in.}/ (Free length)
setting load 176.5 N
Crack, rust and damage {18 kgf, 39.68 lbf}
MAIN
Sub: 20.5 mm
21.6 mm {0.85 in.}/ {0.81 in.}
21.6 mm {0.85 in.}/ (Free length)
9.8 N SUB
{1.0 kgf, 2.20 lbf}
or more
Primary and secondary Primary: 40.5 mm Replace, measure and visual check
piston return spring: 43.2 mm {1.70 in.}/ {1.59 in.} if necessary.
Free length/ 16.5 mm {0.65 in.}/ (Free length)
setting length/ 95.1 N
setting load {9.7 kgf, 21.38 lbf}
Crack, rust and damage PRIMARY
Secondary: 43.2 mm
45.8 mm {1.80 in.}/ {1.70 in.}
49.0 N
{5.0 kgf, 11.02 lbf}
SECONDARY
Primary and secondary — — Replace, Visual check

piston: if necessary.
Wear and damage
SECONDARY PRIMARY
Primary and secondary — — Replace, Visual check

feed valve: if necessary.
Wear and damage
Primary and secondary Primary: 20.4 mm Replace, Measure and visual check
feed valve return spring: 21.4 mm {0.84 in.}/ {0.80 in.} if necessary.
Free length/ 12.5 mm {0.49 in.}/ (Free length)
setting length/ 52.0 N
setting load {5.3 kgf, 11.68 lbf}
Crack, rust and damage PRIMARY
Secondary: 21.8 mm
22.8 mm {0.90 in.}/ {1.13 in.}
49.0 N
{5.0 kgf, 11.02 lbf} SECONDARY
Secondary valve body: — — Replace, Visual check

Primary valve body: — — Replace, Visual check

PROTECTION VALVE (TYPE-A)

EN0680202I200005
Type Spring type

Open 637 kPa {6.5 kgf/cm2, 92.4 lbf/in.2}
Operating pressure
Close 510 kPa {5.2 kgf/cm2, 74.0 lbf/in.2}
DESCRIPTION
EN0680202C100006
SHTS068020200050
1 Valve body 5 Dust seal plate

2 O-ring 6 Retainer ring
3 Valve A Inlet
4 Compression spring B Outlet
COMPONENT LOCATOR
EN0680202D100005
SHTS068020200051
1 Body 4 Spacer 7 Dust seal plate

2 O-ring 5 Shim 8 Retainer ring
3 Piston 6 Spring 9 Dust seal
OVERHAUL
EN0680202H200004
1. LUBRICATION
(1) When reassembling the protection valve, replace the O-rings and
valve with new ones.
(2) Apply adequate amount of silicone grease to the sliding surface of
the component parts.
SHTS068020200052

EN0680202H300006
Unit: mm {in.}
Valve contact surface of — — Clean or Visual check

body cap 1: replace,
Sliding surface of valve — — Clean or

body 2: replace,
Valve spring: 60.0 {2.36} — Replace, Measure

Free length if necessary.
PROTECTION VALVE (TYPE-B)

EN0680202I200006
Type Spring type

Open 540 kPa {5.5 kgf/cm2, 78.3 lbf/in.2}
Operating pressure
Close 390 kPa {4.0 kgf/cm2, 56.6 lbf/in.2}
DESCRIPTION
EN0680202C100007
SHTS068020200055
1 Valve body 5 Dust seal plate

3 Valve A Inlet
4 Compression spring B Outlet
COMPONENT LOCATOR
EN0680202D100006
SHTS068020200056
1 Body 5 Spring
2 O-ring 6 Dust seal plate
3 Piston 7 Retainer ring
4 Shim
OVERHAUL
EN0680202H200005
1. LUBRICATION
(1) When reassembling the protection valve, replace the O-rings and
valve with new ones.
(2) Apply adequate amount of silicone grease to the sliding surface of
the component parts.
SHTS068020200057

EN0680202H300007
Unit: mm {in.}
Sliding surface of valve: — — Clean or Visual check

Rust, wear and damage replace,
if necessary.
Valve spring: 47.5 {1.87} — Replace, Measure

Free length if necessary.
PROTECTION VALVE (WITH 4-WAY PROTECTION VALVE)

EN0680202I200007
Type Spring type (4-way protection)

Opening pressure Open: Port 21, 22, 23 620-660 kPa {6.4-6.7 kgf/cm2, 89.93-95.72 lbf/in.2}
Port 24 570-610 kPa {5.9-6.2 kgf/cm2, 82.67-88.47 lbf/in.2}
Close: Port 21, 22, 24 440-480 kPa {4.5-4.8 kgf/cm2, 63.82-69.61 lbf/in.2}
Port 23 490-530 kPa {5.0-5.4 kgf/cm2, 71.07-76.87 lbf/in.2}
DESCRIPTION
EN0680202C100008
SHTS068020200059
1 Main spring A Port 21 (Outlet)

2 Dust cover B Port 22 (Outlet)
3 Check valve C Port 23 (Outlet)
4 Dust seal rubber D Port 24 (Outlet)
5 Piston E Inlet port
6 Valve spring F No.1 side
G Center check valve
H No.2 side
COMPONENT LOCATOR
EN0680202D100007
8 3
4
9
5
10
11 6
7
12
13
11
10
SHTS068020200060
1 Dust cover 6 Shim 11 Valve

2 Dust seal rubber 7 Spacer 12 Body
3 Retainer ring 8 Piston 13 Check valve
4 Dust seal plate 9 O-ring
5 Main spring 10 Valve spring
NOTICE
The parts in 3, 9 and 11 are not the ones to be reusable.
OVERHAUL
EN0680202H200006
1. LUBRICATION
(1) When assembling the protection valve use the new O-rings and
valves.
(2) Apply the silicone grease on the each sliding surface of the com-
ponent parts and O-ring groove.
• A: O-ring
• B: Sliding surface
SHTS068020200061
ADJUSTMENT
EN0680202H300008
AIR LEAKAGE
1. CHECK VALVE
(1) By-pass check valve at No.1 side.
a. Confirm no leakage of air at inlet port, when applying air pres-
sure 49 kPa {0.5 kgf/cm2, 7.11 lbf/in.2} and 392 kPa {4 kgf/
cm2, 56.89 lbf/in.2} from outlet port No.21 and No.22.
SHTS068020200062
(2) Center check valve

a. Confirm no leakage of air at the outlet port No.21 and No.22,
when applying air pressure 49 kPa {0.5 kgf/cm2, 7.11 lbf/in.2}
and 980 kPa {10 kgf/cm2, 142 lbf/in.2} from the inspection
port.
SHTS068020200063
(3) Check valve at No.2 side

a. Confirm no leakage of air at the inspection port, when apply-
ing air pressure 49 kPa {0.5 kgf/cm2, 7.11 lbf/in.2} and 980
kPa {10 kgf/cm2, 142 lbf/in.2} from the outlet port No.23 and
No.24.
2. OTHER AIR TIGHTNESS

(1) When applying air pressure 0-980 kPa {0-10 kgf/cm2, 0-142 lbf/
in.2}, confirm that any leakage of air should be 0 cm3min.
SHTS068020200064
PERFORMANCE CHRACTERISTIC
1. OPENING VALVE PRESSURE

(1) No.1 side
a. Releasing the compressed air at the outlet port No.21 and
No.22 to air, when applying the compressed air at the speed
specified below, confirm that air pressure of the compressed
air, saturated at the inlet should be of opening valve pressure,
which should be 620-660 kPa {6.3-6.7 kgf/cm2, 89.61-95.29
lbf/in.2}.
Charging speed: From 295 kPa {3.0 kgf/cm2, 42.66 lbf/in.2} to
490 kPa {5.0 kgf/cm2, 71.10 lbf/in.2} within 3-7 seconds.
(2) No.2 side
a. When applying air at charging speed specified below from the
inlet side under air pressure "0" at the outlet port No.23 and
No.24, confirm that a pressure at the inspection port when it
starting to go up at the outlet should be of opening valve pres-
sure, which should be 570-610 kPa {5.8-6.2 kgf/cm2, 82.49-
88.18 lbf/in2}.
Opening valve pressure

620-660 kPa
Port No.23
{6.3-6.7 kgf/cm2, 89.61-95.29 lbf/in.2}
570-610 kPa
Port No.24
{5.8-6.2 kgf/cm2, 82.67-88.47 lbf/in.2}
Charging speed: From 295 kPa {3.0 kgf/cm2, 42.66 lbf/in.2} to

490 kPa {5.0 kgf/cm2, 71.10 lbf/in.2} within 8-22 seconds.
2. CLOSING VALVE PRESSURE

(1) When discharging air through respective No.1 side and No.2 side
inlet under a pressure of 980kPa {10 kgf/cm2, 142 lbf/in.2} at the
inlet and the outlet, at discharging speed specified below, confirm
that a pressure when the pressures saturated should be of closing
valve pressure, which should be 440-480 kPa {4.5-4.8 kgf/cm2,
64.01-68.27 lbf/in.2} (Port No.21, 22 and 24), and 490-530 kPa
{5.0-5.4 kgf/cm2, 71.07-76.87 lbf/in.2} (Port No.23).
Discharging speed: From 590 kPa {6.0 kgf/cm2, 85.32 lbf/in.2} to
295 kPa {3.0 kgf/cm2, 42.66 lbf/in.2} within less than 3 seconds.
NOTICE
• Perform test again by increasing sims, when the respective
pressures is low and by decreasing it when high in the above
inspection.
• After inspecting, make sure to tighten the inspection port
securely.

EN0680202H300009
Unit: mm {in.}
Sliding surface and contact — — Replace, Visual check

surface of body: if necessary.
Wear and damage
Sliding surface and contact — — Replace, Visual check

surface of valve seat and if necessary.
piston:
Wear and damage
Main spring and valve spring: Main spring 137.3 N Replace, Measure and Visual check
Free length/ (Port 21, 22, 24): {14.0 kgf, if necessary.
Setting length/ 42.4 {1.67}/ 30.87 lbf}
Setting load 27.5 {1.08}/ (Setting load)
Crack, rust and damage 158.9 N
{16.2 kgf, 35.72 lbf}
Main spring
(Port 23):
35.3 {1.39}/ MAIN
27.5 {1.08}/
169.7 N
{17.3 kgf, 38.15 lbf}
VALVE
Valve spring: 0.69 N
20.0 {0.79}/ {0.07 kgf,
9.0 {0.35}/ 0.155 lbf}
0.78 N (Setting load)
{0.08 kgf, 0.175 lbf}
QUICK RELEASE VALVE

EN0680202I200008
Type Diaphragm type
DESCRIPTION
EN0680202C100009
SHTS068020200068
1 Cover 6 Bolt
2 Filter A Inlet
3 Gasket B Outlet
4 Diaphragm C Exhaust
5 Valve body
COMPONENT LOCATOR
EN0680202D100008
SHTS068020200069
1 Cover 4 Diaphragm
2 Filter 5 Valve body
3 Gasket 6 Bolt
OVERHAUL
EN0680202H200007
IMPORTANT POINT - DISASSEMBLY

NOTICE
Before disassemble the relay valve apply the aligning mark "A" for
the cover and valve body.
SHTS068020200070
1. ASSEMBLE THE RELAY VALVE.

(1) When assembly the relay valve, use the new diaphragm and gas-
ket.
• A: Gasket
• B: Diaphragm
(2) Coincide the aligning mark "A" which were applied at disassem-
bly.
SHTS068020200071

EN0680202H300010
Valve body and cover — — Replace, Visual check

surface: if necessary.
Rust and damage
LOAD SENSING VALVE

EN0680202I200009
Type Piston with diaphragm type

DESCRIPTION
EN0680202C100010
LOAD SENSING VALVE
SHTS068020200073
1 Cover 13 Operating arm

2 Air pipe 14 Body
3 Piston 15 Plunger return piston
4 Diaphragm guide 16 Plunger spring
5 Diaphragm A Inlet (From Brake valve)
6 Connecting rod B Outlet (To Relay valve)
7 Check valve (Exhaust) C Breathing
8 Cam D Exhaust
9 Cap E MAX.
10 Valve spring F Half
11 Valve G MIN.
12 Plunger
LINKAGE
SHTS068020200074
1 Load sensing valve 6 Connecting rod

2 Operating arm 7 Push rod
3 Adjuster A Rear axle
4 Holder B Rear-front axle
5 Damper assembly C Rear-rear axle
COMPONENT LOCATOR
EN0680202D100009
LOAD SENSING VALVE
SHTS068020200075
1 Cover 12 Piston seal 23 Plunger spring

2 O-ring 13 Piston 24 Cap
3 O-ring retainer 14 Diaphragm protector 25 Hexagonal socket screw
4 Air pipe 15 Diaphragm 26 Cam
5 Pipe retainer 16 Piston guide 27 Connecting rod
6 Filter 17 Plunger 28 Indicator
7 Diaphragm retainer 18 Body 29 Operating arm
8 Retainer ring 19 Oil seal 30 Cotter pin
9 Spring seat 20 Bushing 31 Washer
10 Valve spring 21 Check valve (Exhaust) 32 Valve No. plate
11 Valve 22 Plunger return piston 33 Diaphragm guide

A 7.8-9.8 {80-100, 5.76-7.22} B 3.4-4.9 {35-50, 2.51-3.61}
LINKAGE
SHTS068020200076
1 Load sensing valve 8 Pin 15 Supporter

2 Adjuster (Wire type) 9 Bracket (To Rear-front axle) 16 Spring seat
3 Lock plate 10 Holder assembly 17 Cover
4 Cotter pin 11 Bracket (To Rear-rear axle) 18 Spring
5 Damper assembly 12 Connector 19 Retainer
6 Bracket (To Rear axle) 13 Clamp band
7 Push rod 14 Connecting rod

A 35.3-52.0 {360-530, 27-38} C 19.6-39.2 {200-400, 15-28}
B 17.7-26.5 {180-270, 14-19} D 62.8-91.2 {640-930, 47-67}
OVERHAUL
EN0680202H200008
1. REMOVE THE OPERATING ARM.

(1) Measure and record the fixing length A of the operating arm
before removing.
SHTS068020200077
1. LUBRICATION
(1) When reassembling the L.S.V. replace all rubber parts (Piston
seal, Valves, Diaphragm, Dust seals and O-rings) with new ones.
(2) Apply lithium grease to each sliding surface of the components
parts and the O-ring groove.
A: O-ring
*L.S.V.: Load sensing valve
SHTS068020200078
2. ASSEMBLE THE OPERATING ARM.

(1) Set the dimension "A" of operating arm to the original length or
according to table below.
Unit: mm {in.}
Valve No. 47640-1280 47640-1080
A 84-86 {3.307-3.385} 59-61 {2.323-2.401}
NOTICE
Valve No. is indicated on the cover.
SHTS068020200077
3. INSPECTION OF THE LOAD SENSING VALVE

(1) Connect the L.S.V., nylon tube, air pressure gauge and air tank as
shown in the figure.
SHTS068020200079
(2) Set operating arm to the "A" position and close the outlet port;
then hold a charge with air at a pressure of 686 kPa {7.0 kgf/ cm2,
99.541 lbf/in.2} into the inlet port.
Let the operating arm swing over the entire range.
At this time, check for air leak by applying soapy water around the
body and pipe joint.
Valve No. 47640-1280 47640-1080

A +30° +15°
B -30° -15°
SHTS068020200080
NOTICE
(3) Set the air tank pressure at 686 kPa {7.0 kgf/cm2, 99.54 lbf/in2.},
fix the angle of the operating arm as specified below, and mea-
sure the pressure on the outlet port when compressed air is sup-
plied to the inlet port by using of the cock.
(4) For your information, the relation between angle of the operating
arm and pressure on the outlet port is shown in the adjacent dia-
grams.
Unit: kPa {kgf/cm2, lbf/in.2}
Operating arm Rated pressure on
Valve No.
angle outlet port
+30° 686 {7.0, 99.50}
47640-1020 0° C: 301-359 {3.1-3.6, 43.66-52.06}
47640-1280 -30° B: 170-210 {1.8-2.1, 24.66-30.45}
-40° A: 150-190 {1.6-1.9, 21.76-27.55}
+15° 686 {7.0, 99.50}
0° F: 321-379 {3.3-3.8, 46.56-54.96}
47640-1080
-15° E: 190-230 {2.0-2.3, 27.56-33.35}
SHTS068020200081
-20° D: 160-200 {1.7-2.0, 23.21-29.00}
NOTICE
12
690
DELIVERY PRESSURE (kPa)
590
490
390
290 F
200
E
98 D
0
–20 –15 –10 –5 0 5 10 15 20
OPERATING ARM ANGLE ( ) O
For: 47640-1080
SHTS068020200082
4. DAMPER ASSEMBLY
(1) Before installing the connecting rod to the spring seat, apply the
lock agent to the threads of the rod.
SHTS068020200083
5. PUSH ROD AND HOLDER ASSEMBLY (For tandem axle)

(1) When assembling the push rod and holder assembly, insert the
push rod ends to the connectors so that the groove on the push
rod and connector end will be flush as shown in the figure.
(2) Clamp band should be placed as shown in the figure.
SHTS068020200084
1. ADJUSTER (For single axle)

(1) Position of the lock plate:
After connection the operating arm of the L.S.V., adjust the
adjuster (wire) on the connecting rod then lock the wire as shown
in the figure.
A = 60 mm {2.36 in.}
SHTS068020200085
2. PUSH ROD WITH HOLDER ASSEMBLY (For tandem axle)

(1) Position of bolt for clamp band:
Set the clamp bands so that the bolts for clamp bands will be on
opposite sides of the propeller shaft and differential carrier.
(2) Inserting direction of the pin:
Connect the pin to the push rod as shown in the figure.
SHTS068020200086
ADJUSTMENT
EN0680202H300011
1. ADJUSTER
(1) With the vehicle unloaded, adjust the length of the wire to align
the indicator of the L.S.V. with the mark "•".
SHTS068020200087
(2) Lock the wire as shown in the figure.

a = 60 mm {2.36 in.}
SHTS068020200088
SHTS068020200089

EN0680202H300012
Inner surface of cover: — — Replace, Visual check

Wear, damage and rust if necessary.
Valve contact surface 1 — — Replace, Visual check

and friction surface 2 of if necessary.
piston:
Wear and damage
Friction surface of dia- — — Replace, Visual check

phragm guide: if necessary.
Wear and damage
Friction surface of piston — — Clean or replace. Visual check

guide:
Wear, damage and rust
Valve contact surface 1 — — Clean or replace, Visual check

plunger:
Friction surface of rod 1 — — Clean or replace, Visual check

and cam 2: if necessary.
Valve contact surface 1 — — Clean or replace, Visual check

plunger return piston:
Valve spring and plunger — — Replace, Visual check

spring: if necessary.
Elastic distortion and
damage
Friction surface of body 1 — — Clean or replace, Visual check

and bushing: if necessary.
Friction surface of cap: — — Clean or replace, Visual check

Wear, damage and rust if necessary.
Indicator 1, — — Repair or Visual check

Operating arm 2: replace.
Deformation
Connector: — — Replace, Visual check

Deterioration and damage if necessary.
Components of damper: — — Replace, Visual check

Deformation and damage if necessary.
Push rod assembly — — Replace, Visual check

(Tandem axle): if necessary.
Deformation
SPRING BRAKE CONTROL VALVE (TYPE-A)

EN0680202I200010
Type Variable pressure control type

Outlet pressure difference between parking and releas-
Within 147 kPa {1.5 kgf/cm2, 21.32 lbf/in.2}
ing stroke at a specified lever angle
DESCRIPTION
EN0680202C100011
SHTS068020200104
1 Body cover 11 Handle return spring

2 Feed valve spring 12 Pull rod
3 Piston 13 Knob
4 Feed valve 14 Compression spring
5 Valve seat 15 Release knob
6 Valve body 16 Handle body
7 Piston spring A Inlet
8 Valve spring B Outlet
9 Cam C Exhaust (PARK)
10 Cam holder
COMPONENT LOCATOR
EN0680202D100010
SHTS068020200105
1 Body cover 8 Valve spring

2 Shim 9 Valve seat
3 Piston spring 10 Handle body
4 Valve body 11 Stopper
5 Cam holder 12 Compression spring
6 O-ring 13 Knob sub assembly
7 Piston sub assembly 14 Pull rod

A 5.4-7.4 {55-75, 4.0-5.4} B 3.4-4.9 {35-50, 2.6-3.6}
OVERHAUL
EN0680202H200009

a
1. LUBRICATION
(1) When assembling the spring brake control valve, replace the feed
valve, valve seats and O-rings.
(2) Apply silicone grease to each sliding surface of the assembly
parts, O-rings and O-ring grooves.
a. O-ring
b. Feed valve
c. Piston
b c d e f
d. Valve seat
SHTS068020200106
e. Cam
f. Cam holder
2. ASSEMBLE THE CAM ASSEMBLY.

(1) When assembling the cam and cam holder, make sure that the
cam holder pin and spiral groove of the cam are aligned.
(2) When installing the cam assembly to the valve body, the valve
body pin and straight groove of the cam must be aligned.
SHTS068020200107
(3) Adjust dimension "A" with the shim.

a Assembly standard: 33.8-34.2 mm {1.331-1.346 in.}
a. Cam
A b. Cam holder
c. Shim
b c
SHTS068020200108
3. SPRING BRAKE CONTROL VALVE PERFORMANCE TEST

SPRING BRAKE (1) First, connect the pressure gauge to the outlet line and apply an
AIR
CONTROL VALVE
PRESSURE air pressure of 980 kPa {10.0 kgf/cm2, 142 lbf/in.2} to the inlet line.
GAUGE
TANK
SHTS068020200109
(2) Move the spring brake control lever towards the OFF position,
gradually and confirm that the air pressure in the outlet line meets
the characteristic shown in figure.
Standard:
Handle angle: Outlet pressure: kPa {kgf/cm2, lbf/in.2}
15° 275 {2.8, 39.9}
35° 441.6-500.4 {4.5-5.1, 64.0-72.6}
Over 42° 980 {10.0, 142}
NOTICE
The characteristic shown is under the inlet pressure of 480 kPa
{10.0 kgf/cm2, 142 lbf/in2.}
SHTS068020200110
(3) Confirm the following functions.

980
DISCHARGE PRESSURE (kPa)
a. The control handle is locked at PARK position.

883
785
b. The control handle automatically turn to OFF position when the
686
275 kPa lever is released at PARK position.
588 471 29.4 kPa
490
392
294
196
42
98
0
0 10 20 30 40 45 50 55
PARK 15 35
RELEASE
POSITION HANDLE ROTATION POSITION
ANGLE ( )
(AIR TANK PRESSURE: 980 kPa)
SHTS068020200111

EN0680202H300013
Unit: mm {in.}
Piston and valve body: — — Replace, Visual check

Cam, pin and cam — — Replace, Visual check

holder: if necessary.
Wear and damage
Piston spring, valve Piston spring 500.1 N Replace, Measure and visual check
spring and handle 27.9 {1.10}/ {51.0 kgf, 112.43 lbf} if necessary.
return spring: 25.0 {0.98}/ (Setting load)
Free length/ 553.1 N
Setting length/ {56.4 kgf, 124.34 lbf}
Setting load
Crack, rust and damage Valve spring 17.6 N
19.6 {0.77}/ {1.8 kgf, 3.96 lbf}
10.5 {0.41}/ (Setting load)
19.6 N
{2.0 kgf, 4.41 lbf}
VALVE SPRING
Handle return 6.9 N
spring {0.7 kgf, 1.55 lbf}
13.5 {0.53}/
7.8 N
{0.8 kgf, 1.76 lbf} PISTON SPRING
HANDLE RETURN
SPRING
Feed valve spring: — — Replace, Visual check

Rust and damage if necessary.
SPRING BRAKE CONTROL VALVE (TYPE-B)

EN0680202I200011

Outlet pressure difference between parking and releas-
Within 196 kPa {2.0 kgf/cm2, 28.43 lbf/in.2}
ing stroke at a specified lever angle
DESCRIPTION
EN0680202C100012
SHTS068020200116
1 Body cover 10 Cam holder 19 Retainer

2 Feed valve spring 11 Handle return spring 20 Feed valve
3 Piston 12 Pull rod 21 Plunger
4 Feed valve 13 Knob A Inlet
5 Valve seat 14 Compression spring B Outlet (To spring brake line)
6 Valve body 15 Release knob C Exhaust (PARK)
7 Piston spring 16 Handle body D Outlet (To multiple relay valve)
8 Valve spring A 17 Valve spring B
9 Cam 18 Return spring
COMPONENT LOCATOR
EN0680202D100011
SHTS068020200117
1 Body cover 11 Stopper

2 Shim 12 Compression spring
3 Piston spring 13 Knob sub-assembly
4 Valve body 14 Pull rod
5 Cam holder 15 Retainer
6 O-ring 16 Valve spring B
7 Piston sub-assembly 17 Feed valve
8 Valve spring A 18 Return spring
9 Valve seat 19 Plunger
10 Handle body

A 5.4-7.4 {55-75, 4.0-5.4} B 3.4-4.9 {35-50, 2.6-3.6}
OVERHAUL
EN0680202H200010
1. LUBRICATION
(1) When assembling the spring brake control valve, replace the feed
valve, valve seats and O-rings.
(2) Apply silicone grease to each sliding surface of the assembly
parts, O-rings and O-ring grooves.
a. O-ring
b. Feed valve
c. Piston
d. Valve seat
e. Cam
f. Cam holder
g. Plunger
SHTS068020200118
2. ASSEMBLE THE CAM ASSEMBLY.

(1) When assembling the cam and cam holder, make sure that the
cam holder pin and spiral groove of the cam are aligned.
(2) When installing the cam assembly to the valve body, the valve
body pin and straight groove of the cam must be aligned.
SHTS068020200119
(3) Adjust dimension "A" with the shim.

a Assembly standard: 33.8-34.2 mm {1.331-1.346 in.}
a. Cam
A b. Cam holder
c. Shim
b c
SHTS068020200108
3. SPRING BRAKE CONTROL VALVE PERFORMANCE TEST

SPRING BRAKE (1) First, connect the pressure gauge to the outlet line and apply an
AIR
CONTROL VALVE
PRESSURE air pressure of 980 kPa {10.0 kgf/cm2, 142 lbf/in.2} to the inlet line.
GAUGE
TANK
SHTS068020200109
(2) Move the spring brake control handle towards the OFF position,
gradually and confirm that the air pressure in the outlet line meets
the characteristic shown in figure below.
SHTS068020200120
NOTICE
The characteristic shown is under the inlet pressure of 980 kPa
B {10.0 kgf/cm2, 142 lbf/in.2}
DISCHARGE PRESSURE (kPa)
980
A- Outlet pressure (To multiple relay valve)
883 B- Outlet pressure (To spring brake line and multiple relay valve)
786 A
686
(3) Confirm the following functions.
588 a. The control handle is locked at PARK position.
490
392
b. The control handle automatically turn to OFF position when the
294 handle is released PARK position.
29.4
196
98
29.4
0
0 10 20 30 40 50 60
TEST 7 15 32.5 2 52 70
POSITION
HANDLE RELEASE
PARK ROTATION POSITION
POSITION ANGLE ( )
(AIR TANK PRESSURE: 980 kPa)
SHTS068020200121

EN0680202H300014
Unit: mm {in.}
Piston and valve body: — — Replace, Visual check

Cam, pin and cam — — Replace, Visual check

holder: if necessary.
Wear and damage
Piston spring, valve Piston spring 588.0 N Replace, Measure and visual check
spring, handle return 26.8 {1.06}/ {60.0 kgf, 132.19 lbf} if necessary.
spring: 24.8 {0.98}/ (Setting load)
Free length/ 651.7 N
Setting length/ {66.5 kgf, 146.50 lbf}
Setting load
Crack, rust and damage Valve spring A 17.6 N
19.6 {0.77}/ {1.8 kgf, 3.96 lbf}
19.6 N
{2.0 kgf, 4.41 lbf}
VALVE SPRING "A"
Handle return spring 6.9 N
19.3 {0.76}/ {0.7 kgf, 1.54 lbf}
7.8 N
{0.8 kgf, 1.76 lbf}
PISTON SPRING
Valve spring B 18.0 N HANDLE RETURN
11.2 {0.44}/ {1.8 kgf, 4.05 lbf} SPRING
19.6 N
{2.0 kgf, 4.41 lbf} RETURN
SPRING
Return spring 8.8 N
32.0 {1.26}/ {0.9 kgf, 1.98 lbf}
29.0 {1.14}/ (Setting
VALVE SPRING "B"
9.8 N load)
{1.0 kgf, 2.20 lbf}
Feed valve spring and — — Replace, Visual check

valve seat spring: if necessary.
Rust and damage
RELAY VALVE (TYPE-A)

EN0680202I200012
Type Diaphragm type with double check valve combined

Pressure difference between signal and outlet pressure 29.4 kPa {0.29 kgf/cm2, 4.26 lbf/in.2} or less
DESCRIPTION
EN0680202C100013
SHTS068020200123
1 Cover 9 Valve
2 Diaphragm 10 Plug
3 Valve body 11 Silencer
4 Valve sub assembly A Signal
5 Valve cap B Outlet
6 Spring C Exhaust
7 Valve D Inlet
8 Filter
COMPONENT LOCATOR
EN0680202D100012
SHTS068020200124
1 Valve sub assembly 9 Valve

2 Cover 10 O-ring
3 Guide 11 Spring
4 Valve 12 Valve cap
5 Gasket 13 Clip
6 Plug 14 Silencer
7 Filter 15 Pipe
8 Valve body 16 Dust cover

A 11.8-14.7 {120-150, 9-10} C 58.8-78.4 {600-800, 44-57}
B 34.3-44.1 {350-450, 26-32}
OVERHAUL
EN0680202H200011

NOTICE
Before disassembling the relay valve, mark the aligning marks "A"
on the cover and valve body.
SHTS068020200125
1. LUBRICATION
(1) When assembling the relay valve, use new O-rings and valves.
(2) Apply the silicone grease to each sliding surface of the compo-
A: O-ring
B: Apply the silicone grease
(3) When installing the cover to the body, align the aligning marks
which were applied at disassembly.
SHTS068020200126

EN0680202H300015
Unit: mm {in.}
Check valve: — — Replace, Visual check

Cover, guide and plug: — — Clean or Visual check

Damage, wear and rust replace,
if necessary.
Spring: 46 {1.81}/ 52.0 N Replace, Measure and Visual check

Free length/ 30 {1.18}/ {5.30 kgf, 11.69 lbf} if necessary.
Setting length/ 59.3 N (Setting load)
Setting load {6.05 kgf, 13.33 lbf}
Crack, rust and damage
Relay valve body and — — Clean or Visual check

cap replace,
sliding surface: if necessary.
Damage, wear and rust
RELAY VALVE (TYPE-B)

EN0680202I200013
Type Diaphragm type with double check valve combined

34 kPa {0.34 kgf/cm2, 4.93 lbf/in.2} or less
Pressure difference between signal and outlet pressure (At output pressure is 50 kPa {0.51 kgf/cm2, 7.25 lbf/
in.2} or more)
DESCRIPTION
EN0680202C100014
SHTS068020200131
1 Piston 10 Body
2 O-ring 11 Retainer
3 Valve spring 12 Inlet valve
4 Valve retainer 13 Piston spring
5 Valve guide 14 Cover
6 Valve seat A Signal
7 Exhaust valve B Outlet
8 Rivet C Exhaust
9 Retainer ring D Inlet
COMPONENT LOCATOR
EN0680202D100013
SHTS068020200132

2 Inlet valve 4 Silencer

A 12-19 {123-193, 8.9-14}
OVERHAUL
EN0680202H200012
1. LUBRICATION
A: O-ring
SHTS068020200133

EN0680202H300016
Unit: mm {in.}
Piston and sliding — — Replace, Visual check

surface of cover if necessary.
and valve body:
Wear and damage
Inlet valve, valve — — Clean or replace, Visual check

guide, valve retainer if necessary.
VALVE
and valve body slid- RETAINER
ing surface:
Wear and damage
VALVE
GUIDE
INLET
VALVE
Valve spring and Valve spring 21.8 N Replace, Measure and visual check
piston spring: 23.5 {0.93}/ {2.22 kgf, 4.90 lbf} if necessary.
Free length/ 15.7 {0.62}/ (Setting load)
Setting length/ 29.0 N
Crack, rust and
damage Piston spring 41.0 N
34.5 {1.36}/ {4.18 kgf, 9.22 lbf}
54.6 N
{5.57 kgf, 12.27 lbf}
CUT VALVE
EN0680202I200014
Type Spring type
DESCRIPTION
EN0680202C100015
SHTS068020200137
1 Valve cap 6 Conical spring

2 Piston A Signal
3 Valve body B Outlet
4 Compression spring C Inlet
5 Valve sub assembly D Exhaust
COMPONENT LOCATOR
EN0680202D100014
SHTS068020200138
1 Valve cap 4 Compression spring 7 Valve body

2 O-ring 5 Ring retainer 8 Valve sub assembly
3 Piston 6 Filter 9 Conical spring

A 49.04-58.83 {500-600, 36.2-43.3} B 49.04-58.83 {500-600, 36.2-43.3}
OVERHAUL
EN0680202H200013
1. LUBRICATION
(1) When assembling the cut valve, use the new O-ring and retainer
ring.
(2) Apply the silicone grease to the each sliding surface of the com-
ponent parts and O-ring groove.
NOTICE
Check the air leakage from exhaust port, with the piston at the
released position.
A: Sliding surface
SHTS068020200139
B: O-ring
PERFORMANCE CHARACTERISTIC
1. When the inlet pressure is 686 kPa {7.0 kgf/cm2, 99.54 lbf/
in.2}, the valve should be opened with the signal pressure of
below 343 kPa {3.5 kgf/cm2, 49.77 lbf/in.2} and the valve
should be closed with the signal pressure of 147-245 kPa
{1.5-2.4 kgf/cm2, 21.32-35.53 lbf/in.2}.
2. When the inlet and signal pressure are decreasing at same

time, the valve should be closed at pressure of 99-196 kPa
{1.0-2.0 kgf/cm2, 14.22-28.44 lbf/in.2}.
3. When the inlet and signal pressure are increasing at same

time, the valve should be opened with the pressure of 148-
245 kPa {1.5-2.5 kgf/cm2, 21.33-35.55 lbf/in.2}.

EN0680202H300017
Sliding surface and — — Replace, Visual check

valve contact sur- if necessary.
face of piston:
Wear and damage
Conical spring and Conical spring: 16.6 mm {0.66 in.} Replace, Visual check
compression 17.6 mm {0.69 in.}/ (Free length) if necessary.
spring: 15.4 mm {0.61 in.}/
Free length/ 0.08 N
setting length/ {0.008 kgf, 0.0180 lbf}
setting load
Crack, rust and Compression spring: 20.5 mm {0.81 in.} CONICAL
damage 22.5 mm{0.90 in.}/ (Free length)

15.5 mm {0.51 in.}/ 6.7 N
7.0 N {0.684 kgf, 1.5063 lbf}
{0.714 kgf, 1.5737 lbf} (Setting load) COMPRESSION
Valve body: — — Replace, Visual check

Sliding surface and if necessary.
contact surface:
Wear and damage
REDUCING VALVE (TYPE-A)

EN0680202I200015
Type Piston
520.4-559.6 kPa {5.4-5.7 kgf/cm2, 75.5-81.1 lbf/in.2} at inlet pressure 690 kPa {7.0
Outlet pressure
kgf/cm2, 100.0 lbf/in.2}
DESCRIPTION
EN0680202C100016
SHTS068020200143
1 Bracket 10 Spring
2 Cover 11 Spring seat
3 O-ring 12 Retainer
4 Valve body 13 Ring retainer
5 Spring 14 Valve seat
6 Piston 15 Check valve
7 Shim A Inlet
8 Valve B Outlet
9 Retainer C Exhaust
COMPONENT LOCATOR
EN0680202D100015
SHTS068020200144
1 Bracket 9 Retainer
2 Cover 10 Spring
3 O-ring 11 Spring seat
4 Valve body 12 Retainer
5 Spring 13 Ring retainer
6 Piston 14 Valve seat
7 Shim 15 Check valve
8 Valve

A 9.8-19.6 {100-200, 7.3-14.4}
OVERHAUL
EN0680202H200014
1. LUBRICATION
A: O-ring
SHTS068020200145

EN0680202H300018
Spring: — — Replace, Visual check

Valve body and piston — — Clean or replace, Visual check

Valve contact surface: — —

REDUCING VALVE (TYPE-B)

EN0680202I200016
Type Piston
784-824 kPa {8.0-8.4 kgf/cm2, 113.8-119.5 lbf/in.2} at inlet pressure 980 kPa {10.0
Outlet pressure
DESCRIPTION
EN0680202C100017
SHTS068020200148
1 Retainer ring 8 Piston

2 O-ring 9 Body
3 Valve spring 10 Valve
4 Shim 11 Valve cover
5 Lower cover A Inlet
6 Check valve B Outlet
7 Main spring C Exhaust
COMPONENT LOCATOR
EN0680202D100016
SHTS068020200149
1 Retainer ring 7 Piston

2 Cover 8 Shim
3 O-ring 9 Main spring
4 Valve spring 10 Lower cover
5 Valve 11 Check valve
6 Body

A 6.2-7.8 {64-79, 4.6-5.7}
OVERHAUL
EN0680202H200015
1. LUBRICATION
A: O-ring
SHTS068020200150

EN0680202H300019
Spring: — — Replace, Visual check

Valve body and piston — — Clean or replace, Visual check

Valve contact surface: — —

BRAKE CHAMBER
EN0680202I200017
Type Diaphragm type
DESCRIPTION
EN0680202C100018
SHTS068020200152
1 Push rod 5 Diaphragm

2 Return spring 6 Chamber cover
3 Chamber A Inlet
4 Clamp B Drain hole
COMPONENT LOCATOR
EN0680202D100017
SHTS068020200153
1 Push rod 6 Chamber cover

2 Return spring 7 Clamp nut
3 Chamber 8 Clamp bolt
4 Clamp 9 Spacer
5 Diaphragm

A 26.5-32.3 {270-330, 19.9-24.1}
OVERHAUL
EN0680202H200016
IMPORTANT POINT - DISMOUNTING
1. DISMOUNTING OF THE BRAKE CHAMBER

(1) Before dismounting, apply aligning mark A to the chamber, clamp
and chamber cover.
(2) Apply a position mark R or L to identify the side where the cham-
ber was installed.
SHTS068020200154
1. ASSEMBLING THE BRAKE CHAMBER

(1) Replace the diaphragm with new one.
(2) Align the aligning mark A of the chamber, clamp and chamber
cover.
(3) Insert the bolt from opposite side of drain hole and tighten the
bolts evenly with nut within the specified torque.
SHTS068020200155
2. CHECKING FOR AIR LEAKAGE

(1) Apply soapy water to the chamber as shown and charge with
compressed air of 830 kPa {8.5 kgf/cm2, 121 lbf/in.2} from the
inlet port A then check for leakage.
SHTS068020200156
3. INSTALLING CLEVIS
(1) Install the clevis to the push rod and adjust dimension A to the
specified value.
Assembly Standard: 84-86 mm {3.31-3.38 in.}
SHTS068020200157
IMPORTANT POINT - MOUNTING
1. INSTALLING THE BRAKE CHAMBER

(1) The chamber must be mounted on the side as marked when dis-
mounting.
NOTICE
• See the position mark (R or L) which was applied when dis-
mounting.
• When connecting the clevis with the slack adjuster, lubricate
the clevis pin hole and clevis pin with sufficient chassis
grease.

EN0680202H300020
Cover, clamp, push rod, — — Replace, Visual check

return spring and cham- if necessary.
ber:
Wear and damage
BRAKE CHAMBER (MAKER: WABCO)

EN0680202I200018
Type Diaphragm type
DESCRIPTION
EN0680202C100019
6 5
1 3 2 4
SHTS068020200159
1 Pressure plate 4 Push rod

2 Clamp ring 5 Base
3 Diaphragm 6 Push rod guide
COMPONENT LOCATOR
EN0680202D100018
SHTS068020200160
1 Pressure plate 8 Oil seal

2 Clamp ring 9 Tolerance ring
3 Diaphragm 10 Washer
4 Push rod 11 Guide
5 Base 12 Plate
6 Push rod guide 13 Bushing
7 Snap ring

A 25-30 {260-310, 18.8-22.4}
SPECIAL TOOL
EN0680202K100001
Prior to starting a brake chamber overhaul, it is necessary to have this special tool.
Illustration Part number Tool name Remarks
WEDGE CHAMBER STROKE

09714-1030
TOOL
OVERHAUL
EN0680202H200017
1. REMOVAL OF PRESSURE PLATE

CLAMP RING (1) Make a matching mark to base, clamp ring and pressure plate.
MARK
PRESSURE PLATE BASE

SHTS068020200162
(2) Mark clamp ring not to forget the inserting direction of clamp ring
bolt and remove clamp ring.
NOTICE
When removing clamp ring, do not expand the inserting portion of
clamp ring bolt by more than 80 mm {3.15 in.}.
DO NOT EXPAND MORE THAN 80 mm {3.15 in.}.

SHTS068020200163
(3) Remove pressure plate from base.
SHTS068020200164
2. REMOVAL OF DIAPHRAGM AND PUSH ROD

(1) Remove diaphragm and push rod from base.
NOTICE
• Push rod should be removed out, holding plate and repeating
to push and pull it straightly for a few times.
• When removing, push rod should not be pulled out up or
downward, toward right or left, not hammering from the
square flange side.
SHTS068020200165
3. REMOVAL OF PUSH ROD GUIDE

(1) Take out push rod guide out of the square flange.
NOTICE
When removing push rod guide, do not drop off a washer in it.
SHTS068020200166
4. REMOVAL OF GUIDE
(1) Remove snap ring, plate and oil seal with snap ring pliers.
NOTICE
Make sure not to jump out a snap ring.
(2) Remove guide, using a pipe having outer diameter of about φ37
mm {1.46 in.} and tapping with plastic hammer by making the
square flange of base upside.
SHTS068020200167
5. DISASSEMBLY OF PUSH ROD GUIDE ASSEMBLY

(1) Remove bushing and tolerance ring from push rod guide.
TOLERANCE RING
NOTICE
WASHER • Keep it surely as washer in the push rod guide may be
BUSHING reused when assembling it.
• There is a case that tolerance ring may be in the fitting hole
at the tip of push rod, in case of which, pick it up with screw-
driver, etc.
PUSH ROD GUIDE
SHTS068020200168
1. INSTALLATION OF GUIDE, OIL SEAL AND PLATE

(1) Apply lightly grease (stored in the repair kit) at moving portion of
push rod guide on base.
NOTICE
Never fail to use the grease, stored in the "REPAIR KIT".
SHTS068020200169
(2) Facing the flat side of new guide to diaphragm side, insert it until it
RING TYPE SPRING RETAINER touches down to base by tapping lightly with stick having an outer
diameter of about φ37 mm {1.46 in.} or box-socket.
NOTICE
• Confirm that ring type spring is installed on oil seal.
• Confirm that retainer is in its groove.
PLATE
OIL SEAL
GUIDE
SHTS068020200170
2. INSTALLATION OF PUSH ROD AND DIAPHRAGM

(1) Insert it to base by applying grease (stored in the "REPAIR KIT")
at the rod portion of push rod.
NOTICE
• Never fail to use grease, stored in the "REPAIR KIT".
• When installing push rod, make sure not to damage oil seal.
SHTS068020200171
3. INSTALLATION OF PRESSURE PLATE

(1) Putting pressure plate on base, align those matching marks.
SHTS068020200172
4. INSTALLATION OF CLAMP RING

(1) Matching clamp ring with the fitting mark, catch the both end at
bolt inserting portion of clamp ring with the vice gradually and
make its both end of ring come closer to approx. 15-20 mm {0.60-
0.78 in.} in the distance. After that, removing the vice, tighten tem-
MATCHING MARK
porally them toward inserting direction with the bolt and nut.
(2) Tap all periphery of clamp ring with plastic hammer and tighten
15-20 mm securely the nut. Repeat this 2-3 times for gradual tightening.
{0.60-0.78 in.} CATCH IT IN THE VICE.
SHTS068020200173
5. INSTALLATION OF PUSH ROD GUIDE

(1) Putting new bush into pushing rod guide, insert it deeply to base
SPECIAL TOOL
until push rod guide contacts with the internal hole of push rod
guide by special tool.
SST: Wedge Chamber Stroke Tool (09714-1030)
NOTICE
In this case, do not install tolerance ring and washer.
THE SURFACE TO
CHECK THE DIMENSION
SHTS068020200174
(2) Under the status that the special tool remains pushed against
138 Unit: mm push rod guide, piling washers on the depression for adjustment
at the end-face of special tool and picking out one top washer
102.1
piled up, determine Max. quantity of washers, installable in the
30
internal diameter of base.
NOTICE
37
30
The washer quantity at this time is adjusted one for setting dimen-
sion of push rod guide. Accordingly, keep them securely.
13
THE SURFACE TO CHECK DIMENSION HINT

DEPRESSION FOR WASHER ADJUSTMENT • Do not mind to use the washers picked out in dismounting.
SHTS068020200175 • Target for washer quantity: 0-4 pcs.
• Washer thickness (1 pierce): 0.5 mm {0.02 in.}
(3) Picking out special tool and push rod guide for a while and install-
ing the washer of quantities determined in the above (3) and new
tolerance ring on push rod guide, insert it deeply with special tool
again until push rod guide contacts with the bottom.
NOTICE
• Be careful not to drop off the washers.
• After installing, confirm that, under the status that the spe-
cial tool remains pushed against push rod guide, the end-
face of base side is almost identical with the surface to check
setting dimension of special tool.
(4) Apply grease at the depression portion of push rod guide.
Using grease:
COSMO Heat-resistant grease B No. 2 or equivalent.
6. INSPECTION AFTER INSTALLATION

(1) When adding air of 700-800 kPa {7.2-8.2 kgf/cm2, 102-116 lbf/
SERVICE BRAKE PORT in2.} to service brake port, check that push rod moves smoothly.
(2) Make sure not to leak air from diaphragm.
SHTS068020200176

EN0680202H300021
Pressure plate, clamp, — — Replace, Visual check

push rod, diaphragm and if necessary
base:
Wear and damage
SPRING BRAKE CHAMBER

EN0680202I200019
Spring and piston type brake chamber combined with diaphragm type chamber
Type
with breather tube
DESCRIPTION
EN0680202C100020
SHTS068020200178
1 Retainer 15 Clamp band

2 Release bolt 16 Diaphragm
3 Slotted nut 17 Service brake chamber
4 Spring pin 18 Compression spring
5 Dust cover 19 Push rod
6 Spring brake chamber 20 Clevis
7 Spring 21 Breather tube
8 Piston ring A Spring brake air port
9 O-ring (Emergency and parking) - for releasing air
10 Piston B Service brake air port (Service) - for braking air
11 Retainer ring C Spring brake portion
12 Bushing D Service brake portion
13 Piston follower E Drain hole
14 Bulkhead
SPECIAL TOOL
EN0680202K100002
Prior to starting a spring brake chamber overhaul, it is necessary to have this special tool.
SPRING BRAKE PISTON

09683-1051
RELEASE BOLT
COMPONENT LOCATOR
EN0680202D100019
SHTS068020200180
1 Dust cover 10 Retainer 19 Push rod

2 Spring pin 11 Plain washer 20 Spring retainer
3 Slotted nut 12 Release bolt 21 Compression spring
4 Caution plate 13 Retainer ring 22 Clamp band
5 Spring brake chamber 14 Bushing 23 Spacer
6 Spring 15 Bulkhead 24 Clamp band bolt
7 Piston ring 16 Chamber cover bolt 25 Service brake chamber
8 Piston 17 Piston follower 26 Clevis
9 O-ring 18 Diaphragm 27 Breather tube

A 39.0-44.0 {400-450, 29-32} D 39.0-49.0 {400-500, 29-36}
B 9.8-17.6 {100-180, 7.3-13.0} E 26.5-32.3 {270-330, 20-23}
C 39.0-49.0 {400-500, 29-36}
OVERHAUL
EN0680202H200018
1. DISMOUNTING THE CHAMBER ASSEMBLY

(1) Before dismounting the chamber, turn the release bolt counter-
clockwise to release the spring brake.
(2) Apply a position mark R or L to make clear the side where the
chamber was installed.
SHTS068020200181

NOTICE
Before disassembling, put aligning marks to the clamp band, ser-
vice brake chamber, bulkhead and spring brake chamber.
SHTS068020200182
1. DISASSEMBLING THE SPRING BRAKE CHAMBER

(1) Remove the piston follower and then remove the dust cover,
spring pin and release bolt.
SHTS068020200183
(2) Use a press or special tool to hold the spring in compression then
remove the chamber cover bolt.
SST: Spring Brake Piston Release Bolt (09683-1051)
SHTS068020200184
1. LUBRICATION
(1) When assembling the spring brake chamber, replace the piston
ring, bushing and O-ring with new ones.
(2) Apply grease or oil to each point.
• a Silicone grease: O-ring, Bushing, Piston ring and

Spring brake chamber inner side.
• b Bearing grease: Release bolt
• c Rust preventive oil: Spring
SHTS068020200185
2. ASSEMBLING THE SPRING BRAKE CHAMBER

(1) Attach guide bolts to align the holes.
NOTICE
Align the aligning marks of the spring brake chamber and bulk-
head.
SHTS068020200186
(2) Use a press or special tool to compress the spring then tighten
the chamber cover with the bolts.
SST: Spring Brake Piston Release Bolt (09683-1051)
SHTS068020200187
(3) Screw in the release bolt until its head contacts the piston flange,
then return the release bolt one or two turns, then install the slot-
ted nut and spring pin.
NOTICE
The spring pin should be installed as shown in the figure.
SHTS068020200188
(4) Install the piston follower on the piston.

NOTICE
Apply locking adhesive (LOCTITE 242 or equivalent) to the thread
of the piston follower.
SHTS068020200189
3. ASSEMBLING THE SERVICE BRAKE CHAMBER

(1) Turn the release bolt counterclockwise to compress the spring of
the spring brake chamber.
NOTICE
To make turning easy, apply compressed air to the spring brake
chamber.
SHTS068020200190
(2) When reassembling the chamber, replace the diaphragm with

new one.
NOTICE
Align the aligning marks of the chamber, clamp band and bulk-
head.
(3) Insert the clamp band bolts from opposite side of drain hole and
tighten the bolts evenly with nuts within specified torque.
SHTS068020200191
(4) Turn the release bolt clockwise to release the spring of the spring
brake chamber.
SHTS068020200192
4. INSPECTION FOR AIR LEAKAGE

(1) Apply compressed air of 834 kPa {8.5 kgf/cm2, 121 lbf/in.2} to
both inlet ports marked "E" and "S", and make sure that there is
no air leakage from the joints of the assembly.
SHTS068020200193
5. INSPECTION FOR PISTON MOVEMENT

(1) Apply compressed air of 640-830 kPa {6.5-8.5 kgf/cm2, 93-120
lbf/in.2} to the inlet port with mark E gradually and make sure that
the push rod is completely returned.
Piston stroke: 64 mm {2.52 in.}
for spring brake chamber parts No.
47850 -4290/ -4300/ -4310/ -4320/ -4330/
-4340/ -4350/ -4360
: 56 mm {2.20 in.}
47850 -4370/ -4380/ -4390/ 4400
SHTS068020200194
6. INSTALLING THE CLEVIS

(1) Install the clevis to the push rod and adjust dimension "A" to the
specified value.
A: 261-263 mm {10.28-10.35 in.}
47850-4290/ -4300/ -4330/ -4340
A: 84-86 mm {3.31-3.38 in.}
47850-4310/ -4320/ -4350/ -4360/ -4370/ -4380/ -4390/ -4400
SHTS068020200360
1. INSTALLING THE CHAMBER ASSEMBLY

(1) Before mounting, turn the release bolt counterclockwise to
release the spring brake.
NOTICE
• Note the position mark R or L on the chamber which mark
was applied when dismounting and install it to its former
side.
• When connecting the clevis with slack adjuster, lubricate cle-
vis pin-hole and clevis pin with sufficient chassis grease.
SHTS068020200181
(2) After mounting, the release bolt must be set at the specified
torque.

EN0680202H300022
Inspection item Standard Limit Remedy Inspection procedure

Piston: — — Replace, Visual check
Chamber: — — Replace, Visual check

Spring and compression spring: — — Replace, Visual check

SPRING BRAKE CHAMBER (MAKER: NABCO)

EN0680202I200020
Type Spring and piston type brake chamber combined with diaphragm type chamber
DESCRIPTION
EN0680202C100021
SHTS068020200199
1 Elbow 4 Diaphragm
2 Clamp 5 Push rod assembly
3 Piggyback 6 Base
COMPONENT LOCATOR
EN0680202D100020
11
10
6
7
9
8
3
1
A
2
12
: Apply grease (Dynamax No.2: COSMO OIL CO., LTD product or equivalent).
SHTS068020200200
1 Elbow 7 Pin
2 Clamp 8 Bushing
3 Piggyback 9 Push rod guide
4 Diaphragm 10 Push rod boot
5 Push rod assembly 11 Push rod
6 Spring 12 Base

A 14.7-20.0 {150-204, 11.0-14.8}
OVERHAUL
EN0680202H200019
1. DISASSEMBLY OF THE SPRING BRAKE CHAMBER
! WARNING
Piggyback is very dangerous because there is very strong spring
inside it. Never disassemble the piggyback.
SHTS068020200201
(1) Disconnect the breather tube from the service chamber side
ELBOW BREATHER TUBE elbow.
NOTICE
• Do not disconnect the breather tube from the piggyback side.
• Pulling the center of the elbow obliquely can easily discon-
nect the breather tube from the elbow.
SHTS068020200202
(2) Apply the aligning mark on the clamp, piggyback and base.
(3) Remove the clamp, the piggyback and diaphragm from the
bracket.
(4) Remove the ring and pin, then disassemble the push rod assem-
bly.
SHTS068020200203
1. ASSEMBLY OF THE PUSH ROD ASSEMBLY

(1) Before assembling, apply grease (Dynamax No.2: COSMO OIL.,
LTD. product or equivalent) to each component parts.
SHTS068020200204
2. ASSEMBLY OF THE SPRING BRAKE CHAMBER

(1) Apply grease to inside of the bracket, and install the push rod
assembly, new diaphragm, piggyback and clamp.
NOTICE
• Do not adhere grease to the diaphragm.
• Before assembling, align the aligning marks on the clamp,
piggyback and bracket.
• Spring cylinder (piggyback) portion should be changed every
3 years, even though it does not fail.
• Diaphragm, dust cover and bushing, etc. are the parts to be
SHTS068020200203
changed periodically.
(2) After wiping the breather tube, apply lock agent (LOCTITE 414 or
equivalent) on the tube open end.
13 mm {0.512 in.} (3) Insert the breather tube in the elbow as shown in the figure.
ELBOW or MORE BREATHER TUBE
SHTS068020200205
3. INSPECTION FOR AIR LEAKAGE

lbf/in.2} to both inlet ports marked "E" and "S", and make sure that
there is no air leakage from the joints of the assembly.
SHTS068020200206
4. INSPECTION FOR PISTON MOVEMENT

lbf/in.2} to the inlet port marked "E" gradually and measure the
service chamber stroke.
Piston stroke: 58-61 mm {2.28-2.40 in.}

EN0680202H300023
Bracket, push rod, dia- — — Replace, Visual check

phragm and piggyback: if necessary
Wear and damage
SPRING BRAKE CHAMBER (MAKER: WABCO)

EN0680202I200021
Type Spring and piston type brake chamber combined with diaphragm type chamber
DESCRIPTION
EN0680202C100022
3 7 2 6 5 4
SHTS068020200208
1 Elbow 5 Push rod guide

2 Clamp 6 Push rod
3 Spring brake cylinder 7 Diaphragm
4 Base
COMPONENT LOCATOR
EN0680202D100021
SHTS068020200209
1 Elbow 10 Plate
2 Plug 11 Oil seal
3 Filter 12 Guide
4 Tube 13 Tolerance ring
5 Spring brake cylinder 14 Washer
6 Clamp ring 15 Push rod guide
7 Diaphragm 16 Bushing
8 Push rod 17 Base
9 Snap ring

A 25-30 {260-310, 18.8-22.4}
SPECIAL TOOL
EN0680202K100003
Prior to starting a spring brake chamber overhaul, it is necessary to have this special tool.
WEDGE CHAMBER STROKE

09714-1030
TOOL
OVERHAUL
EN0680202H200020

SPRING CYLINDER SERVICE CHAMBER
! WARNING
• Before disassembling it, check and verify that the release
bolt is extruded.
• Spring cylinder is very dangerous because there is very
strong spring inside it. Never disassembly the spring cylin-
der.
RELEASE BOLT
SHTS068020200210
1. REMOVAL OF BREATHER TUBE

BREATHER TUBE (1) Remove off breather tube from service chamber side.
NOTICE
When carrying or moving to other place it, don't hold breather
ELBOW tube.
(2) Remove the filter in the elbow.
SERVICE
CHAMBER
SHTS068020200211
2. REMOVAL OF SPRING CYLINDER

SPRING CYLINDER (1) Make a matching mark to base, clamp ring and spring cylinder.
MARK
CLAMP RING
BASE
SHTS068020200212
(2) Mark clamp ring not to forget the inserting direction of clamp ring
bolt and remove clamp ring.
NOTICE
When removing clamp ring, do not expand the inserting portion of
clamp ring bolt by more than 80 mm {3.15 in.}.
DO NOT EXPAND MORE THAN 80 mm {3.15 in.}.

SHTS068020200163
(3) Remove spring cylinder from base.
SHTS068020200213
3. REMOVAL OF DIAPHRAGM AND PUSH ROD

(1) Remove diaphragm and push rod from base.
NOTICE
• Push rod should be removed out, holding plate and repeating
to push and pull it straightly for a few times.
• When removing, push rod should not be pulled out up or
downward, toward right or left, not hammering from the
square flange side.
SHTS068020200165
4. REMOVAL OF PUSH ROD GUIDE

(1) Take out push rod guide out of the square flange.
NOTICE
When removing push rod guide, do not drop off a washer in it.
SHTS068020200166
5. REMOVAL OF GUIDE
(1) Remove snap ring, plate and oil seal with snap ring pliers.
! WARNING
Make sure not to jump out a snap ring.
(2) Remove guide, using a pipe having outer diameter of about φ37
mm {1.46 in.} and tapping with plastic hammer by making the
square flange of base upside.
SHTS068020200167
6. DISASSEMBLY OF PUSH ROD GUIDE ASSEMBLY

(1) Remove bushing and tolerance ring from push rod guide.
TOLERANCE RING
NOTICE
WASHER • Keep it surely as washer in the push rod guide may be
BUSHING reused when assembling it.
• There is a case that tolerance ring may be in the fitting hole
at the tip of push rod, in case of which, pick it up with screw-
driver, etc.
PUSH ROD GUIDE
SHTS068020200168
7. REMOVAL OF ELBOW
(1) By inserting a stick of φ6 - φ8 mm {0.24-0.31 in.} or screw-driver
from inserting side of elbow hose, remove the plug from base,
tapping with plastic hammer.
SHTS068020200214
1. MOUNTING OF ELBOW
(1) Install new elbow on base. In that case, set the direction of elbow
tip to be faced toward diaphragm side and put plug in from the tip
of elbow. Inserting the stick used in dismounting it or screw-driver,
insert it so that both tips of plug and elbow may be aligned by tap-
ping lightly with plastic hammer.
NOTICE
• Check and verify if the direction of plug and its installing
condition are shown in the figure.
• When inserting the stick or the screw-driver, make sure not
to damage elbow with their tips.
• After installing plug, make sure that elbow is not taken out by
a force of 60 N {6.1 kgf, 27 lbf}.
ELBOW REVERSE INSTALLED
PLUG
NOT ALIGNED
CORRECT INCORRECT INCORRECT
SHTS068020200215
2. INSTALLATION OF GUIDE, OIL SEAL AND PLATE

(1) Apply lightly grease (stored in the repair kit) at moving portion of
push rod guide on base.
NOTICE
Never fail to use the grease, stored in the "REPAIR KIT".
SHTS068020200216
(2) Facing the flat side of new guide to diaphragm side, insert it until it
RING TYPE SPRING RETAINER touches down to base by tapping lightly with stick having an outer
diameter of about φ37 mm {1.46 in.} or box-socket.
NOTICE
• Confirm that ring type spring is installed on oil seal.
• Confirm that retainer is in its groove.
PLATE
OIL SEAL
GUIDE
SHTS068020200217
3. INSTALLATION OF PUSH ROD AND DIAPHRAGM

(1) Insert it to base by applying grease (stored in the "REPAIR KIT")
at the rod portion of push rod.
NOTICE
• Never fail to use grease, stored in the "REPAIR KIT".
• When installing push rod, make sure not to damage oil seal.
SHTS068020200171
4. INSTALLATION OF SPRING CYLINDER

(1) Putting spring cylinder on base, align those matching marks.
SHTS068020200218
5. INSTALLATION OF CLAMP RING

(1) Matching clamp ring with the fitting mark, catch the both end at
bolt inserting portion of clamp ring with the vice gradually and
make its both end of ring come closer to approx. 15-20 mm {0.60-
0.78 in.} in the distance. After that, removing the vice, tighten tem-
MATCHING MARK
porally them toward inserting direction with the bolt and nut.
(2) Tap all periphery of clamp ring with plastic hammer and tighten
15-20 mm securely the nut. Repeat this 2-3 times for gradual tightening.
{0.60-0.78 in.} CATCH IT IN THE VICE.
SHTS068020200219
6. INSTALLATION OF PUSH ROD GUIDE

LEFT WHEEL (1) Add into the parking brake side port a compressed air of 700-800
SERVICE BRAKE SIDE PORT kPa {7.2-8.2 kgf/cm2, 102-116 lbf/in.2}
BREATHER TUBE
PARKING BRAKE SIDE PORT

SHTS068020200220
RIGHT WHEEL
BREATHER TUBE
SERVICE BRAKE SIDE PORT

SHTS068020200221
(2) Putting new bushing into push rod guide, insert it deeply to base
until push rod guide contacts with the internal hole of push rod
SPECIAL TOOL guide by special tool.
SST: Wedge Chamber Stroke Tool (09714-1030)
NOTICE
In this case, do not install tolerance ring and washer.
THE SURFACE TO
CHECK THE DIMENSION
SHTS068020200222
(3) Under the status that the special tool remains pushed against
138 Unit: mm push rod guide, piling washers on the depression for adjustment
at the end-face of special tool and picking out one top washer
102.1
piled up, determine Max. quantity of washers, installable in the
30
internal diameter of base.
NOTICE
37
30
The washer quantity at this time is adjusted one for setting dimen-
sion of push rod guide. Accordingly, keep them securely.
13
THE SURFACE TO CHECK DIMENSION HINT

DEPRESSION FOR WASHER ADJUSTMENT • Do not mind to use the washers picked out in dismounting.
SHTS068020200175 • Target for washer quantity: 0-4 pcs.
• Washer thickness (1 pierce): 0.5 mm {0.02 in.}
(4) Picking out special tool and push rod guide for a while and install-
ing the washer of quantities determined in the above (3) and new
tolerance ring on push rod guide, insert it deeply with special tool
again until push rod guide contacts with the bottom.
NOTICE
• Be careful not to drop off the washers.
• After installing, confirm that, under the status that the spe-
cial tool remains pushed against push rod guide, the end-
face of base side is almost identical with the surface to check
setting dimension of special tool.
(5) Exhaust the air of parking brake side port.
(6) Apply grease at the depression portion of push rod guide.
Using grease:
COSMO Heat-resistant grease B No. 2 or equivalent.
7. INSTALLATION OF BREATHER TUBE

BREATHER TUBE (1) Insert new filter into the tip of breather tube, after which it should
ELBOW be inserted into elbow. In this case, make sure that the hose
bulge should come to the center between two protuberant por-
tions, located at the end of elbow.
NOTICE
• Pay attention to the direction of filter. (Its small path side
should be tube side)
• When inserting breather tube into elbow, do not apply any
grease or the like.
SHTS068020200223
8. INSPECTION AFTER INSTALLATION

LEFT WHEEL (1) When adding air of 700-800 kPa {7.2-8.2 kgf/cm2, 102-116 lbf/
SERVICE BRAKE SIDE PORT in.2} to service brake side port or parking brake side port, check
that push rod moves smoothly.
BREATHER TUBE
(2) Make sure not to leak air from diaphragm.

SHTS068020200224
RIGHT WHEEL
BREATHER TUBE
SERVICE BRAKE SIDE PORT

SHTS068020200225

EN0680202H300024
Base, push rod, dia- — — Replace, Visual check

phragm and spring brake if necessary
cylinder:
Wear and damage
TRAILER HAND BRAKE CONTROL VALVE

EN0680202I200022
DESCRIPTION
EN0680202C100023
SHTS068020200227
1 Cam 7 Feed valve 13 Steel ball

2 Spring 8 Piston 14 Holder
3 Handle 9 Inner spring A Inlet
4 Shim 10 Cover B Outlet
5 Conical spring 11 Outer spring C Exhaust
6 Valve body 12 Exhaust valve
COMPONENT LOCATOR
EN0680202D100022
SHTS068020200228
1 Valve body 8 Cam 15 Retainer ring

2 O-ring 9 Holder 16 Valve seat
3 Exhaust valve 10 Spring 17 Feed valve
4 Conical spring 11 Cover 18 Piston
5 Spring seat 12 Pin 19 Inner spring
6 Shim 13 Handle 20 Outer spring
7 Steel ball 14 Connector

A 9.8-19.6 {100-200, 8-14} C 2.5-3.9 {25-40, 1.9-2.8}
B 5.4-7.4 {55-75, 4.0-5.4}
OVERHAUL
EN0680202H200021

NOTICE
Before disassembling the hand brake valve, mark the aligning
mark "A" on the holder and valve body.
SHTS068020200229
1. LUBRICATION
(1) When assembling the hand brake valve, use new O-ring and feed
valve.
(2) Apply silicone grease to each sliding surface of the component
parts and O-ring groove.
a. O-ring
b. Contact of steel ball
c. Sliding surface
(3) Align the aligning mark of the holder and valve body.
SHTS068020200230
IMPORTANT POINTS - ADJUSTMENT
1. EXHAUST VALVE FITTING HEIGHT

(1) Measure the exhaust valve fitting height "L" and adjust it.
NOTICE
Adjust this dimension with shims.
L: 38.3-38.7 mm {1.508-1.523 in.}
SHTS068020200231
2. HAND BRAKE VALVE PERFORMANCE CHARACTERISTIC

a. Air pressure at outlet port (kPa {kgf/cm2, lbf/in.2})
b. Handle turning angle (°)
Part No. -1341
(a1) (a2)
a 19.6-68.6 313.6-411.8
{0.2-0.7, 2.8-9.9} {3.2-4.2, 45.5-59.7}
(b1) (b2)
b
7-13 37-43
SHTS068020200232 Part No. -1350/ -1360

(a1) (a2)
a 19.6-68.6 421-559
{0.2-0.7, 2.8-9.9} {4.3-5.7, 61.1-81.0}
(b1) (b2)
b
7-13 42-48
NOTICE
The characteristic shown in both diagrams are for inlet air pres-
sure of 690 kPa {7.0 kgf/cm2, 99.54 lbf/in.2}.
The characteristic can be adjusted by changing the shim thick-
ness of the steel ball and of the outer spring.

EN0680202H300025
Unit: mm {in.}
Sliding surface of — — Replace, Visual check

exhaust valve: if necessary.
Wear and damage
Conical spring: 28.5 {1.12}/ 29.4 N Replace, Measure and visual check
Free length/ 18 {0.71}/ {3.0 kgf, if necessary.
Setting length/ 31.4 N 6.61 lbf}
Crack, rust and damage {3.2 kgf, 7.06 lbf} (Setting load)
Spring, outer spring and Spring 44.1 N Replace, Measure and Visual check
inner spring: 25 {0.98}/ {4.5 kgf, 9.92 lbf} if necessary.
Free length/ 15 {0.59}/ (Setting load)
Setting length/ 50.0 N
Crack, rust and damage
SPRING
Outer spring 29.5 {1.16}
31.3 {1.23}/ (Free length)
30.5 {1.20}/ 122.6 N
152.0 N {12.5 kgf, 27.56 lbf}
{15.5 kgf, 34.17 lbf} (Setting load) OUTER SPRING
Inner spring 27.5 {1.08}

28.5 {1.12}/ (Free length) INNER SPRING
18 {0.71}/ 28.4 N
31.4 N {2.9 kgf, 6.39 lbf}
{3.2 kgf, 7.06 lbf} (Setting length)
Piston and valve seat: — — Replace, Visual check

Cam and steel ball: — — Replace, Visual check

Valve body: — — Replace, Visual check

WHEEL BRAKE (TYPE: S-CAM BRAKE)

EN0680202I200023
Drum brake with internally expanding, leading-trailing shoes

Type
operating by cam shaft and slack adjuster in all wheels.
Brake drum inside With ISO type wheel 406.4 mm {16.0 in.} for both front and rear
diameter With spoke type wheel 440.0 mm {17.3 in.} for both front and rear
Front 152 x 15.5 mm {6.0 x 0.61 in.}

With ISO type wheel
Brake lining Rear 216 x 15.5 mm {8.5 x 0.61 in.}
Width x Thickness Front 127 x 15.5 mm {5.0 x 0.61 in.}
With spoke type wheel
Rear 203 x 15.5 mm {8.0 x 0.61 in.}
DESCRIPTION
EN0680202C100024
FRONT (With ISO type wheel)
SHTS068020200239
1 Brake shoe return spring 10 Spring brake chamber

2 Lubrication fitting 11 Hole plug
3 Slack adjuster 12 Brake shoe
4 Cam shaft 13 Brake lining
5 Anchor pin 14 Wheel sensor (If so equipped)
6 Brake spider 15 Sensor ring (If so equipped)
7 Brake drum 16 Brake chamber
8 Brake drum cover A Front
9 Brake chamber bracket
FRONT (With spoke type wheel)
SHTS068020200240
1 Brake shoe return spring 8 Brake drum cover

2 Lubrication fitting 9 Brake chamber bracket
3 Slack adjuster 10 Spring brake chamber
4 Cam shaft 11 Hole plug
5 Anchor pin 12 Brake shoe
6 Brake spider 13 Brake lining
7 Brake drum A Front
REAR-FRONT (With ISO type wheel)
SHTS068020200241
1 Anchor pin 9 Lubrication fitting

2 Brake spider 10 Brake shoe return spring (Inner)
3 Brake drum 11 Brake shoe return spring (Outer)
4 Brake drum cover 12 Brake lining
5 Cam shaft 13 Brake shoe
6 Slack adjuster 14 Wheel sensor (If so equipped)
7 Spring brake chamber 15 Sensor ring (If so equipped)
8 Brake chamber bracket A Front
REAR-FRONT (With spoke type wheel)
SHTS068020200242
1 Anchor pin 8 Brake chamber bracket

2 Brake spider 9 Lubrication fitting
3 Brake drum 10 Brake shoe return spring (Inner)
4 Brake drum cover 11 Brake shoe return spring (Outer)
7 Spring brake chamber A Front
REAR-REAR (With ISO type wheel)
SHTS068020200243

2 Brake spider 10 Brake shoe return spring (Inner)
3 Brake drum 11 Brake shoe return spring (Outer)
4 Brake drum cover 12 Brake lining
5 Cam shaft 13 Brake shoe
6 Slack adjuster 14 Wheel sensor (If so equipped)
7 Brake chamber 15 Sensor ring (If so equipped)
8 Brake chamber bracket A Front
REAR-REAR (With spoke type wheel)
SHTS068020200244
1 Anchor pin 8 Brake chamber bracket

2 Brake spider 9 Lubrication fitting
3 Brake drum 10 Brake shoe return spring (Inner)
4 Brake drum cover 11 Brake shoe return spring (Outer)
7 Brake chamber A Front
SPECIAL TOOL
EN0680202K100004
Prior to starting a wheel brake overhaul, it is necessary to have these special tools.
09683-1070 SPRING PULL BACK TOOL
09420-1510 ANCHOR PIN PULLER
09684-1010 ANCHOR PIN TOOL

COMPONENT LOCATOR
EN0680202D100023
FRONT (With ISO type wheel)
SHTS068020200248
1 Retainer ring 17 Anchor pin 33 Seal

2 Thrust washer 18 Brake shoe assembly (Trailing) 34 Roller
3 Slack adjuster 19 Brake drum 35 Brake shoe
4 Collar 20 Spring cover 36 Bracket (If so equipped)
5 Oil seal 21 Brake shoe return spring 37 Auto slack adjuster
(If so equipped)
6 Brake chamber bracket 22 Brake shoe assembly (Leading) 38 Pin (If so equipped)
7 Pin 23 Cam shaft 39 Spacer (If so equipped)
8 Washer 24 Collar 40 Plate (If so equipped)
9 Cotter pin 25 O-ring 41 Indicator (If so equipped)
10 Clevis 26 Bushing 42 Lock washer (If so equipped)
11 Spring brake chamber 27 Lubrication fitting 43 Wheel sensor (If so equipped)
12 Hole plug 28 Spacer 44 Sleeve (If so equipped)
13 Brake drum cover 29 Rivet 45 Brake chamber
14 Brake spider 30 Brake lining 46 Roller pin
15 Retainer 31 Spring pin
16 Lock plate 32 Retainer ring

A 119-225 {1,214-2,294, 88-165} D 246-324 {2,509-3,303, 182-238}
B 109-147 {1,112-1,498, 81-108} E 20.5-39.5 {210-402, 16-29}
C 34.5-51.5 {352-525, 26-37}
FRONT (With spoke type wheel)
SHTS068020200249
1 Retainer ring 16 Lock plate 31 Spring pin

2 Thrust washer 17 Anchor pin 32 Retainer ring
3 Slack adjuster 18 Brake shoe assembly (Trailing) 33 Seal
4 Collar 19 Brake drum 34 Roller
5 Oil seal 20 Spring cover 35 Brake shoe
6 Brake chamber bracket 21 Brake shoe return spring 36 Bracket (If so equipped)
7 Pin 22 Brake shoe assembly (Leading) 37 Auto slack adjuster
(If so equipped)
8 Washer 23 Cam shaft 38 Pin (If so equipped)
9 Cotter pin 24 Collar 39 Spacer (If so equipped)
10 Clevis 25 O-ring 40 Plate (If so equipped)
11 Spring brake chamber 26 Bushing 41 Indicator (If so equipped)
12 Hole plug 27 Lubrication fitting 42 Lock washer (If so equipped)
13 Brake drum cover 28 Spacer 43 Roller pin
14 Brake spider 29 Rivet
15 Retainer 30 Brake lining

A 119-225 {1,214-2,294, 88-165} D 246-324 {2,509-3,303, 182-238}
B 109-147 {1,112-1,498, 81-108} E 393-471 {4,008-4,802, 290-347}
C 34.5-51.5 {352-525, 26-37}
REAR-FRONT (With ISO type wheel)
SHTS068020200250
1 Retainer ring 19 Lock plate 37 Holder (If so equipped)

2 Slack adjuster 20 Brake shoe assembly (Trailing) 38 Pin (If so equipped)
3 Thrust washer 21 Brake shoe return spring 39 Brake lining
(Inner)
4 Collar 22 Brake shoe return spring 40 Rivet
(Outer)
5 Oil seal 23 Spring cover 41 Cotter pin
6 Bushing 24 Brake drum 42 Pivot pin
7 Plate (If so equipped) 25 Spring pin 43 Spring pin
8 Auto slack adjuster 26 Brake shoe assembly (Leading) 44 Retainer ring
(If so equipped)
9 Bracket (If so equipped) 27 Cam shaft 45 Seal
10 Brake chamber bracket 28 Collar 46 Roller
11 Cotter pin 29 O-ring 47 Roller pin
12 Washer 30 Bushing 48 Brake shoe
13 Pin 31 Brake spider 49 Bushing
14 Spring brake chamber 32 Spacer 50 Lock washer (If so equipped)
15 Hole plug 33 Connector 51 Indicator (If so equipped)
16 Brake drum cover 34 Lubrication fitting 52 Spacer (If so equipped)
17 Anchor pin 35 Wheel sensor (If so equipped)
18 Retainer 36 Sleeve (If so equipped)

A 109-147 {1,112-1,498, 81-108} D 168-226 {1,714-2,304, 124-166}
B 119-225 {1,214-2,294, 88-165} E 20.5-39.5 {210-402, 16-29}
C 34.5-51.5 {352-525, 26-37}
REAR-FRONT (With spoke type wheel)
SHTS068020200251
1 Retainer ring 18 Retainer 35 Indicator (If so equipped)

2 Slack adjuster 19 Lock plate 36 Spacer (If so equipped)
3 Thrust washer 20 Brake shoe assembly (Trailing) 37 Pin (If so equipped)
4 Collar 21 Brake shoe return spring 38 Plate (If so equipped)
(Inner)
5 Oil seal 22 Brake shoe return spring 39 Brake lining
(Outer)
6 Bushing 23 Spring cover 40 Rivet
7 Lock washer (If so equipped) 24 Brake drum 41 Cotter pin
8 Auto slack adjuster 25 Spring pin 42 Pivot pin
(If so equipped)
9 Bracket (If so equipped) 26 Brake shoe assembly (Leading) 43 Spring pin
10 Brake chamber bracket 27 Cam shaft 44 Retainer ring
11 Cotter pin 28 Collar 45 Seal
12 Washer 29 O-ring 46 Roller
13 Pin 30 Bushing 47 Roller pin
14 Spring brake chamber 31 Brake spider 48 Brake shoe
15 Hole plug 32 Spacer 49 Bushing
16 Brake drum cover 33 Connector

A 109-147 {1,112-1,498, 81-108} D 34.5-51.5 {352-525, 26-37}
B 119-225 {1,241-2,294, 88-165} E 168-226 {1,714-2,304, 124-166}
C 393-471 {4,008-4,802, 290-347}
REAR-REAR (With ISO type wheel)
SHTS068020200252
1 Brake chamber 19 Brake spider 37 Bushing

2 Pin 20 Cam shaft 38 Retainer ring
3 Washer 21 Retainer 39 Roller pin
4 Cotter pin 22 Lock plate 40 Seal
5 Brake chamber bracket 23 Brake shoe assembly (Leading) 41 Roller
6 Retainer ring 24 Brake shoe return spring 42 Lock washer (If so equipped)
(Inner)
7 Slack adjuster 25 Brake shoe return spring 43 Indicator (If so equipped)
(Outer)
8 Thrust washer 26 Brake shoe assembly (Trailing) 44 Spacer (If so equipped)
9 Collar 27 Spring pin 45 Pin (If so equipped)
10 Oil seal 28 Brake drum 46 Auto slack adjuster
(If so equipped)
11 Bushing 29 Brake lining 47 Plate (If so equipped)
12 O-ring 30 Cotter pin 48 Bracket (If so equipped)
13 Spacer 31 Washer 49 Sleeve (If so equipped)
14 Hole plug 32 Clamp 50 Holder (If so equipped)
15 Brake drum cover 33 Brake shoe 51 Wheel sensor (If so equipped)
16 O-ring 34 Pivot pin 52 Cam shaft bracket
17 Lubrication fitting 35 Rivet
18 Anchor pin 36 Spring pin

A 50-68 {510-693, 37-50} D 34.5-51.5 {352-525, 26-37}
B 119-225 {1,214-2,294, 88-165} E 168-226 {1,714-2,304, 124-166}
C 109-147 {1,112-1,498, 81-108} F 20.5-39.5 {210-402, 16-29}
REAR-REAR (With spoke type wheel)
SHTS068020200253
1 Brake chamber 18 Anchor pin 35 Rivet

2 Pin 19 Brake spider 36 Spring pin
3 Washer 20 Cam shaft 37 Bushing
4 Cotter pin 21 Retainer 38 Retainer ring
5 Brake chamber bracket 22 Lock plate 39 Roller pin
6 Retainer ring 23 Brake shoe assembly (Leading) 40 Seal
7 Slack adjuster 24 Brake shoe return spring 41 Roller
(Inner)
8 Thrust washer 25 Brake shoe return spring 42 Lock washer (If so equipped)
(Outer)
9 Collar 26 Brake shoe assembly (Trailing) 43 Indicator (If so equipped)
10 Oil seal 27 Spring pin 44 Spacer (If so equipped)
11 Bushing 28 Brake drum 45 Pin (If so equipped)
12 O-ring 29 Brake lining 46 Auto slack adjuster
(If so equipped)
13 Spacer 30 Cotter pin 47 Plate (If so equipped)
14 Hole plug 31 Washer 48 Bracket (If so equipped)
15 Brake drum cover 32 Clamp 49 Cam shaft bracket
16 O-ring 33 Brake shoe
17 Lubrication fitting 34 Pivot pin

A 50-68 {510-693, 37-50} D 34.5-51.5 {352-525, 26-37}
B 119-225 {1,214-2,294, 88-165} E 168-226 {1,714-2,304, 124-166}
C 109-147 {1,112-1,498, 81-108} F 393-471 {4,008-4,802, 290-347}
OVERHAUL
EN0680202H200022
1. REMOVAL OF TIRE
(1) Refer to chapter for WHEEL & TIRE.
2. REMOVAL OF BRAKE DRUM WITH WHEEL HUB AND WHEEL

HUB BEARINGS.
(1) Refer to chapter FRONT AXLE and REAR AXLE.
3. REMOVAL OF BRAKE SHOE RETURN SPRING

(1) Using the special tool, remove the return spring.
(FRONT WHEEL)
SST: Spring Pull Back Tool (09683-1070)
SHTS068020200254
(2) Using the special tool, remove the outer return spring.
(REAR WHEEL)
SHTS068020200255
(3) Turn the pivot pin and pull out the spring pin then remove the
return spring, inner. (REAR WHEEL)
SHTS068020200256
4. REMOVAL OF ANCHOR PIN

(1) Remove the lock plate and anchor pin retainer.
(2) Using the special tool, remove the pin and the brake shoe assem-
bly.
SST: Anchor pin puller (09420-1510)
SHTS068020200257
5. REMOVAL OF CAM SHAFT AND SLACK ADJUSTER

(1) If the vehicle is equipped with spring brake chamber, before
removing the cam shaft and slack adjuster, release the spring
brake.
NOTICE
Before removing the slack adjuster and cam shaft, apply a mark to
them to make clear the side (Left or Right) where they were
installed.
SHTS068020200258
1. INSPECTION OF SLACK ADJUSTER

(1) Measure the axial play and if the play exceed the limit, inspect the
spline of cam shaft and disassemble the adjuster.
Dimension "A": 150 mm {5.9 in.}
Assembly Standard: 1.5 mm {0.06 in.}
Service Limit: 3.0 mm {0.12 in.}
SHTS068020200259
(2) Measure the circumference play and if the play exceed the limit,
inspect the spline of cam shaft and disassemble the adjuster.
Dimension "A": 150 mm {5.9 in.}
Assembly Standard: 3.0 mm {0.12 in.}
Service Limit: 10.0 mm {0.39 in.}
SHTS068020200260
2. ASSEMBLY OF SLACK ADJUSTER

(1) Install the body cover.
(2) Use new rivets and caulk the rivet ends.
NOTICE
Apply enough chassis grease on the worm gear shaft before
installing the cover.
SHTS068020200261
(3) Tighten the worm gear shaft stopper fully then loose it by 1/12-1/6
turn.
NOTICE
• Replace the O-ring with new one.
• Apply enough chassis grease on the worm gear shaft before
installing the worm gear shaft.
SHTS068020200262
(4) Install the lock ball, spring and plug.

(5) After tighten the plug, caulk it to the body by a punch.
NOTICE
Apply enough chassis grease on the lock ball and spring.
SHTS068020200263
3. REPLACEMENT OF BRAKE LINING

(1) Remove the brake lining from the brake shoe.
a. Drill the rivet caulking section with a drill smaller than the rivet
diameter.
NOTICE
At this time, be careful not to scratch the brake shoe.
SHTS068020200264
b. After drilling, remove the remaining portion of the rivet with a

fine chisel or a riveting machine.
SHTS068020200265
(2) Install the brake lining to the brake shoe.

NOTICE
If a notched lining is used, the brake shoe and brake lining should
be installed as shown in figure.
SHTS068020200266
a. Set the lining on the shoe and insert the rivets into all holes,
then hold them in place with adhesive tape "A".
SHTS068020200267
b. Caulk the rivets lightly in a circular pattern as shown in figure

"B", repeat several times assure proper seating of the lining.
Recommended configuration of punch: shown in "C".
Recommended force of staking the rivet: 2.4 tons.
c. Remove adhesive tape.
SHTS068020200268
4. ASSEMBLY OF BRAKE SHOE

(1) Seals "A" for roller "B" should be replaced with new ones.
(2) Apply adequate amount of heat resistance grease on the roller
and seals.
SHTS068020200269
5. INSTALLATION OF O-RING AND OIL SEAL

(1) When assembling the wheel brake, replace the O-rings and oil
seals with new ones.
NOTICE
• The lip parts of the seal should always be facing outside.
• The seal should be caulked to the bracket (or bracket spider)
with a punch.
SHTS068020200270
6. INSTALLATION OF CAM SHAFT AND SLACK ADJUSTER

(1) Apply adequate amount of chassis grease on the O-ring, oil seal
and bushing before installing the cam shaft.
(2) If the clearance "A" between the retainer ring and slack adjuster
exceed 2.0 mm {0.078 in.}, install the washer between them.
NOTICE
Install the cam shaft and slack adjuster on the correct side (Left or
Right) according to the mark on them which were applied when
disassembling.
SHTS068020200271
NOTICE
• Make sure that the slack adjuster is installed, so that the
arrow on the adjuster points to the direction of the brake
chamber rod stroke as shown in figure.
• When connecting the slack adjuster with the brake chamber
and/or spring brake chamber, lubricate the clevis pin-hole
and the pin with sufficient chassis grease.
SHTS068020200272
(3) If the vehicle is equipped with a spring brake chamber, after con-
necting the slack adjuster with the brake chamber push rod, turn
the spring brake release bolt clockwise and securely tighten (with
mechanical released device).
SHTS068020200273
7. INSTALLATION OF CAM SHAFT AND AUTO SLACK

ADJUSTER (IF SO EQUIPPED)
(1) Apply adequate amount of chassis grease on the O-ring, oil seal
and bushing before installing the cam shaft.
(2) Make sure that the auto slack adjuster is installed so that the
arrow on the adjuster points in the direction of the brake chamber
rod stroke, as shown in figure.
NOTICE
Install the cam shaft and auto slack adjuster on the correct side
(Left or Right) according to the mark which was applied when dis-
assembly.
SHTS068020200274
(3) Make sure that clearance "A" between the spacer and auto slack
adjuster is 0.5-2.0 mm {0.020-0.078 in.}. Install or remove the
washer to maintain the required clearance.
SHTS068020200275
(4) When connection the auto slack adjuster with the brake chamber
and/or spring brake chamber, lubricate the clevis pin-hole and pin
with sufficient chassis grease.
(5) If the clevis pin-hole and auto slack adjuster pin-hole are mis-
aligned, turn the set screw of auto slack adjuster for clockwise.
SHTS068020200276
(6) Rotate by hand, the control arm as for as possible in the direction
of the arrow on the adjuster point.
(7) Make sure that clearance between set bolt and control arm is cor-
rect, and tighten the nut.
SHTS068020200277
(8) If the spring brake chamber is the equipped, after connecting the
auto slack adjuster with the brake chamber push rod, turn the
spring brake release bolt for clockwise fully (with mechanical
released device).
SHTS068020200273
8. INSTALLATION OF BRAKE SHOE ASSEMBLY

(1) Apply adequate amount of heat resistance grease on the bushing
of the brake shoe.
(2) Set the brake shoe assembly in place, then insert the anchor pins.
SHTS068020200278
(3) Using the special tool, set the grooves of the two anchor pin paral-
lel and then insert the retainer in the grooves so that the retainer
hole and brake spider hole are aligned.
SST: Anchor Pin Tool (09684-1010)
SHTS068020200279
(4) Place the lock plate on the retainer so that its hole is aligned with
the lock plate hole, then insert the bolt and tighten it.
SHTS068020200280
9. INSTALLATION OF BRAKE SHOE RETURN SPRING

(1) Hook the inner spring to the clamp and turn the pivot pin to align
the holes, then insert the spring pin. (REAR WHEEL)
NOTICE
Painted part of the spring must be placed in the upper side.
SHTS068020200281
(2) Use the special tool to install the return spring. (FRONT WHEEL,
REAR WHEEL - OUTER SPRING).
NOTICE
The folded part of the spring cover must be placed in the upper
side.
SHTS068020200282
10. INSTALL THE WHEEL SENSOR. (IF SO EQUIPPED)

(1) Push in the clamping bushing until the stopper makes contact with
the wheel sensor holder.
(2) Push the wheel sensor forcefully into the clamping bushing until
you feel that the wheel sensor has contact with the sensor ring.
NOTICE
When inserting the wheel sensor, do not tap on it with a hammer
or attempt to pry it into place using a screwdriver, or the like.
Doing so could damage the wheel sensor.
(FRONT)
SHTS068020200283
(3) Arrange the wire harness.
(REAR)
SHTS068020200284
11. ASSEMBLE THE BRAKE DRUM AND WHEEL HUB.

(FRONT WHEEL)
(1) See the mark located at 1 or 1' on the brake drum as shown in fig-
ure. Install the drum according to NOTICE.
NOTICE
• The drums, number with R or L.
With R: Install in right side.
With L: Install in left side.
• The drums, with no R or L.
New drums: Install in any side.
Reused drums: Install in the side originally installed.
SHTS068020200285
(2) When assembling the brake drum and wheel hub, make sure that
their aligning marks are aligned as close to each other as possi-
ble.
NOTICE
Position of marks are located at 2 as shown in the figure. (Broken
line shows alternative position).
12. MOUNTING OF WHEEL HUB WITH BRAKE DRUM

(1) Refer to chapter FRONT AXLE and REAR AXLE.
NOTICE
1. Be careful not to push back the wheel sensor too far when
mounting the wheel hub and brake drum. Also, make sure
they are straight so that you do not bump the tip of the wheel
sensor.
2. When inserting the outer hub bearing, avoid tapping on it
with a hammer as this will expose the wheel sensor to
bumps. Insert the outer hub bearing carefully using a lock
nut.
(2) Slowly turn the wheel hub and brake drum and confirm that they
move smoothly.
13. MOUNTING OF TIRE

(1) Refer to chapter WHEEL & TIRE.
14. GREASING
(1) After completion of assembly, lubricate the bushings of the brake
spider, cam shaft bracket (REAR WHEEL) and slack adjuster wire
with chassis grease from the lubrication fittings.
15. ADJUSTMENT
(1) Finally, adjust the brake chamber rod stroke as explained in Sec-
tion "ADJUSTMENT".
ADJUSTMENT
EN0680202H300026
1. REMAINING THICKNESS OF THE BRAKE LINING

(1) Check remaining thickness of lining through the inspection hole of
the brake drum cover. If the lining has been worn to the limit
marking or if it is foreseen that the lining will be worn to the limit by
the time the next inspection is made, replace the lining.
SHTS068020200286
2. AIR PRESSURE IN THE AIR TANK

(1) Operate the engine and obtain an air pressure of the 690 kPa {7.0
NOTICE
The specified air pressure in the air tank should be maintained
when making the adjustment.
SHTS068020200287
3. ADJUST THE BRAKE CHAMBER STROKE

(1) Lift the wheel to be adjusted off the ground.
(2) Step on the brake pedal several times while turning the wheel in
the forward direction to make sure that the brake shoes are cor-
rectly positioned.
NOTICE
In the case of spring brake chamber, set the spring brake control
valve to the "OFF" position.
SHTS068020200288
(3) Turn the worm gear shaft of the slack adjuster clockwise fully and
then turn it back at least two notches.
SHTS068020200289
(4) Depress the brake pedal fully and measure the brake chamber
push rod stroke "A".
Assembly standard: 22-30 mm {0.87-1.18 in.}
Repair limit: Brake chamber: 40 mm {1.57 in.}
Spring brake chamber: 45 mm {1.77 in.}
SHTS068020200290
(5) While turning the wheel by hand in the forward direction, step on
the brake pedal several times to make sure that the brake shoes
are correctly positioned.
SHTS068020200288
(6) Make sure that there is no dragging, when turning the wheel by
hand. If there is any dragging, repeat the operation over again
from (2).
NOTICE
In accordance with the same procedure as above, adjust the
stroke for all wheels.
SHTS068020200291

EN0680202H300027
Unit: mm {in.}
Slack adjuster body: — — Replace, Visual check

Wear and damage. if necessary.
Slack adjuster, worm — — Replace, Visual check

gears: if necessary.
Wear and damage.
Slack adjuster, body cover: — — Replace, Visual check

Cam shaft: 39.8 {1.57} 39.5 {1.56) Replace. Measure

Diameter.
Clearance between cam 0.23-0.30 0.6 Replace

shaft and bushing of brake {0.0091-0.0110} {0.024} bushing and/
spider, chamber bracket, or cam shaft.
cam shaft bracket.
Cam shaft collar and — — Replace, Visual check

spacer: if necessary.
Wear and damage.
Brake drum: — — Regrind or Visual check

Cracks and damage. replace,
if necessary.
Brake drum: 406.4 {16.0} Regrind Regrind or Visual check

Inside diameter. 409.4 replace.
{16.12}
Service
410.4
{16.16}
440.0 {17.3} Regrind

443.0
{17.44}
Service
444.0
{17.48}
Brake drum: 0-0.1 0.2 Regrind or Measure

Run out. {0-0.0039} {0.0079} replace.
Brake shoe assembly: — — Replace, Visual check

Cracks and damage. if necessary.
Brake lining: 15.5 {0.61} 5.5 Replace. Visual check

Thickness. {0.217}
Clearance between brake 0.02-0.07 0.25 Replace the Visual check

shoe bushing and anchor {0.0008-0.0027} {0.0098} brake shoe
pin. bushing and/
or anchor
pin.
Brake shoe roller and pin: — — Replace, Visual check

Brake shoe return spring — — Replace, Visual check

and spring cover: if necessary.
Damage, Lacking elastic
strength distortion.
WHEEL BRAKE (TYPE: WEDGE BRAKE)

EN0680202I200024
Drum brake with internally expanding, leading-trailing shoes operating by expander in

Type
all wheels.
Brake drum inside diameter 406.4 mm {16.0 in.} for both front and rear.
Front 152 x 15.5 mm {6.0 x 0.61 in.}
216 x 15.5 mm {8.5 x 0.61 in.} (Models: FR, FS, FY, ZS)
Frontward
Brake lining 203 x 15.5 mm {8.0 x 0.61 in.} (Models: SH, SS)
Width x Thickness Rear 152 x 15.5 mm {6.0 x 0.61 in.} (Model: FR)
Rearward 216 x 15.5 mm {8.5 x 0.61 in.} (Models: FS, FY)
203 x 15.5 mm {8.0 x 0.61 in.} (Model: SS)
DESCRIPTION
EN0680202C100025
FRONT
SHTS068020200305
1 Brake shoe return spring 7 Brake chamber

2 Expander 8 Brake lining
3 Brake shoe 9 Anchor pin retainer
4 Anchor pin 10 Lock plate
5 Brake spider A Front
6 Brake drum
REAR
SHTS068020200306
1 Brake shoe return spring 7 Spring brake chamber

2 Expander 8 Brake lining
3 Brake shoe 9 Anchor pin retainer
4 Anchor pin 10 Lock plate
5 Brake spider A Front
6 Brake drum
SPECIAL TOOL
EN0680202K100005
Prior to starting a wheel brake overhaul, it is necessary to have these special tools.
09420-1510 ANCHOR PIN PULLER

COMPONENT LOCATOR
EN0680202D100024
FRONT
SHTS068020200308
1 Brake chamber 11 Brake shoe return spring

2 O-ring 12 Brake drum cover
3 Hole plug 13 Brake drum
4 Brake spider 14 Rivet
5 Anchor pin 15 Brake lining
6 Anchor pin retainer 16 Retainer spring
7 Lock plate 17 Return spring pin
8 Brake shoe assembly (Leading) 18 Bushing
9 Brake shoe assembly (Trailing) 19 Wheel sensor (If so equipped)
10 Expander 20 Sleeve (If so equipped)

A 35.8-51.4 {366-524, 26.4-37.9} D 20.1-33.9 {205-345, 14.9-24.9}
B 36.2-51.8 {370-528, 26.7-38.1} E 20.5-39.5 {210-402, 15.2-29.1}
C 14.1-23.9 {144-243, 10.4-17.6}
REAR
SHTS068020200309
1 Brake chamber 10 Expander 19 Sensor holder (If so equipped)

2 O-ring 11 Brake shoe return spring 20 Pivot pin
3 Hole plug 12 Brake drum cover 21 Washer
4 Brake spider 13 Brake drum 22 Cotter pin
5 Anchor pin 14 Rivet 23 Return spring hanger
6 Anchor pin retainer 15 Brake lining 24 Wheel sensor (If so equipped)
7 Lock plate 16 Retainer spring 25 Sleeve (If so equipped)
8 Brake shoe assembly (Trailing) 17 Return spring pin
9 Brake shoe assembly (Leading) 18 Bushing

A 35.8-51.4 {366-524, 26.4-37.9} D 20.5-39.5 {210-402, 15.2-29.1}
B 14.1-23.9 {144-243, 10.4-17.6} E 34.5-51.5 {352-525, 25.5-37.9}
C 20.1-33.9 {205-345, 14.9-24.9}
OVERHAUL
EN0680202H200023
1. REMOVAL OF TIRE
(1) Refer to chapter for WHEEL AND TIRE.
2. REMOVAL OF BRAKE DRUM, WHEEL HUB AND WHEEL HUB

BEARINGS
(1) Refer to chapter for FRONT AXLE and for REAR AXLE.
3. COMPRESSION OF SPRING IN SPRING BRAKE CHAMBER

BY RELEASE BOLT
(1) Remove the release bolt, washer and release nut from the cham-
ber.
SHTS068020200310
(2) Remove the end cap. Insert the release bolt to the brake cham-
SPRING BRAKE CHAMBER ber, then turn the release bolt by 1/4.
NOTICE
2
1 • Make sure that the release bolt can not be pulled out.
• When the release bolt is pulled out, insert the release bolt
again and turn it by 1/4 similarly.
RELEASE BOLT
END CAP
SHTS068020200311
(3) Apply compressed air of 640 kPa {6.5 kgf/cm2, 92.5 lbf⋅in.2} to the
spring brake port.
NOTICE
When compressed air cannot be applying, coat grease to the
release bolt.
(4) Install the washer and release nut to the release bolt and pull out
the release bolt by 85 mm {3.34 in.}.
NOTICE
Do not turn the release nut at the strong torque (68.6 N⋅m {700
kgf⋅cm, 50.6 lbf⋅ft} or more).
SHTS068020200312
4. REMOVAL OF BRAKE SHOE RETURN SPRING

(1) Using the special tool, remove the return spring.
(FRONT WHEEL)
SHTS068020200313
(2) Using the special tool, remove the outer return spring.
(REAR WHEEL)
SHTS068020200314
(3) Turn the pivot pin and pull out the return spring pin then remove
the inner return spring (REAR WHEEL).
SHTS068020200315
5. REMOVAL OF ANCHOR PIN

(1) Remove the lock plate and anchor pin retainer.
(2) Using the special tool, remove the pin and brake shoe assembly.
SST: Anchor Pin Puller (09420-1510)
SHTS068020200316
6. REMOVAL OF BRAKE CHAMBER AND EXPANDER

(1) Remove the air hose.
(2) Remove the brake chamber and O-ring from the brake spider.
(3) Using a hexagon wrench, remove the expander from the brake
spider.
SHTS068020200317
1. REPLACEMENT OF BRAKE LINING

(1) Remove the brake lining from the brake shoe.
a. Drill the rivet caulking section with a drill smaller than the rivet
diameter.
NOTICE
At this time, be careful not to scratch the brake shoe.
SHTS068020200264
b. After drilling, remove the remaining portion of the rivet with a

fine chisel or a riveting machine.
SHTS068020200265
(2) Install the brake lining to the brake shoe.

a. Set the lining on the shoe and insert the rivets into all holes,
then hold them in place with adhesive tape "A".
SHTS068020200267
b. Caulk the rivets lightly in a circular pattern as shown in figure

"B", repeat several times assure proper seating of the lining.
Recommended configuration of punch: shown in "C".
Recommended force of staking the rivet: 2.4 tons.
c. Remove adhesive tape.
SHTS068020200268
2. INSTALLATION OF EXPANDER AND BRAKE CHAMBER

(1) Apply grease (Darina Grease: Showa Shell Sekiyu K.K. product
or equivalent) to the expander as shown in the figure.
SHTS068020200318
(2) Using a hexagon wrench, install the expander to the brake spider.
Tightening Torque:
14.1-23.9 N⋅m {144-243 kgf⋅cm, 10.4-17.6 lbf⋅ft}
NOTICE
Pay attention to assembling way.
(3) Install the new O-ring and brake chamber to the brake spider.
SHTS068020200319
3. INSTALLATION OF BRAKE SHOE ASSEMBLY

(1) Apply adequate amount of heat resistance grease on the brake
LOCK WASHER
shoe bushing and anchor pin.
(2) Set the brake shoe assembly in place, then insert the anchor pins.
(3) Insert the anchor pin retainer in the grooves of the two anchor
pins.
(4) Place the lock plate on the anchor pin retainer so that its hole is
aligned with the lock plate hole, then insert the bolt and tighten it.
LOCK PLATE
SHTS068020200320
4. INSTALLATION OF BRAKE SHOE RETURN SPRING

(1) Hook the inner spring to the clamp and turn the pivot pin to align
the holes, then insert the spring hanger.
(REAR WHEEL)
NOTICE
Painted part of the spring must be placed in the upper side.
SHTS068020200315
(2) Use the special tool to install the return spring.

(FRONT WHEEL, REAR WHEEL OUTER SPRING)
NOTICE
The folded part of the spring cover must be placed in the upper
side.
SHTS068020200313
5. INSTALL THE WHEEL SENSOR. (IF SO EQUIPPED)

(1) Push in the clamping bushing until the stopper makes contact with
the wheel sensor holder.
(2) Push the wheel sensor forcefully into the clamping bushing until
you feel that the wheel sensor has contact with the sensor ring.
NOTICE
(FRONT)
SHTS068020200321
(REAR)
SHTS068020200322
6. ASSEMBLE THE BRAKE DRUM AND WHEEL HUB.

(FRONT WHEEL)
(1) See the mark located at 1 or 1' on the brake drum as shown in fig-
ure. Install the drum according to NOTICE.
NOTICE
• The drums, number with R or L.
With R: Install in right side.
With L: Install in left side.
• The drums, with no R or L.
New drums: Install in any side.
Reused drums: Install in the side originally installed.
SHTS068020200285
(2) When assembling the brake drum and wheel hub, make sure that
their aligning marks are aligned as close to each other as possi-
ble.
NOTICE
Position of marks are located at 2 as shown in the figure. (Broken
line shows alternative position).

RELEASE
BOLT 1. REMOVAL OF THE RELEASE BOLT
FITTING
POSITION (1) After mounting, turn the release bolt counterclockwise to release
the spring brake.
NOTICE
Note the position mark R or L on the chamber which mark was
applied when dismounting and install it to its former side.
(2) After mounting, the release bolt must be set at the specified
torque.
Tightening Torque:
SHTS068020200323 13.7-15.7 N⋅m {140-160 kgf⋅cm, 10.2-11.5 lbf⋅in.}
2. MOUNTING OF WHEEL HUB AND BRAKE DRUM

(1) Refer to chapter for FRONT AXLE and for REAR AXLE.
NOTICE
1. Be careful not to push back the wheel sensor too far when
sensor.
2. When inserting the outer hub bearing, avoid tapping on it
bumps. Insert the outer hub bearing carefully using a lock
nut.
move smoothly.
3. MOUNTING OF TIRE
(1) Refer to chapter for WHEEL AND TIRE.
4. ADJUSTMENT
(1) Finally, adjust the brake shoe clearance as explained in Section
WHEEL BRAKE.
ADJUSTMENT
EN0680202H300028
1. REMAINING THICKNESS OF THE BRAKE LINING

(1) Check remaining thickness of lining through the inspection hole of
the brake drum cover. If the lining has been worn to the limit
marking or if it is foreseen that the lining will be worn to the limit by
the time the next inspection is made replace the lining.
SHTS068020200286
2. AIR PRESSURE IN THE AIR TANK

(1) Operate the engine and obtain an air pressure of the 740-840 kPa
{7.5-8.5 kgf/cm2, 107-121 lbf/in.2}
NOTICE
The specified air pressure in the air tank should be maintained
while making the adjustment.
3. INSPECTION OF THE CLEARANCE BETWEEN BRAKE LIN-

ING AND BRAKE DRUM
(1) Step on the brake pedal several times to make sure that the brake
shoes are correctly positioned.
SHTS068020200287
(2) Insert a thickness gauge from the inspection hole to inspect the
clearance between brake lining and brake drum. If the clearance
exceeds standard value, disassemble auto adjuster and perform
maintenance service because auto adjuster possibly may be out
of order.
STANDARD (mm {in.})

FRONT 0.2-1.0 {0.0079-0.0393}
REAR 0.2-1.0 {0.0079-0.0393}
4. ADJUSTMENT OF THE CLEARANCE BETWEEN BRAKE LIN-

ING AND BRAKE DRUM
NOTICE
As this brake has auto adjuster function, it is not necessary to
adjust the clearance between brake lining and brake drum. Adjust
the clearance in accordance with the following method, if the
brake lining is replaced and maintenance service is performed.
(1) Lift the wheel to be adjusted off the ground.
(2) While turning the wheel in the forward direction and step on the
brake pedal several times to make sure that the brake shoes are
correctly positioned.
SHTS068020200288 NOTICE
When adjusting the clearance between brake lining and brake
drum, set spring brake control valve to the OFF position.
(3) Remove the brake drum cover.

(4) Insert the thickness gauge and turn the adjusting screw with
screwdriver so that brake shoe clearance come to the standard
value.
SHTS068020200324
(5) While turning the wheel by hand in the forward direction, step on
the brake pedal several times to make sure that the brake shoes
are correctly positioned.
(6) See to it that there is no dragging, when turning the wheel by
hand. If there is any dragging, repeat the operation over again
from 2.
NOTICE
Using the same procedure as above, adjust the clearance for all
wheels.
SHTS068020200288

EN0680202H300029
Unit: mm {in.}
Brake drum: — — Regrind or Visual check

Cracks and damage replace,
if necessary.
Brake drum: 406.4 {16.0} Regrind Regrind or Measure

Inside diameter 409.4 {16.12} replace.
Service
410.4 {16.16}
Brake drum: 0-0.1 {0-0.0039} 0.2 {0.0079} Regrind or Measure

Runout replace.
Brake shoe assembly: — — Replace, Visual check

Cracks and damage if necessary.
Brake lining: 15.5 {0.610} 5.5 {0.217} Replace. Measure

Thickness
Clearance between brake 0.02-0.07 0.25 {0.0098} Replace the Measure

shoe bushing and anchor {0.0008-0.0027} brake shoe
pin bushing and/
or anchor
pin.
Brake shoe return spring — — Replace, Visual check

and spring cover: if necessary.
Damage, lacking elastic
strength distortion
EXPANDER
DESCRIPTION
EN0680202C100026
1 2
4
3
5
6
11 12 10 9
8
7
13
SHTS068020200331
1 Clip 8 E-retainer
2 Adjusting screw 9 Spring retainer
3 Boot 10 Wedge spring
4 Case 11 Retainer ring
5 Adjusting spring 12 Wedge
6 Drive ring 13 Body
7 Sleeve assembly
SPECIAL TOOL
EN0680202K100006
Prior to starting an expander overhaul, it is necessary to have these special tools.
09657-2330 GUIDE
09685-1020 BOOT SETTING TOOL
09659-1610 ADAPTER
COMPONENT LOCATOR
EN0680202D100025
SHTS068020200336
1 Clip 11 Retainer ring

2 Adjusting screw 12 Wedge assembly
3 Boot 13 Wedge boot
4 Case 14 Wedge cap
5 Adjusting spring 15 Wedge
6 Drive ring 16 Cage
7 Sleeve assembly 17 Roller
8 E-retainer 18 Expander body
9 Spring retainer 19 Locating screw
10 Wedge spring

A 12-18 {120-180, 9-13}
OVERHAUL
EN0680202H200024
1. DISASSEMBLY OF THE EXPANDER

(1) Remove the boot from the body.
(2) Turn the adjusting bolt counterclockwise and remove the boot
with adjusting bolt.
SHTS068020200337
(3) Remove the boot and retainer from the adjusting bolt.
NOTICE
When removing the retainer, take care not to damage it.
(4) Using the screwdriver, remove the cover and then remove the
adjust lock spring and adjust ring.
! WARNING
Pay attention to adjusting lock spring jump-out.
SHTS068020200338
(5) Remove the screw and then remove the sleeve assembly.
NOTICE
Sleeve assembly can not be disassembly.
SHTS068020200339
(6) Install the special tool to the body and tighten the bolt.
(7) Remove the E-ring.
(8) Remove the special tool and then remove the retainer, return
spring and wedge assembly.
! WARNING
Pay attention to return spring jump-out when removing the special
tool.
SHTS068020200340
2. DISASSEMBLY OF THE WEDGE ASSEMBLY

(1) Remove the retainer ring and then remove the boot, retainer and
HOLDER wedge assembly.
(2) Remove the holder and the roller from the wedge.
NOTICE
ROLLER Do not expand open end of holder 26 mm {1.023 in.} or more.
26 mm {1.023 in.}
SHTS068020200341
IMPORTANT POINTS - INSPECTION
1. INSPECTION FOR SLEEVE ASSEMBLY

(1) Fix the sleeve assembly in a vise and install the special tool to the
tappet part.
SST: Adapter (09659-1610)
(2) Install the torque wrench to the special tool to measure the start-
ing torque of the tappet part. Replace the sleeve assembly if the
torque exceeds the standard value.
Standard (N⋅m {kgf⋅cm, lbf⋅ft})

SHTS068020200342
Clockwise (Right turn) 0.6 {6.0, 0.433} or less
Counterclockwise (Left turn) 2.0 {20.0, 1.447} or more
2. INSPECTION FOR RETAINER KEEP TORQUE OF ADJUSTING

BOLT ASSEMBLY
(1) Fix the adjusting bolt fitted retainer in a vise and install the special
tool to clip.
NOTICE
Take care not to damage thread of the adjusting bolt when fixing
adjusting bolt in a vise.
(2) Install the torque wrench to the special tool to measure the start-
ing torque of the retainer. Replace the adjusting bolt if the torque
SHTS068020200343 exceeds the standard value.
Standard: 2.0-5.5 N⋅m {20-55 kgf⋅cm, 1.45-3.97 lbf⋅ft}

HOLDER 1. ASSEMBLY OF THE WEDGE ASSEMBLY
(1) Assemble the roller to the holder and assemble them to the
wedge.
ROLLER NOTICE
Do not expand open end of holder 26 mm {1.023 in.} or more.
(2) Apply grease (Darina Grease 2: Showa Shell Sekiyu K.K. product
or equivalent) to engaged part and contact part of the roller,
holder and wedge.
26 mm {1.023 in.}
(3) Assemble the boot and retainer to the wedge, applying grease to
SHTS068020200341 wedge axle part and boot contact surface.
2. ASSEMBLY OF THE EXPANDER

(1) Fill up grease (Darina Grease 2: Showa Shell Sekiyu K.K. product
or equivalent) to the "A" part of body.
(2) Apply grease (Darina Grease 2: Showa Shell Sekiyu K.K. product
or equivalent) to the following part.
1. Adjust ring seat surface of body
2. Sleeve sliding part of body and tappet part stabbing part
3. Roller contact surface of tappet part and outer periphery
4. Sleeve assembly outer periphery and gear part
5. Sleeve assembly thread part.
SHTS068020200344
(3) Assemble wedge assembly to body, and install the new retainer
ring using the snap ring pliers.
(4) Install the return spring and then install the special tool.
(5) Install the new E-ring and remove the special tool.
SHTS068020200340
(6) After assembling the sleeve assembly to the body, tighten the
screw applied the LOCTITE 202 or ThreeBond 2415 or equiva-
lent.
NOTICE
Align the screw setting hole of body with the groove of tappet
part.
SHTS068020200339
(7) Install the adjust ring and adjust lock spring.

(8) Using the special tool, Install the cover.
NOTICE
• Be sure to install by hand using such as hammer.
• Before driving cover into sleeve assembly, assemble the
cover to the body groove.
• After assembling the cover, turn the cover while pushing it
and make sure that the cover turns smoothly in order to con-
firm the cover fits securely to the groove of the body.
SST: Guide (09657-2330)
SHTS068020200345
(9) Assemble the new boot to the adjusting bolt. Apply grease
(Darina Grease 2: Showa Shell Sekiyu K.K. product or equivalent)
to contact part of boot and adjusting bolt, and thread part of
adjusting bolt.
NOTICE
Be sure to assemble the boot to the groove of the adjusting bolt
securely.
SHTS068020200346
(10) Screw adjusting bolt into the sleeve assembly until the dimension
of end surfaces from adjusting bolt to body is about 20 mm {0.787
in.}.
(11) Pull the adjusting bolt lightly to confirm the sleeve slides.
(12) Using the plastic hammer and special tool, press a new boot in.
SST: Boot setting tool (09685-1020)
(13) Install the retainer to the adjusting bolt.

NOTICE
• Do not cut the boot.
• Pay attention to installing direction of the retainer.
SHTS068020200347

EN0680202H300030
Adjust lock spring: 78.3 N 73.6 N Replace. Measure

Setting load at the specified {8.0 kgf, 17.6 lbf} {7.5 kgf,
setting length at 11.3 {0.45} 16.5 lbf}
Return spring: 147 N 132 N

Setting load at the specified {15 kgf, 33.1 lbf} {13.5 kgf,
setting length at 105.8 {4.17} 29.8 lbf}
Sliding parts of sleeve — — Replace, Visual check

assembly and roller: if necessary.
Wear and damage
Axle dent of sleeve assembly — 0.010 mm Replace, Visual check

and roller: {0.0004 in.} sleeve
Wear and damage or less assembly or
roller.
Sliding parts of wedge and — — Replace, Visual check

roller: if necessary.
Wear and damage
Body inside diameter 38.05 mm 38.10 mm Replace. Measure

{1.498 in.} {1.5 in.}
or less
Sleeve assem- Clockwise 0.6 N⋅m — Replace. Measure

bly turning {6.0 kgf⋅cm,
torque 0.433 lbf⋅ft}
or less
Counter- 2.0 N⋅m

clockwise {20.0 kgf⋅cm,
1.447 lbf⋅ft}
or more
Retainer keep torque of 2.0-5.5 N⋅m — Replace. Measure

adjusting bolt assembly {20-55 kgf⋅cm,
1.45-3.97 lbf⋅ft}
PRESSURE REGULATOR
EN0680202I200025
Spring type, regulates air pressure together with

Type
unloader valve on compressor
Regulating pressure:
860-980 kPa {8.8-10.0 kgf/cm2, 125-142 lbf/in.2}
Regulator No. 44530-1420
DESCRIPTION
EN0680202C100027
SHTS068020200352
1 Dust cover 7 Main spring 13 Valve spring

2 Retainer ring 8 Valve rod 14 Filter
3 Adjusting screw 9 Rod spring 15 Piston
4 Lock nut 10 O-ring A To Unloader valve
5 Spring seat 11 Washer B From Air tank
6 Valve body 12 Valve seat C Exhaust
COMPONENT LOCATOR
EN0680202D100026
SHTS068020200353
1 Dust cover 6 Main spring 11 Valve seat

2 Adjusting screw 7 Valve rod 12 Valve spring
3 Lock nut 8 Washer 13 Filter
4 Retainer ring 9 O-ring 14 Rod spring
5 Spring seat 10 Piston 15 Valve body

A 2.4-3.5 {24-36, 1.8-2.6} B 0.29-0.49 {3-5, 0.22-0.36}
OVERHAUL
EN0680202H200025
1. LUBRICATION
(1) When reassembling the pressure regulator, replace all rubber
parts with new ones.
(2) Apply adequate amount of silicone grease to the O-rings, and
sliding surface S of the piston and valve rod.
SHTS068020200354
1. ADJUSTMENT
(1) Loosen the adjusting screw until the rod spring tension is
released, and start and idle the engine to charge the air for the air
tank.
SHTS068020200355
(2) Stop the engine when the gauge indicates valve opening pres-
sure shown below.
Valve opening pressure Pressure kPa {kgf/cm2, lbf/in.2}

44530-1420 940-980 {9.6-10.0, 136.3-142.1}
SHTS068020200356
(3) Tighten the adjusting screw gradually till the air starts to leak from
the port to the unloader valve side.
(4) Tighten the adjusting screw lock nut.
SHTS068020200357
(5) Watch the pressure gauge needle and see that it stops at the
valve closing pressure shown below.
(6) Connect the pipe and pressure regulator.
Valve closing pressure Pressure kPa {kgf/cm2, lbf/in.2}

44530-1420 820-860 {8.4-8.8, 118.9-124.7}
SHTS068020200358

EN0680202H300031
Valve body 1, piston 2 and — — Replace, Visual check

valve rod 3. Sliding surface: if necessary.
Valve rod 4.
Valve contact surface:
Wear and any other dam-
ages
Main spring 5. rod spring 6. — — Replace,

and valve spring 7: if necessary.
Rust and damage
ABS (ANTI-LOCK BRAKE SYSTEM) (WABCO MAKE) BR03–1
ABS (ANTI-LOCK BRAKE SYSTEM)

BR 03
(WABCO MAKE) BR03-001
ABS ...........................................................BR03-2
OVERVIEW ..................................................... BR03-2
COMPOSITION AND OPERATION................. BR03-3
FUNCTION ...................................................... BR03-6
OVERVIEW AND FUNCTION ......................... BR03-7
FRONT WHEEL BRAKE.........................BR03-12

OVERHAUL ................................................... BR03-13
INSPECTION ................................................. BR03-14
REAR WHEEL BRAKE...........................BR03-16

OVERHAUL ................................................... BR03-17
INSPECTION ................................................. BR03-18
BR03–2 ABS (ANTI-LOCK BRAKE SYSTEM) (WABCO MAKE)
ABS
OVERVIEW
EN06Z0803C100001
ABS is a system that makes effective use of the friction between the
tires and the road surface to maintain vehicle stability while the brakes
are being applied and for stopping the vehicle.
Applying the brakes forcefully on a slippery road surface can cause the
wheels to be locked, due to excessive braking force. This causes the
vehicle to lose a stability because the locked wheels lose resistance in
the lateral direction. More specifically, if the front wheels are locked, it
becomes impossible to steer the vehicle, and if the rear wheels are
locked, the rear of the vehicle may fishtail from side to side.
Also, when wheel-locking occurs, it is not possible to make effective
use of friction between the tires and the road surface. This may cause
the braking distance to be increased.
ABS uses wheel sensors mounted on the axles to constantly monitor
the rotation of the wheels. If any of the wheels is starting to lock up, the
ABS ECU sends signals to the ABS control valve and immediately
adjusts the brake pressure to prevent wheel-locking.
In this way, ABS maintains the stability of the vehicle while stopping by
making effective use of the friction between the tires and the road sur-
face.
(REPRESENTATIVE MODEL)
REAR RELAY VALVE
FRONT RELAY VALVE
ABS CONTROL VALVE
BRAKE VALVE
ABS WARNING LIGHT
BRAKE CHAMBER
BRAKE CHAMBER
AIR TANK
ABS CONTROL VALVE
BRAKE CHAMBER
SENSOR RING
WHEEL SENSOR
ABS ECU : AIR PIPING
: ELECTRICAL WIRING
SHTS06Z080300001
COMPOSITION AND OPERATION

EN06Z0803C100002
The ABS system is comprised of the sensor rings mounted on the

wheels, the ABS ECU, which receives signals from the wheel sensors
that monitor the rotational speed of the wheels and outputs control sig-
nals to maintain the appropriate braking force; ABS control valves,
which increase or decrease the braking force, based on the control sig-
nals; the warning light, which gives an alarm if the system malfunctions;
the piping, wire harnesses, etc., that link together the various units that
compose the system.
Pulse signals transmitted by the sensor rings mounted on the wheel
hubs, rotated together with the wheels, and the wheel sensors mounted
near sensor ring on the axles are sent to the ABS ECU. The ABS ECU
then calculates the wheels' rotational speed, acceleration, deceleration,
and amount of slippage, based on these signals.
If the limit values for the wheel's deceleration, or slippage ratio are
exceeded, the ABS ECU immediately transmits signals to the ABS con-
trol valves to adjust any excess braking force.
This ABS system controls the four wheels, front, rear, right, and left,
independently.
SYSTEM COMPOSITION DIAGRAM
SHTS06Z080300002
1 Brake valve 5 ABS ECU

2 Brake chamber 6 Wheel sensor
3 Relay valve 7 ABS warning light
4 ABS control valve A From air tank
ABS CONTROL FLOWCHART
INPUT SIGNAL ABS ECU OUTPUT SIGNAL
Front left wheel sensor
Front right wheel sensor ABS control valve for

front left wheel
Rear left wheel sensor

ABS control function ABS control valve for
front right wheel
(ABS control valve control

Rear right wheel sensor function)
ABS control valve for
rear left wheel
ABS control valve for

rear right wheel
Sub brake cut relay
Sub brake control

function
Malfunction code
(diagnostic code)
Malfunction diagnostic
function
Switches off ABS to allow

normal brake operation
Fail-safe function
(safety function)
ABS warning light
SHTS06Z080300003
BASIC PRINCIPLE
Based on its relationship with the slip ratio, which is determined from
the wheels' rotational speed and the vehicle's speed, ABS controls the
brake force so that it will be most effective.
When the driver applies the brakes, the rotation of the wheels is con-
trolled and the vehicle speed drops. However, the momentum of the
vehicle attempts to push it forward further even though the rotation of
the wheels is being braked. At this point, slipping will occur if there is a
gap between the wheels' rotational speed and the vehicle's speed. The
slip ratio is a value that indicates the rate of slippage.
Vehicle's speed - Wheel's rotational speed

Slip ratio = 100 %
Vehicle's speed
Slip ratio 0 %: No slipping between the wheels and the

road surface
100 %: Wheels locked
The graph shown at left shows the relationship between the friction
coefficient of the tires and of the road surface and the slip ratio.
In an ABS-equipped vehicle, the brake force is controlled to ensure that
it is within the range where the friction coefficient is high (shaded por-
tion of the graph) without locking the wheels. This ensures efficient
braking performance.
SHTS06Z080300005
OPERATION
The ABS control characteristics line graph at left illustrates how the
vehicle's speed, the wheels' rotational speed, the wheel acceleration/
deceleration, and the air pressure at the ABS control valve outlet
change over time after the brakes are applied.
When the brakes are applied, the vehicle's speed and the wheels' rota-
tional speed drop and at the same time, the wheel acceleration/decel-
eration speed also drops. At point T1, a gap begins to open between
the wheels' rotational speed and the vehicle's speed. Passing on point
T2, the ABS ECU detects that the wheels are beginning to lock and is
lowering the outlet air pressure of the ABS control valve to prevent
wheel locking from occurring.
At point T3, the wheel acceleration/deceleration speed is starting to
return to normal one, and the ABS ECU stops lowering the air pressure
at the ABS control valve outlet and maintains it at a constant level.
At point T5, the wheels' rotational speed and the vehicle's speed are
about the same. The ABS ECU detects that the wheels are no longer
likely to be locked and increases the air pressure at the ABS control
valve outlet.
The above processes is repeated over and over until the vehicle comes
to a complete stop.
SHTS06Z080300006
FUNCTION
EN06Z0803C100003
FAIL-SAFE FUNCTION
This ABS system is equipped with a fail-safe function that causes the
ABS warning light on the instrument panel to light and to restore the
normal (non-ABS) brake system, should an ABS malfunction occur.
Note that the ABS system consists of two independent circuits. Should
a malfunction occur for whatever reason in the electrical circuits, that
system's ABS is switched off and the normal brake system is restored
while ABS control continued for the other system. This configuration is
designed to minimize the effects of any malfunction on ABS function.
SUB BRAKE CONTROL FUNCTION

The ABS system of this vehicle is equipped with a function that controls
the sub brake while ABS is operating.
If the sub brake is applied independently or together with the service
brake on a road surface with very low friction coefficient, the driving
wheels may lock. This ABS system prevents the driven wheels from
locking in such cases by automatically releasing the sub brake, if nec-
essary, during ABS operation.
CLUTCH ACCELERATOR SUB BRAKE

PEDAL PEDAL SWITCH
SWITCH SWITCH SUB BRAKE
CONTROL SIGNAL
+ 24V
+ 24V
SUB BRAKE
ABS ECU
CUT RELAY
SHTS06Z080300007
OVERVIEW AND FUNCTION

EN06Z0803C100004
1. ABS ECU
Based on pulse signals from the wheel sensors, the ABS ECU
mounted in the vehicle calculates and evaluates the slip ratio and the
acceleration/deceleration speed of the wheels. Based on the results, it
sends signals to the various control valves as necessary, causing them
to operate and apply the brakes to maintain the slippage of the wheels
within the optimal range.
During braking, the air pressure applied to the brake chambers is regu-
lated to prevent the wheels from locking. The brakes are applied so as
to maintain the slippage of the wheels within the optimal range.
Regardless of whether the vehicle is stopped or being driven, and
whether or not the brakes are being applied, the circuit consisting of the
wheel sensors, control valves, ABS ECU, and wire harnesses are con-
stantly being checked by the ABS ECU's fail-safe circuit. If some sort of
malfunction occurs, the fail-safe circuit warns the driver by lighting the
ABS warning light. At the same time, the ABS system that is experienc-
ing the malfunction is shut off and braking is restored to normal (non-
ABS) operation.
SHTS06Z080300008
2. ABS CONTROL VALVES

(1) Overview
• The ABS control valves are positioned in the brake air circuit
between the relay valves and brake chambers. Based on signals
from the ABS ECU, they adjust the air pressure sent to the brake
chambers in one of three modes: pressure increase, pressure
reduction, or pressure maintenance.
SHTS06Z080300009
SHTS06Z080300010
(2) Operation
PRESSURE INCREASE a. PRESSURE INCREASE MODE
• When the driver steps on the brake pedal, air from the relay valve
14 5 enters through inlet port (6), pushes open diaphragm (5), passes
through outlet port (9), and flows into the brake chamber. At this
VALVE OPERATING STATUS
10 point, solenoid coil (1) is not energized, so solenoid valve (3) is

6 closed and pilot chamber (14) is open to the atmosphere. Also,
3 9 solenoid coil (2) is also not energized, so solenoid valve (4) is
closed. As a result, air passes through pilot hole (10) and enters
13 pilot chamber (12). It then pushes up diaphragm (11) and closes
exhaust valve (13).
1
2
4 12 11
Solenoid valve for driving inlet

OFF
STATUS
valve 3
Solenoid valve for driving

OFF
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SHTS06Z080300011
b. PRESSURE REDUCTION MODE

PRESSURE REDUCTION • When solenoid coil (1) is energized, solenoid valve (3) opens and
air also flows into pilot chamber (14). It pushes down on dia-
14 5 phragm (5), shutting off chambers (7) and (8). At the same time,
solenoid coil (2) is also energized. This causes solenoid valve (4)
to open and the operating air from pilot chamber (12) passes
7
3 9 through exhaust port (15) and is released into the atmosphere.
8 Consequently, the air from the outlet port (9) side (brake cham-
ber) pushes down on diaphragm (11) and air is released into the
atmosphere. This causes the air pressure of the brake chamber to
1 decrease.
2
12
4 15 11

ON
STATUS
valve 3

ON
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SHTS06Z080300012
c. PRESSURE MAINTENANCE MODE

PRESSURE MAINTENANCE • When solenoid coil (1) is energized, solenoid valve (3) opens and
air flows through chamber (7) and acts on pilot chamber (14). On
14 5 the other hand, since solenoid coil (2) is not energized, solenoid
valve (4) is closed and air flows through pilot hole (10) and acts on
10 pilot chamber (12). This causes diaphragms (5) and (11) to shut
7 off their air passages, and the chamber (8) pressure, that is to say
3 8 the air acting on the brake chamber, is maintained at the pressure
that was current when the switch from the pressure reduction
mode to the pressure maintenance mode took place.
2
11
12
4

ON
STATUS
valve 3

OFF
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SHTS06Z080300013
3. WHEEL SENSORS
These sensors are mounted, facing the sensor rings on each wheel on
the front and rear axles.
The wheel sensors are electromagnet sensors consisting of a perma-
nent magnet core with a coil of wire wrapped around it.
The frequency of the pulse signals generated by magnetic inductance
between the sensors and the sensor rings they face is proportional to
the rotational speed of the wheels. These pulse signals are sent to the
ABS ECU and are used to determine the wheels, rotational status.
SHTS06Z080300014
PERMANENT
MAGNET
CORE
SENSOR RING
CLAMPING
WHEEL HUB BUSHING
SHTS06Z080300015
4. SENSOR RINGS
The sensor rings are press-fitted into the insides of the wheel hubs of
each wheel on the front and rear axles, and they face the wheel sen-
sors described in the preceding section. The sensor rings are made of
a magnetic material, and teeth are cut into the surface which faces the
wheel sensor at regular intervals. Also, when the sensor ring performs
one complete rotation, the sensor generates pulse signals correspond-
ing to the number of teeth.
SHTS06Z080300016
5. CLAMPING BUSHINGS
The wheel sensors are held in place through friction by clamping bush-
ings that are inserted into the mounting brackets. If they are assembled
properly, the clamping bushings serve to eliminate the need to adjust
the clearance between the wheel sensors and sensor rings.
SHTS06Z080300017
6. WHEEL SENSOR HARNESSES

Each wheel sensor wire harness employs a two-conductor twisted wire
cable. Its function is to protect the wheel sensor signals, which are vital
to the proper operation of the ABS system, from electromagnetic inter-
ference. Under no circumstances should any part of the wheel sensor
wire harnesses be cut or connected to any other wire.
SHTS06Z080300018
7. ABS WARNING LIGHT

The status of the ABS system is indicated.
It lights when the starter switch is turned "ON" and automatically goes
off when the system functions correctly.
If malfunction occurs in the ABS system while the vehicle is being
ABS driven, the light goes on to alert the driver.

However, when a defects code is eliminated after repairing it and the
starter switch is turned "ON", the light will remain lit until the vehicle
speed reaches 7-10 km/h {11.2 - 16 mile/h}.
Then, note that even when the warning light is lit, the ABS system,
unaffected by the malfunction, continues to operate. Also, the brake
whose ABS system experiences the malfunction is reverted to normal
SHTS06Z080300019
braking operation without ABS.
When a diagnosis switch is turned "ON", this light will goes on and off,
which indicates defect code.
8. SUB BRAKE CUT RELAY

When this relay is energized during ABS operation, the relay contact
opens, the current to the solenoid valve for the sub brake is shut down,
and the sub brake is released.
FRONT WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100001
FRONT AXLE
SHTS06Z080300020
1 Knuckle 12 Cam shaft

2 Oil seal guide 13 Sensor ring
3 O-ring 14 Wheel hub
4 Oil seal 15 Brake drum
5 Brake drum cover 16 Outer wheel hub bearing
6 Brake spider 17 Washer
7 Wheel sensor 18 Wheel hub bearing lock nut
8 Clamping bushing 19 Lock plate
9 Brake shoe 20 Gasket
10 Inner wheel hub bearing 21 Wheel nut
11 Hub bolt 22 Wheel hub cap
OVERHAUL
EN06Z0803H200001
1. REMOVE THE WHEEL SENSOR.

(1) Remove the brake drum cover.
(2) Pull off the wheel sensor.
NOTICE
Exposing the wheel sensor to strong bumps could cause interior
damage. Never hit the wheel sensor with a hammer or bang it into
other parts.
SHTS06Z080300021
2. REMOVE THE WHEEL HUB, WHEEL HUB BEARINGS AND

BRAKE DRUM.
(1) Refer to chapter FRONT AXLE.
SHTS06Z080300022
SHTS06Z080300023
3. REMOVE THE SENSOR RING.

(1) Use a screwdriver or the like to gradually remove the sensor ring
by tapping evenly on its outer ring.
NOTICE
• When tapping on the sensor ring to remove it, be careful not
to scratch the wheel hub.
• Do not remove the sensor ring unless it is required.
• Do not reuse the removed sensor ring, be sure to replace it
with new one.
SHTS06Z080300024
INSPECTION
EN06Z0803H300001
1. INSPECTION OF ONLY WHEEL SENSOR

(1) With a tester, measure the resistance of wheel sensor.
Standard: 1.0-1.3 kΩ
(2) When the measured value is out of the basic standard, change
the wheel sensor as it might be considered presumably to be
abnormal.
SHTS06Z080300025
2. INSPECTION OF THE SENSOR RING.

(1) Make a visual inspection to check for damage or deformation of
the sensor ring, and also to make sure it is not coming loose from
the wheel hub.
(2) If any damage or malformation is discovered, replace the sensor
ring.
(3) If the sensor ring is coming loose from the wheel hub, use a dolly
block and press in it with a press again.
SHTS06Z080300026
3. INSPECTION OF THE CLAMPING BUSHING.

(1) Make sure that wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed
in with a lightly force.
SHTS06Z080300027
4. MOUNTING THE SENSOR RING

(1) Place the sensor ring on the wheel hub and use the dolly block
and a press to evenly pressure mount it.
NOTICE
Warming up the sensor ring with hot water will make it easier to
pressure mount it. Do not use a gas burner or the like to warm the
sensor ring. Doing so could cause malformation of the sensor
ring.
(2) After pressure mounting it, check for flutter of the sensor ring in
the axle direction.
Assembly standard: 0.2 mm {0.0078 in.} or less
SHTS06Z080300028
5. MOUNTING THE WHEEL HUB AND BRAKE DRUM

(1) Refer to chapter FRONT AXLE.
NOTICE
If the wheel sensors are mounted, hammering on the wheel hubs
and the like on that axle could cause internal damage to the wheel
sensors. Either mount the tire and then tap on the tire or tap on
the wheel hub after removing the right and left wheel sensors.
6. MOUNTING THE WHEEL SENSOR

(1) Apply a light coating of chassis grease to the inner surface of the
knuckle wheel sensor boss. Then push in the clamping bushing
until the stopper makes contact with the knuckle's wheel sensor
holder.
SHTS06Z080300029
(2) Apply a light coating of chassis grease to the hub of the wheel
sensor. Then push it forcefully into the clamping bushing until you
feel that the wheel sensor has made contact with the sensor ring.
NOTICE
or attempt to pry it into place with a screwdriver, or the like. Doing
so could damage the wheel sensor.
move smoothly.
(4) Mount the drum dust cover.
SHTS06Z080300030
7. INSPECT THE WHEEL SENSOR

SENSOR RING
(2) With a circuit tester, confirm the output voltage of the wheel sen-
sor (By rotating the tire by one time for 5 seconds)
Standard: 150-1,999 mV
(Range of Alternating Current Voltage)
(3) In case of out of the standard range at (2), push the wheel sensor
PUSH
softly by fingers until the sensor contacts with the sensor ring,
then inspect again from (1).
WHEEL SENSOR
SHTS06Z080300031
REAR WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100002
REAR AXLE
SHTS06Z080300032
1 Wheel sensor 12 Hub bolt

2 Clamping bushing 13 Inner wheel hub bearing
3 Wheel sensor holder 14 Sensor ring
4 Axle shaft 15 Wheel hub
5 Oil seal collar 16 Brake drum
6 Axle housing assembly 17 Wheel nut
7 Oil seal 18 Outer wheel hub bearing
8 Brake drum cover 19 Washer
9 Brake spider 20 Lock nut
10 Cam shaft 21 Lock plate
11 Brake shoe
OVERHAUL
EN06Z0803H200002
1. REMOVE THE WHEEL HUB, WHEEL HUB BEARINGS AND

BRAKE DRUM.
(1) Refer to chapter REAR AXLE.
SHTS06Z080300033
SHTS06Z080300034
2. REMOVING THE SENSOR RING

(1) Use a screwdriver or the like to gradually remove the sensor ring
by tapping evenly on its outer ring.
NOTICE
• When tapping on the sensor ring to remove it, be careful not
to scratch the wheel hub.
• Do not remove the sensor ring unless it is required.
• Do not reuse the removed sensor ring, be sure to replace it
with new one.
SHTS06Z080300035
3. REMOVING THE WHEEL SENSOR

NOTICE
• Exposing the wheel sensor to strong bumps could cause
interior damage. Never hit the wheel sensor with a hammer
or bang it into other parts.
• Pull out the wheel sensor from the sensor holder by hand.
SHTS06Z080300036
4. REMOVING THE CLAMPING BUSHING.

(1) Remove the clamping bushing out of the wheel sensor holder.
SHTS06Z080300037
INSPECTION
EN06Z0803H300002
1. INSPECTION OF ONLY WHEEL SENSOR

(1) With a tester, measure the resistance of wheel sensor.
Standard: 1.0-1.3 kΩ
(2) When the measured value is out of the basic standard, change
the wheel sensor as it might be considered presumably to be
abnormal.
SHTS06Z080300038
2. INSPECTION OF THE SENSOR RING.

(1) Make a visual inspection to check for damage or deformation of
the sensor ring, and also to make sure it is not coming loose from
the wheel hub.
(2) If any damage or malformation is discovered, replace the sensor
ring.
(3) If the sensor ring is coming loose from the wheel hub, use a dolly
block and a press to pressure mount it again.
SHTS06Z080300039
3. INSPECTION OF THE CLAMPING BUSHING.

(1) Make sure that the wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed
in with a lightly force.
SHTS06Z080300040
4. MOUNTING THE WHEEL SENSOR

(1) Apply a lightly coating of chassis grease to the inner surface of
the wheel sensor holder. Then push in the clamping bushing until
the stopper makes contact with the wheel sensor holder.
SHTS06Z080300041
(2) Push the wheel sensor fully in the wheel sensor holder with hands
until the wheel sensor makes contact with the clamping bushing.
NOTICE
SHTS06Z080300042
5. MOUNTING THE SENSOR RING

(1) Place the sensor ring on the wheel hub and use the dolly block
and a press to evenly pressure mount it.
NOTICE
Warming up the sensor ring with hot water will make it easier to
pressure mount it. Do not use a gas burner or the like to warm the
sensor ring. Doing so could cause malformation of the sensor
ring.
(2) After pressure mounting it, check for flutter of the sensor ring in
the axle direction.
Assembly standard: 0.2 mm {0.0078 in.} or less
SHTS06Z080300043
6. MOUNTING THE WHEEL HUB AND BRAKE DRUM

(1) Refer to chapter REAR AXLE.
NOTICE
• Be careful not to push back the wheel sensor too far when
sensor.
• When inserting the outer hub bearing, avoid tapping on it
bumps. Insert the outer hub bearing carefully with a lock nut.
7. INSPECT THE WHEEL SENSOR.

(2) With a circuit tester, confirm the output voltage of the wheel sen-
PUSH sor (By rotating the tire by one time for 5 seconds)
Standard: 150-1,999 mV
(Range of Alternating Current Voltage)
(3) In case of out of the standard range at (2), remove the dust cover
located on the back plate unit, and the wheel sensor softly by
WHEEL SENSOR using round end bar until the sensor contacts with the sensor ring.
Then inspect again from (1).
SENSOR RING
NOTICE
SHTS06Z080300044
Do not tap by hammer or turn when pushing the wheel sensor.
This may damage the wheel sensor.
(4) Mount the axle shaft to the wheel hub and tighten the bolt on the
axle shaft.
Refer to chapter REAR AXLE.
8. ABS WIRE HARNESSES

(1) Front axle ABS wire harnesses
• The front axle chassis harnesses, particularly the ones that pass
over the front axle and extend as far as the wheel sensors, must
absorb the movement when the wheels are turned and when the
springs move. It is therefore necessary to always maintain an opti-
mal spacing between the clips.
In addition, if there is a large amount of variation in the spacing
between the clips, the wheel sensor harnesses can come into
contact with tire chains and sustain damage.
The wire harness for the front axle wheel sensor extends directly
from the clip on top of the king pin cover to the frame. In particular,
make sure that the distance between the clip on top of the king pin
cover and the clip on the frame side is as indicated in the diagram
below. There are markings on the wheel sensors in cases where
the wheel sensor harness clips are in locations where the relative
movement is particularly great. These places should be inspected
regularly to ensure that the clip positions are still meeting with the
same marking.
SHTS06Z080300045
(2) Rear axle chassis harness
• The rear axle chassis harnesses is arranged so that the left and
right wheel sensor harnesses are near each other. Therefore,
special care should be taken not to make incorrect connections if
the harnesses have been removed for inspection or repairs.
If incorrect connections are made, it will interfere with the function-
ing of the ABS system. For this reason, caution plates indicating
"LEFT" and "RIGHT" are affixed to the harnesses. Be sure to
check when connecting the harnesses. (The left harness is on the
left side of the vehicle when viewed from the behind and facing
toward the front, and the right harness is on the right side of the
vehicle.)
The wheel sensor harnesses are arranged along the top of the
rear axle housing. Therefore, make sure to allow sufficient har-
ness length between the chassis and the rear axle so that the har-
nesses can absorb the up-and-down motion of the rear axle.
ES START (EASY & SMOOTH START SYSTEM) BR04–1
ES START (EASY & SMOOTH START SYSTEM)

BR04
BR04-001
ES START .................................................BR04-2
DESCRIPTION ................................................ BR04-2
DIAGRAM ........................................................ BR04-4
SPECIAL TOOL ............................................... BR04-5
INITIAL SETTING OF ES START ................... BR04-6
ES START CONTROL VALVE ................BR04-12

OVERHAUL ................................................... BR04-13
BR04–2 ES START (EASY & SMOOTH START SYSTEM)
ES START
DESCRIPTION
EN06Z0804C100001
ES START CONTROL VALVE
SHTS06Z080400001
CLUTCH FLUID PRESSURE SWITCH
SHTS06Z080400002
CLUTCH PEDAL STROKE SENSOR
SHTS06Z080400003
STOP LIGHT SWITCH
SHTS06Z080400004
DIAGRAM
EN06Z0804J100001
SYSTEM DIAGRAM
ES MAIN SWITCH
RELEASE TIMING
SWITCH
ES START CONTROL
BRAKE AIR VALVE
PRESSURE SWITCH
ES START
CONTROLLER
NEUTRAL SWITCH
COURTESY SWITCH
SPRING BRAKE ES START

SWITCH SLOPE INDICATOR LIGHT
SENSOR
BUZZER CANCEL
SWITCH
BUZZER
BACK-UP LIGHT
SWITCH
CLUTCH FLUID
PRESSURE SWITCH
CLUTCH PEDAL
STROKE SENSOR
SPEED SENSOR
DIAGNOSIS MONITOR
SHTS06Z080400005
PIPING DIAGRAM
SHTS06Z080400006
SPECIAL TOOL
EN06Z0804K100001
FOR DIAGNOSING AND

09630-1370 DIAGNOSIS MONITOR
SETUP OF ES START
SPECIAL WIRING HARNESS

FOR CONNECTING
09630-2300 FOR INTENSIVE DIAGNOSIS
DIAGNOSIS MONITOR
CONNECTOR
INITIAL SETTING OF ES START

EN06Z0804H300001
INITIAL SETTING
NOTICE
When replacing a controller of "ES Start", be sure to execute this
OFF
initial setting.
1. CHECK "ON" OF POWER SUPPLY WHEN SWITCHING THE

STARTER KEY "ON".
(1) Turn "OFF" ES main switch while turning "ON" the starter key.
SHTS06Z080400009
(2) Check the operation of "ES start" indicator in the meter and also
the buzzer.
Standard:
After the indicator light is lit for a second, the buzzer to
switch off the light beeps one time.
NOTICE
Unless the buzzer beeps, the indicator is not lit. When it does not
turn off even after one second, inspect the electrical circuit.
SHTS06Z080400010
(3) Turn "ON" the ES main switch.
ON
SHTS06Z080400011
2. CHECK OF INSTALLING CONDITION OF CLUTCH STROKE

SENSOR.
NOTICE
OFF • When replacing clutch stroke sensor, execute this inspection
without fail.
• Execute this under the condition that clutch adjustment (for
normal clearance of clutch pedal) completed.
(1) Turn "ON" starter key and turn "OFF" the ES main switch.
SHTS06Z080400012
(2) White color connector, one of two intensive diagnosis connectors,

FIXING DAMMY CONNECTOR located at lower part of right side of the instrument panel, should
be connected to the specific harness and the diagnosis monitor
be connected to the connector with a tag of "ES start".
SST:
Dedicated Harness (09630-2300)
Diagnosis Monitor (09630-1370)
WHITE CONNECTOR
BLACK CONNECTOR
SHTS06Z080400013
NOTICE
As intensive diagnosis connector is normally connected to the
fixed dummy connector, pull it out from the dummy connector to
use. Also, couple it with the fixed dummy connector while not
using it.
SHTS06Z080400014
(3) Turn on "FAST" release timing switch three times within 5 sec-
onds.
SHTS06Z080400015
(4) Checking function of sensor installation condition starts and check

that indicator is flashing as shown in the figure.
NOTICE
When indicator not flashing, inspect the electrical circuit.
(5) Check sensor installation condition with the buzzer beeping when
clutch pedal is free.
Standard: The buzzer beeps continuously.
NOTICE
INDICATOR
OPERATING When not beeping the buzzer, inspect clutch stroke sensor and its
PATTERN relating circuit.
SHTS06Z080400016
(6) After turning again release timing switch on "FAST", remove diag-
nosis monitor.
SHTS06Z080400017
3. INITIAL SETTING FOR RELEASING POSITION

NOTICE
Execute initial setting of releasing position without fail when
replacing clutch.
(1) Confirm the following condition of the vehicle.
• Starter key: ON
• ES main switch: OFF
• Clutch pedal: Free position
• Parking brake: Operating
(2) Starting engine, check that idling revolution is normal.
(3) White color connector, one of two centralized diagnosis connec-
FIXING DAMMY CONNECTOR tors located at lower part of right side of the instrument panel,
should be connected to the dedicated harness and diagnosis
monitor be connected to the connector with a tag of "ES start".
SST:
WHITE CONNECTOR
BLACK CONNECTOR
SHTS06Z080400018
NOTICE
As centralized diagnosis connector is normally connected to the
using it.
SHTS06Z080400019
(4) Put release timing switch on "FAST" for more than 3 seconds.
(5) Initial setting function of release position starts. Check that buzzer
and indicator are working as it follows.
• Buzzer: 1 long beeping continuously.
• Indicator: Flashes in synchronization with the buzzer beeping.
(6) When buzzer does not beep, check the following points:
• Relating circuit with parking brake (buzzer cancel switch)
• Relating circuit with "ES start" switch.
• Controller
(7) Depress the clutch pedal and shift the gear to 3rd speed.
SHTS06Z080400020 (8) Release slowly the pedal for clutch engagement.
(9) When tachometer needle descends and then comes back again,
put again release timing switch on "FAST". At this moment, con-
troller memorizes signal of clutch stroke sensor.
(10) Once controller memory completed, buzzer stops after it beeps
one time. Indicator light goes off.
(11) Remove diagnosis monitor from the coupler.
SHTS06Z080400021
4. INITIAL SETTING OF SLOPE SENSOR AT "0" POINT.

NOTICE
When any style of body mounted on the chassis of vehicle and the
vehicle level changed, implement this initial setting without fail.
(1) Confirm that the following condition of the vehicle.
• ES main switch: OFF
• Road surface condition: Flat (±1 deg)
• Parking brake: Operating
(2) White color connector, one of two intensive diagnosis connectors,
FIXING DAMMY CONNECTOR located at lower part of right side of the instrument panel, should
be connected to the dedicated harness and the diagnosis monitor
be connected to the connector with a tag of "ES Start".
SST:
WHITE CONNECTOR
BLACK CONNECTOR
SHTS06Z080400013
NOTICE
As intensive diagnosis connector is normally connected to the
using it.
SHTS06Z080400014
(3) Put release timing switch on "SLOW" for more than 3 seconds.
(4) Initial setting function of slope sensor starts. Check that buzzer
and indicator are working as it follows:
• Buzzer: 2 short beeping continuously.
• Indicator: Flashes in synchronization with the buzzer beeping.
(5) When not beeping nor flashing as mentioned above, check the fol-
lowing points:
• Relating circuit with parking brake (buzzer cancel switch)
• Relating circuit with "ES start" switch
• Controller
SHTS06Z080400022
(6) Put again release timing switch on "SLOW". At this moment, con-
troller memorizes signal of slope sensor.
(7) Once controller memory completed, buzzer stops after it beeps
one time.
(8) Indicator light goes off.
SHTS06Z080400023
CHECKING PROCEDURE OF OPERATION
1. PREPARATION
(1) Confirm that the vehicle is under the following condition:
• The road surface is not at down hill.
• Starter key: ON
• Parking brake released
• The both doors of the cab at driver's and the other side are
closed.
NOTICE
• Operation check can be done, even though the engine is not
in motion.
• In case of operation checking while the engine is in motion,
you will need to perform a starting operation by paying much
attention not to start out the vehicle suddenly.
2. OPERATION OF "ES START"

(1) Free clutch pedal by shifting the gear to the neutral position.
(2) Turn "ON" ES main switch.
(3) Once continuing to depress the brake pedal, "ES start" will start to
work within about one second.
ON (4) Confirm the operation of "ES start" with the following points.
• Buzzer beeps one time.
• Indicator light is lit.
• The braking force will be retained, even though setting your leg
free from the brake pedal.
Braking axle when operating "ES Start"

SHTS06Z080400024 Axle position
Model
Front-front Front-rear Rear-front Rear-rear
FS X —
FY X X
: Operating, X: Not operating, —: Not available

(5) When "ES start" does not work, check the following points:
a. Indicator light is not lit.
• Inclination of road (when at down hill, shift the gear to "R", it does
not work unless the clutch pedal is depressed.)
• Neutral switch and its relating circuit
• Stop light switch and its relating circuit
b. Indicator flashes and the buzzer beeps.
• Check it through diagnosis function.
c. Indicator light is lit. But the buzzer beeps.
• Courtesy switch and its relating circuit.
d. Braking force is not retained.
• ES start valve and brake air circuit
• Controller
3. RELEASE OF "ES START"

(1) Depressing deep and surely the clutch pedal, shift the gear for
moving forward.
(2) Release the pedal for clutch engagement.
(3) "ES start" will be released at the partial clutch engagement.
Check the following conditions:
• Indicator light is not lit.
• Release of braking force.
(4) When "ES start" not released, check the following points:
a. Indicator light does not turn out.
• It will not be released by mis-handling (when the clutch pedal is
not deeply depressed at shifting the gear)
• Neutral switch and its relating circuit
• Clutch pedal stroke sensor and its relating circuit.
b. Braking force is not retained.
• "ES start" valve and the brake air circuit.
• Controller
ES START CONTROL VALVE

COMPONENT LOCATOR
EN06Z0804D100001
SHTS06Z080400025
1 Hose 11 O-ring 21 O-ring

2 Bolt 12 Piston 22 Valve seat
3 Bracket 13 O-ring 23 O-ring
4 Cover 14 Screw 24 Valve
5 O-ring 15 Solenoid assembly 25 Spring
6 Spring 16 Spring 26 Filter
7 Inlet valve 17 Plunger 27 Body
8 Straight pin 18 Rod 28 Cover
9 Spring seat 19 Coil cover 29 O-ring
10 Spring 20 O-ring

A 4.0-6.0 {40-60, 2.9-4.3} B 1.3-1.7 {13-17, 0.49-1.22}
OVERHAUL
EN06Z0804H200001

NOTICE
• When dismounting and storing parts, place a cap on all ports
so not dirt or dust enters.
• Be careful so water, dirt, or dust does not enter inside the
harness connector to prevent solenoid short circuits or
faulty connections.

NOTICE
Apply an adequate amount of grease to each O-ring before assem-
bly.
1. ASSEMBLING ES START CONTROL VALVE

(1) Insert the spring in the valve and assemble it in the body.
SHTS06Z080400026
NOTICE
Assemble the valve and the spring as shown in the figure.
SHTS06Z080400027
(2) Align and attach the O-ring to the groove of the inside valve seat
VALVE SEAT HOLE correctly and install it in the body.
NOTICE
Align the valve seat holes and body holes to perform the assem-
bly.
BODY HOLE
SHTS06Z080400028
(3) Assemble the O-rings (2 units) in the piston and lubricate the
inside diameter of the piston with grease.
NOTICE
Verify the diameter of the O-ring (small one) because there are
multiple settings and then assemble the unit.
Dimension "D" and "d"= 22 mm {0.87 in.}
SHTS06Z080400029
(4) Assemble the spring, piston and inlet valve. Press in the inlet
valve and install the straight pin.
NOTICE
Align the inlet valve pin hole and piston pin hole and assemble the
parts. After the assembly is completed, do not rotate the inlet
valve to align the pin holes.
SHTS06Z080400030
(5) Position the spring seat collar so it faces the rear side and install
the unit.
(6) Apply grease to the outer surface of the O-ring installed in the pis-
ton.
SHTS06Z080400031
(7) Apply grease to the inner surface of the body.

(8) Insert the piston inlet valve assembly in the body.
NOTICE
Do not turn the piston when inserting it.
SHTS06Z080400032

EN06Z0804H300002
NOTICE
Isopropyl alcohol should only be used to wash the ES start con-
trol valve components.
Valve body inside, piston, — — Replace, Visual check

valve, valve seat, spring if necessary.
and inlet valve:
Wear and damage
O-ring: — — Replace, Visual check

Crack and damage if necessary.
STEERING EQUIPMENT SR01–1
STEERING EQUIPMENT
SR01
SR01-001
STEERING SYSTEM................................. SR01-2

TROUBLESHOOTING..................................... SR01-2
SR01–2 STEERING EQUIPMENT
STEERING SYSTEM
TROUBLESHOOTING
EN07Z0701F300001

Hard steering or poor return of Bent steering shaft, sliding shaft or Replace parts.
steering wheel to center column
Universal joint oscillates or catches. Replace universal joint in the assem-
bly.
Column bearing does not revolve or Replace parts.
catch.
Lack of lubrication in steering linkage. Lubricate.
Wheel alignment is incorrect. Refer to chapter FRONT AXLE.
Power steering system is faulty. Refer to chapter POWER STEERING.
Tire air pressure is too low. Adjust properly.
Steering wheel shimmy Steering system linkage is loose. Tighten properly.
Too much wear or play in steering link- Replace parts.
age (spline and ball joints).
Other front axle problems. Refer to chapter FRONT AXLE.
Power steering gear badly adjusted. Refer to chapter POWER STEERING.
The wheels are out of balance. Balance the wheels.
Wheel wobbles. Replace wheel.
Tire air pressure is not uniform or suffi- Adjust tire pressure.
cient.
Distorted disc wheel. Replace parts.
Abnormal noises Lack of lubrication in steering linkage. Lubricate.
Power steering system is faulty. Refer to chapter POWER STEERING.
STEERING UNIT SR02–1
STEERING UNIT
SR02
SR02-001
STEERING LINKAGE ............................... SR02-2

DESCRIPTION ................................................ SR02-2
COMPONENT LOCATOR ............................... SR02-4
SPECIAL TOOL ............................................... SR02-8
OVERHAUL ..................................................... SR02-9
INSPECTION AND REPAIR .......................... SR02-17
SR02–2 STEERING UNIT
STEERING LINKAGE
DESCRIPTION
EN07Z0702C100001
FOR RIGHT-HAND DRIVE MODEL
SHTS07Z070200001
1 Steering wheel 6 Pitman arm

2 Horn button 7 Drag link
3 Steering column assembly 8 Relay rod
4 Dust cover 9 Idler arm
5 Steering gear unit 10 Power steering booster
FOR LEFT-HAND DRIVE MODEL
SHTS07Z070200002
1 Steering wheel 6 Pitman arm

2 Horn button 7 Drag link
3 Steering column assembly 8 Relay rod
4 Dust cover 9 Idler arm
5 Steering gear unit 10 Power steering booster
COMPONENT LOCATOR
EN07Z0702D100001
FOR RIGHT-HAND DRIVE MODEL
SHTS07Z070200003
1 Steering wheel 17 Drag link

2 Horn button 18 Lubrication fitting
3 Column cover 19 Cotter pin
4 Column boot 20 Steering gear bracket
5 Column tube 21 Ball joint socket
6 Spiral cable 22 Relay rod
7 Combination switch 23 Power steering booster assembly
8 Steering column assembly 24 Anchor bracket
9 Dust cover 25 Retainer
10 Dust seal 26 Fixture plate
11 Sliding yoke 27 Idler arm
12 Steering gear unit 28 Idler arm dust seal
13 Steering gear unit dust cover 29 Taper roller bearing
14 Pitman arm 30 Lock pin
15 Plain washer 31 Idler arm bracket
16 Lock washer 32 Idler arm pin

A 48.5-77.5 {495-790, 36-57} H 205-227 {2,091-2,314, 152-167}
B 6.5-13.5 {67-137, 4.8-9.9} I 85.5-114.5 {872-1,167, 64-84}
C 9.5-16.5 {97-168, 7.1-12.1} J 64-78 {653-795, 48-57}
D 48.5-57.5 {495-586, 36-42} K 135.5-184.5 {1,382-1,881, 100-136}
E 326-424 {3,325-4,323, 241-312} L 291-389 {2,968-3,966, 215-286}
F 146-244 {1,489-2,488, 108-179} M 166-224 {1,693-2,284, 123-165}
G 391-489 {3,988-4,986, 289-360} N 39.5-48.5 {403-494, 30-35}
NOTICE
When retightening the nut "H", be sure to replace the nut with new one, because the nut "H" is coated with fric-
tional coefficient stabilizer.
FOR LEFT-HAND DRIVE MODEL
SHTS07Z070200004
1 Steering wheel 17 Drag link

2 Horn button 18 Lubrication fitting
3 Column cover 19 Cotter pin
4 Column boot 20 Steering gear bracket
5 Column tube 21 Ball joint socket
6 Spiral cable 22 Relay rod
7 Combination switch 23 Power steering booster assembly
8 Steering column assembly 24 Anchor bracket
9 Dust cover 25 Retainer
10 Dust seal 26 Fixture plate
11 Sliding yoke 27 Idler arm
12 Steering gear unit 28 Idler arm dust seal
13 Steering gear unit dust cover 29 Taper roller bearing
14 Pitman arm 30 Lock pin
15 Plain washer 31 Idler arm bracket
16 Lock washer 32 Idler arm pin

A 48.5-77.5 {495-790, 36-57} H 205-227 {2,091-2,314, 152-167}
B 6.5-13.5 {67-137, 4.8-9.9} I 85.5-114.5 {872-1,167, 64-84}
C 9.5-16.5 {97-168, 7.1-12.1} J 64-78 {653-795, 48-57}
D 48.5-57.5 {495-586, 36-42} K 135.5-184.5 {1,382-1,881, 100-136}
E 326-424 {3,325-4,323, 241-312} L 291-389 {2,968-3,966, 215-286}
F 146-244 {1,489-2,488, 108-179} M 166-224 {1,693-2,284, 123-165}
G 391-489 {3,988-4,986, 289-360} N 39.5-48.5 {403-494, 30-35}
NOTICE
When retightening the nut "H", be sure to replace the nut with new one, because the nut "H" is coated with fric-
tional coefficient stabilizer.
SPECIAL TOOL
EN07Z0702K100001
Prior to starting a steering linkage overhaul, it is necessary to have these special tools.
09650-1341 STEERING WHEEL PULLER
09657-1790 GUIDE 2 PIECES
09657-1800 GUIDE
9209-20120 NUT
09650-1260 PITMAN ARM PULLER
09603-1280 SOCKET WRENCH

OVERHAUL
EN07Z0702H200001
1. REMOVE THE STEERING WHEEL.

(1) Loosen the torx bolt for fixing the horn button using torx wrench.
(2) Remove the horn button from the steering wheel.
SHTS07Z070200011
(3) Remove the connector for the horn.
CONNECTOR FOR HORN
SHTS07Z070200012
(4) Remove the steering wheel lock nut.

(5) Use the special tool or commercial tool to remove the steering
wheel as shown in the figure.
SST: Steering Wheel Puller (09650-1341)
NOTICE
• Before removing the steering wheel from the steering shaft,
make aligning marks on both so that they can be assembled
in the same position.
• Because the puller hole is made of aluminum and it is easily
damaged, screw the puller bolt deeply.
SHTS07Z070200013 (6) Fix the rotating part of spiral cable with tape etc. to prevent the
spiral cable from rotating.
2. REMOVE THE STEERING COLUMN.

(1) Remove the steering column bracket mounting bolts.
SHTS07Z070200014
(2) Remove the steering column and the shaft integrally with the col-
umn bracket from the steering support bracket.
NOTICE
• Before removing the steering column from the steering sup-
port bracket, make the aligning marks on both sliding shaft
and sliding yoke.
ALIGNING MARK
• When removing the sliding shaft, be careful not to scratch
the nylon coating of fitting part.
SHTS07Z070200015
3. REMOVE THE UNIVERSAL JOINT.

(1) Remove the universal joint clamp nut.
SHTS07Z070200016
(2) Disconnect the universal joint from the steering gear unit.
NOTICE
Before disconnecting, make the aligning marks on both universal
joint and steering gear unit.
ALIGNING MARK
SHTS07Z070200017
4. REMOVE THE PITMAN ARM.

(1) Remove the nut, lock washer and plain washer from the sector
shaft.
NOTICE
Do not use wedges or hit with a hammer.
SST: Socket Wrench (09603-1280)
(2) Using the special tool, remove the pitman arm.

SST: Pitman Arm Puller (09650-1260)
SHTS07Z070200018
1. INSTALL THE PITMAN ARM.

(1) Through the pitman arm, install the plain washer and lock washer
to the sector shaft.
NOTICE
Align the aligning marks.
(2) Tighten the nut to the specified torque.
SHTS07Z070200019
2. INSTALL THE IDLER ARM. (MODEL: FY)

(1) Fill chassis grease with the taper roller bearings and the space
between the bearings "A".
(2) Install the idler arm to the idler arm pin, and tighten the inner nut.
Tightening Torque:
147.5-156.5 N⋅m {1,504-1,595 kgf⋅cm, 109-115 lbf⋅ft}
NOTICE
Before installation, apply chassis grease to the lip part of the dust
seal "B".
SHTS07Z070200020
(3) Loosen the inner nut by 1/4 turn, and then tighten the outer nut.
Tightening Torque:
291-389 N⋅m {2,968-3,966 kgf⋅cm, 215-286 lbf⋅ft}
SHTS07Z070200021
(4) Swing the idler arm and gently strike the bracket with a copper
hammer then measure the turning torque, using spring balancer.
Turning torque (N⋅m {kgf⋅cm, lbf⋅ft}) 1.97-3.92 {20-39, 1.5-2.8}

Spring balancer reading (N {kgf, lbf}) 6.5-12.4 {0.7-1.2, 1.4-2.8}
306 mm
{12.05 in.}
(5) If the turning torque is out of above range, readjust from item 1.
(6) After adjusting the turning torque, bend the lock washer.
SHTS07Z070200022
3. INSTALL THE POWER STEERING BOOSTER. (MODEL: FY)

BALL JOINT SOCKET NOTICE
PORT 2 (BOTTOM SIDE)
• When installation of ball joint socket, it should be made an
PORT 1
angle of 43°-47° with slit of the ball joint socket and the port
45
1, and then tighten clamp bolt.
2
• After tighten the clamp bolt, check that the slit of ball joint
socket is aligned with the mark on power steering booster
body.
ALIGNING
MARK SLIT STUD
CLAMP BOLT
SHTS07Z070200023
4. IF NECESSARY, REPLACE THE DUST SEAL OF DRAG LINK

AND RELAY ROD.
(1) Observe the following procedure when changing the dust seal.
a. Pry off the dust seal with a screw driver.
b. Put 6.5 g {0.23 oz} of lithium molybdenum grease in the seal.
c. Use the special tools to install the dust seal onto the socket
without damaging it.
SST:
Dust Cover Guide Inner (09657-1790)
Dust Cover Guide Outer (09657-1800)
Dust Cover Guide Nut (9209-20120)
SHTS07Z070200044
5. INSTALL THE DRAG LINKS AND RELAY ROD.

(1) Connect the drag links and relay rod with the pitman arm, the
knuckle arm and the idler arm.
NOTICE
• At this time, make sure that the arrow "FRONT" or numeral
on the drag links is positioned toward the front of vehicle.
• When handling the drag links and relay rod, take care not to
damage the dust seal.
SHTS07Z070200024
(2) Tighten the slotted nuts of the ball studs at both ends of the link to
the specified torque, and then secure the nuts with the cotter pins.
SHTS07Z070200025
6. INSTALL THE STEERING COLUMN.

(1) Apply chassis grease to the nylon coating part of sliding shaft,
and install the steering column to the steering support bracket.
NOTICE
When assembling, take care not to damage the steering shaft
spline.
SHTS07Z070200026
7. INSTALL THE UNIVERSAL JOINT.

(1) Set front axles toward rectilinear direction.
(2) Apply chassis grease to sliding shaft of steering shaft and install
the steering yoke to the sliding shaft.
NOTICE
Align the aligning mark.
(3) Install the universal joint to steering gear unit with clamp bolt and
clamp nut.
ALIGNING MARK
NOTICE
Align the aligning mark.
SHTS07Z070200027
8. LUBRICATE THE STEERING SHAFT.

(1) Lubricate the steering shaft with chassis grease, using the lubri-
cation fitting located on the steering yoke.
SHTS07Z070200028
9. LUBRICATE THE DRAG LINK.

(1) Lubricate the ball joint of drag link with chassis grease, using the
lubrication fittings.
NOTICE
Lubricate the grease till it overflows from the dust cover hole.
DRAG LINK
SHTS07Z070200029
10. INSTALL THE STEERING WHEEL.

CONNECTOR FOR HORN
(1) Set front axles toward rectilinear direction.
LOCK PIN (NEW)
(2) When spiral cable is new, make sure that the lock pin is seated in
the spiral cable assembly and the seal is not cut. When spiral
HARNESS CLAMP cable is reused, make sure that the neutral position of the spiral
SEAL (NEW) cable does not get out of position.
SPIRAL
CABLE
FRONT
SHTS07Z070200030
NOTICE
When there is no lock pin though the spiral cable is new, or when
the seal is cut though there is a lock pin, or when the neutral posi-
tion of the spiral cable gets out of position in reuse, turn the spiral
cable counterclockwise lightly. And turn it back clockwise by 4
rotations at the point of beginning of the hard steering. Then
match the neutral position marks on the upper side of the spiral
cable assembly.
(3) Pass the spiral cable through the steering wheel opening area
and set the steering wheel straight to install it with nut. When the
NEUTRAL POSITION MARK
spiral cable is new, remove the lock pin. When it is reused,
SHTS07Z070200031 remove the tape etc. for fixing the rotation of the spiral cable.
(4) Tighten the set screw for fixing the horn button after pushing it in
by using a torx wrench.
Tightening Torque:
6.5-13.5 N⋅m {66-138, 4.8-9.9 kgf⋅cm}
SHTS07Z070200011
11. ADJUST THE ALIGNMENT BETWEEN FRONT FORWARD

AXLE AND FRONT REARWARD AXLE. (MODEL: FY)
(1) Refer to the section "INSPECTION AND ADJUSTMENT" in the
chapter "FRONT AXLE (MF78I)".
12. INSPECT THE STEERING SYSTEM FOR OPERATING ABIL-

ITY.
(1) Place the front wheels on turn tables.
(2) Make sure that the steering wheel turns smoothly without any jolts
or abnormal resistance when the steering wheel is turned full
range.
SHTS07Z070200032
(3) Check the steering wheel free play while engine is idling.
FREE PLAY Wheel free play: 15-35 mm {0.591-1.377 in.}
(4) Check the steering wheel axial play.
Wheel axial play: Less than 0.1 mm {0.004 in.}
(5) If wheel free play exceeds 15-35 mm {0.591-1.377 in.}, turn the
set screw clockwise to decrease wheel free play and counter-
clockwise to increase it.
! WARNING
Excessive steering wheel free play may adversely affect vehicle
handling. This can result in personal injury and/or property dam-
age.
SHTS07Z070200033
(6) Measure the steering wheel turning force. Use a spring balancer
to measure the steering wheel turning force.
NOTICE
Measure the steering wheel turning force while the engine is
idling.
Turning force: 40 N {4.1 kgf, 8.9 lbf}
SHTS07Z070200034
(7) The steering wheel must be locked securely in any position up,
down, forward and backward.
! WARNING
Before moving the vehicle, tighten the lever securely and try to
LEVER move the steering wheel up and down, and forward and backward
to make sure that it is locked securely. Never try to adjust the
steering wheel position while the vehicle is moving. Any adjust-
RELEASE
ment of the steering wheel while driving can cause the driver to
lose control, and result in personal injury and/or property dam-
LOCK age.
SHTS07Z070200035
(8) Check to see that the combination switch is operating properly.

EN07Z0702H300001
Steering wheel: — — Replace, Visual check

Cracks, distortion and if necessary.
damage
Steering wheel serration: — — Replace, Visual check

Steering column assem- — — Replace, Visual check

bly: Bent, oscillation and if necessary
cracks
Nylon coating part:
Damage
Drag link: Cracks and — — Replace the Use the magnetic flaw
damage whole drag link detector or color checking
Ball joint: Play assembly or instrument.
Dust seal: Damage replace only
dust cover.
Universal joint assembly: — — Replace, Use the magnetic flaw

Oscillation, Play, Damage if necessary. detector or color checking
Oil seal: instrument.
Damage
Column tube: Cracks, — — Replace, Visual check

Bent if necessary.
UPPER
Ball bearing: BEARING
Play, Poor rotation
LOWER
BEARING
Pitman arm: Cracks, Bent — — Replace, Use the magnetic flaw

Dust cover, Wear, Damage if necessary. detector or color checking
instrument.
Idler arm: Cracks, Bend — — Replace, Use the magnetic flaw

Dust seal: Wear, Damage if necessary. detector or color checking
Taper roller bearing: instrument.
Play, Poor rotation, Burns,
Pitting
Idler arm pin:
Cracks, Bend
Idler arm bracket:
Cracks, Bend
POWER STEERING SR03–1
POWER STEERING
SR03
SR03-001
POWER STEERING SYSTEM .................. SR03-2

TROUBLESHOOTING..................................... SR03-2
AIR BLEEDING................................................ SR03-4
HYDRAULIC TEST .......................................... SR03-5
HYDRAULIC TEST (STEERING BOOSTER).. SR03-8
POWER STEERING GEAR UNIT ........... SR03-11

DATA AND SPECIFICATIONS...................... SR03-11
DESCRIPTION .............................................. SR03-12
OPERATION.................................................. SR03-13
SPECIAL TOOL ............................................. SR03-15
COMPONENT LOCATOR ............................. SR03-17
OVERHAUL ................................................... SR03-21
POWER STEERING BOOSTER UNIT.... SR03-36

DESCRIPTION .............................................. SR03-36
SPECIAL TOOL ............................................. SR03-37
OVERHAUL ................................................... SR03-39
POWER STEERING PUMP..................... SR03-43

DESCRIPTION .............................................. SR03-43
OPERATION.................................................. SR03-44
OVERHAUL ................................................... SR03-46
OIL RESERVOIR ..................................... SR03-52

DESCRIPTION .............................................. SR03-52
OVERHAUL ................................................... SR03-56
SR03–2 POWER STEERING
POWER STEERING SYSTEM

TROUBLESHOOTING
EN07Z0703F300001

Fluid leakage Pump Replace pump.
Fluid leakage (Gear box, steering Oil seal, O-rings other than those for Repair oil seal or O-ring.
booster) the seal lock nut and drain plug
Seal lock nut, drain plug Replace lock nut or plug.
Fluid leakage Line joints Replace leaky parts.
Hard steering (Excessive steering Steering gear is faulty Hydraulic test. Replace piston sub-
effort) (One side is hard) assembly.
Hard steering (Excessive steering Steering gear pump faulty Hydraulic test.
effort) (Both sides are hard) Measure pump discharge pressure.
Replace pump.
Incorrect preload of the sector shaft Measure system hydraulic pressure.
bearing Replace piston sub-assembly.
Adjust sector shaft preload.
Hard steering (Excessive steering Incorrect preload of the sector shaft Adjust sector shaft preload.
effort) (Hard, when starting to steer) bearing
NOTICE
Basic inspection items
• Fluid level, Fluid cleanliness
• Air in fluid
• Tire pressure
• Front alignment
• Steering linkage
• Universal joint
Abnormal noise (Pump) Air sucked in at input pipe Repair and bleed air or replace pump.
NOTICE
Basic inspection items
• Fluid level, fluid cleanliness
• Air mixed in fluid
• Pump piping
• Steering linkage
Abnormal noise Gear box Replace piston sub-assembly.
SHTS07Z070300001
AIR BLEEDING
EN07Z0703H200001
1. FILL THE OIL RESERVOIR WITH POWER STEERING FLUID.

NOTICE
• Use only specified fluid.
• Do not overfill the oil reservoir.
• Replace old fluid with new fluid after overhauling power
steering gear unit or power steering pump.
• Specified fluid....Refer to recommended lubricant list.
2. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME

WITH STANDS.
NOTICE
Block the rear wheels.
SHTS07Z070300002
3. TURN THE STEERING WHEEL FULLY IN BOTH DIRECTIONS

SEVERAL TIMES.
4. CHECK THE FLUID LEVEL IN THE OIL RESERVOIR.

(1) Add the fluid, if necessary.
SHTS07Z070300003
5. START THE ENGINE AND TURN THE STEERING WHEEL

FULLY IN BOTH DIRECTIONS SEVERAL TIMES WITH
ENGINE IDLING.
NOTICE
The fluid in the oil reservoir should be continuously replenished
while air bleeding so that the oil reservoir never become empty.
6. RETURN THE STEERING WHEEL TO STRAIGHT AHEAD.
SHTS07Z070300004
7. RECHECK THE FLUID LEVEL WHEN THE ENGINE IS

STOPPED.
(1) If necessary, add or decrease the power steering fluid to match
the between "MAX" and "MIN".
SHTS07Z070300005
HYDRAULIC TEST
EN07Z0703H300001
SHTS07Z070300006
HYDRAULIC TEST

WITH STANDS.
NOTICE
SHTS07Z070300002
2. SET THE STOP VALVE AND OIL PRESSURE GAUGE AS

SHOWN IN THE FIGURE.
NOTICE
After setting the stop valve and oil pressure gauge, perform the air
bleeding in the system according to "AIR BLEEDING".
SHTS07Z070300007
3. CHECK THE FLOW CONTROL VALVE OPERATION.

(1) Start the engine and idle then close the stop valve until the fluid
pressure is at 5.0 MPa {51 kgf/cm2, 725 lbf/in.2}.
(2) Run the engine up to 1,500 r/min, then reduce the engine speed
suddenly.
NOTICE
This operation should be repeated more than 5 times.
(3) Good, if the set pressure of 5.0 MPa {51 kgf/cm2, 725 lbf/in.2} is
recovered immediately.
If the set pressure is not recovered immediately, stop the engine
and replace the flow control valve assembly.
SHTS07Z070300008
(4) Open the stop valve fully.
4. CHECK THE RELIEF VALVE OPERATION.

(1) Run the engine up to 2,000 r/min.
(2) Close the stop valve until the fluid pressure is at 14.7 MPa {150
kgf/cm2, 2,132 lbf/in.2}.
NOTICE
Be careful not to exceed 14.7 MPa {150 kgf/cm2, 2,132 lbf/in.2}
(3) Good, if the fluid pressure is maintained at 14.0-14.7 MPa {143-

150 kgf/cm2, 2,030-2,132 lbf/in.2}.
(4) If pressure is higher, stop the engine and replace the flow control
valve assembly.
SHTS07Z070300009
5. MEASURE THE SYSTEM HYDRAULIC PRESSURE.

(1) Make sure that the stop valve is fully open.
(2) Start the engine and idle and then turn the steering wheel to a full
stop.
(3) Apply a force of approx. 147.1 N {15 kgf, 33 lbf} to the steering
wheel and measure the hydraulic pressure.
(4) Repeat the measurement by fully turning the steering wheel in the
opposite direction.
Hydraulic pressure:
14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}
(5) If the above pressure is not attained, measure the discharge pres-
SHTS07Z070300010 sure or stop the engine and repair the power steering gear unit.
6. MEASURE THE DISCHARGE PRESSURE.

(2) Start the engine and idle and measure the discharge pressure
with the stop valve fully close.
Discharge Pressure:
14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}
NOTICE
Do not allow the stop valve to remain closed for more than 15 sec-
onds.
SHTS07Z070300009
7. REMOVE THE STOP VALVE AND OIL PRESSURE GAUGE.

(1) Stop the engine and remove the stop valve and oil pressure
gauge.
NOTICE
After removing stop valve and oil pressure gauge, perform the air
bleeding in according to "AIR BLEEDING".
8. INSPECT THE STEERING SYSTEM FOR OPERATION ABIL-

ITY.
(1) Place the front wheels on turn tables then start the engine and
idle.
SHTS07Z070300011 (2) Check to see that the steering wheel turned smoothly without any
jolts or abnormal resistance, when it is turned fully in both direc-
tions.
(3) Measure the steering wheel turning force.
Turning force: Less than 40 N {4.1 kgf, 8.9 lbf}
SHTS07Z070300012
HYDRAULIC TEST
(STEERING BOOSTER)
EN07Z0703H300002
SHTS07Z070300013
HYDRAULIC TEST

WITH STANDS.
NOTICE
SHTS07Z070300002
2. SET THE STOP VALVE AND OIL PRESSURE GAUGE AS

SHOWN IN THE FIGURE.
NOTICE
After setting the stop valve and oil pressure gauge, perform the air
bleeding in the system according to "AIR BLEEDING".
SHTS07Z070300014
3. CHECK THE FLOW CONTROL VALVE OPERATION.

(1) Start the engine and idle then close the stop valve until the fluid
pressure is at 5.0 MPa {51 kgf/cm2, 725 lbf/in.2}
(2) Run the engine up to 1,500 r/min, then reduce the engine speed
suddenly.
NOTICE
This operation should be repeated more than 5 times.
(3) Good, if the set pressure of 5.0 MPa {51 kgf/cm2, 725 lbf/in.2} is
recovered immediately.
If the set pressure is not recovered immediately, stop the engine
and replace the flow control valve assembly.
SHTS07Z070300008
4. CHECK THE RELIEF VALVE OPERATION.

(2) Close the stop valve fully.
(3) Good, if the fluid pressure is maintained at 14.0-14.7 MPa {143-
150 kgf/cm2, 2,030-2,132 lbf/in.2}.
(4) If pressure is higher, stop the engine and replace the flow control
valve assembly.
NOTICE
Be careful not to exceed 14.7 MPa {150 kgf/cm2, 2,132 lbf/in.2}
SHTS07Z070300009
5. MEASURE THE SYSTEM HYDRAULIC PRESSURE.

(3) Repeat the measurement by fully turning the steering wheel in the
opposite direction.
Hydraulic pressure:
14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}
(4) If the above pressure is not attained, measure the discharge pres-
sure or stop the engine and repair the steering booster unit.
SHTS07Z070300010
6. MEASURE THE DISCHARGE PRESSURE.

(2) Start the engine and idle and measure the discharge pressure
with the stop valve fully close.
Discharge Pressure:
14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}
NOTICE
Do not allow the stop valve to remain closed for more than 15 sec-
onds.
SHTS07Z070300009
7. REMOVE THE STOP VALVE AND OIL PRESSURE GAUGE.

(1) Stop the engine and remove the stop valve and oil pressure
gauge.
NOTICE
After removing stop valve and oil pressure gauge, perform the air
bleeding in according to "AIR BLEEDING".
8. INSPECT THE STEERING SYSTEM FOR OPERATION ABIL-

ITY.
(1) Place the front wheels on turn tables then start the engine and
idle.
SHTS07Z070300011 (2) Check to see that the steering wheel turned smoothly without any
jolts or abnormal resistance, when it is turned fully in both direc-
tions.
(3) Measure the steering wheel turning force.
Turning force: Less than 24.5 N {2.5 kgf, 5.5 lbf}
SHTS07Z070300012
POWER STEERING GEAR UNIT

EN07Z0703I200001
FR, FS, SH, SS, ZS Integral type power steering

Type MODEL
FY Integral type power steering with steering booster
FR, FS, SH, SS, ZS 21.4-23.8

Gear ratio MODEL
FY 22.4
FR, FS, SH, SS, ZS 110 mm {4.331 in.}

Cylinder inside diameter MODEL
FY 100 mm {3.937 in.}
DESCRIPTION
EN07Z0703C100001
4 3 2 1
6 7 8 9 10
SHTS07Z070300015
1 Valve housing assembly 6 Dust cover

2 Worm valve assembly 7 Needle roller bearing
3 Steel ball 8 Oil seal
4 Ball nut assembly 9 Adjusting screw
5 Sector shaft 10 Adjusting screw lock nut
OPERATION
EN07Z0703C100002
SHTS07Z070300016
1 Oil reservoir 6 Spool valve

2 Oil pump 7 Sleeve
3 Flow control valve assembly 8 Ball nut
4 Relief valve 9 Torsion bar
5 Stud shaft 10 Worm shaft
SHTS07Z070300017
1 Oil reservoir 6 Spool valve

2 Oil pump 7 Sleeve
3 Flow control valve assembly 8 Ball nut
4 Relief valve 9 Torsion bar
5 Stud shaft 10 Worm shaft
SPECIAL TOOL
EN07Z0703K100001
Prior to starting a power steering gear unit overhaul, it is necessary to have the following special tools.
Tool and accessory set: 09030-4180
TOOL ASSEMBLY
09657-1870
• For 85 mm {3.346 in.}
• For 90-110 mm
{3.544-4.330 in.}
(Used together with tool assem-
bly)
09659-1400 ATTACHMENT ASSEMBLY
09603-1560 WRENCH ASSEMBLY
INSERTER ASSEMBLY
A:
For 40 mm {1.575 in.}
09657-1860
For 45 mm {1.772 in.}
For 48 mm {1.890 in.}
For 53 mm {2.087 in.}
For 58 mm {2.283 in.}
(Used together with inserter
assembly)
A
09659-1410 PRESS FITTER
09699-1360 NEEDLE
09657-1840 INSERTER
09694-1020 CAULKING TOOL
09657-1850 INSERTER
09712-1130 BAR
COMPONENT LOCATOR
EN07Z0703D100001
RIGHT-HAND DRIVE VEHICLE
SHTS07Z070300028
1 Dust cover 17 Valve housing

2 Stab shaft 18 Power piston (Ball nut)
3 Pin 19 Ball tube
4 Plug 20 Tube clip
5 O-ring 21 Plug
6 Oil seal 22 Dust cover
7 Ball bearing 23 Oil seal
8 Washer 24 Steering body
9 Rotor 25 Back up ring
10 Needle roller bearing 26 Y-packing
11 Side race 27 Needle roller bearing
12 Ball bearing 28 Sector shaft
13 Ball bearing cage 29 Adjusting screw
14 Torsion bar 30 Retainer
15 Worm shaft 31 Side cover
16 Seal ring

A 226-245 {2,305-2,498, 167-180} D 118-127 {1,203-1,295, 87-93}
B 4.4-5.4 {45-55, 3.3-4.0} E 74-83 {755-846, 55-61}
C 294-392 {2,998-3,997, 217-289} F 112-127 {1,142-1,295, 83-93}
LEFT-HAND DRIVE VEHICLE
SHTS07Z070300029
1 Dust cover 17 Valve housing

2 Stab shaft 18 Power piston (Ball nut)
3 Pin 19 Ball tube
4 Plug 20 Tube clip
5 O-ring 21 Plug
6 Oil seal 22 Dust cover
7 Ball bearing 23 Oil seal
8 Washer 24 Steering body
9 Rotor 25 Back up ring
10 Needle roller bearing 26 Y-packing
11 Side race 27 Needle roller bearing
12 Ball bearing 28 Sector shaft
13 Ball bearing cage 29 Adjusting screw
14 Torsion bar 30 Retainer
15 Worm shaft 31 Side cover
16 Seal ring

A 226-245 {2,305-2,498, 167-180} D 118-127 {1,203-1,295, 87-93}
B 4.4-5.4 {45-55, 3.3-4.0} E 74-83 {755-846, 55-61}
C 294-392 {2,998-3,997, 217-289} F 112-127 {1,142-1,295, 83-93}
MODEL: FY (LEFT-HAND DRIVE VEHICLE)
SHTS07Z070300030
1 Dust cover 20 Tube clip

2 Stab shaft 21 Plug
3 Pin 22 Dust cover
4 Plug 23 Oil seal
5 O-ring 24 Steering body
6 Oil seal 25 Back up ring
7 Ball bearing 26 Y-packing
8 Washer 27 Needle roller bearing
9 Rotor 28 Sector shaft
10 Needle roller bearing 29 Adjusting screw
11 Side race 30 Retainer
12 Ball bearing 31 Side cover
13 Ball bearing cage 32 Power steering control valve body
14 Torsion bar 33 Spring
15 Worm shaft 34 Spool valve
16 Seal ring 35 Plug
17 Valve housing 36 Valve assembly
18 Power piston (Ball nut) 37 Connector
19 Ball tube

A 226-245 {2,305-2,498, 167-180} F 112-127 {1,142-1,295, 83-93}
B 4.4-5.4 {45-55, 3.3-4.0} G 24.5-34.3 {250-350, 18-25}
C 294-392 {2,998-3,997, 217-289} H 29.4-39.2 {300-400, 22-29}
D 118-127 {1,203-1,295, 87-93} J 49.0-53.9 {500-550, 36-40}
E 74-83 {755-846, 55-61} K 8.8-12.7 {90-130, 6.5-9.4}
OVERHAUL
EN07Z0703H200002
NOTICE
OBSERVE THE FOLLOWING INSTRUCTIONS BEFORE DISASSEM-
BLY AND ASSEMBLY.
1. All functional parts should be clean. Blow dirty parts off with
dry compressed air, then clean them with volatile metal
cleanser. Never use brushes or cloth.
2. Handle rubber parts, seals, etc., in clean condition. Any worn
part should be replaced immediately.
Volatile metal cleanser may attack rubber parts, so they
should never be used. Always use fluid.
3. For disassembling and assembling, only use the specified
fluid.
4. Standard tools can generally be used for assembling and dis-
assembling, although special tools may be required. When
using special tools, read the instruction carefully, and never
use standard tools in place of special tools.
1. BEFORE DISASSEMBLY, SECURE THE POWER STEERING IN

THE VISE, AND THEN CENTER THE POWER PISTON.
SHTS07Z070300031
2. REMOVE THE SIDE COVER ASSEMBLY AND SECTOR

SHAFT.
(1) Loosen and remove the nut fixing the adjusting screw to the side
cover.
BOLT
(2) Remove the eight bolts and washers fitting the side cover to the
steering body.
NUT
SHTS07Z070300032
(3) Confirm that the power piston is located in the center, and then
gently tap the output end of the sector shaft with a plastic (or
wooden) hammer to remove the sector shaft assembly and the
side cover together from the steering body.
NOTICE
Never use a steel hammer when removing the sector shaft (as the
PLASTIC HAMMER threads will be damaged).
SHTS07Z070300033
(4) Turn the adjusting screw clockwise using a screwdriver to raise

and separate the side cover assembly from the sector shaft
SCREWDRIVER assembly.
ADJUSTING SCREW
SIDE COVER NOTICE
• Do not secure the sector shaft directly in the vise.
• Always use a cloth etc. to protect the sector shaft.
SECTOR SHAFT
SHTS07Z070300034
(5) Remove the O-ring from the groove around the outside of the side
BACK-UP RING cover using the special tool. Then remove the Y-packing from
behind the needle roller bearing and the back-up ring using the
Y-PACKING special tool.
NOTICE
O-RING
It is not necessary to remove the needle bearing unless it is dam-
aged.
SIDE COVER SST: Needle (09699-1360)
SHTS07Z070300035
3. REMOVE THE VALVE HOUSING AND BALL NUT ASSEMBLY.

(1) Remove the dust cover from the valve housing.
WRENCH ASSEMBLY
(2) Loosen the plug and seal assembly in the valve housing section
using the special tool. At this time, only back off the plug and seal
assembly 180°. Do not remove it.
NOTICE
If the plug and seal assembly is removed, the steel balls (bearing)
in the valve housing may spring out.
SST: Wrench Assembly (09603-1560)
SHTS07Z070300036
(3) Remove the bolts to remove the worm shaft assembly and valve
housing assembly from the steering body.
NOTICE
• Do not damage the internal surface of the steering body
when removing the worm shaft assembly and valve housing
assembly.
• Do not let the steel balls spring out.
• Never damage the power piton.
BOLT
SHTS07Z070300037
4. REMOVE THE ADJUSTING SCREW AND SECTOR SHAFT.

(1) Uncaulk the retainer at two caulked positions.
NOTICE
RETAINER
• Do not disassemble the sector shaft assembly unless it is
damaged.
SECTOR
SHAFT • Do not secure the sector shaft directly in the vise. Always
use a cloth etc. to protect the sector shaft.
SHTS07Z070300038
(2) Remove the retainer using the special tool. Remove the adjusting
RETAINER screw at the same time.
BAR SST: Bar (09712-1130)
ADJUSTING SCREW
SHTS07Z070300039
5. REMOVE THE WORM SHAFT ASSEMBLY, VALVE HOUSING

STUB SHAFT AND POWER PISTON ASSEMBLY.
(1) Place the assembly on the work bench with the power piston side
VALVE
down. Turn the stub shaft while holding the valve housing, and
HOUSING remove the worm shaft from the power piston.
(2) Let the steel balls assembled in the power piston and ball race of
the worm shaft drop into the power piston.
WORM SHAFT POWER PISTON
NOTICE
Do not tilt the piston as it contains the steel balls. Do not lose the
steel balls.
SHTS07Z070300040
(3) Secure the special tool in the vise.

SST: Attachment Assembly (09659-1400)
WRENCH (4) Remove the O-rings fitted on the contact surfaces of the steering
ATTACHMENT ASSEMBLY body of the valve housing.
ASSEMBLY (5) Attach the valve housing to the attachment assembly, and remove
the previously loosened plug and seal assembly.
SST: Wrench Assembly (09603-1560)
SHTS07Z070300041
(6) Remove the ball bearing and oil seal from the plug and seal
BEARING assembly.
OIL SEAL
PLUG AND
SEAL ASSEMBLY
SHTS07Z070300042
6. REMOVE THE WORM SHAFT ASSEMBLY AND VALVE HOUS-

VALVE HOUSING ING.
(1) Prepare a plastic box, etc. Hold the valve housing over the box
BEARING CAGE
and remove the worm shaft assembly by pushing it from the
STEEL BALLS power piston side as shown in figure. The side race, steel balls,
SIDE RACE
and bearing cage will come apart and fall into the box.
NOTICE
• Do not lose any steel balls.
• If only one side race and/or steel ball is lost, the worm shaft
and valve housing assembly must be replaced.
Number of the steel balls: 18 pieces.
SHTS07Z070300043
(2) Remove the rotor from the worm shaft assembly, and then remove
the seal ring from the rotor using the special tool.
SEAL RING SST: Needle (09699-1360)
ROTOR
SHTS07Z070300044
(3) Remove the three seal rings and three O-rings from the valve
SEAL RING (3) housing using the special tool.
SST: Needle (09699-1360)
O-RING (3)
VALVE HOUSING
SHTS07Z070300045
7. REMOVE THE POWER PISTON.

BALL TUBE SCREW (1) Place the piston's steel balls in a separate container.
WASHER (2) Loosen the screw of the tube clip securing the ball tube using a
PISTON wrench. Remove the ball tube from the power piston by pinching it
CLIP with your fingers and shaking it.
NOTICE
• Never insert a screwdriver etc., between the ball tube and the
piston to pry them apart.
• Check for any steel balls remaining in the ball tube.
Number of the steel balls: 32 pieces.
SHTS07Z070300046
(3) Remove the seal ring and O-ring from the power piston using the
PISTON
special tool.
SEAL RING SST: Needle (09699-1360)
O-RING
SHTS07Z070300047
8. REMOVE THE STEERING BODY.

OIL SEAL (1) Remove the oil seal, back-up ring, and Y-packing from the section
BACK-UP RING of the steering body contacting the sector shaft.
Y-PACKING
NOTICE
STEERING BODY
Do not remove the needle roller bearing and taper plug unless
they are damaged.
SHTS07Z070300048

RETAINER 1. INSTALL THE SECTOR SHAFT.
(1) Secure the sector shaft in the vise while protecting the geared
BAR
base of the shaft with a rag.
ADJUSTING
SCREW
(2) Fill the assembly with grease through the adjusting screw hole.
Then, insert the adjusting screw, and fix the retainer using the
special tool.
SST: Bar (09712-1130)
SHTS07Z070300049
NOTICE
How to tighten the retainer; After fully tightening, back off the
CAULKING TOOL
retainer 180° and then, after retightening it to 39 N⋅m {400 kgf⋅cm,
29 lbf⋅ft}, back it off 20°. Ensure the adjusting screw rotates
smoothly.
(3) After tightening the retainer, securely caulk it at two positions

using the special tool.
SST: Caulking Tool (09694-1020)
SHTS07Z070300050
2. INSTALL THE SIDE COVER.

O-RING (1) Insert the Y-packing and back-up ring in the bottom of the needle
BACK-UP RING
roller bearing press fitted inside the side cover.
NOTICE
Y-PACKING • The back-up ring can be assembled easily if inserted by
pinching it with the fingers as shown in figure.
SIDE COVER • After filling the groove with grease, assemble the Y-packing
so that the lip faces to the needle roller bearing side.
SHTS07Z070300051
(2) Form the back-up ring using the special tool.

SST: Inserter Assembly (09657-1860)
NOTICE
INSERTER ASSEMBLY There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 48 mm {1.890 in.}.
INSERTER
SIDE COVER
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SHTS07Z070300052
48 {1.890}
53 {2.087}
58 {2.283}
3. INSTALL THE VALVE HOUSING.

O-RING (1) Insert an O-ring and a seal ring into each of the three narrower
grooves of the five grooves in the valve housing.
(2) Then, form the seal ring using the special tool.
INSERTER
SST: Inserter (09657-1850)
SEAL RING
SHTS07Z070300053
4. INSTALL THE PLUG AND SEAL ASSEMBLY.

HAND PRESS
(1) Press fit the oil seal into the inside of the plug and seal assembly
using the special tool.
OIL SEAL NOTICE
PRESSFITTER Always use a hand press when press fitting the oil seal.
PLUG SST: Press Fitter (09659-1410)
SHTS07Z070300054
(2) Apply grease to the oil seal and then install the ball bearing.
OIL SEAL
GREASE
SHTS07Z070300055
5. INSTALL THE WORM SHAFT AND THE VALVE HOUSING.

(1) Form the seal ring using the special tool after assembling the seal
INSERTER ring in the outer groove of the rotor.
SEAL RING
ROTOR
SHTS07Z070300056
(2) Insert the rotor between the stub shaft and the worm shaft. At this
ROTOR time, assemble it so that the straight pin in the bottom fits in the
rotor notch.
ROTOR NOTCH
WORM SHAFT STRAIGHT PIN
SHTS07Z070300057
(3) Fit the guide into the special tool and insert the previously assem-
bled worm shaft assembly into the guide with the input side down.
SST: Tool Assembly (09657-1870)
WORM SHAFT
BEARING CAGE NOTICE
GUIDE
There are two kinds of guide as below, and install worm shaft
STEEL BALL
assembly using the guide for power piston diameter 90-110 mm
TOOL {3.544-4.330 in.}.
ASSEMBLY
Unit: mm {in.}
POWER PISTON DIAMETER
SHTS07Z070300058
85 {3.346}
90-110 {3.544-4.330}
(4) Install the race of bearing side (one side), the bearing cage and
the steel balls, and allow the tool assembly to slide down and set
the balls in position.
(5) Remove the guide and fit the other side race.
SIDE RACE
SIDE RACE
BEARING CAGE
STEEL BALL
SHTS07Z070300059
(6) Assemble the valve housing to the worm shaft assembly and pre-
viously assembled bearing sub-assembly by inserting it from the
worm shaft side.
NOTICE
VALVE HOUSHING
• When fitting the valve housing, do not damage the seal ring
in the valve housing.
• Inserter (09657-1850) can be used to form the seal rings of
the valve housing part.
SHTS07Z070300060
(7) Secure the special tool in the vise.

PLUG AND
SECTION ON SST: Attachment Assembly (09659-1400)
SEAL ASSEMBLY
WITH LIQUID
GASKET IS (8) Fit the previously assembled worm shaft assembly and valve
O-RING APPLIED housing onto the attachment assembly, place the O-ring in the
(SEE NOTE)
inner groove of the valve housing, and screw the plug and seal
assembly into the valve housing.
NOTICE
• Apply liquid gasket (equivalent to ThreeBond 1102) to the
ATTACHMENT
ASSEMBLY screw section of the plug and seal assembly.
• The O-ring must not be fitted in the thread escape groove of
SHTS07Z070300061 the valve housing.
• When assembling the plug and seal assembly, do not let the
stub shaft serration damage the oil seal.
(9) Tighten the plug and seal assembly using the special tool.
LOOSEN THE PLUG SST: Wrench Assembly (09603-1560)
AND SEAL ASSEMBLY
BY 180 FOR STUB SHAFT
SUBSEQUENT WORK NOTICE
Check that the stub shaft rotates smoothly and uniformly while
holding the valve housing.
(10) Loosen the plug and seal assembly by approx 180°.
SHTS07Z070300062
(11) Install O-rings in the groove around the outside of the valve hous-
ing, and in the oil port recess.
NOTICE
Do not twist the O-rings.
O-RING
O-RING
SHTS07Z070300063
6. INSTALL THE POWER PISTON.

(1) Fit the O-ring and seal ring in the groove around the outside of the
power piston and form the seal ring using the special tool.
O-RING NOTICE
INSERTER SEAL RING Do not twist the O-ring or stretch the seal ring.
PISTON
SHTS07Z070300064
(2) Place the power piston on the bench.

(3) Fill the ball tube with grease, lay 10-11 steel balls in the tube, and
BALL TUBE place the other side of the ball tube on top.
NOTICE
Never fix the piston in a vise.
STEEL BALL
SHTS07Z070300065
(4) Insert the worm shaft and valve housing assembly in the center
PUNCH STEEL BALL hole of the power piston, align the power piston and worm shaft
STUB SHAFT ball races, and drop the remaining steel balls one by one through
PISTON the piston's ball tube hole.
NOTICE
• Drop the steel balls while turning the stub shaft to facilitate
assembly.
• Steel balls sometimes come out of the hole on the other side
of the ball tube after a certain number are inserted. Plug the
hole with a punch to prevent the steel balls from coming out.
• When installing the steel balls, the worm shaft and valve
SHTS07Z070300066 housing assembly must not be drawn out to its extreme posi-
tion, as the steel balls may drop outside the ball race.
(5) After inserting the steel balls in the power piston, insert the ball
BALL TUBE tube into the power piston and fix it using the clip, washer, and
screw.
NOTICE
Always push in the ball tube by hand. Never force or strike it. If
forced or struck, the ball tube may be deformed, the edge may be
nipped, or otherwise damaged, causing malfunctions.
(6) Tighten the screw to the specified torque.
CLIP
SHTS07Z070300067
(7) Measure the axial play between the power piston and the worm
B (AXIAL PLAY) shaft assembly.
2 mm (0.079 in.) A (point of application) 20 mm {0.787 in.}

F (force) 5 kg
B (axial play) 0.5 mm {0.0197 in.} or less
A
NEUTRAL POSITION F
SHTS07Z070300068
7. INSTALL THE STEERING BODY.

(1) Fit the Y-packing and back-up ring in the groove in front of the
Y-PACKING BACK-UP RING needle roller bearing (in the hole for the steering body output
shaft).
NOTICE
• Back-up ring installation is facilitated by pinching the ring
with the fingers as shown in figure.
• After filling the groove with grease, assemble the Y-packing
so that the lip faces to the needle roller bearing.
STEERING BODY
SHTS07Z070300069
(2) Form the back-up ring using the special tool.

INSERTER ASSEMBLY
NOTICE
INSERTER There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 58 mm {2.283 in.}.
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SHTS07Z070300070
48 {1.890}
53 {2.087}
58 {2.283}
(3) Press fit the oil seal into the steering body using the special tool.
INSERTER ASSEMBLY
(4) Fill the oil seal with grease.

OIL SEAL
SHTS07Z070300071
8. INSTALL THE VALVE HOUSING AND BALL NUT ASSEMBLY.

STEERING BODY
(1) Secure the steering body in the vise.
PISTON (2) Fit the worm shaft and valve housing assembly by inserting it into
the steering body with the power piston gear placed on the side of
the sector shaft. Hold the power piton lightly by hand so that it
dose not rotate.
NOTICE
• When inserting the worm shaft and valve housing assembly,
do not damage the piston seal ring.
• Be careful that the O-ring dose not fall out.
SHTS07Z070300072
(3) Align the steering body and valve housing oil passage holes and
tighten the bolt to the specified torque.
NOTICE
Insert a bar into the bolt hole to align the body and housing oil
passage holes. Prevent housing rotation to prevent the O-ring
from being cut or dislodged.
SHTS07Z070300073
(4) Tighten the plug and seal assembly (which was previously loos-
ened through 180°) to the specified torque using the wrench
assembly.
WRENCH ASSEMBLY SST: Wrench Assembly (09603-1560)
NOTICE
After applying a thin and uniform coat of liquid gasket to 3-5 whole
threads of the screw part of the plug and seal assembly and tight-
ening it with the indicated torque, apply turning stopper punches
every 180°.
Liquid gasket: Equivalent to ThreeBond 1102

SHTS07Z070300074
(5) Attach the dust cover to the valve housing.
DUST COVER
NUT
SHTS07Z070300075
9. INSTALL THE SIDE COVER ASSEMBLY AND SECTOR

SHAFT.
SCREWDRIVER ADJUSTING SCREW (1) Assemble the side cover assembly to the sector shaft assembly
by aligning the screw hole in the center of the side cover with the
SIDE COVER
adjusting screw and turning the adjusting screw.
Install the O-ring around the outside of the side cover.
SECTOR SHAFT
SHTS07Z070300076
(2) Insert the sector shaft into the steering body so that its gear and
the power piston gear engage in the center.
NOTICE
When inserting the sector shaft, do not let the sector shaft serra-
tion damage the lip of the Y-packing. Damage may affect oil tight-
ness.
SHTS07Z070300077
(3) Assemble the side cover to the steering body using the bolts.
STEERING BODY Tighten them to the specified torque.
SIDE COVER
SHTS07Z070300078
10. MEASURE THE SECTOR SHAFT BACKLASH.

(1) Align the marks on the sector shaft with pitman arm.
(2) Install the pitman arm and tighten the nut finger tight.
SHTS07Z070300079
(3) Use a dial gauge to check to see that the sector shaft backlash in
neutral position.
L Backlash
0.05-0.25 mm
270 mm {10.63 in.}
{0.002-0.009 in.}
(4) If measurement is not within specification, readjust the backlash

with adjusting screw.
SHTS07Z070300080
11. INSPECT THE WORM VALVE ASSEMBLY ROTATION CONDI-

TION.
(1) Check to see that the worm valve assembly rotate smoothly with-
out any shocks, abnormal resistance, noise and drag, when the
worm valve assembly rotates full lock in both direction.
12. TIGHTEN THE PITMAN ARM LOCK NUT.
SHTS07Z070300081

EN07Z0703H300003
METALLIC PARTS
Inspection item Location Remedy
Steering body • The internal surface of the cyl- Repair or replace the steering body if there is evi-
inder dence of abrasion or stepped wear. Check visu-
ally and by touch for any flaws that may affect
smooth piston stroke.
• Side cover assembly surface Repair or replace the steering body if there is evi-
dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).
• Y-packing groove in the sector Repair or replace the steering body if there is evi-
shaft hole dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).
Sector shaft • Gear Replace the gear if it is severely flawed or worn.

Chipped gears must also be replaced. (Check
visually and by touch)
• Gear shaft and serrations Check for cracks using magnetic-particle test
equipment and a color penetration test. Replace
any cracked parts.
• Needle roller bearing contact Check for wear, flaws or gouging (visually and by
surface touch). Repair or replace if necessary.
• Y-packing contact surface Repair or replace if any flaws, rust or gouging

affecting oil tightness are found (check visually
and by touch).
• Adjusting screw Measure the axial clearance of the adjusting

screw with a dial gauge.
0.01-0.1 mm is acceptable, but if excessive, the
screw must be disassembled for inspection. Also
check whether the adjusting screw rotates
smoothly. If not, the screw must be disassembled
and inspected.
Power piston • Cylinder contact surface Any wear or abrasion that affects smooth piston
stroke must be corrected, or the power piston
must be replaced.
• Rack gear Replace the rack gear if severely flawed, worn or

chipped.
• Steel ball race surface Any wear or flaw that disturbs smooth rotation
and movement of steel balls must be corrected,
or the race must be replaced. (Visual inspection)
• Seal ring and O-ring Replace the seal ring or O-ring if any flaws or
tears affecting oil tightness are found.
Ball tube • Steel ball rotation surface Replace the ball tube if any wear, flaws or goug-
ing that affect smooth ball rotation are found on
the inside at the tube.
• Tang (end) Replace the ball tube if any warping, bending,

flaws or pits that affect smooth ball rotation are
found on the tang.
Inspection item Location Remedy
Worm shaft • Steel ball race surface Repair or replace the race if any wear, flaws or
(stub shaft) pits that affect smooth ball rotation are found.
• Seal ring Any wear, flaw, or gouge affecting oil tightness

must be corrected or the seal ring must be
replaced.
• Y-packing contact surface Any wear, flaw, rust, or gouge which may affect
oil tightness must be corrected or the packing
must be replaced.
• Thrust bearing (steel ball) con- Check the bearing for wear, flaws or pits if shaft
tact surface rotation is stiff or uneven. Repair or replace if
found.
Thrust bearing • Bearing race and steel ball Check the bearing for wear, flaws or pits if shaft
(steel ball) rotation is stiff or uneven. Repair or replace if
and bearing cage found.
• Bearing cage Replace the cage if any flaws or damage affecting

smooth rotation are found.
Rotor • External surface Repair or replace the rotor if any wear, flaws or
gouging affecting smooth rotation are found.
• Chamber Replace the chamber if any flaws, breaks, or

chips affecting steering characteristics are
found.
• Seal ring groove Replace the seal ring if any flaws or tears affect-
ing oil tightness are found.
Side cover • Steering body contact surface Repair or replace the side cover if any flaws,
gouging or rust affecting oil tightness are found.
• Y-packing groove Repair or replace the side cover if any flaws,

• O-ring groove Repair or replace the side cover if any flaws,

Plug and seal • Thrust bearing side race con- Repair or replace the plug and seal assembly if
assembly tact surface any flaws, rust or gouging affecting uniform tight-
ening are found.
• Y-packing press fitted section Replace the plug and seal assembly if any flaws,
rust or gouging affecting oil tightness are found.
• O-ring contact surface Replace the plug and assembly if any flaws, rust
or gouging affecting oil tightness are found.
Bearings Check that the bearing rotates smoothly. Replace

the bearing if rotation is stiff or uneven.
POWER STEERING BOOSTER UNIT

EN07Z0703I200002
Bore 50 mm {1.968 in.}
Stroke 280 mm {11.024 in.}
Piston rod diameter 22 mm {0.866 in.}
DESCRIPTION
EN07Z0703C100003
SHTS07Z070300082
1 Ball joint socket 5 Guide assembly

2 Piston 6 Boot
3 Cylinder 7 Dust seal
4 Rod
SPECIAL TOOL
EN07Z0703K100002
Prior to starting a power steering booster unit overhaul, it is necessary to have these special tools.
09603-1540 GUIDE REMOVER
09657-1780 DUST SEAL INSTALLING JIG
09657-1770 ROD CAP
09434-1120 ROD END STAKING JIG
09657-1760 PISTON INSTALLING JIG

COMPONENT LOCATOR
EN07Z0703D100002
SHTS07Z070300088
1 Cylinder 7 Dust seal

2 Nut 8 Back up ring
3 Piston 9 Guide assembly
4 Slipper seal 10 Dust seal
5 O-ring 11 Ring retainer
6 Rod

A 98 {1,000, 72}
OVERHAUL
EN07Z0703H200003
1. INSTALL THE POWER CYLINDER IN VICE.

(1) When disassembling the power cylinder, hold in a vice using wood
block to prevent damage.
2. REMOVE THE BALL JOINT SOCKET.
SHTS07Z070300089
3. LOOSEN THE GUIDE ASSEMBLY.

(1) Raise staked portion of the guide and using the special tool,
loosen the guide assembly.
Do not remove the guide assembly from the rod side but remove
integral with the rod from the cylinder.
SST: Guide Remover (09603-1540A)
SHTS07Z070300090
4. REMOVE THE PISTON.

(1) Loosen the nut and remove the piston and guide assembly. Do
not reuse the nut. Be sure to replace it with a new one. Correct the
piston side threaded portion of the rod by dies.
SHTS07Z070300091
5. REMOVE THE RETAINER RING AND DUST SEAL.

(1) Remove the retainer ring, dust seal, etc. from the guide assembly,
using care not to damage grooves and rod sliding surface.
SHTS07Z070300092
6. REMOVE THE BALL JOINT SOCKET.

(1) Loosen the lock bolt of ball joint socket, then turn the ball joint
socket to counterclockwise and remove it.
SHTS07Z070300093
1. ASSEMBLE THE GUIDE ASSEMBLY.

(1) Install the dust seal.
When inserting the dust seal, bend it to heart shape.
SHTS07Z070300094
(2) Install the dust seal.

Install the dust seal using the special tool.
SST: Dust Seal Installing Jig (09657-1780A)
SHTS07Z070300095
2. INSTALL THE GUIDE ASSEMBLY.

(1) Using the special tool, at the piston rod end, insert the guide
assembly.
SST: Rod Cap (09657-1770A)
SHTS07Z070300096
3. INSTALL THE PISTON.

(1) Install the piston, and then tighten the nut.
(2) Staking the rod end (three places) using the special tool.
SST: Rod End Staking Jig (09434-1120A)
SHTS07Z070300097
4. INSTALL THE PISTON AND ROD.

(1) Apply hydraulic oil to inside of cylinder.
(2) Install the piston and rod using the special tool.
SST: Piston Installing Jig (09657-1760A)
SHTS07Z070300098
5. STAKING THE GUIDE ASSEMBLY.

(1) Tighten the guide assembly using the special tool.
SST: Guide Remover (09603-1540A)
(2) Secure the guide assembly on the cylinder by staking the tube
end on the outer circumference groove of the guide assembly.
SHTS07Z070300099
6. INSTALL THE BALL JOINT SOCKET.
SHTS07Z070300100

EN07Z0703H300004
Unit: mm {in.}
Clearance between piston and 0.064 - 0.137 0.18 Replace the Measure
cylinder {0.0025-0.0054} {0.0071} piston and/or
cylinder.
Cylinder: — — Replace, Visual check

Scratches on inner surface. if necessary.
Clearance between rod and 0.024-0.112 0.12 Replace the rod Measure
guide assembly {0.0009-0.0044} {0.0047} and/or guide.
Rod: — — Replace, Visual check

Bent and/or damaged. if necessary.
Boots: — — Replace, Visual check

Damaged. if necessary.
POWER STEERING PUMP

EN07Z0703I200003
Type Vane type
Speed range 707-5,200 r/min
Relief pressure 14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}
Front single axle model 18.5-21.5 L/min. {4.89-5.67 U.S.gal, 4.07-4.72 lmp.gal} at 2,000 r/min.
Flow rate
Front tandem axle model 26-29 L/min. {6.87-7.66 U.S.gal, 5.72-6.38 lmp.gal} at 2,000 r/min.
DESCRIPTION
EN07Z0703C100004
SHTS07Z070300106
1 Flow control valve assembly 9 Ball bearing

2 Relief valve 10 Pump shaft
3 Spring 11 Pump body
4 Rotor 12 Pump cover
5 Cam ring 13 Dowel
6 Vane 14 Front plate
7 Suction connector 15 Rear plate
8 Oil seal
OPERATION
EN07Z0703C100005
SHTS07Z070300107
1 Reservoir 5 Flow control valve assembly

2 Vane 6 Relief valve
3 Cam ring A To power steering gear unit
4 Rotor B From power steering gear unit
COMPONENT LOCATOR
EN07Z0703D100003
SHTS07Z070300108
1 Plug 7 Bearing 13 Vane

2 O-ring 8 Oil seal 14 Rotor
3 Drive gear 9 Pump body 15 Cam ring
4 Retainer ring 10 Spring 16 Dowel
5 Suction connector 11 Flow control valve 17 Rear plate
6 Pump shaft 12 Front plate 18 Pump cover

A 108-127 {1,100-1,295, 80-93} B 29-39 {295-397, 22-28}
OVERHAUL
EN07Z0703H200004
1. REMOVE THE FLOW CONTROL VALVE ASSEMBLY.

(1) Remove the plug, spring and flow control valve assembly.
NOTICE
Be careful not to drop, scratch or nick the flow control valve
assembly.
SHTS07Z070300109
2. REMOVE THE BODY COVER.

(1) Remove the retainer ring.
(2) Remove the body cover and spring.
SHTS07Z070300110
3. REMOVE THE VANE PUMP CORE.

(1) As shown in the figure, face the vane pump core side downward
and remove the rear plate and vane pump core. The vane pump
core consists of the cam ring, rotor and vane. Since dimensional
checks of these parts have been completed, handle the vane
pump core carefully. Remove the front plate.
SHTS07Z070300111
4. REMOVE THE PUMP SHAFT ASSEMBLY.

(1) Remove the retainer ring from the pump body, and push and
remove the spline edge surface of the pump shaft by hand or by
using a plastic hammer. Be careful not to damage the oil seal lip.
This process completes disassembly. Carry out inspection.
SHTS07Z070300112
REPLACEMENT
1. REPLACE THE BALL BEARING, IF NECESSARY.

(1) Use a pair of snap ring pliers to remove the retainer ring.
SHTS07Z070300113
(2) Use a press, press out the ball bearing.
SHTS07Z070300114
(3) Use a press to press in the ball bearing.
SHTS07Z070300115
(4) Use snap ring pliers to install the retainer ring.
SHTS07Z070300116
2. REPLACE THE OIL SEAL, IF NECESSARY.

(1) Use a screw driver to remove the oil seal.
NOTICE
Do not scrape or damage the inside of pump body.
SHTS07Z070300117
(2) Insert the oil seal as shown in the figure.

NOTICE
To prevent oil leakage from oil seal due to lip wear, apply lithium
base grease to A and B.
(3) Using a press, press in the oil seal into the pump body.
SHTS07Z070300118

NOTICE
• Before assembling, clean all the parts and lubricate them
with fluid.
• When assembling the power steering pump, be sure to use
new O-rings.
1. INSTALL THE FLOW CONTROL VALVE ASSEMBLY.

(1) Apply fluid to the valve and check to see that it falls smoothly into
the valve hole by its own weight.
I II If a problem is detected, replace the flow control valve assembly.
NOTICE
• There are three different valve diameters, therefore be careful
that the mark on both valve and the pump body are always
matched.
• Rank indication of flow control valve is not found on the
valve built-in the power steering pump assembly. On flow
control valve of spare parts, the rank is indicated.
SHTS07Z070300119
• On the body of “A”rank, the rank is not indicated.
I: Letter on the valve, II : Letter of the body
I A B C
March mark
II — B C
(2) Install the spring and the flow control valve assembly, and tighten
the plug.
NOTICE
Apply lithium base grease to an O-ring.
SHTS07Z070300120
2. INSTALL THE PUMP SHAFT.

(1) Using a press, press in the pump shaft with bearing into the pump
body.
(2) Install the retainer ring.
NOTICE
When installing the retainer ring, face the chamfer side toward ball
bearing.
SHTS07Z070300121
3. INSTALL THE FRONT PLATE.

(1) As shown in the figure, insert the front plate into the pump body
and the dowel into the standard hole and the long one of front
plate
A A: Front plate
B: Pump body
NOTICE
When inserting the front plate, the face with a stamped “RR“ indi-
B cation should be turned to the rear side and also the long hole be
faced against the suction pipe side for the installation.
SHTS07Z070300122
4. INSTALL THE CAM RING.

(1) Insert the cam ring into the pump body through the standard hole
and elliptic one with the dowel, as shown in the figure.
NOTICE
At this moment, the stamped side should be faced against ball
bearing side and also the long hole turned against suction pipe
side.
SHTS07Z070300123
5. INSTALL THE ROTOR AND VANE.

(1) Insert the rotor with the cut spline "A" side facing toward the ball
bearing.
(2) Insert the vanes with the rounded part facing outward.
SHTS07Z070300124
6. INSTALL THE REAR PLATE, SPRING, O-RING AND PUMP

COVER.
(1) Put the rear plate on the cam ring through the standard hole and
elliptic one with the dowel.
NOTICE
At this moment, the stamped side should be faced against ball
bearing side and also the long hole turned against suction pipe
side.
(2) Put the spring on the rear plate and insert the O-ring into the
groove of the pump body.
SHTS07Z070300125
(3) Using a press, press in the pump cover and then install the
retainer ring securely.
NOTICE
• Be careful to see that the O-ring is not pinched by the rear
cover.
• With the pump cover pressed in completely fit the retainer
ring to pump body.
SHTS07Z070300126
7. INSPECT PUMP SHAFT ROTATING CONDITION.

(1) Check to see that the pump shaft rotates smoothly without abnor-
mal noise.
SHTS07Z070300127

EN07Z0703H300005
Shaft: — — Replace, Visual check

Damage if necessary.
Side plate: — — Replace, Visual check

Abrasion and flaw if necessary.
Flow control valve assembly: — — Replace, Visual check

Ball bearing: — — Replace, Visual check

Scratched and damage if necessary.
Cam ring inner surface: — — Replace, Visual check

Rotor surface: if necessary.
Vane surface:
Wear, scratches and scoring
Oil seal: — — Replace, Visual check

Bushing: — — Replace the Visual check

Scratched and damage pump body,
if necessary.
OIL RESERVOIR
DESCRIPTION
EN07Z0703C100006
EXCEPT FY LEFT-HAND DRIVE MODEL
SHTS07Z070300135
1 Oil reservoir cap 3 Oil strainer

2 Oil seal 4 Oil filter
SHTS07Z070300136
1 Oil reservoir cap 3 Oil strainer

2 Oil seal 4 Oil filter
COMPONENT LOCATOR
EN07Z0703D100004
SHTS07Z070300137
1 Oil reservoir cap 4 Oil filter

2 Oil seal 5 Oil reservoir
3 Oil strainer
FOR FY LEFT-HAND DRIVE MODEL
SHTS07Z070300138
1 Oil reservoir cap 4 Oil filter

2 Oil seal 5 Oil reservoir
3 Oil strainer
OVERHAUL
EN07Z0703H200005

NOTICE
• Use only compressed air to clean the oil filter.
• The oil filter is made of synthetic resin, so never wash it with
hot water, solvent or detergent.
• Before assembling, clean all the parts.

EN07Z0703H300006
Oil strainer: — — Clean or replace, Visual check

Clogged and damage if necessary.
Oil reservoir: — — Replace,

FRONT AXLE (ISO 10-STUDS TYPE) AX02–1
FRONT AXLE (ISO 10-STUDS TYPE)

AX02
AX02-001
FRONT AXLE (ISO 10-STUDS TYPE) ..... AX02-2

DATA AND SPECIFICATIONS........................ AX02-2
DESCRIPTION ................................................ AX02-3
TROUBLESHOOTING..................................... AX02-4
SPECIAL TOOL ............................................... AX02-5
COMPONENT LOCATOR ............................... AX02-7
OVERHAUL ..................................................... AX02-9
INSPECTION AND ADJUSTMENT ............... AX02-16
INSPECTION AND REPAIR .......................... AX02-18
AX02–2 FRONT AXLE (ISO 10-STUDS TYPE)
FRONT AXLE (ISO 10-STUDS TYPE)

EN0861902I200001
Specifications
Model FR, FS, FY, SH, SS ZS
Front axle series No. MF78I MFM08I
Axle beam type Reversed Elliot "I" beam
Axle beam material Heat-treated carbon
Brake drum location Outboard mounted
Wheel bearing Two tapered roller bearings
King pin thrust bearing Ball bearing
Amount of grease in a hub 600 g {21.2 oz} at one wheel
Wheel alignment
Camber 0°-2°
King pin angle 6°-8°
Caster 1°30'
Diagonal tires 1-3 mm {0.0394-0.1181 in.}

Toe-in
Radial tires 0-2 mm {0-0.0787 in.}
Knuckle turning angle
Models Tire size Inner turn Outer turn
295/80R 22.5 48°-50° 39°

FR, FS, SH, SS
315/80R 22.5 45°-47° 39°
ZS 385/80R 22.5 41° 34°
295/80R 22.5 44°-46° 34.5°

Front forward axle
315/80R 22.5 39°-41° 34°
FY
295/80R 22.5 34°-36° 30°
Front rearward axle
315/80R 22.5 29.5°-31.5° 27.5°
DESCRIPTION
EN0861902C100001
SHTS086190200001
1 Axle beam 12 Lock pin

2 Stopper bolt 13 Wheel nut
3 Tie-rod arm 14 Lock nut
4 Knuckle arm 15 Hub cap
5 Tie rod 16 Wheel hub bearing
6 Hub bolt 17 Wheel hub
7 Knuckle 18 Ball stud
8 Thrust washer 19 Tie-rod end
9 King pin 20 Oil seal
10 King pin cover 21 Oil seal guide
11 Lubrication fitting
TROUBLESHOOTING
EN0861902F300001

Hard steering or poor return of Lack of lubrication in steering linkage Lubricate king pins and ball joints.
steering wheel to center Incorrect front wheel alignment (Toe-in Correct the toe-in.
angle is incorrect.)
Incorrect front wheel alignment (Cam- Inspect king pin bushings for wear or
ber, caster of king pin angles are not deflection of knuckles axle beam and
within specifications.) tie rod, and replace if necessary.
Worn out or damaged thrust bearing Replace thrust bearings.
Tire pressure is too low Inflate to proper pressure.
Vibration or shimmy Incorrect front wheel alignment Adjust or replace parts if necessary.
Worn out king pin bushing Replace king pin bushings.
The preload of the wheel bearing is off Adjust wheel bearing preload.
Badly worn hub bearings Replace hub bearings.
Loose tie-rod ends ball joints Replace all the tie-rod ends.
Loose U-bolt nuts holding the springs Tighten the nuts properly.
to the beams
Loose hub nuts Tighten the hub nuts properly.
Distorted disc wheels Replace the disc wheels.
The tires are out of balance Balance the tires.
Run-out of the tire and wheel rim Correct the run-out of the tire and
wheel rim.
Tire and wheel are out of balance Balance the wheel using a balancing
machine.
Tire pressure is not uniform or suffi- Adjust the pressure of all tires.
cient
Other faults in the steering system Refer to the chapter STEERING
EQUIPMENT.
Abnormal tire wear Incorrect front wheel alignment Adjust properly or replace parts, if nec-
essary.
Improper tire pressure Adjust to proper pressure.
Grease leakage from wheel hub Worn out oil seal Replace oil seal.
Hub cap bolts are not tightened prop- Tighten the bolts properly.
erly
Too much grease Apply only the specified amount of
grease.
SPECIAL TOOL
EN0861902K100001
Prior to starting a front axle overhaul, it is necessary to have these special tools.
09650-1790 WHEEL HUB PULLER
09849-2001 HANDLE
09652-1210 SCREW PULLER 2 PIECES
09659-1010 ADAPTER
9209-20120 DUST COVER GUIDE NUT
09657-1790 DUST COVER GUIDE (INNER) 2 PIECES

09657-1800 DUST COVER GUIDE (OUTER)
09657-1350 KING PIN GUIDE
09654-1300 PLATE
9201-16130 NUT
09712-1100 BAR
COMPONENT LOCATOR
EN0861902D100001
FOR RIGHT-HAND DRIVE MODELS
SHTS086190200014
1 Axle beam 12 Tie-rod arm 23 Lock plate

2 Thrust washer 13 Tie rod 24 Gasket
3 Lock pin 14 Dust cover 25 Wheel hub cap
4 Thrust bearing 15 Tie-rod end assembly 26 Knuckle
5 King pin cover 16 Oil seal guide 27 Lubrication fitting
6 King pin 17 O-ring 28 Hub bolt
7 Bushing 18 Inner wheel hub bearing 29 Wheel nut
8 Oil seal 19 Brake drum 30 Caster shim
9 Stopper bolt 20 Wheel hub 31 ABS sensor ring
(If so equipped)
10 Outer wheel hub bearing 21 Washer
11 Knuckle arm 22 Wheel hub bearing lock nut

A 147-343 {1,499-3,497, 109-252} E 96-144 {979-1,468, 71-106}
B 85.5-114.5 {872-1,167, 64-84} F 105.5-144.5 {1,076-1,473, 78-106}
C 685-1,175 {6,986-11,981, 506-866} G 37.5-48.5 {383-494, 28-35}
D 8.5-10.5 {87-107, 6.3-7.7} H 20.5-39.5 {210-402, 16-29}
FOR LEFT-HAND DRIVE MODELS
SHTS086190200015

7 Bushing 18 Inner wheel hub bearing 29 Wheel nut
8 Oil seal 19 Brake drum 30 Caster shim
9 Stopper bolt 20 Wheel hub 31 ABS sensor ring
(If so equipped)
10 Outer wheel hub bearing 21 Washer

A 147-343 {1,499-3,497, 109-252} E 96-144 {979-1,468, 71-106}
B 85.5-114.5 {872-1,167, 64-84} F 105.5-144.5 {1,076-1,473, 78-106}
C 685-1,175 {6,986-11,981, 506-866} G 37.5-48.5 {383-494, 28-35}
D 8.5-10.5 {87-107, 6.3-7.7} H 20.5-39.5 {210-402, 16-29}
OVERHAUL
EN08619022300001
1. REMOVAL OF THE WHEELS

2. REMOVAL OF THE WHEEL HUB BEARING LOCK NUT

SST:
Socket Wrench (09839-7001)
Handle (09849-2001)
SHTS086190200016
3. REMOVAL OF THE WHEEL HUB ASSEMBLY AND THE INNER

RACE OF OUTER WHEEL HUB BEARING
SST:
Wheel Hub Puller (09650-1790)
Handle (09849-2001)
NOTICE
Wheel hub assembly is heavy, therefore be careful when handling
it.
SHTS086190200017
4. REMOVAL OF THE INNER RACE OF INNER WHEEL HUB

BEARING TOGETHER WITH OIL SEAL GUIDE
SST: Screw Puller (09652-1210)
5. REMOVAL OF THE WHEEL BRAKE

(1) Refer to chapter SERVICE BRAKE.
SHTS086190200018
6. REMOVAL OF THE LOCK PIN

(1) Remove the lock nut.
(2) Drive out the lock pin, using a special tool and a hammer.
NOTICE
Be careful not to bend the thread part.
SHTS086190200019
7. REMOVAL OF THE KING PIN

(1) Drive out the king pin, using a brass bar and a hammer.
NOTICE
• Be careful not to damage the inner surface of bush of
knuckle and insert part of king pin of axle beam.
• Be careful not to drop the king pin.
SHTS086190200020
8. REMOVAL OF THE KNUCKLE

(1) Remove the knuckle, thrust washer and thrust bearings.
NOTICE
Be careful not to drop the thrust washer and thrust bearings.
SHTS086190200021
9. SEPARATION OF THE BRAKE DRUM AND WHEEL HUB

(EXAMPLE)
(1) Remove the bolts, and separate the brake drum and wheel hub.
SHTS086190200022
1. REPLACEMENT OF THE DUST COVER

NOTICE
Apply lithium molybdenum sulfide grease to the inside and lip
part of the dust cover.
SST:
SHTS086190200023
2. REPLACEMENT OF THE WHEEL HUB BEARING RACE

(1) Remove the outer race of bearing by striking the race lightly and
evenly through the 4 access holes in the wheel hub, using a tap-
ping rod.
(2) To install the outer race, use a tapping rod and a hammer, or a
press.
SHTS086190200024
3. REPLACEMENT OF THE HUB BOLTS

(1) Remove the hub bolts from the wheel hub.
(2) Install the new hub bolts.
NOTICE
The right and left hub bolts differ, so install them according to the
chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
SHTS086190200025
4. ASSEMBLY OF THE BRAKE DRUM AND WHEEL HUB

(EXAMPLE)
(1) Assemble the brake drum and wheel hub, and tighten the bolts.
SHTS086190200022
NOTICE
When assembling the brake drum and wheel hub, make sure that
their aligning marks are oriented as closely to each other as pos-
sible.
SHTS086190200026
5. INSTALLATION OF THE AXLE BEAM

(1) Secure the axle to the leaf springs with U-bolts.
NOTICE
Confirm the direction of caster shim.
SHTS086190200027
6. INSTALLATION OF THE KNUCKLE

NOTICE
Before installation, apply chassis grease to the king pin bush, the
rip part of the oil seal and the sliding surfaces of axle beam and
knuckle.
SHTS086190200028
7. ADJUSTMENT OF THE CLEARANCE BETWEEN THE

THRUST WASHER AND KNUCKLE
(1) Adjust the clearance with the correct thickness thrust washer.
Assembly Standard: Less than 0.1 mm {0.004 in.}
Thickness of Thrust Washer: mm {in.}
3.2 {0.126} 3.3 {0.130} 3.4 {0.134} 3.5 {0.138}
3.6 {0.142} 3.7 {0.146} 3.8 {0.150}
SST:
King Pin Guide (09657-1350)
Plate (09654-1300)
Nut (9201-16130)
SHTS086190200029 Bar (09712-1100)
8. ASSEMBLY OF THE WHEEL BRAKE

9. LUBRICATION
(1) Lubricate the king pin with chassis grease, using the lubrication
fittings located on the two king pin covers.
(2) Lubricate the ball joint of the drag link and the tie rod with the
chassis grease, using the lubrication fittings.
SHTS086190200030
10. INSTALLATION OF THE OIL SEAL GUIDE

OIL SEAL GUIDE NOTICE
• Install the O-ring to bore side of oil seal guide as shown in
the figure.
• Align the stopper bolt hole of the knuckle and oil seal guide
hole.
• If oil seal guide is warmed up with hot water, it can easily be
installed.
O-RING
SHTS086190200031
SHTS086190200032
11. GREASING
(1) Before assembling, apply wheel hub bearing grease to the follow-
ing parts as shown in the figure.
1. Inner wheel hub bearing inner race

2. Outer wheel hub bearing inner race
3. Sealing lip of the oil seal
4. Wheel hub
5. Knuckle spindle
SHTS086190200033
12. INSTALLATION OF THE WHEEL HUB BEARINGS AND

WHEEL HUB ASSEMBLY
(1) Install the inner race of inner wheel hub bearing.
NOTICE
Using a tool as shown, simplifies installation.
SHTS086190200034
(2) Install the oil seal in the wheel hub.

(3) Install the wheel hub assembly and the inner race of outer wheel
hub bearing.
NOTICE
• Using a tool as shown, simplifies installation.
• The wheel hub assembly is heavy, therefore be careful when
handling it.
(4) Install the lock washer.
NOTICE
Apply bearing grease to the space between outer wheel hub bear-
SHTS086190200035
ing and lock washer.
13. ADJUSTMENT OF THE WHEEL HUB BEARING PRELOAD

(1) Tighten the wheel hub bearing lock nut with the specified torque
then loosen the nut by 1/6 - 1/4 turn.
Tightening Torque:
Approx. 343 N⋅m {3,500 kgf⋅cm, 253 lbf⋅ft}
SHTS086190200036
SHTS086190200068
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub, and check the return of the bearing. (Check that the
hub can be turned by hands, and the nut cannot be turned by
hands.)
(3) Measure the wheel bearing preload. If it exceeds or it is less than
the standard value shown below, and adjust the preload with the
lock nut.
Assembly Standard:
New bearing Re-used bearing
Turning Torque 3.14-5.10 2.94-5.10
N⋅m {kgf⋅cm, lbf⋅ft} {33-35, 2.4-3.7} {30-35, 2.2-3.7}
Spring balancer reading 18.7-30.4 17.6-30.4
N {kgf, lbf} {2.0-3.0, 4.3-6.8} {1.8-3.0, 4.0-6.8}
SHTS086190200038
14. INSTALLATION OF THE LOCK PLATE

NOTICE
• If the holes of the plate are not aligned with the screw holes
of the nut, turn over the plate.
• If alignment is still unattainable, turn the lock nut further
within the limits of wheel hub bearing preload.
SHTS086190200039
15. INSTALLATION OF THE HUB CAP

NOTICE
Before installing the cap, apply wheel hub bearing grease to the
inner surface of the cap.
16. INSTALLATION OF THE WHEELS

SHTS086190200040
17. TURN THE STEERING WHEEL TO THE FULL RANGE TO THE

RIGHT AND THE LEFT, AND CONFIRM THAT ALL STEERING
LINKAGES MOVE FREELY (ESPECIALLY THE BALL JOINTS).
SHTS086190200041
18. THE BRAKE SHOE CLEARANCE AND THE BRAKE CHAM-

BER ROD STROKE ADJUSTMENT
(1) On completion of the wheel hub and related parts reassembly,
conduct the followings:
• Adjust the brake shoe clearance according to the section WHEEL
BRAKE in the chapter SERVICE BRAKE.
INSPECTION AND ADJUSTMENT

EN0861902H300001
1. INSPECTION OF THE WHEEL ALIGNMENT

(1) Park the vehicle on a level surface and check the tire pressure.
SHTS086190200042
(2) Adjust the king pin inclination, caster, and camber.

Refer to section DATA AND SPECIFICATIONS.
SHTS086190200043
(3) Check the toe-in.

• B - A =Toe-in
SHTS086190200044
2. ADJUSTMENT OF ALIGNMENT BETWEEN FRONT FOWERD

AXLE AND FRONT REARWARD AXLE (MODEL: FY)
NOTICE
Following procedures to Right-hand drive models.
(1) Toe-in must be adjusted within the specified value for both for-
ward and rearward front axles.
(2) Park the unloaded vehicle on a level surface.
(3) Remove the right side tires from front axles with placing a stand or
a jack under the front axle beams at the right-hand side.
SHTS086190200045
(4) Place the turn table under the left side tires of the both front axles.
SHTS086190200046
(5) Adjust the height of the stand or jack so that the front axle beams
are level.
SHTS086190200047
(6) Set the brake drum surface of first axle and frame for parallel.
STRETCH BAR (7) Set the stretch bar on the sides of the hub at the right-hand side of
RELAY ROD SOCKET
the forward and rearward front axles.
A B C D (8) Make proper adjustment by mean of the relay rod so that the four
RELAY ROD points, "A", "B", "C" and "D" may be on the same line.
Clearance between front rearward axle hub side face and the
stretch bar:
0.4 mm {0.016 in.} or less
(9) Check the toe-in after the tire has been installed.
FORWARD REARWARD NOTICE
AXLE AXLE At this time, if adjusted the tie rod, confirm above item 7 and 8.
SHTS086190200048
3. ADJUSTMENT OF THE WHEEL TURNING ANGLE WITH

STOPPER BOLT
(1) Refer to section DATA AND SPECIFICATIONS.
SHTS086190200049

EN0861902H300002
Unit: mm {in.}
Bearing and race: — — Replace, Visual check

Burns and pitting if necessary.
Replace, Visual check

if necessary.
Oil seal guide: — — Replace, Visual check

Wear if necessary.
Hub bolts: — — Replace, Visual check

Threads wear and if necessary.
damage
Knuckle: — — Replace, Use the magnetic flaw detec-

Wear and damage if necessary. tor or color checking instru-
ment.
King pin: — — Replace, Use the magnetic flaw

Wear and damage if necessary. detector or color checking
instrument.
Knuckle arm and tie-rod — — Replace, Use the magnetic flaw detec-
arm: if necessary. tor or color checking instru-
Crack and damage ment.
King pin diameter 50 49.85 Replace. Measure

{1.969} {1.9626}
King pin clearance 0.025-0.080 0.35 Replace. Measure

{0.0010-0.0031} {0.0138}
Thrust bearing: — — Replace, Visual check

Tie rod: — — Replace, Visual check

Distortion if necessary.
Tie-rod end ball stud: — — Replace the tie-rod Visual check

Threads wear and dam- end assembly.
age
Tie-rod end ball joint: — —

Gutter
Tie-rod end and dust — — Replace, Visual check

cover: if necessary.
Crack
Muddy water in the — — Replace the tie-rod

cover end assembly.
(Sealed type ball stud)
Axle beam: — — Replace, Use the magnetic flaw

Crack and damage if necessary. detector or color checking
instrument.
Clearance between 0-0.036 0.1 Replace. Measure

king pin and axle beam {0-0.0014} {0.0039}
Axle beam: — 1.0 Repair or replace. Measure

Bend of cross direction {0.039} NOTICE TRY SQUARE TRY SQUARE
Never heat repair. LINE
WEIGHT WEIGHT
BEND OF CROSS
DIRECTION
LINE
TRY SQUARE
BEND =MEASURED VALUE -10 mm {0.39 in.}
King pin mounting 7°30' 6°30'-8°30' Replace. Measure

angle AXLE BEAM
KING PIN
CASTER
SHIM (2.5 )
V-BLOCK
LEVEL BLOCK ANGLE GAUGE
Thrust washer: — 0.5 Replace the thrust Measure

wear (Clearance {0.0197} washer.
between knuckle and
axle beam)
FRONT AXLE (TRILEX TYPE) AX02–1
FRONT AXLE (TRILEX TYPE)

AX02
AX02-002
FRONT AXLE (TRILEX TYPE) ................. AX02-2

DESCRIPTION ................................................ AX02-3
SPECIAL TOOL ............................................... AX02-5
OVERHAUL ..................................................... AX02-8
INSPECTION AND ADJUSTMENT ............... AX02-14
AX02–2 FRONT AXLE (TRILEX TYPE)
FRONT AXLE (TRILEX TYPE)

EN0862002I200001
Front axle series No. MF88S
Axle beam type Reversed Elliot "I" beam
Axle beam material Chrome molybdenum steel
Brake drum location Inboard mounted
Wheel bearing Two tapered roller bearings
King pin thrust bearing Ball bearing
Camber 0°-2°
King pin angle 6°-8°
Caster 1°30'
Diagonal tires 1-3 mm {0.0394-0.1181 in.}

Toe-in
Radial tires 0-2 mm {0-0.0787 in.}
Inner turn 32°-34°

Knuckle turning angle
Outer turn 29°
Amount of grease in a hub 600 g {21.2 oz} at one wheel

DESCRIPTION
EN0862002C100001
SHTS086200200001
1 Axle beam 12 Lock pin

2 Stopper bolt 13 Hub nut
3 Tie-rod arm 14 Lock nut
4 Knuckle arm 15 Hub cap
5 Tie rod 16 Wheel hub bearing
6 Hub bolt 17 Wheel hub
7 Knuckle 18 Ball stud
8 Thrust washer 19 Tie-rod end
9 King pin 20 Oil seal
10 King pin cover 21 Oil seal guide
11 Lubrication fitting
TROUBLESHOOTING
EN0862002F300001

Hard steering or poor return of Lack of lubrication in steering linkage Lubricate king pins and ball joints.
steering wheel to center Incorrect front wheel alignment (Toe-in Correct the toe-in.
angle is incorrect.)
Incorrect front wheel alignment (Cam- Inspect king pin bushings for wear or
ber, caster of king pin angles are not deflection of knuckles axle beam and
within specifications.) tie rod, and replace if necessary.
Worn out or damaged thrust bearing Replace thrust bearings.
Tire pressure is too low Inflate to proper pressure.
Vibration or shimmy Incorrect front wheel alignment Adjust or replace parts if necessary.
Worn out king pin bushing Replace king pin bushings.
The preload of the wheel bearing is off Adjust wheel bearing preload.
Badly worn hub bearings Replace hub bearings.
Loose tie-rod ends ball joints Replace all the tie-rod ends.
Loose U-bolt nuts holding the springs Tighten the nuts properly.
to the beams
Loose hub nuts Tighten the hub nuts properly.
Distorted disc wheels Replace the disc wheels.
The tires are out of balance Balance the tires.
Run-out of the tire and wheel rim Correct the run-out of the tire and
wheel rim.
Tire and wheel are out of balance Balance the wheel using a balancing
machine.
Tire pressure is not uniform or suffi- Adjust the pressure of all tires.
cient
Other faults in the steering system Refer to the CHAPTER, STEERING
EQUIPMENT.
Abnormal tire wear Incorrect front wheel alignment Adjust properly or replace parts, if nec-
essary.
Improper tire pressure Adjust to proper pressure.
Grease leakage from wheel hub Worn out oil seal Replace oil seal.
Hub cap bolts are not tightened prop- Tighten the bolts properly.
erly
Too much grease Apply only the specified amount of
grease.
SPECIAL TOOL
EN0862002K100001
Prior to starting a front axle overhaul, it is necessary to have these special tools.
09849-2001 HANDLE
09652-1210 SCREW PULLER 2 PIECES
09659-1010 ADAPTER
9209-20120 DUST COVER GUIDE NUT
09657-1790 DUST COVER GUIDE (INNER) 2 PIECES

09657-1800 DUST COVER GUIDE (OUTER)
09657-1350 KING PIN GUIDE
09654-1300 PLATE
9201-16130 NUT
09712-1100 BAR
COMPONENT LOCATOR
EN0862002D100001
SHTS086200200014

7 Bushing 18 Inner wheel hub bearing 29 Pin
8 Oil seal 19 Brake drum 30 Clamp
9 Stopper bolt 20 Wheel hub 31 Hub nut
10 Outer wheel hub bearing 21 Lock washer 32 Caster shim

A 147-343 {1,499-3,497, 109-252} E 96-144 {979-1,468, 71-106}
B 85.5-114.5 {872-1,167, 64-84} F 105.5-144.5 {1,076-1,473, 78-106}
C 685-1,175 {6,986-11,981, 506-866} G 37.5-48.5 {383-494, 28-35}
D 8.5-10.5 {87-107, 6.3-7.7} H 393-471 {4,008-4,802, 290-347}
OVERHAUL
EN08620022300001


SST:
Handle (09849-2001)
SHTS086200200015
3. REMOVAL OF THE WHEEL HUB ASSEMBLY AND THE INNER

RACE OF OUTER WHEEL HUB BEARING
SST:
Handle (09849-2001)
NOTICE
Wheel hub assembly is heavy, therefore be careful when handling
it.
SHTS086200200016
4. REMOVAL OF THE INNER RACE OF INNER WHEEL HUB

BEARING TOGETHER WITH OIL SEAL GUIDE
SST: Screw Puller (09652-1210)

SHTS086200200017
6. REMOVAL OF THE LOCK PIN

(1) Remove the lock nut.
(2) Drive out the lock pin, using a special tool and a hammer.
NOTICE
Be careful not to bend the thread part.
SHTS086200200018
7. REMOVAL OF THE KING PIN

(1) Drive out the king pin, using a brass bar and a hammer.
NOTICE
• Be careful not to damage the inner surface of bush of
knuckle and insert part of king pin of axle beam.
• Be careful not to drop the king pin.
SHTS086200200019
8. REMOVAL OF THE KNUCKLE

(1) Remove the knuckle, thrust washer and thrust bearings.
NOTICE
Be careful not to drop the thrust washer and thrust bearings.
SHTS086200200020
1. REPLACEMENT OF THE DUST COVER

NOTICE
Apply lithium molybdenum sulfide grease to the inside and lip
part of the dust cover.
SST:
SHTS086200200021

evenly, using a tapping rod.
(2) To install the outer race, use a tapping rod and a hammer, or a
press.
SHTS086200200022
3. ASSEMBLY OF THE BRAKE DRUM AND WHEEL HUB

(1) Assemble the brake drum and wheel hub, and tighten the bolts
and nuts.
NOTICE
When assembling the brake drum and wheel hub, make sure that
their aligning marks are oriented as closely to each other as pos-
sible.
SHTS086200200023
4. INSTALLATION OF THE AXLE BEAM

(1) Secure the axle to the leaf springs with U-bolts.
NOTICE
Confirm the direction of caster shim.
SHTS086200200024
5. INSTALLATION OF THE KNUCKLE

NOTICE
Before installation, apply chassis grease to the king pin bush, the
rip part of the oil seal and the sliding surfaces of axle beam and
knuckle.
SHTS086200200025
6. ADJUSTMENT OF THE CLEARANCE BETWEEN THE

THRUST WASHER AND KNUCKLE
(1) Adjust the clearance with the correct thickness thrust washer.
Assembly Standard: Less than 0.1 mm {0.004 in.}
Thickness of Thrust Washer: mm {in.}
3.2 {0.126} 3.3 {0.130} 3.4 {0.134} 3.5 {0.138}
3.6 {0.142} 3.7 {0.146} 3.8 {0.150}
SST:
King Pin Guide (09657-1350)
Plate (09654-1300)
Nut (9201-16130)
SHTS086200200026 Bar (09712-1100)
7. ASSEMBLY OF THE WHEEL BRAKE

8. LUBRICATION
(2) Lubricate the ball joint of the drag link and the tie rod with the
chassis grease, using the lubrication fittings.
SHTS086200200027
9. INSTALLATION OF THE OIL SEAL GUIDE

OIL SEAL GUIDE NOTICE
• Install the O-ring to bore side of oil seal guide as shown in
the figure.
• Align the stopper bolt hole of the knuckle and oil seal guide
hole.
• If oil seal guide is warmed up with hot water, it can easily be
installed.
O-RING
SHTS086200200028
SHTS086200200029
10. GREASING
(1) Before assembling, apply wheel hub bearing grease to the follow-
ing parts as shown in the figure.
1. Inner wheel hub bearing inner race

2. Outer wheel hub bearing inner race
3. Sealing lip of the oil seal
4. Wheel hub
5. Knuckle spindle
SHTS086200200030
11. INSTALLATION OF THE WHEEL HUB BEARINGS AND

WHEEL HUB ASSEMBLY
(1) Install the inner race of inner wheel hub bearing.
NOTICE
Using a tool as shown, simplifies installation.
SHTS086200200031
(2) Install the oil seal in the wheel hub.

(3) Install the wheel hub assembly and the inner race of outer wheel
hub bearing.
NOTICE
• Using a tool as shown, simplifies installation.
handling it.
(4) Install the lock washer.
NOTICE
Apply bearing grease to the space between outer wheel hub bear-
SHTS086200200032 ing and lock washer.

Tightening Torque:
Approx. 343 N⋅m {3,500 kgf⋅cm, 253 lbf⋅ft}
SHTS086200200033
wheel hub, and check the return of the bearing. (Check that the
hub can be turned by hands, and the nut cannot be turned by
hands.)
the standard value shown below, and adjust the preload with the
lock nut.
Assembly Standard:
New bearing Re-used bearing
Turning Torque 3.14-5.10 2.94-5.10
N⋅m {kgf⋅cm, lbf⋅ft} {33-35, 2.4-3.7} {30-35, 2.2-3.7}
Spring balancer reading 18.7-30.4 17.6-30.4
N {kgf, lbf} {2.0-3.0, 4.3-6.8} {1.8-3.0, 4.0-6.8}
SHTS086200200034
NOTICE
• If the holes of the plate are not aligned with the screw holes
of the nut, turn over the plate.
14. INSTALLATION OF THE HUB CAP

NOTICE
Before installing the cap, apply wheel hub bearing grease to the
inner surface of the cap.

SHTS086200200035
16. TURN THE STEERING WHEEL TO THE FULL RANGE TO THE

RIGHT AND THE LEFT, AND CONFIRM THAT ALL STEERING
LINKAGES MOVE FREELY (ESPECIALLY THE BALL JOINTS).
SHTS086200200036

conduct the followings:
• Adjust the brake shoe clearance according to the section WHEEL
BRAKE in the chapter SERVICE BRAKE.
INSPECTION AND ADJUSTMENT

EN0862002H300001
1. INSPECTION OF THE WHEEL ALIGNMENT

(1) Park the vehicle on a level surface and check the tire pressure.
SHTS086200200037
(2) Adjust the king pin inclination, caster, and camber.

Refer to section DATA AND SPECIFICATIONS.
SHTS086200200038
(3) Check the toe-in.

• B - A =Toe-in
SHTS086200200039
2. ADJUSTMENT OF THE WHEEL TURNING ANGLE WITH

STOPPER BOLT
(1) Refer to section DATA AND SPECIFICATIONS.
SHTS086200200040

EN0862002H300002
Unit: mm {in.}
Bearing and race: — — Replace, Visual check

Replace, Visual check

if necessary.

Wear if necessary.
Hub bolts: — — Replace, Visual check

Threads wear and if necessary.
damage
Knuckle: — — Replace, Use the magnetic flaw detec-

Wear and damage if necessary. tor or color checking instru-
ment.
King pin: — — Replace, Use the magnetic flaw

Wear and damage if necessary. detector or color checking
instrument.
Knuckle arm and — — Replace, Use the magnetic flaw detec-

tie-rod arm: if necessary. tor or color checking instru-
Crack and damage ment.
King pin diameter 50 49.85 Replace. Measure

{1.969} {1.9626}
King pin clearance 0.025-0.080 0.35 Replace. Measure

{0.0010-0.0031} {0.0138}
Thrust bearing: — — Replace, Visual check

Tie rod: — — Replace, Visual check

Distortion if necessary.
Tie-rod end ball stud: — — Replace the tie-rod Visual check

Threads wear and dam- end assembly.
age
Tie-rod end ball joint: — —

Gutter
Tie-rod end and dust — — Replace, Visual check

cover: if necessary.
Crack
Muddy water in the — — Replace the tie-rod

cover end assembly.
(Sealed type ball stud)
Axle beam: — — Replace, Use the magnetic flaw

Crack and damage if necessary. detector or color checking
instrument.
Clearance between 0-0.036 0.1 Replace. Measure

king pin and axle beam {0-0.0014} {0.0039}
Axle beam: — 1.0 Repair or replace. Measure

Bend of cross direction {0.039} NOTICE TRY SQUARE TRY SQUARE
Never heat repair. LINE
WEIGHT WEIGHT
BEND OF CROSS
DIRECTION
LINE
TRY SQUARE
BEND =MEASURED VALUE -10 mm {0.39 in.}
King pin mounting 7°30' 6°30'-8°30' Replace. Measure

angle
AXLE BEAM
KING PIN
CASTER
SHIM (2.5 )
V-BLOCK
LEVEL BLOCK ANGLE GAUGE
Thrust washer: — 0.5 Replace the thrust Measure

wear (Clearance {0.0197} washer.
between knuckle and
axle beam)
REAR AXLE (WITH ISO TYPE WHEEL) AX03–1
REAR AXLE (WITH ISO TYPE WHEEL)

AX03
AX03-001
REAR AXLE .............................................. AX03-2

DESCRIPTION ................................................ AX03-2
SPECIAL TOOL ............................................... AX03-5
OVERHAUL ................................................... AX03-12
AX03–2 REAR AXLE (WITH ISO TYPE WHEEL)
REAR AXLE
EN0861903I200001
Type Full-floating axle shaft
Housing Banjo type, with extension tubes welded on both ends
Type of drive Torque rod drive or hotchkiss drive
DESCRIPTION
EN0861903C100001
DIFFERENTIAL GEAR SERIES: THD17/THD18
SHTS086190300001
1 Differential carrier assembly 8 Wheel hub

2 Brake drum 9 Axle shaft
3 Oil seal collar 10 Lock nut
4 Oil seal 11 Axle housing
5 Wheel hub bearing 12 ABS sensor ring (If so equipped)
6 Hub bolt 13 Lock washer
7 Wheel nut 14 Lock plate
DIFFERENTIAL GEAR SERIES: SH17/SH18/SH19
SHTS086190300002

5 Wheel hub bearing 12 ABS sensor ring (If so equipped)
6 Hub bolt 13 Lock washer
7 Wheel nut 14 Lock plate
TROUBLESHOOTING
EN0861903F300001

Abnormal noise (Bearing system) Worn or damaged pinion bearings Replace bearings.
Worn or damaged differential side Replace bearings.
bearings
Loose pinion bearings Adjust bearing preload.
Loose differential side bearings Adjust bearing preload.
Abnormal noise (Gear system) Inadequate backlash on ring gear and Adjust backlash.
pinion gear
Worn thrust washers Replace.
Worn differential spider Replace.
Worn or damaged ring gear and pinion Replace.
Worn or damaged differential side Replace.
gears and pinions
Loose ring gear tightening bolts Tighten bolts.
Inadequate tooth contact of ring gear Replace or adjust tooth contact.
and pinion gear
Worn pinion spline Replace.
Abnormal noise (Rear axle system) Worn rear axle shaft spline Replace.
Worn hub bearings Replace.
Loose hub bearings Adjust bearing preload.
Loose differential case tightening bolts Tighten bolts.
Abnormal noise (Oil system, etc.) Insufficient oil Add oil; check for leakage.
Poor oil quality Change oil.
Abnormal noise of propeller shaft Refer to chapter PROPELLER SHAFT.
SPECIAL TOOL
EN0861903K100001
Prior to starting a rear axle overhaul, it is necessary to have these special tools.
09650-1310 HUB BEARING PULLER
09849-1601
HANDLE
09849-2001
COMPONENT LOCATOR
EN0861903D100001
DIFFERENTIAL GEAR SERIES: THD17/THD18
SHTS086190300007
1 Axle housing assembly 12 Oil seal

2 Air breather 13 Inner wheel hub bearing
3 O-ring 14 Axle shaft
4 Gasket 15 Wheel hub
5 Oil filler plug 16 Outer wheel hub bearing
6 Oil drain plug 17 Lock washer
7 Spring bracket 18 Lock nut
8 Through shaft assembly 19 Lock plate
9 Differential carrier assembly 20 Hub bolt
10 ABS sensor ring (If so equipped) 21 Wheel nut
11 Oil seal guide 22 Brake drum

A 9.8-19.6 {100-200, 7.3-14.4} F 167-213 {1,700-2,200, 123-159}
B 78.4-117.6 {800-1,200, 58-86} G 148-192 {1,500-2,000, 109-144}
C 39.2-68.6 {400-700, 29-50} H 8.33-10.79 {85-110, 6.2-8.0}
D 236-324 {2,400-3,300, 175-238} I 20.5-39.5 {210-400, 16-29}
E 64-84 {650-850, 47-63}
DIFFERENTIAL GEAR SERIES: SH17/SH18/SH19
SHTS086190300008
1 Axle housing assembly 12 Inner wheel hub bearing

2 Air breather 13 Axle shaft
3 O-ring 14 Wheel hub
4 Gasket 15 Outer wheel hub bearing
5 Oil filler plug 16 Lock washer
6 Oil drain plug 17 Lock nut
7 Spring bracket 18 Lock plate
8 Differential carrier assembly 19 Hub bolt
9 ABS sensor ring (If so equipped) 20 Wheel nut
10 Oil seal guide 21 Brake drum
11 Oil seal

A 9.8-19.6 {100-200, 7.3-14.4} E 167-213 {1,700-2,200, 123-159}
B 78.4-117.6 {800-1,200, 58-86} F 148-192 {1,500-2,000, 109-144}
C 39.2-68.6 {400-700, 29-50} G 8.33-10.79 {85-110, 6.2-8.0}
D 236-324 {2,400-3,300, 175-238} H 20.5-39.5 {210-400, 16-29}
DEAD AXLE
SHTS086190300009
1 Dead axel tube 9 Lock nut

2 Oil seal guide 10 Lock plate
3 Expansion plug 11 Gasket
4 Oil seal 12 Wheel hub cover
5 Inner wheel hub bearing 13 Hub bolt
6 Wheel hub 14 Wheel nut
7 Outer wheel hub bearing 15 Brake drum
8 Lock washer

A 8.33-10.79 {85-110, 6.2-8.0} C 20.5-39.5 {210-400, 16-29}
B 10.7-146.6 {1,100-1,500, 81-110}
OVERHAUL
EN0861903H200001


SST:
Handle (09849-1601)
Handle (09849-2001)
SHTS086190300010
3. REMOVAL OF THE WHEEL HUB ASSEMBLY AND THE

OUTER WHEEL HUB BEARING
SST:
Handle (09849-1601)
Handle (09849-2001)
NOTICE
The wheel hub assembly is heavy, therefore be careful when han-
dling it.
SHTS086190300011
4. REMOVAL OF THE INNER WHEEL HUB BEARING

TOGETHER WITH OIL SEAL COLLAR
SST:
Hub Bearing Puller (09650-1310)
Handle (09849-1601)
Handle (09849-2001)

SHTS086190300012

evenly through the 4 access holes in the wheel hub, using a tap-
ping rod.
SHTS086190300013
(2) Using a tapping rod and a hammer or a press, install the outer
race.
SHTS086190300014
2. SEPARATION OF THE BRAKE DRUM

(1) Loosen the drum set screws, separate the brake drum and wheel
hub.
NOTICE
• If the drum does not easily come out, screw the set screws
into the drum removing hole.
• Brake drum is heavy, therefore be careful when handling it.
3. REPLACEMENT OF THE HUB BOLTS

(1) Remove the hub bolts from the wheel hub.
(2) Install the new hub bolts.
SHTS086190300015 NOTICE
The left and right hub bolts differ, so install them according to the
chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
4. ASSEMBLING OF THE BRAKE DRUM

(1) Assemble the brake drum and the wheel hub, and tighten the
drum set screw.
5. GREASING
(1) Pack sufficient amount of wheel hub bearing grease between the
bearing rollers.
NOTICE
"1": Fill the grease to spaces among the inner race, rollers and
retainer to the extent that there is not any vacancy remained.
SHTS086190300016
(2) Apply bearing grease to wheel hub.

NOTICE
• "2": Fill the grease between the oil seal and inner bearing,
and at this time some grease may flow out to the oil seal.
• "3": The grease has to ooze out to the extent that the retainer
is buried.
• "4": After pressing in the inner race of the inner bearing,
apply the grease to the end of race circumferentially with the
width of 15 mm {0.591 in}.
• "5": When filling the grease to this space, do it up to the line
which connects between the small diameter sides edges of 2
SHTS086190300017
bearings.
• "6": Fill the grease up the half depth of the lock nut.
6. INSTALLATION OF THE OIL SEAL, THE WHEEL HUB BEAR-

INGS AND WHEEL HUB ASSEMBLY
(1) Install the oil seal and the inner wheel hub bearing.
NOTICE
• If the guide is warmed up with hot water, it can easily be
installed.
SHTS086190300018
(2) Install the wheel hub assembly and the outer wheel hub bearing.
NOTICE
• Using a tool as shown simplifies installation.
handling it.
SHTS086190300019

Tightening Torque:
588-1,176 N⋅m {6,000-12,000 kgf⋅cm, 434-867 lbf⋅ft}
SHTS086190300020
wheel hub.
SHTS086190300021

the standard value shown below, adjust the preload with the lock
nut.
Assembly standard:
Turning Torque 3.9-7.9
N⋅m {kgf⋅cm, lbf⋅ft} {40-80, 2.9-5.8}
Spring balancer reading 23.3-47.1
N {kgf, lbf} {2.4-4.8, 5.3-10.5}
SHTS086190300022

(1) Install the lock plate to the lock nut.
NOTICE
• If the holes of the plate are not aligned with screw holes of
the nut, turn over the plate.
TIGHTENING
DIRECTION
SHTS086190300023
conduct the followings.
a. Adjust the brake shoe clearance according to the section
WHEEL BRAKE in the chapter SERVICE BRAKE.

EN0861903H300001
Unit: mm {in.}
Wheel hub bearing race: — — Replace, Visual check

Burns, pitting and cracks if necessary.
Wheel hub bearings: — — Replace, Visual check

Hub bolt: — — Replace, Visual check


Axel shaft: 0.8 — Replace. Measure

Bend {0.0314}
(Measure the bend at 2 or or less A
3 points of the range "A".)
Axel shaft flange: 0.3 — Replace. Measure

Bend {0.0118}
or less
Axle shaft flange and — — Replace, Use the magnetic flaw

spline: if necessary. detector or color checking
Wear and damage instrument.
Axle tube: — — Replace, Visual check

REAR AXLE (WITH SPOKE TYPE WHEEL) AX03–1
REAR AXLE (WITH SPOKE TYPE WHEEL)

AX03
AX03-002
REAR AXLE .............................................. AX03-2

DESCRIPTION ................................................ AX03-2
SPECIAL TOOL ............................................... AX03-4
OVERHAUL ..................................................... AX03-6
AX03–2 REAR AXLE (WITH SPOKE TYPE WHEEL)
REAR AXLE
EN0862003I200001
Type Full-floating axle shaft
Housing Banjo type, with extension tubes welded on both ends
Type of drive Torque rod drive
DESCRIPTION
EN0862003C100001
SHTS086200300001

5 Wheel hub bearing 12 Lock washer
6 Hub bolt 13 Lock plate
7 Wheel nut
TROUBLESHOOTING
EN0862003F300001

Abnormal noise (Bearing system) Worn or damaged pinion bearings Replace bearings.
Worn or damaged differential side Replace bearings.
bearings
Loose pinion bearings Adjust bearing preload.
Loose differential side bearings Adjust bearing preload.
Abnormal noise (Gear system) Inadequate backlash on ring gear and Adjust backlash.
pinion gear
Worn thrust washers Replace.
Worn differential spider Replace.
Worn or damaged ring gear and pinion Replace.
Worn or damaged differential side Replace.
gears and pinions
Loose ring gear tightening bolts Tighten bolts.
Inadequate tooth contact of ring gear Replace or adjust tooth contact.
and pinion gear
Worn pinion spline Replace.
Abnormal noise (Rear axle system) Worn rear axle shaft spline Replace.
Worn hub bearings Replace.
Loose hub bearings Adjust bearing preload.
Loose differential case tightening bolts Tighten bolts.
Abnormal noise (Oil system, etc.) Insufficient oil Add oil; check for leakage.
Poor oil quality Change oil.
Abnormal noise of propeller shaft Refer to chapter PROPELLER
SHAFT.
SPECIAL TOOL
EN0862003K100001
Prior to starting a rear axle overhaul, it is necessary to have these special tools.
09650-1310 HUB BEARING PULLER
09849-1601
HANDLE
09849-2001
COMPONENT LOCATOR
EN0862003D100001
SHTS086200300006
1 Axle housing assembly 8 Oil seal 15 Outer wheel hub bearing

2 Air breather 9 Inner wheel hub bearing 16 Lock washer
3 Gasket 10 Spoke wheel hub 17 Lock nut
4 Oil filler plug 11 Hub bolt 18 Lock plate
5 Oil drain plug 12 Pin 19 Axle shaft
6 Differential carrier assembly 13 Clamp 20 Brake drum
7 Through shaft assembly 14 Wheel nut

A 148-192 {1,510-1,957, 110-141} F 9.8-19.6 {100-199, 7.3-14.4}
B 78.4-117.6 {800-1,199, 58-86} G 64-84 {653-856, 48-62}
C 39.2-68.6 {400-699, 29-50} H 107.4-146.6 {1,096-1,495, 80-108}
D 8.33-10.79 {85-110, 6.2-7.9} I 393-471 {4,008-4,802, 290-347}
E 167-213 {1,703-2,171, 124-157}
OVERHAUL
EN0862003H200001
1. REMOVAL OF THE RIM AND TIRE


SST:
Handle (09849-1601)
Handle (09849-2001)
SHTS086200300007
3. REMOVAL OF THE WHEEL HUB ASSEMBLY AND THE

OUTER WHEEL HUB BEARING
SST:
Handle (09849-1601)
Handle (09849-2001)
NOTICE
The wheel hub assembly is heavy, therefore be careful when han-
dling it.
SHTS086200300008
4. REMOVAL OF THE INNER WHEEL HUB BEARING

TOGETHER WITH OIL SEAL COLLAR
SST:
Hub Bearing Puller (09650-1310)
Handle (09849-1601)
Handle (09849-2001)

SHTS086200300009

(1) Remove the outer race of bearing by striking the race (part "A")
lightly and evenly through the 4 access holes in the wheel hub,
using a tapping rod.
SHTS086200300010
(2) Using a tapping rod and a hammer or a press, install the outer
race (part "B").
SHTS086200300011
2. GREASING
(1) Pack sufficient amount of wheel hub bearing grease between the
bearing rollers, apply bearing grease to the lip part of oil seal.
NOTICE
"1": Fill the grease to spaces among the inner race, rollers and
retainer to the extent that there is not any vacancy remained.
SHTS086200300012
(2) Apply wheel hub bearing grease to wheel hub.

NOTICE
• "2": Fill the grease between the oil seal and inner bearing,
and at this time some grease may flow out to the oil seal.
• "3": The grease has to ooze out to the extent that the retainer
is buried.
• "4": After pressing in the inner race of the inner bearing,
apply the grease to the end of race circumferentially with the
width of 15 mm {0.591 in}.
• "5": When filling the grease to this space, do it up to the line
which connects between the small diameter sides edges of 2
SHTS086200300013
bearings.
• "6": Fill the grease up the half depth of the lock nut.
3. INSTALLATION OF THE OIL SEAL, THE WHEEL HUB BEAR-

INGS AND WHEEL HUB ASSEMBLY
(1) Install the oil seal and the inner wheel hub bearing.
NOTICE
• If the collar is warmed up with hot water, it can easily be
installed.
SHTS086200300014
(2) Install the wheel hub assembly and the outer wheel hub bearing.
NOTICE
• Using a tool as shown simplifies installation.
handling it.
SHTS086200300015
4. ADJUSTMENT-OF THE WHEEL HUB BEARING PRELOAD

Tightening Torque:
588-1,176 N⋅m {6,000-12,000 kgf⋅cm, 434-867 lbf⋅ft}
SHTS086200300016
wheel hub.
SHTS086200300017

the standard value shown below, adjust the preload with the lock
nut.
Assembly standard:
Turning Torque 4.9-8.9
N⋅m {kgf⋅cm, lbf⋅ft} {50-90, 3.7-6.5}
Spring balancer reading 17.8-32.3
N {kgf, lbf} {1.8-3.3, 4.0-7.3}
SHTS086200300018

(1) Install the lock plate to the lock nut.
NOTICE
• If the holes of the plate are not aligned with screw holes of
the nut, turn over the plate.

SHTS086200300019
7. BRAKE SYSTEM AIR BLEEDING AND BRAKE SHOE CLEAR-
ANCE ADJUSTMENT.
conduct the followings.
a. Adjust the brake chamber rod stroke according to the section
WHEEL BRAKE in the chapter SERVICE BRAKE.

EN0862003H300001
Unit: mm {in.}
Wheel hub bearing race: — — Replace, Visual check

Burns, pitting and cracks if necessary.
Wheel hub bearings: — — Replace, Visual check

Hub bolt: — — Replace, Visual check


Axel shaft: 0.8 — Replace. Measure

Bend {0.0314}
(Measure the bend at 2 or or less A
3 points of the range "A".)
Axel shaft flange: 0.3 — Replace. Measure

Bend {0.0118}
or less
Axle shaft flange and — — Replace, Use the magnetic flaw

spline: if necessary. detector or color checking
Wear and damage instrument.
Axle tube: — — Replace, Visual check

WHEEL & TIRE AX04–1
WHEEL & TIRE

AX04
AX04-001
WHEEL AND TIRE.................................... AX04-2

DESCRIPTION ................................................ AX04-4
SPECIAL TOOL ............................................. AX04-11
PRECAUTIONS ............................................. AX04-12
INSPECTION ................................................. AX04-13
SAE, JIS, DIN AND ISO TYPE

WHEEL.................................................... AX04-15
OVERHAUL ................................................... AX04-15
SPOKE WHEEL AND ADAPTER

TYPE WHEEL ......................................... AX04-21
OVERHAUL ................................................... AX04-21
AX04–2 WHEEL & TIRE
WHEEL AND TIRE

EN08Z0904I200001
The figures given in the table are based on the recommendation by European Tire and Rim Technical Organi-
zation. (E.T.R.T.O.), Japan Automobile Tire Manufacturers’ Association (J.A.T.M.A.) and Australian Design
Rule (ADR).
*(1). Tire radius given is dynamic effective radius for single tire, for dual tires, add 1.0 mm {0.039 in.} to the
figure given.
*(2). The max. air pressure and max. load for New Zealand.
*(3). Industrial tire, Max. speed 40km/h {25 mile/h}, tire radius is static loaded radius.
1. Diagonal tires
*
Allowable max. load kg {lb} (1)
Max. air pressure
Tire size Tire radius Rim size
kPa {kgf/cm2, lbf/in.2} Single Dual mm {in.}
750 3,000 2,725 505

10.00-20-16PR ETRTO 20 x 7.00T
{7.65, 109} {6,614} {6,008} {19.88}
675 2,840 2,670

11.00-20-14PR JATMA
{6.75, 98} {6,261} {5,886} 519
20 x 7.50V
725 3,100 2,785 {20.43}
11.00-20-16PR JATMA
{7.25, 105} {6,834} {6,140}
700 3,115 2,965 538

11.00-20-16PR JATMA 20 x 8.50V
{7.00, 102} {6,867} {6,537} {21.18}
*
*(3) (3)
700 4,605
JATMA 512 24 x 8.50V
12.00-20-16PR {7.00, 102} {10,152}
{20.16}
700 3,660 3,485 592

12.00-24-18PR JATMA 24 x 8.50V
{7.00, 102} {8,069} {7,683} {23.31}
2. Radial tires (with tube)
Allowable max. load kg {lb} *(1)

Max. air pressure
725 2,840 2,670

11.00R-20-14PR JATMA
{7.25, 105} {6,261} {5,886} 522
20 x 7.50V
775 3,100 2,785 {20.55}
{7.75, 112} {6,834} {6,140}
750 3,660 3,485

{7.50, 109} {8,069} {7,683}
775 4,000 3,650 593

12.00R-24-18PR ETRTO 24 x 8.50V
{7.90, 112} {8,818} {8,047} {23.35}
850 4,500 4,000

12.00R-24-160/156 ETRTO
{8.67, 123} {9,921} {8,818}
3. Radial tires (with tubeless)

*
Allowable max. load kg {lb} (1)
Max. air pressure
800 3,000 2,725 22.5 x 7.50

11R22.5-16PR JATMA
{8.00, 116} {6,614} {6,008} 22.5 x 8.25
850 3,150 2,900 507

11R22.5 148/145 ETRTO
{8.67, 123} {6,944} {6,393} {19.96}
22.5 x 8.25
825 3,000 2,725
11R22.5 148/145 ADR
{8.41, 120} {6,614} {6,008}
800 3,250 2,900

12R22.5-16PR JATMA
{8.00, 116} {7,165} {6,393} 522
22.5 x 8.25
850 3,350 3,150 {20.55}
12R22.5 152/148 ETRTO
{8.67, 123} {7,826} {6,944}
275/70R22.5 900 3,150 2,900

JATMA
148/145J {9.00, 131} {6,944} {6,393}
*
(2)
825 2,995 2,755
275/70R22.5 JATMA
{8.25, 120} {6,603} {6,074}
148/145J 464
22.5 x 8.25
275/70R22.5 900 3,150 2,900 {18.27}
ETRTO
148/145 {9.18, 131} {6,944} {6,393}
*(2)
825 2,995 2,755
275/70R22.5 ETRTO
{8.25, 120} {6,603} {6,074}
148/145
295/80R22.5 900 3,650 3,350

JATMA
153/150J {9.00, 131} {8,047} {7,385}
295/80R22.5 850 3,550 3,150 504

ETRTO 22.5 x 8.25
152/148 {8.67, 123} {7,826} {6,944} {19.84}
295/80R22.5 825 3,250 3,000

ADR
152/148 {8.41, 120} {7,165} {6,614}
315/80R22.5 900 4,000 3,650

JATMA
156/153J {9.00, 131} {8,818} {8,047}
315/80R22.5 825 3,750 3,350 519

ETRTO 22.5 x 9.00
154/150 {8.41, 120} {8,267} {7,385} {20.43}
315/80R22.5 850 4,000 3,350

ETRTO
156/150 {8.67, 123} {8,818} {7,385}
900 4,500 517

385/65R22.5 ETRTO — 22.5 x 11.75
{9.18, 131} {9,921} {20.35}
DESCRIPTION
EN08Z0904C100001
SHTS08Z090400001
SAE AND JIS TYPE

1 Tire 5 Inner wheel nut
2 Disc wheel 6 Outer wheel nut
3 Side ring 7 Hub
4 Hub bolt 8 Wheel nut
Hub bolt diameter mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

20 {0.787} 392.27-470.71 {4,000-4,800, 290-347}
A
18 {0.709} 235.36-294.19 {2,400-3,000, 174-216}
20 {0.787} 392.27-470.71 {4,000-4,800, 290-347}
B, C
18 {0.709} 235.36-294.19 {2,400-3,000, 174-216}
SHTS08Z090400002
DIN AND ISO TYPE

1 Tire 4 Hub bolt
2 Disc wheel 5 Wheel nut
3 Side ring 6 Hub
Type Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

DIN 490.34-588.39 {5,000-6,000, 362-433}
A
ISO 490-539 {5,000-5,500, 362-397}
DIN 490.34-588.39 {5,000-6,000, 362-433}
B
ISO 490-539 {5,000-5,500, 362-397}
SHTS08Z090400003
SPOKE WHEEL TYPE

1 Tire 5 Clamp
2 Rim 6 Spoke wheel
3 Clamp bolt 7 Brake drum
4 Clamp nut 8 Band spacer
Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

A 265-295 {2,700-3,000, 196-216}
SHTS08Z090400004
ADAPTER TYPE SPOKE WHEEL (Only for rear)

1 Tire 7 Hub bolt
2 Rim 8 Hub nut
3 Clamp bolt 9 Adapter
4 Clamp nut 10 Brake drum
5 Clamp 11 Band spacer
6 Axle shaft 12 Hub
Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

A 294.20-323.61 {3,000-3,300, 217-238}
B 490.34-588.39 {5,000-6,000, 362-433}
SHTS08Z090400005
WHEEL AND TIRE

1 Tire 4 Side ring
2 Tube 5 Disc wheel
3 Flap 6 Valve
TROUBLESHOOTING
EN08Z0904F300001

Excessive wear on edges of tread Under inflated tires Properly inflate with the recommended
pressure.
Vehicle overloading Correct as required by Factory spec.
High speed cornering Correct as required by Factory spec.
Incorrect wheel alignment Set to the correct specifications.
Tires show excessive wear in center Tires overinflated Properly inflate with the recommended
of tread pressure.
Excessive tire wear Improper tire pressure Properly inflate with the recommended
pressure.
Incorrect tire wheel usage Install the correct tire wheel combina-
tion.
Bent wheel Repair or replace.
Defective shock absorbers Repair or replace.
Front end out of alignment Align front end.
Loose, worn or damaged steering Inspect, repair or replace as required
linkage, joints, suspension compo-
nents, bushing or ball joints
Wheel hopping (vehicle vibration Rocks or debris wedged between dual Remove the rocks and the debris.
and rough steering) disc wheels
(Disc wheels) Out-of-balance tire and/or hub and Determine the out-of-balance compo-
drum nent and balance or replace.
Improper positioning of the side ring Reassemble with ring split, opposite
split (180 degrees) to the valve opening to
improve the balance.
Wheel hopping (vehicle vibration Loose or worn drive line or suspension Identify the location of vibration care-
and rough steering) fully. Then repair or replace the loos-
(Vehicle) ened or worn parts. (Refer to
PROPELLER SHAFT for vehicle vibra-
tion.)
Wobbling (vehicle vibration and Bent or distorted due to the overload- Replace the wheel.
rough steering) ing or improper handling
(Disc wheels) Loose mountings, damaged studs, Replace worn or damaged parts.
wheel nuts, enlarged stud holes, worn Clean mounting surfaces.
or broken hub face, or foreign material
on mounting surfaces
Wobbling (vehicle vibration and Improper alignment Have vehicle aligned.
rough steering) Loose, worn or broken suspension Repair or replace.
(Vehicle) parts
Cracked or broken wheel discs Metal fatigue resulting from overload- Replace wheel.
(cracks develop in the wheel disc ing
from hand hole to hand hole, from
hand hole to rim, or from hand hole
to stud hole.)

Damaged hub bolt holes (hub bolt Loose wheel mounting • Replace wheel and check the
holes become worn, elongated or installation of correct hub bolts
deformed, metal builds up around and nuts.
hub bolt hole edges, cracks develop • Check the cracked or broken hub
from hub bolt hole to hub bolt hole.) bolt-replace.
• Check the worn hub face-
replace.
• Check the broken or cracked
hub-replace.
• Clean mounting surfaces
(Retighten the wheel nuts period-
ically.)
• Rust streaks fanning out from
hub bolt holes: indicates that the
wheel nuts are or have been
loosen.
Tire slippage on rim (Disc wheels) Improper storage or operating condi- Correct as required.
tions
Poor maintenance Follow the proper maintenance proce-
dures.
Rust, corrosion or bead seating Correct as required.
Loss of pressure Follow the proper maintenance proce-
dures.
Tire mounting difficulties Mismatched tire and rim sizes Correct as required.
(Wheel rims) Defective or mismatched rings for the Correct as required.
rim
Tires overinflated Properly inflate with the recommended
pressure.
Corrosion and dirt Correct as required.
Loose inner wheel Excessive hub bolt stand out from the Replace with the proper length hub
mounting face of hub allowing the bolt.
wheel nut to bottom out
Improper torque Follow the recommended torque pro-
cedure.
Wrong inner nut Use correct inner nuts.
Broken hub bolts Loose wheel nuts Replace the hub bolt and follow the
proper torque procedures.
Overloading Replace the hub bolt.
Stripped threads Excessive clamp load Replace hub bolt and follow the proper
torque procedures.
Rust streaks from hub bolt holes Loose wheel nuts Check complete assembly, replace
damaged parts and follow the proper
torque procedures.
Damaged inner or outer wheel nuts Loose wheel assembly Replace wheel nuts. Check the proper
torque procedures.
Frozen inner or outer wheel nuts Corrosion or damage Replace wheel nuts and hub bolts.
SPECIAL TOOL
EN08Z0904K100001
Prior to starting a wheel and tire overhaul, it is necessary to have these special tools.
09672-1010 LEVER
09672-1020 LEVER
09672-1040 LEVER
09609-1210 LEVER
09609-1220 RUBBER HUMMER

PRECAUTIONS
EN08Z0904C100002
! CAUTION
Failure to comply with the following procedures may result in faulty positioning of the tire and/or rim parts, and
can cause the assembly to burst with a explosive force sufficient to cause serious physical injury or death.
1. DEFLATION AND DISASSEMBLY

(1) Always check the tire/rim assembly for the proper components seating prior to the removal from the vehicle.
(2) Always deflate the tire by removing the valve core prior to removing the wheel from vehicle or disassembling of the
components.
(3) Never position your body in front of the rim during deflation.
(4) Always follow the assembly and disassembly procedures outlined in this instruction manual and obtain safety litera-
ture from the Authorities.
(5) Never use a steel hammer to assemble or disassemble the rim components. Use a lead, brass, or plastic type mallet.
2. RIM INSPECTION
(1) Always select the proper tire size and construction to match the rim or wheel rating and size.
(2) Never use damaged, worn, or corroded rims, wheels, or mounting hardware.
(3) Always clean and repaint lightly rusted rims.
(4) Never use a rim or wheel component you cannot identify.
3. ASSEMBLY AND INFLATION

(1) Always perform the double check to see that the removable rings are properly seated before inflating.
(2) Always inflate the tire in a safety cage or use a portable lock ring guard. Use a clip-on type air chuck with a remote
valve so that you can stand clear during the tire inflation.
(3) Never attempt to seat the rings while the tire is totally or partially inflated.
(4) Never re-inflate or add inflation pressure to a tire that has been run flat or seriously under inflated without removing
and checking for ring seating and rim damage.
(5) Tire pressure should be checked while cold. Do not bleed air from tires while hot. This will result in an under inflated
condition. Under inflated tires build up excessive heat due to overdeflection that may result in sudden tire deteriora-
tion, causing severe handling problems.
(6) Never use an assembly with excessive side ring play, wide gaps between ring ends, or butting ring ends.
(7) Never hammer on the components of an inflated or partially inflated assembly.
INSPECTION
EN08Z0904H300001
1. GENERAL INSPECTION
(1) Check the tire tread wear (groove depth) and tire damage. If the
slip sign on the tire tread comes out, replace the tire.
Groove depth (Remaining groove)
General running: 1.6 mm {0.063 in.}
High-speed running: 3.2 mm {0.126 in.}
SHTS08Z090400011
(2) Check the air pressure.

If improper, inflate the tire to the proper pressure as previously
described in this chapter.
SHTS08Z090400012
2. CHECK RUNOUT IN THE TIRE AND WHEEL RIM.

NOTICE
Eliminate any flat spots in the tire by driving the vehicle a little.
(1) Jack up the vehicle and the check the runout in the tire and wheel
rim.
Unit: mm {in.}
Tire Wheel rim
Lateral runout Less than 3.5 {0.138} Less than 1.8 {0.071}
Radial runout Less than 2.5 {0.098} Less than 1.8 {0.071}
SHTS08Z090400013
(2) If the wheel rim does not conform to the runout limits, try re-
mounting the wheel in a different position.
(3) If the wheel rim is still not within 1.8 mm {0.072 in.} of runout, then
replace it with a new rim.
(4) If the tire does not conform to runout standards, reinstall it in dif-
ferent position on the rim.
3. WHEEL AND TIRE BALANCING.

(1) Driving with a rim or tire that is unbalanced may cause the vehicle
and steering wheel to shimmy, and will produce an abnormal tire
wear.
In this situation, we recommend that you should balance the
SHTS08Z090400014
wheels.
• Static balancing
This is relatively effective when operating at low speeds; however,
if operating at high speeds, dynamic balancing is recommended.
• Dynamic balancing
Please balance the wheels, using a balancing machine.

EN08Z0904H300002
Tire: — — Replace, Visual check

Damage, foreign matter, if necessary.
etc.
Tubeless tire: — — Replace, Visual check

Tube: — — Replace, Visual check

Air leakage if necessary.
Wheel (With tube): — — Replace, Visual check

Cracks and deformation if necessary.
Wheel (Tubeless tire): — — Replace, Visual check

Cracks and deformation if necessary.
Rim (Tubeless tire): — — Replace, Visual check

Pipe, nut and O-ring of — — Replace, Visual check

the valve (tubeless tire): if necessary.
Damage
SAE, JIS, DIN AND ISO TYPE WHEEL

OVERHAUL
EN08Z0904H200001
IMPORTANT POINT - REMOVAL
1. REMOVE THE WHEEL AND TIRE.

(1) Loosen the wheel nuts, but do not remove them.
(2) Raise the vehicle until the tire clear the floor.
(3) Remove the wheel nuts and tire from the hub and drum.
On dual tires, the inner wheel nuts will also have to be removed
for the inner tire to be removed.
NOTICE
• Be sure to apply the wheel stoppers in the front or rear tires.
• The wheel nuts on the right side of the vehicle have right
SHTS08Z090400022
hand threads, and those on the left side have left hand
threads.
1. DISASSEMBLE THE WHEEL AND TIRE (WITH TUBE).

(1) Place the wheel and tire on the floor with side ring up.
(2) Make certain that the tire is completely deflated with the valve
core removed.
(3) With a suitable tools, insert the hook end between the side ring
and side wall of the tire and pry the bead loose from the side ring
with a downward pressure on the tools.
(4) Continue prying progressively around the tire until the bead is
completely freed from side ring.
SHTS08Z090400023
(5) With the special tool, pry the side ring from its groove in the rim by
prying progressively around the tire until the ring is freed.
SST: Lever (09672-1040)
SHTS08Z090400024
(6) Turn the assembly over and unseat the second tire bead from the
rim. Lift the rim from the tire.
Remove the tube and flap, if any, from the tire.
SHTS08Z090400025
2. DISASSEMBLE THE WHEEL AND TIRE (TUBELESS).

(1) Make certain the tire completely deflated with the valve core
removed.
(2) With the tire lying flat, loosen both beads with the special tool or
by standing on the tire with your heels close to the rim.
SST: Rubber hammer (09609-1220)
SHTS08Z090400026
(3) With the wide side of the rim down, lubricate the top bead.
(4) With the stops toward the rim, insert the spoon ends of the special
tools about 250 mm {10 in.} apart. Holding the bead in the well
with one foot, pull one tool towards the center of the rim.
SST: Lever (09609-1210)
SHTS08Z090400027
(5) Hold the tool in position with one foot and pull the second tool
toward the center of the rim. Progressively work the bead off the
rim, taking additional bites with the tools as necessary.
SHTS08Z090400028
(6) Stand the assembly in a vertical position.

Lubricate the second bead.
(7) At the top of the assembly, insert the straight end of the tool
between the bead and back the flange of the rim at about 45
degrees angle.
Turn the tool so that it is perpendicular to the rim. Pry the second
bead off.
SHTS08Z090400029
1. ASSEMBLY THE WHEEL AND TIRE (WITH TUBE).

(1) Insert the tube and the flap into the tire and partially inflate to
round out the tube. Apply the rubber lubricant to the inside and
outside surfaces of both beads and to that portion of the tube and
flap that appears between the beads. Lay the rim flat on the floor
with the valve slot up. Align the valve with the rim valve slot, and
place the tire onto the rim, and insert the valve through the valve
slot.
SHTS08Z090400030
(2) Place the side-ring on the rim base so that the ring split is oppo-
site to the valve stem. Place the leading end of the ring into the
groove in the rim as shown.
SHTS08Z090400031
(3) Starting at the valve side progressively walk the side-ring into
place. Check to ensure that the ring is fully seated in the groove.
SHTS08Z090400032
(4) Place the tire assembly in a safety cage and inflate the tire as pre-
viously described in this chapter. Again check the side-ring, tap-
ping lightly with a mallet to ensure the proper engagement. Check
to see that the beads are properly seated. Completely deflate the
tire to prevent the tube from the buckling. Reinflate according to
the recommended pressure, and check the tire assembly.
SHTS08Z090400033
2. ASSEMBLY THE WHEEL AND TIRE (TUBELESS).

(1) Be sure that the proper valve is used and is properly installed in
the rim.
Valve nut tightening torque: 12.7 N⋅m {130 kgf⋅cm, 9.4 lbf⋅ft}
(2) Inspect the rim to ensure that the bead seats are clean and
smooth.
(3) Place the rim on the floor with the wide side down and lubricate
the first bead of the tire and upper bead seat of the rim.
SHTS08Z090400034
(4) Push the first bead into the well of the rim and onto the rim as far
as possible.
With the special tool, hammer the first bead so that the bead gets
over the rim flange.
SHTS08Z090400035
(5) Insert the lever between the rim flange and the tire bead and then
raise the lever so that the bead gets over the rim flange.
SST: Lever (09609-1210)
SHTS08Z090400036
(6) With the special tool, hammer the tire tread so that the bead and
the rim will be seated.
(7) Inflate the tire as described in this chapter, making certain that all
the safety precautions are followed. Check for the leakage.
SHTS08Z090400037
IMPORTANT POINTS - INSTALLATION
1. INSTALL THE WHEEL AND TIRE.

(1) Be sure to check all parts and replace any parts that are overly
worn or damaged. Clean and remove any foreign matter from hub
bolts, wheel nuts and wheel side is contacting with the brake
drum.
SHTS08Z090400038
(2) Apply lubricant (engine oil or grease) to the thread part of the hub
bolts and wheel nuts.
SHTS08Z090400039
(3) Rotate the wheel if necessary and check to see that the hub bolts
are in the center of the wheel's hub bolt holes, then tighten the
wheel nuts lightly.
NOTICE
The wheel nuts on the right side of the vehicle have right hand
threads, and those on the left side have left hand threads.
SHTS08Z090400040
(4) Using a wheel nut wrench, tighten the wheel nuts in accordance
with specified torque using diagonal method.
Tightening torque
N⋅m {kgf⋅cm, lbf⋅ft}
490.34-588.39
DIN type
{5,000-6,000, 362-434}
10 stud
392.27-470.71
8 stud
SAE and {4,000-4,800, 290-347}
JIS type 6 stud
235.36-294.19
5 stud
{2,400-3,000, 174-217}
490-539
ISO type
{5,000-5,500, 362-397}
NOTICE
Tighten the wheel nuts with several repetitions in the tightening
order so as to reach the proper torque evenly and gradually.
! WARNING
SHTS08Z090400041 The specified torque should be referred to the torque tightening
wheel nuts. Tightening it with incorrect can cause the wheel to
come off while driving. This can result in physical injury and/or
property damage due to the loss of vehicle control.
When the vehicle, wheels, or wheel nuts are new, the wheel nuts
should be checked and tightened with specified torque at 50-100
km {30-60 miles} since they may not be well tightened. The tight-
ening torque should be checked with the proper torque wrench.
2. THE FOLLOWING ORDER AND INSTRUCTIONS ARE NECES-

SARY FOR INSTALLING THE DUAL TIRES.
(1) Installation procedures for the inner wheel nuts are the same as in
1. through 4. above.
(2) Installation procedures for the outer wheel nuts are the same as
above.
(3) When only the outer wheel is replaced, first tighten all the inner
wheel nuts to the specified torque. Then mount the outer wheel
and tighten all the outer wheel nuts to the specified torque.
NOTICE
• Install the dual rear wheels with their valve stems positioned
at 180 degrees apart to facilitate inflation.
• Tighten all the inner nuts and outer nuts according to the
above-mentioned procedures.
3. WHEEL AND TIRE BALANCING

(1) Driving with a rim or tire that is unbalanced may cause the vehicle
and steering wheel to shimmy, and will produce an abnormal tire
wear.
In this situation, we recommend that you should balance the
wheels.
• Static balancing
This is relatively effective when operating at low speeds; however,
if operating at high speeds, dynamic balancing is recommended.
• Dynamic balancing
Please balance the wheels, using a balancing machine.
SPOKE WHEEL AND ADAPTER TYPE WHEEL

OVERHAUL
EN08Z0904H200002
IMPORTANT POINT – REMOVAL
1. REMOVAL OF THE RIM AND TIRE.

(1) Loosen the clamp nuts, but do not remove them completely.
(2) Raise the vehicle until the tire clear from floor.
(3) Remove the clamp nuts and then use the special tool to pry off the
clamps.
SST: Lever (09672–1010)
NOTICE
Block the wheels.
SHTS08Z090400042
(4) On the dual tires, the band spacer will also have to be removed
and then remove the inner wheel.
SHTS08Z090400043
IMPORTANT POINT – DISASSEMBLY
1. DISASSEMBLE THE RIM AND TIRE.

(1) Place the wheel on the floor with valve side up.
(2) Make sure the tire is completely deflated with the valve core
removed.
(3) With the special tools, insert the hook end between the rim and
side wall of tire and pry the bead loose from the rim with a down-
ward pressure on the tools.
SST: Lever (09672–1010, 09672–1020)
SHTS08Z090400044
(4) Continue prying progressively around the tire until the bead is
completely freed from the rim.
(5) Make a matching marks on the segments.
(6) Place the special tool in the rim joint groove and pry the rim seg-
ments apart.
SST: Lever (09672–1010)
(7) Remove the rim segments.
SHTS08Z090400045
IMPORTANT POINT – ASSEMBLY
1. ASSEMBLE THE RIM AND TIRE.

(1) Clean the rim segments and check for damages, if there is any
damage, repair or replace.
(2) Fit the tube and flap in the tire.
(3) Place the segment with valve hole in the tire.
The valve must point upwards.
SHTS08Z090400046
(4) Place the other segment on the first one as shown in the figure.
NOTICE
Align the matching marks on the segments.
SHTS08Z090400047
(5) Place the other segment together with the first one.
Fit the segment so that the valve lies against the side of the hole
marked with an arrow.
SHTS08Z090400048
(6) With the special tool, pry the segments to fit the last segment in
position.
SST: Lever (09672–1020)
NOTICE
Do not pull upwards.
(7) Install the valve core and then inflate the tire as previously
described in this chapter, making sure that all the safety precau-
tions are followed. Check for the leakage.
SHTS08Z090400049
IMPORTANT POINTS – INSTALLATION
1. INSTALL THE SINGLE WHEEL.

(1) Clean the spoke ends, rim edges, clamps and nuts.
(2) Lubricate the clamp bolts.
(3) Install the wheel over the spoke ends so that the valve and rim
stopper are between two spokes.
(4) Install two clamps and nuts on opposite sides of the rim as indi-
cated by arrows on the drawing.
Tighten the nuts lightly.
SHTS08Z090400050
(5) Install the remaining clamps and nuts.

Tighten the nuts in sequence round the rim edge to sufficient
torque as described in this chapter.
(6) Check and retighten the nuts after driving the vehicle in a dis-
tance.
SHTS08Z090400051
2. INSTALL THE DUAL WHEEL.

(1) Clean the spoke ends, rim edge, band spacer, clamps and nuts.
(2) Lubricate the clamp bolts.
(3) Install the inner wheel so that the valve and rim stopper are
between two spokes.
SHTS08Z090400052
(4) Install the band spacer over the spokes so that it may tightened
up against the inner wheel rim.
The band spacer stopper must be between two spokes. Make
sure that the band spacer stopper does not cover the inner wheel
valve.
SHTS08Z090400053
(5) Install the outer wheel and press it, and then tighten up against
the band spacer. Make sure that the rim stopper and valve are
between two spokes and diagonally to the inner wheel valve.
Install two top clamps and nuts as indicated by the arrows on the
drawing and tighten the nuts lightly.
SHTS08Z090400054
(6) Install the remaining clamps and nuts.

(7) Tighten the nuts in sequence round the rim edge to sufficient
torque as previously described in this chapter.
(8) Check and retighten the nuts after driving the vehicle in a dis-
tance.
SHTS08Z090400055
SUSPENSION (FRONT) SU02–1
SUSPENSION (FRONT)
SU 02
SU02-001
LEAF SUSPENSION ASSEMBLY ............ SU02-2

DATA AND SPECIFICATIONS........................ SU02-2
DESCRIPTION ................................................ SU02-3
TROUBLESHOOTING..................................... SU02-5
SPECIAL TOOL ............................................... SU02-5
COMPONENT LOCATOR ............................... SU02-6
OVERHAUL ..................................................... SU02-8
INSPECTION AND REPAIR .......................... SU02-12
SU02–2 SUSPENSION (FRONT)
LEAF SUSPENSION ASSEMBLY

EN09A0302I200001
Unit: mm {in.}
Models FR, FS, FY, SH, SS ZS
Type Semi-elliptic leaf springs with shock absorber
1,700
Span 1,500 {59.06}
{66.93}
Width 90 {3.54}
Dimensions of Taper leaf

Multi leaf spring Taper leaf spring
leaf springs spring
Thickness 12 {0.47} 21 {0.83} 24 {0.94}
of leaves
13 {0.51} 22 {0.87} 25 {0.98}
— 23 {0.91} —
Double
Type Single acting Single acting Double acting
acting
270 290 270 300 270 280 340

Stroke
Shock {10.63} {11.42} {10.63} {11.81} {10.63} {11.02} {13.39}
absorbers Min. 420 440 420 450 423 433 489
length {16.54} {17.32} {16.54} {17.72} {16.65} {17.05} {19.25}
Max. 690 730 690 750 693 713 829

length {27.17} {28.74} {27.17} {29.53} {27.28} {28.07} {32.64}
Stabilizer (If so equipped) Torsion bar —

DESCRIPTION
EN09A0302C100001
MODELS: FS, FR, SH, SS, ZS
SHTS09A030200001
1 Spring assembly 4 Shackle

2 Shock absorber 5 Spring bumper
3 Stabilizer (If so equipped) 6 U-bolt
MODEL: FY
SHTS09A030200002
1 Spring assembly 4 Shackle

2 Shock absorber 5 Spring bumper
3 Stabilizer (If so equipped) 6 U-bolt
TROUBLESHOOTING
EN09A0302F300001

Rough ride Broken leaves Replace the leaves. Check the load
capacity rating.
Cracked or damaged Replace the leaves. Check the load
capacity rating.
Overloading Decrease the load.
Heavy sway Inoperative shock absorber Replace the shock absorber.
Leaves broken at the center bolt Loosen U-bolts Tighten to specified torque.
hole
Squeaking of the leaves Friction between the leaves Replace the silencers and/or apply
chassis grease between leaves.
SPECIAL TOOL
EN09A0302K100001
Prior to starting a suspension overhaul, it is necessary to have this special tool.
09603-1550 SOCKET WRENCH FOR FRONT U-BOLT

COMPONENT LOCATOR
EN09A0302D100001
FRONT SUSPENSION
SHTS09A030200004
1 U-bolt 14 Bushing
2 Spring bumper 15 Dust seal
3 Leaf spring assembly 16 Rivet
4 Thrust washer 17 Center bolt
5 Spring pin 18 Clip
6 Lubrication fitting 19 Caster shim
7 Seat 20 Bracket (If so equipped)
8 Dust seal 21 Lower seat (If so equipped)
9 Shackle 22 Stabilizer (If so equipped)
10 Shock absorber bracket 23 Holder (If so equipped)
11 Shock absorber 24 Rubber bushing (If so equipped)
12 Cushion washer 25 Stabilizer link rod (If so equipped)
13 Shock absorber bracket

A 73-109 {745-1,111, 54-80} E 490-590 {4,997-6,016, 362-435}
B 236-324 {2,407-3,304, 175-239} F 107.5-146.5 {1,097-1,493, 80-108}
C 73-109 {745-1,111, 54-80} G 128-172 {1,306-1,753, 95-126}
D 148-176 {1,510-1,794, 110-129}
OVERHAUL
EN09A0302H200001
1. SUPPORT OF THE FRAME WITH STANDS

(1) Park the vehicle on level ground.
(2) Be sure to block the wheels before dismounting.
SHTS09A030200005
(3) Jack up the axle, and support the frame with stands.
(4) Remove the tires.
SHTS09A030200006
2. REMOVAL OF THE U-BOLT

(1) Remove the shock absorber.
(2) Support the axle with a floor jack.
(3) Remove the U-bolt mounting nuts.
NOTICE
When cutting off the U-bolts (Due to rusted threads) with a torch,
never direct the flame toward the leaves or allow sparks to come
in contact with the leaves.
SST: Socket Wrench for Front U-bolt (09603-1550)
SHTS09A030200007
3. REMOVAL OF THE SPRING PIN

(1) Remove the lubrication fitting and spring pin lock bolt.
(2) Use a brass rod to remove the spring pins.
SHTS09A030200031
1. REPLACEMENT OF THE EYE BUSHING

(1) Use a suitable tool to press out the old eye bushing.
(2) Use a suitable tool to press in the new eye bushing.
SHTS09A030200009
2. DISASSEMBLY OF THE LEAF SPRING

! WARNING
When removing the center bolt lock nut, the spring leaves may
jump. Care should be taken to avoid possible personal injury.
(1) Remove the clip bolts.
(2) Use a vise or an arbor press to hold the leaf spring near the cen-
ter bolt.
(3) Remove the center bolt.
(4) Loosen a vise or an arbor press slowly, and separate the leaves.
SHTS09A030200010
1. ASSEMBLY OF THE LEAF SPRING

! WARNING
When clamping the spring leaves, they may jump. Care should be
taken to avoid possible personal injury.
(1) Apply coating on the leaf after removing rust, and apply chassis
grease on both surface at leaves.
SHTS09A030200011
(2) Align the leaf holes and secure the leaves with a vise or an arbor
press.
(3) Insert the center bolt and tighten the lock nut.
NOTICE
When reassembling the leaf spring, replace the center bolt with a
new one.
SHTS09A030200012
(4) Tighten the clip bolts.

NOTICE
When tightening the clip bolts, use a new clip bolts.
(5) Use a punch to peen the thread of the clip bolts.
SHTS09A030200013
1. INSTALLATION OF THE SPRING PIN

(1) Use a brass rod to install the spring pin with thrust washers.
NOTICE
Apply chassis grease on the surface of the eye bushing and
spring pin before installing.
(2) Install the spring pin lock bolt.
SHTS09A030200014
2. INSTALLATION OF THE U-BOLT

(1) Put the spacer on the front axle I-beam part of the driver's seat
side.
SHTS09A030200015
(2) Place the caster shim between the spring seat and leaf spring.
NOTICE
When installing the caster shim, the thick end should face the rear
of the vehicle.
To Front
SHTS09A030200018
(3) Lift the axle using a jack and align the hole of the leaf spring cen-
ter bolt and the hole of the axle I-beam.
NOTICE
Axle and suspension assembly are heavy, therefore be careful
when handling them.
(4) Put the spring pads on the leaf springs.
(5) Set the U-bolts so that they catch the spring pads and tighten the
U-bolt nuts temporarily.
SHTS09A030200007
(6) Using the special tool, tighten the U-bolt nuts (4 pieces) alter-
nately right and left and equally.
After repeating this operation 3 to 5 times, tighten the nuts to the
1 3 specified torque.
FRONT SST: Socket Wrench for Front U-bolt (09603-1550)
2 4
SHTS09A030200019
3. ADJUSTMENT OF THE SUSPENSION AFTER ASSEMBLING

(1) If the vehicle inclination is observed after assembling suspension,
correct it by inserting the following spacer between the spring and
the axle.
Spacer:
Part No. Thickness (mm)
9004-85492 4.5
9004-85493 9.0
4. LUBRICATION
(1) Lubricate the following parts with chassis grease.
a. Spring pins
SHTS09A030200020

EN09A0302H300001
Unit: mm {in.}
Spring pin: 30 {1.181} 29.7 Replace. Measure

Outside diameter {1.170}
Clearance between spring pin 0.020-0.13 0.5 Replace the pin Measure
and eye bushing {0.0008-0.0051} {0.0196} and/or bushing.
Thrust washer: Pivot Replace. Measure

1.8 {0.071} 1.5 {0.059}
Wear side
Shackle
side 3.5
4.0 {0.157}
{0.138}
Leaf: — More than Replace. Measure

Damage and wear 15%
Silencer: 5.0 1.0 Replace. Measure

Wear {0.1968} {0.0394}
Spring bumper: — — Replace, Visual check

Damage and wear if necessary.
U-bolt: — — Replace, Visual check

Shock absorber: — — Replace, Visual check

Operation, oil leak and dam- if necessary.
age
Cushion: — —
Damage and wear
Shock absorber pin and — —

bracket:
Damage and wear
Shackle: — — Replace, Visual check

Stabilizer bar: — — Replace, Visual check

(If so equipped)
Stabilizer sleeve:
Wear
(If so equipped)
Stabilizer bushing:
Wear
(If so equipped)
SUSPENSION (REAR, MODELS: FR, FS, FY, SS, ZS) SU02–1
SUSPENSION SU02
(REAR, MODELS: FR, FS, FY, SS, ZS) SU02-002

DESCRIPTION ................................................ SU02-2
SPECIAL TOOL ............................................... SU02-3
OVERHAUL ..................................................... SU02-5
INSPECTION AND REPAIR ............................ SU02-9
SU02–2 SUSPENSION (REAR, MODELS: FR, FS, FY, SS, ZS)

EN09A0602I200001
Unit: mm {in.}
Models FR FS FY SS ZS
Type Semi-elliptic springs with torque rod
1,500
Span 1,310 {51.57}
{59.06}
Width 90 {3.54}
Taper
Multi leaf
Dimensions of Multi leaf spring leaf
spring
leaf springs spring
Thickness of
14 16 22 16 21 33 20
leaves
{0.55} {0.63} {0.87} {0.63} {0.83} {1.30} {0.79}
16 18 25 18 22 22
—
{0.63} {0.71} {0.98} {0.71} {0.87} {0.87}
DESCRIPTION
EN09A0602C100001
SHTS09A060200001
1 Torque rod bracket 4 Torque rod

2 U-bolt 5 Leaf spring assembly
3 Trunnion assembly
TROUBLESHOOTING
EN09A0602F300001

capacity rating.
capacity rating.
hole
SPECIAL TOOL
EN09A0602K100001
Prior to starting a suspension overhaul, it is necessary to have these special tools.
09603-1010 SOCKET WRENCH FOR REAR U-BOLT
09404-1060 HANDLE
COMPONENT LOCATOR
EN09A0602D100001
SHTS09A060200004
1 Leaf spring assembly 9 Clip 17 Trunnion bracket

2 Spring pad 10 Shim 18 Torque rod
3 U-bolt 11 Clamp plate 19 Rubber bushing
4 Nut 12 Lock plate 20 Torque rod bracket
5 Bushing 13 Trunnion gasket 21 Spring bumper
6 Trunnion seat 14 Trunnion cover 22 Spacer
7 Oil seal 15 Breather valve 23 Rivet
8 Center bolt 16 Lubrication fitting

A 782-978 {7,975-9,972, 577-721} D 341-459 {3,478-4,680, 252-338}
B 236-324 {2,407-3,303, 175-238} E 37-49 {378-499, 28-36}
C 170-230 {1,734-2,345, 126-169} F 226-284 {2,305-2,895, 167-209}
OVERHAUL
EN09A0602H200001

SHTS09A060200005
SHTS09A060200006

NOTICE
SST:
Socket Wrench for Rear U-bolt (09603-1010)
Handle (09404-1060)
SHTS09A060200007
3. REMOVAL OF THE LEAF SPRING FROM THE TRUNNION

SEAT
(1) Remove the leaf spring from the trunnion seat.
SHTS09A060200008
4. REMOVAL OF THE TRUNNION SEAT

(1) Remove the trunnion shaft cover.
(2) Uncaulk the lock plate of the clamp plate bolts with a chisel, then
remove the bolts, lock plate, clamp plate and shims.
(3) Remove the trunnion seat from trunnion shaft.
! WARNING
Since the trunnion seat is too heavy, be careful not to drop it on
your feet.
SHTS09A060200009
1. REPLACEMENT OF THE RUBBER BUSHING

(1) Use a commercial tool to press out the old tubber bushing.
(2) Use a commercial tool to press in the new rubber bushing.
SHTS09A060200010

SHTS09A060200011

NOTICE
new one.
SHTS09A060200012

NOTICE
SHTS09A060200013
1. INSPECT THE CLEARANCE BETWEEN THE CLAMP PLATE

AND THE TRUNNION SEAT.
NOTICE
• Replace the oil seal and trunnion gasket with new ones.
• Apply chassis grease to lip of the oil seal and the inside of
the bushing.
• Insert two trunnion seat bolts before installing the trunnion
seat on the trunnion shaft.
SHTS09A060200014 (1) Install the trunnion seat to the trunnion shaft.
(2) Set the shim and clamp plate and tighten the bolts with the lock
plate.
(3) Inspect the clearance between the clamp plate and trunnion seat.
Standard clearance: 0.05-0.1 mm {0.0020-0.0039 in.}
Service limit: 0.4 mm {0.0157 in.}
NOTICE
If the standard clearance is not correct, adjust the clearance by
decreasing or increasing the shim.
The following shims are available.
0.30 mm {0.0118 in.}, 0.40 mm {0.0157 in.},
0.45 mm {0.0177 in.}, 0.50 mm {0.0197 in.}.
(4) Lock the clamp plate bolts with the lock plate.
SHTS09A060200015

(1) Put the spring pads on the leaf springs.
(2) Set the U-bolt so that they catch the spring pads and tighten the
U-bolt nuts temporarily.
SHTS09A060200016
FRONT SST:
Handle (09404-1060)
2 4
SHTS09A060200017
3. LUBRICATION
a. Spring surface of the spring and axle housing
b. Trunnion shaft
SHTS09A060200018
NOTICE
Use the lubrication fitting to chassis grease the trunnion shaft,
until the grease flows out from the breather valve of trunnion seat
and trunnion cover.
SHTS09A060200020

EN09A0602H300001
Unit: mm {in.}

Damage and wear. 15%
U-Bolt: — — Replace, Visual check

Damage. if necessary.

Damage and wear. if necessary.
Trunnion shaft outside 100 — Replace, Measure

diameter. {3.937} if necessary.
Clearance between trunnion 0.26-0.43 0.7 Replace,

shaft and bushing. {0.0103-0.0169} {0.0275} if necessary.
Dust shield: — — Replace,

Trunnion oil seal: — — Replace, Visual check

Rubber bushing: — 15 In case cracks Measure and Visual check

Damage and crack. {0.59} have developed
on the rubber
circumference in
the range (A or
B) shown in fig-
ure, replace the
torque rod bush-
ing.
SUSPENSION (REAR, MODEL: SH) SU02–1
SUSPENSION (REAR, MODEL: SH)

SU02
SU02-003

DESCRIPTION ................................................ SU02-3
SPECIAL TOOL ............................................... SU02-4
OVERHAUL ..................................................... SU02-7
SU02–2 SUSPENSION (REAR, MODEL: SH)

EN09A0502I200001
Unit: mm {in.}
Semi-elliptic main and auxiliary leaf springs with shock absorber

Type
(if so equipped) and stabilizer (if so equipped)
Span 1,430 {56.30}
Width 90 {3.54}
Dimensions of leaf
spring Multi leaf spring Taper leaf spring
Thickness of
10.0 {0.39} 18.0 {0.71}
leaves
12.0 {0.47} 19.0 {0.75}
Spain 980 {38.58}
Dimensions of Width 90 {3.54}

auxiliary leaf springs
Thickness of
10.0 {0.39} 15.0 {0.59}
leaves
Type *Single acting *Double acting
Stroke 280 {11.02} 270 {10.63}

Shock absorbers
Min. length 458 {18.03} 460 {18.11}
Max. length 738 {29.06} 730 {28.74}
Stabilizer Option
*: If so equipped
DESCRIPTION
EN09A0502C100001
SHTS09A050200001
1 Spring pin 4 Shock absorber (If so equipped)

2 Auxiliary leaf spring assembly 5 Main leaf spring assembly
3 U-bolt 6 Stabilizer (If so equipped)
TROUBLESHOOTING
EN09A0502F300001

capacity rating.
capacity rating.
hole
SPECIAL TOOL
EN09A0502K100001
Prior to starting a suspension overhaul, it is necessary to have these special tools.
09839-3202
SOCKET WRENCH FOR REAR U-BOLT
09839-3203
09841-2560 BAR FOR REAR U-BOLT

COMPONENT LOCATOR
EN09A0502D100001
SHTS09A050200004
1 U-bolt 11 Spring pin 21 Stabilizer (If so equipped)

2 Spring pad 12 Lubrication fitting 22 Holder (If so equipped)
3 Slide seat 13 Thrust washer 23 Stabilizer link pin
(If so equipped)
4 Spacer 14 Main leaf spring assembly 24 Stabilizer lever (If so equipped)
5 Auxiliary leaf spring assembly 15 Center bolt 25 Slotted cap (If so equipped)
6 Cotter pin 16 Clip 26 Cushion washer
(If so equipped)
7 Slotted nut 17 Rivet 27 Shock absorber
(If so equipped)
8 Wear plate 18 Bushing 28 Cushion (If so equipped)
9 Collar 19 Holder pin (If so equipped)
10 Spring bumper 20 Rubber bushing
(If so equipped)

A 73-109 {745-1,111, 54-80} E 341-459 {3,478-4,680, 252-338}
B 641-739 {6,537-7,535, 473-544} F 166-224 {1,693-2,284, 123-165}
C 226-284 {2,305-2,895, 167-209} G 106-144 {1,081-1,468, 79-106}
D 64-86 {653-876, 48-63} H 106-144 {1,081-1,468, 79-106}
OVERHAUL
EN09A0502H200001

SHTS09A050200005
SHTS09A050200006

(1) Remove the stabilizer.
NOTICE
SST:
SHTS09A050200007
Bar (09841-2560)
3. REMOVAL OF THE SPRING PIN

(1) Remove the lubrication fitting and spring pin lock bolt.
SHTS09A050200008
(2) Use a brass rod to remove the spring pins from the shackle and
spring bracket.
SHTS09A050200009
1. REPLACEMENT OF THE EYE BUSHING

(1) Use a suitable tool to press out the old eye bushing.
(2) Use a suitable tool to press in the new eye bushing.
SHTS09A050200010

! WARNING
When removing the center bolt lock nut, the spring leaves may
jump. Care should be taken to avoid possible personal injury.
(2) Use a vise or an arbor press to hold the leaf spring near the cen-
ter bolt.
(4) Loosen a vise or an arbor press slowly, and separate the leaves.
SHTS09A050200011

! WARNING
When clamping the spring leaves, they may jump. Care should be
taken to avoid possible personal injury.
(1) Apply coating on the leaf after removing rust, and apply chassis
grease on both surface at leaves.
SHTS09A050200012
(2) Align the leaf holes and secure the leaves with a vise or an arbor
press.
NOTICE
new one.
SHTS09A050200013

NOTICE
(5) Use a punch to peen the thread of the clip bolts.
SHTS09A050200014
1. INSTALLATION OF THE SPRING PIN

(1) Use a brass rod to install the spring pin with thrust washers.
NOTICE
Apply chassis grease on the surface of the eye bushing and
spring pin before installing.
(2) Install the spring pin lock bolt and nut.
(3) Install and secure the lock nut.
SHTS09A050200015

(1) Set the U-bolts and tighten the U-bolt nuts temporarily.
SHTS09A050200016
FRONT SST:
Bar (09841-2560)
2 4
SHTS09A050200017
3. ADJUSTMENT OF THE SUSPENSION AFTER ASSEMBLING

(1) If the vehicle inclination is observed after assembling suspension,
correct it by inserting the following spacer between the spring and
the axle.
Spacer:
Part No. Thickness (mm)
9004-85244 4.5
4. LUBRICATION
a. Spring pins
b. Auxiliary spring slide seats
SHTS09A050200018

EN09A0502H300001
Unit: mm {in.}
Spring pin: 38 {1.496} 37.7 Replace. Measure

Outside diameter {1.484}
Clearance between spring pin 0.020-0.125 0.5 Replace the pin Measure
and eye bushing {0.0008-0.0049} {0.0196} and/or bushing.
Thrust washer: 2.0 {0.079} 1.5 Replace. Measure

Wear {0.059}

Damage and wear 15%

Damage and wear if necessary.
U-bolt: — — Replace, Visual check


age
Cushion: — —
Damage and wear
Shock absorber pin and — —

bracket:
Damage and wear
Stabilizer bar: — — Replace, Visual check

Stabilizer sleeve:
Wear
Stabilizer bushing:
Wear
Inter leaf: 1.0 0.5 Replace. Measure

Wear {0.0397} {0.0197}
Wear plate: 4.5 4.0 Replace. Measure

Wear {0.177} {0.0158}
SUSPENSION (HENDRICKSON HAS 250, HAS 460) SU02–1
SUSPENSION SU02
(HENDRICKSON HAS 250, HAS 460) SU02-004
SUSPENSION ASSEMBLY....................... SU02-2

DESCRIPTION ................................................ SU02-2
OVERHAUL ................................................... SU02-11
SU02–2 SUSPENSION (HENDRICKSON HAS 250, HAS 460)
SUSPENSION ASSEMBLY
EN09A0702I200001
MODEL FR, FS, FY, SS SH
TYPE HENDRICKSON HAS 460 HENDRICKSON HAS 250
DESCRIPTION
EN09A0702C100001
MODEL: FR
SHTS09A070200001
1 Frame hanger 6 Air spring

2 Leaf spring 7 U-bolt
3 Transverse rod 8 Torque rod
4 Height sensor 9 Tension leaf
5 Shock absorber
MODELS: FS, FY, SS

(FOR AUSTRALIA AND CHILE)
SHTS09A070200002
1 Frame hanger 5 Shock absorber

2 Leaf spring 6 Air spring
3 Transverse rod 7 U-bolt
4 Leveling valve 8 Torque rod
MODEL: SH
SHTS09A070200003

2 Leaf spring No. 2 7 Air spring
4 Leaf spring No.1 9 Tension leaf
5 Leveling valve
MODEL: SS
(FOR SOUTH AFRICA)
SHTS09A070200004

2 Leaf spring 6 Air spring
4 Leveling valve 8 Tension leaf
TROUBLESHOOTING
EN09A0702F300001

Abnormal sound occurs from the Eccentric wear of the shock absorber Replace the pin and/or rubber bush-
spring while driving. fitting pin ing.
Wear and deflection of the rebound Remove the rebound roller and/or
roller rebound bolt spacer.
Uncomfortably Deflection and damage of the bush- Replace the bushings.
(Rolling and pitching) ings of the torque rod and the trans-
verse rod
Faulty of the shock absorber Replace the shock absorber.
Faulty of the leveling valve Repair the leveling valve.
Vibration of the steering wheel, and Deflection of the bushing in the torque Replace the bushings.
the car shake rod and the transverse rod
Looseness of the torque rod and the Replace the lock nut and tighten with
transverse rod bracket bolt the specified torque.
Vehicle height is not adjusted cor- Faulty of the leveling valve Repair the parts.
rectly.
COMPONENT LOCATOR
EN09A0702D100001
MODEL: FR
SHTS09A070200005
1 Spacer 15 Spacer tube

2 Plate 16 Tension leaf
3 Transverse rod bracket 17 Caster wedge
4 Transverse rod 18 Leaf spring
5 Spacer 19 Spring pad
6 Air spring 20 U-bolt
7 Cross channel 21 Adjusting rod
8 Spacer 22 Height sensor
9 Shock absorber upper bracket 23 Sensor bracket
10 Shock absorber 24 Lever
11 Shock absorber lower bracket 25 Torque rod
12 Back plate 26 Torque rod bracket
13 Frame hanger 27 Spring seat
14 Rebound roller

A 104-156 {1,061-1,590, 77-115} F 27-41 {276-418, 20-30}
B 203-277 {2,070-2,824, 150-204} G 352-434 {3,590-4,425, 260-319}
C 237-305 {2,417-3,110, 175-224} H 460-520 {4,691-5,302, 340-383}
D 212-318 {2,162-3,242, 157-234} I 11-17 {113-173, 9-12}
E 70-98 {714-999, 52-72} J 41-61 {418-622, 31-44}
MODELS: FS, FY, SS (FOR AUSTRALIA AND CHILE)
SHTS09A070200006
1 Spacer 13 Frame hanger

2 Plate 14 Rebound roller
3 Transverse rod bracket 15 Spacer tube
4 Transverse rod 16 Torque rod
5 Spacer 17 Spring seat
6 Air spring 18 Torque rod bracket
7 Cross channel 19 Spring pad
8 Spacer 20 U-bolt
9 Shock absorber upper bracket 21 Leaf spring
10 Shock absorber 22 Leveling valve
11 Shock absorber lower bracket 23 Lever
12 Back plate 24 Tension leaf

A 104-156 {1,061-1,590, 77-115} F 27-41 {276-418, 20-30}
B 203-277 {2,070-2,824, 150-204} G 352-434 {3,590-4,425, 260-319}
C 237-305 {2,417-3,110, 175-224} H 460-520 {4,691-5,302, 340-383}
D 212-318 {2,162-3,242, 157-234} I 11-17 {113-173, 9-12}
E 70-98 {714-999, 52-72} J 41-61 {418-622, 31-44}
MODEL: SH
SHTS09A070200007
1 Spacer (If so equipped) 13 Spring pad

2 Plate 14 Leaf spring No. 2
3 Transverse rod bracket 15 Leaf spring No. 1
4 Transverse rod 16 Leveling valve
5 Back plate 17 Cross channel
6 Frame hanger 18 Lever
7 Rebound roller 19 Spacer
8 Spacer tube 20 Air spring
9 Tension leaf 21 Spacer
10 Dowel 22 Shock absorber upper bracket
11 Caster wedge 23 Shock absorber
12 U-bolt 24 Shock absorber lower bracket

A 160-240 {1,632-2,447, 117-176} F 41-61 {418-622, 31-44}
B 203-277 {2,070-2,824, 150-204} G 11-17 {113-173, 9-12}
C 212-318 {2,162-3,242, 157-234} H 237-305 {2,417-3,110, 175-224}
D 460-520 {4,691-5,302, 340-383} I 27-41 {276-418, 20-30}
E 352-434 {3,590-4,425, 260-319} J 70-98 {714-999, 52-72}
MODEL: SS (FOR SOUTH AFRICA)
SHTS09A070200008
1 Spacer 13 Frame hanger

2 Plate 14 Rebound roller
3 Transverse rod bracket 15 Spacer tube
4 Transverse rod 16 Tension leaf
5 Spacer 17 Spring seat
6 Air spring 18 Caster wedge
7 Cross channel 19 Spring pad
8 Spacer 20 U-bolt
9 Shock absorber upper bracket 21 Leaf spring
10 Shock absorber 22 Leveling valve
11 Shock absorber lower bracket 23 Lever
12 Back plate

A 104-156 {1,061-1,590, 77-115} F 27-41 {276-418, 20-30}
B 203-277 {2,070-2,824, 150-204} G 352-434 {3,590-4,425, 260-319}
C 237-305 {2,417-3,110, 175-224} H 460-520 {4,691-5,302, 340-383}
D 212-318 {2,162-3,242, 157-234} I 11-17 {113-173, 9-12}
E 70-98 {714-999, 52-72} J 41-61 {418-622, 31-44}
OVERHAUL
EN09A0702H200001
1. SUPPORT THE FRAME WITH THE STAND.

SHTS09A070200009
(3) Release air pressure from the air springs.

(FOR FR) NOTICE
Before release air pressure, turn down vehicle height by the
remote controller or the dump control switch. (Models: FR and
semi-tractors)
SHTS09A070200011
SHTS09A070200010
(4) Turn the starter switch to "LOCK" position. (Model: FR)

(5) Jack up the axle, and support the frame with the stand.
SHTS09A070200012
2. REMOVAL OF LEAF SPRINGS

FRAME HANGER
(1) Remove the leveling valve or height sensor link from the valve by
removing the nut and the lock washer.
AIR SPRING
SHTS09A070200013
(2) Remove the rebound bolts, lock nuts, washers, spacer tube, and
REBOUND BOLT rebound roller from the frame hanger.
REBOUND (3) Jack up the axle then support it to remove the load from leaf
ROLLER spring.
SPACER TUBE
SHTS09A070200014
(4) Remove the U-bolt lock nuts and washers.

(5) Remove the U-bolts, bottom cap, and top pad.
(6) Remove both the lock nuts and washers which connect the cross
channel to both the leaf springs.
(7) Lift cross channel off the leaf spring with jacks.
(8) Remove the leaf spring assembly.
SHTS09A070200015
3. REPLACEMENT OF THE SPRING SEAT

(1) Remove the spring seat.
SHTS09A070200016
4. REPLACEMENT OF THE TORQUE ROD (TENSION LEAF)

BUSHINGS
(1) Remove the straddle mount bar pin lock nuts and washers at the
axle end of the torque rod.
(2) Loosen the rebound bolt lock nut in the frame hanger.
(3) Remove the straddle mount bar pin lock nuts, bolts, and washers
at the frame hanger ends of the torque rod.
LOCK NUTS
SHTS09A070200017
(4) Push out oil bushings. Use a vertical shock press with a capacity
of at least 10 tons. Steel tube receiving tool is required. These
bushings are not cartridge type bushings. They do not have outer
metals. Support the torque rod end on receiving tool with the end
tube of torque rod centered on tool. Push directly on the bushing
straddle mount bar pin until the bushing clears the torque rod end
tube.
! WARNING
RECEIVING TOOL Be sure the torque rod is securely supported on the press bed for
safety.
Do not use heat or cutting torch to remove the bushings from the
SHTS09A070200018 torque rod. The use of heat will adversely affect a strength of the
torque rod.
(5) Clean and inspect the torque rod ends, removing any nick with
emery cloth.
(6) Lubricate the torque rod ends and the new rubber bushings with a
vegetable base oil (cooking oil or lard). Do not use a petroleum or
soap base lubricant.
(7) Press in new bushings. Support the torque rod end on receiving
tool with end tube of torque rod centered on receiving tool. Strad-
dle mount bar pin bushing must have mounting flats positioned
zero degrees to shank of torque rod as shown in the figure. Press
RECEIVING TOOL directly straddle mount bar pin of bushing. Bushing must be cen-
tered within torque rod end tubes. When pressing in new bush-
ings, overshoot desired final position by approximately 3/16 and
SHTS09A070200018 press bushing again from opposite side to center bushing within
torque rod end.
5. REPLACEMENT OF THE FRAME HANGER SLIPPER PADS

(1) In most cases removal of the rebound roller and spacer may be
required to disassemble the slipper pad. Remove the rebound bolt
lock nut, washer bolt rebound roller and spacer.
(2) Procure the slipper pad locally from Hendrickson's Agent.
PIN
SLIPPER PAD
SHTS09A070200019
6. REMOVAL OF CROSS CHANNEL

(1) Remove the lock nuts and washers which connect the air spring to
cross channel.
CROSS CHANNEL (2) Raise the cross channel by using jack if required.
LOCK NUT
SHTS09A070200020
7. REMOVAL OF AIR SPRING

FRAME HANGER
(1) Remove the air line to the air spring seat.
(2) Remove the brass air fittings from the air spring.
(3) Remove the lock nuts and washers which connect the air spring to
the upper air spring frame hanger.
(4) Remove the air spring.
(5) Remove the air spring frame hanger.
AIR SPRING
SHTS09A070200013
8. REMOVAL OF SHOCK ABSORBER UPPER BRACKET

(1) Remove the lock nuts and washers at both ends of the shock
absorber.
(2) Remove the shock absorber completely from the chassis.
(3) Remove the lock nuts and washers which connect the shock
absorber upper bracket to the frame.
(4) Remove the shock absorber upper bracket.
SHTS09A070200021
9. REMOVAL OF SHOCK ABSORBER LOWER BRACKET

(1) Remove the shock absorber completely from the chassis.
(2) Remove the lock nuts and washers which connect the cross chan-
nel to the leaf spring.
(3) Remove the shock absorber lower bracket by sliding the bracket
to rear.
LOWER BRACKET
SHTS09A070200022
10. REMOVAL OF TRANSVERSE ROD

(1) Remove the lock nuts and washers which connect the transverse
rod to the frame.
(2) Remove the lock nuts and washers which connect to the axle
bracket.
(3) Use Owatonna Tool Company's tool set to remove and install the
transverse rod bushings. Follow their instructions.
SHTS09A070200023
1. INSTALLATION OF TRANSVERSE ROD

(1) Assemble the washer and lock nut to the bolt. Tighten the lock nut
to specified torque.
(2) Install the spacer and plate.
Thickness: 8 mm {0.315 in.}
(3) Position the straddle mount end of torque rod at the transverse
rod to the frame, tighten the lock nuts to specified torque.
SHTS09A070200024
2. INSTALLATION OF FRAME HANGER

(1) Install new slipper pad.
A
ROLL PIN (2) Raise the main support member to secure slipper pad in place.
(3) Drive new roll pin in place with punch until flush with the front of
frame hanger.
(4) Tighten fasteners to specified torque.
B
3. CHECK THE AIR LEAKAGE.
(1) Apply soapy water for each joint of air line and charge the com-
pressed air of 780 kPa {8.0 kgf/cm2, 113 lbf/in.2} then check the
SLIPPER PAD
leakage.
SHTS09A070200025
4. ADJUSTMENT OF THE VEHICLE HEIGHT

NOTICE
• Adjustment should be done only after assembling.
• Adjustment should be done with the air pressure of 687-833
kPa {7.0-8.5 kgf/cm2, 100-120 lbf/in.2}, keeping on supplying
the air while rotating the engine at the idle speed.
(1) Measure the shock absorber length between upper and lower
pins.
Assembly standard: Unit: mm {in.}
Model Dimension "A"
FR 642-688 {25.28-27.08}
FS, FY 582-628 {22.92-24.72}
SH 611-657 {24.06-25.86}
SS
584-630 {23.00-24.80}
(For Australia, Chile)
SS
592-638 {23.31-25.11}
(For South Africa)
(2) If the shock absorber length is not the assembly standard, adjust
the extension rod length, so that the shock absorber length is the
assembly standard.
SHTS09A070200026

EN09A0702H300001
Air spring: — — Replace, Visual check

Wear, damage and crack if necessary.
Leaf spring: — — Replace, Visual check

Cross channel: — — Replace, Visual check

Spring seat: — — Replace, Visual check

U-Bolt: — — Replace, Visual check

Pad: — —
Wear, damage and crack

age
Upper and lower brackets: — —

Crack and damage
Rebound roller: — — Replace, Visual check

Slipper pad: — —
Torque rod (Tension leaf): — — Replace, Visual check

Torque rod (Tension leaf) — —

bushings:
Transverse rod: — — Replace, Visual check

Transverse rod bushings: — —

Spacer: — —
Crack and damage
Plate: — —
Crack and damage
1-1, HINODAI 3-CHOME, HINO-SHI, TOKYO 191-8660 JAPAN
PRINTED IN JAPAN
Pub. No. S1-YFSE16A 2/3 ’04-4

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■■■■■■■■

Manual Name Pub. No.

MANUAL NO. S1-YFSE16A 2/3

GENERAL INTRODUCTION GN02-001

CLUTCH MAIN UNIT CL02-001 CL02-002 CL02-003 CL02-004

CLUTCH CONTROL CL03-001 CL03-002 CL03-003 CL03-004

TRANSMISSION MAIN UNIT TR02-001 TR02-002 TR02-003 TR02-004

P.T.O. (POWER TAKE-OFF) TR05-001 TR05-002 TR05-003

TRANSMISSION/TRANSFER CONTROL TR06-001

PROPELLER SHAFT PP02-001 PP02-002 PP02-003

DIFFERENTIAL EQUIPMENT DF01-001

DIFFERENTIAL CARRIER DF02-001 DF02-002 DF02-003 DF02-004 DF02-005

BRAKE EQUIPMENT BR01-001

SERVICE BRAKE BR02-001

ABS (ANTI-LOCK BRAKE SYSTEM) BR03-001

ES START (EASY & SMOOTH START) SYSTEM BR04-001

STEERING EQUIPMENT SR01-001

STEERING UNIT SR02-001

POWER STEERING SR03-001

FRONT AXLE AX02-001 AX02-002

REAR AXLE AX03-001 AX03-002

WHEEL & TIRE AX04-001

SUSPENSION SU02-001 SU02-002 SU02-003 SU02-004

CHASSIS FRAME FC02-001

COUPLER (5TH WHEEL) FC03-001

PINTLE HOOK FC04-001

ELECTRICAL EQUIPMENT EL01-001

ELECTRIC WIRE EL02-001

BRAKE CONTROL DN03-001 DN03-002

SUSPENSION CONTROL DN04-001

This manual does not contain items on half-tone dot meshing.

CLUTCH MAIN UNIT

WORKSHOP CLUTCH CONTROL

MANUAL TRANSMISSION EQUIPMENT

TRANSMISSION MAIN UNIT

TRANSFER MAIN UNIT

P.T.O. (POWER TAKE-OFF)

TRANSMISSION / TRANSFER CONTROL

PROPELLER SHAFT EQUIPMENT

ABS (ANTI-LOCK BRAKE SYSTEM)

ES START (EASY & SMOOTH START) SYSTEM

WHEEL & TIRE

COUPLER (5TH WHEEL)

CAB EQUIPMENT CONTROL

SERVICE BRAKE ASSEMBLY.................BR01-2

SERVICE BRAKE ASSEMBLY

WITH MZ12 TRANSMISSION WITH ZF TRANSMISSION

WITH HX07 TRANSMISSION WITH INER-AXLE DIFFERENTIAL LOCK

WITHOUT AIR DRYER WITH LOAD SENSING VALVE

WITH TRANSMISSION P.T.O. WITH TRANSMISSION P.T.O.

WITH ES START WITH TIRE INFLATOR WITH TIRE INFLATOR

1 Air compressor 18 Relay valve-Spring brake

MODEL: FS (For AUSTRALIA)

NYLON TUBE R20 R17

WITH TIRE INFLATOR WITH TIRE INFLATOR

1 Air compressor 19 Reducing valve

MODEL: FS (CARGO TRUCK) (For HONG KONG, IRELAND, TAIWAN)

NYLON TUBE 26L 26L

WITH HX07 TRANSMISSION WITH AIR DRYER