Chapter 9 BRAKE SYSTEM

1. Structure .................................................................................................. 9-1

1.1 Brake System .......................................................................................................... 9-1
2. Disassembly and Reassembly............................................................... 9-2
2.1 Master Cylinder ....................................................................................................... 9-2
2.2 Wheel Brakes .......................................................................................................... 9-4
2.3 Wheel Cylinder ...................................................................................................... 9-12
3. Inspection and Adjustment .................................................................. 9-14
3.1 Automatic Adjuster Test ........................................................................................ 9-14
3.2 Manual Adjustment................................................................................................ 9-14
3.3 Parking Brake Cable Adjustment........................................................................... 9-15
3.4 Brake Pedal Adjustment ........................................................................................ 9-16
3.5 Brake Lines Bleeding............................................................................................. 9-17
3.6 Braking Performance Test..................................................................................... 9-17
3.7 Parking Brake Lever .............................................................................................. 9-18
4. Troubleshooting.................................................................................... 9-19
5. Service Data........................................................................................... 9-20

9
 BRAKE SYSTEM

Chapter 9 BRAKE SYSTEM

1. Structure
1.1 Brake System

Parking brake lever

Reservoir tank

Brake pedal

Stop lamp switch

Parking brake
cable

Wheel cylinder
Master cylinder
Wheel brake

213744

9-1
BRAKE SYSTEM

2. Disassembly and Reassembly

2.1 Master Cylinder
2.1.1 Disassembly
3
1
2
*

4 5 6

7
* * *

213745

Sequence
1 Clevis, Nut, Push rod 6 Valve seat
2 Boot 7 Cylinder
3 Snap ring 8 Bushing
4 Piston assembly 9 Filler union
5 Valve assembly
Note: The parts marked by ＊ or ‫ ڏ‬are included in the Repair Kit and should be changed periodically.

9-2
 BRAKE SYSTEM

Inspections after Disassembly

(1) Cylinder body
(a) Check the cylinder bore for rusting, erosion,
abnormal wear, or scoring.
(b) Check the inlet and relief ports for restriction.
Check the threads on each joint for damage.
Also, check the boot and other parts for dam-
age.
(2) Piston
Check the piston for damage. Replace if it is dam-
aged. Insert the piston into the cylinder, and mea-
sure the piston-to-cylinder clearance. If the
clearance is in excess of the service limit, replace
the cylinder and piston.
Unit: mm (in.)
0.020 to 0.105
Clearance between A
(0.0079 to 0.0041)
piston and cylinder
B 0.15 (0.0059)
A: Standard value B: Service limit

(3) Return spring

Replace if defective. Replace if the free length is
below the service limit.
Unit: mm (in.)
A 59.2 (2.3)
Free length of spring
B 53.9 (2.1)
A: Standard value B: Service limit

(4) Cups in piston assembly

Check the rubber parts for damage or swelling. If
the lips are damaged even slightly, the base is bit-
ten, or abnormal fatigue, wear or swelling is evi-
dent, replace the piston assembly. If the cup
tightness is 0.4 mm (0.02 in.) or less, replace the
piston assembly.
Note: The cups must be replaced periodically. It is a
safe and good practice to replace them when-
ever the master cylinder is disassembled.

2.1.2 Reassembly
To reassemble, follow the disassembly sequence in
reverse. Also follow the instructions given below.
(1) Wash all metal parts with volatile cleaning solvent,
and completely dry them with compressed air.
(2) Apply a thin coat of rubber grease exclusively
designed for brake components or brake fluid to
the cylinder bore, piston cups, and the inner face
of the filler union bushing mounting hole.

9-3
BRAKE SYSTEM

2.2 Wheel Brakes

2.2.1 1 ton class

4 3 6 11 9 1 2 7 12 5
A

10

Adjusting screw
rotating direction
Drum rotating direction to expand shoes
during forward movement

15 A 13 Section A-A
14

The illustration shows a left-hand wheel brake

213746

1 Wheel cylinder 9 Shoe guide plate

2 Backing plate 10 Fitting cable
3 Shoe and lining (primary) 11 Return spring
4 Parking brake lever 12 Sheave
5 Shoe and lining (secondary) 13 Adjusting lever
6 Strap 14 Adjusting screw
7 Return spring 15 Return spring
8 Hold-down spring

Note: The illustration shows a left-hand wheel brake.

9-4
 BRAKE SYSTEM

2.2.2 2-3 ton class

3 A 11
14
6
9
13
7

5
8

10
10 10

12
4

15
Section A – A
17 2 A
16

The illustration shows a left-hand wheel brake.

213747

1 Backing plate assembly 10 Pin, Hold-down spring, Cup

2 Parking brake cable, Snap ring 11 Shoe guide plate
3 Wheel cylinder 12 Fitting ring
4 Parking brake lever 13 Return spring (primary)
5 Primary shoe and lining assembly 14 Return spring (secondary)
6 Retainer, Washer 15 Adjusting lever, Adjusting spring
7 Pin, Sheave, Washer 16 Adjusting screw
8 Secondary shoe and lining assembly 17 Return spring
9 Strut, Anti-rattle spring

Note: The illustration shows a left-hand wheel brake.

9-5
BRAKE SYSTEM

2.2.3 Disassembly

10 9

12
1

11  5

8 7

5 4

213748

Sequence
1 Return spring 8 Shoe and lining (primary), Parking brake lever, Re-
2 Cable with spring tainer, Spring washer
3 Hold-down spring, Cup, Pin 9 Wheel cylinder
4 Adjusting lever, Adjusting spring, Return spring 10 Parking brake cable
5 Cable guide, Sheave, Adjusting screw, Pin, Washer 11 Mounting bolt, Spring washer
6 Shoe guide plate, Shoe and lining (secondary) 12 Backing plate
7 Strut, Anti-rattle spring
Note: The parts marked by ＊ are included in the repair kit, and should be changed periodically.

Start by
(1) Remove the front wheels.
(2) Remove the wheel hub and brake drum.
(3) Separate the parking brake lever and cable at the
bottom of wheel brake.
(4) Disconnect the brake pipe from the wheel brake
assembly.

9-6
 BRAKE SYSTEM

Suggestions for Disassembly

(1) Removing return springs
Use a special tool to remove the return springs
from the shoe guide plates.

Special tool needed

Spring remover 64309-15411

213749

(2) Removing hold-down springs

Use a special tool to remove the hold-down
springs from the backing plate.

Special tool needed

Spring retainer 64309-15412

213750
Inspections after Disassembly
(1) Backing plate
(a) Check the backing plate for cracks.

(2) Shoes and linings

(a) Check each shoe and lining for cracks.
(b) Replace the lining if it is heavily soiled with
grease, burnt or otherwise deteriorated.
(c) Measure the thickness of the lining. Replace if
it is worn to less than the service limit.
Unit: mm (in.)
Truck type
Items 2 ton class
1 ton class 213751
3 ton class
Thickness of lin- A 4.87 (0.19) 5.7 (0.22)
ings B 1.0 (0.04) 1.0 (0.04)
A: Standard value B: Service limit

9-7
BRAKE SYSTEM

(3) Brake drums

Check the inside (friction) surface of the drum for
abnormal wear, grooving and other defects. Minor
grooving can be removed by grinding, provided
that the inside diameter does not exceed the ser-
vice limit.

Unit: mm (in.)
Truck type
Items 2 ton class
1 ton class
3 ton class
Brake drums A 254 (10.0) 310 (12.2)
Inner diameter B 256 (10.1) 312 (12.3)
A: Standard value B: Service limit

(4) Adjusting screw

Check the wheel teeth for wear. Turn the screw by
hand to see if its rotating parts turn smoothly.

213752
(5) Parking brake cable
Replace a cable if it shows stretching, rust or
damage.

(6) Other parts

(a) Check the shoe return springs for cracks or
fatigue.
(b) Check the adjusting springs for cracks or
fatigue.
(c) Check the cable with spring for stretching.

9-8
 BRAKE SYSTEM

2.2.4 Reassembly
1 ton class

4 3 7 5 12 10 1 2 12 8 13 6
A

11

14
A Section A – A

The illustration shows a left-hand wheel brake

213753

Reassembly sequence
1 Wheel cylinder 9 Hold-down spring, Cup, Pin
2 Backing plate 10 Shoe guide plate
3 Shoe and lining (primary) 11 Fitting cable
4 Parking brake lever 12 Return spring
5 Retainer, Washer 13 Cable guide, Sheave, Pin, Washer
6 Shoe and lining (secondary) 14 Adjusting lever, Adjusting screw,
7 Strut Adjusting spring
8 Anti-rattle spring

9-9
BRAKE SYSTEM

2-3 ton class

3 A 11
14
6
9
13
7

5
8

10
10 10

12
4

15
Section A – A
17 2 A
16

The illustration shows a left-hand wheel brake.

213747

Reassembly sequence
1 Backing plate assembly 10 Pin, Hold-down spring, Cup
2 Parking brake cable, Snap ring 11 Shoe guide plate
3 Wheel cylinder 12 Fitting ring
4 Parking brake lever 13 Return spring (primary)
5 Primary shoe and lining assembly 14 Return spring (secondary)
6 Retainer, Washer 15 Adjusting lever, Adjusting spring
7 Pin, Sheave, Washer 16 Adjusting screw
8 Secondary shoe and lining assembly 17 Return spring
9 Strut, Anti-rattle spring

Prepare parts 4 through 8 in assembly beforehand.

9-10
 BRAKE SYSTEM

Suggestions for Reassembly

(1) Installing wheel cylinder
Apply liquid gasket to the mounting face of the
wheel cylinder before installing it. Tighten to the
specified torque.
Unit: N·m (kgf·m) [lbf·ft]
Truck type
Items 2 ton class
1 ton class
3 ton class
8 to 12 18 to 26
Tightening torque (0.82 to 1.22) (1.84 to 2.65)
[5.9 to 8.85] [13.3 to 19.2] 213754
(2) Greasing
Apply a thin coat of the specified brake grease to
the following areas.
(a) Shoe ledges (6 locations)
(The ledges are those portions of the backing
plate in contact with the shoe.)
(b) Anchor pin surface in contact with the shoe
ends

(3) Installing shoe and lining

Ensure that each connector link of the wheel cylin-
der has been correctly inserted into the shoe web.

(4) Installing return spring

Use a special tool to install the return springs to
the backing plate pins.

Special tool needed

Spring installer 65309-15413 213755

(5) Installing automatic adjuster

(a) Clean the adjusting screw and associated
parts. Apply grease to the threaded portions
and the screw socket. Ensure that the screw
turns easily when rotated by hand.
If a screw is hard to turn, replace it with a new
one.
(b) Identification of adjusting screws and levers
Left side (left-hand thread) = Plated in yellow-
ish color
Right side (right-hand thread) = Plated in whit- 213756
ish color
Note: After reassembly, bleed air out of the brake
lines. (Refer to "Inspection and Adjustment.")

9-11
BRAKE SYSTEM

2.3 Wheel Cylinder

2.3.1 Disassembly

1
2

3
4

*
7

3
2

213757

Sequence
1 Connector link 5 Return spring
2 Boot 6 Bleeder screw, Cap
3 Piston 7 Cylinder body
4 Piston cup
Note: The parts marked by ＊ are included in the repair kit, and should be changed periodically.

9-12
 BRAKE SYSTEM

2.3.2 Inspection and Repair

(1) Cylinder body
(a) Check the cylinder bore for rusting, erosion or
scoring.
(b) Check threads of both the bleeder screw and
oil pipe for damage.
(2) Piston
(a) Check the sliding surface for rust or scratches.
(b) With the piston installed in the cylinder body,
measure the piston-to-cylinder clearance.
Replace if the clearance is in excess of the ser-
vice limit.
Unit: mm (in.)
0.020 to 0.105
Clearance between A
( 0.00079 to 0.0041)
piston and cylinder
B 0.15 (0.0059 )
213759
A: Standard value B: Service limit

(3) Piston cup

Check for swelling, damage or other defects.
Replace the cup if defective even slightly.
Unit: mm (in.)
Tightness between pis- A 1.85 ( 0.07 )
ton cup and cylinder
body B 0.65 ( 0.025 )
A: Standard value B: Service limit

(4) Boot
Replace the boots if they show damage or aged
deterioration. In any event, the boots must be
replaced every year.
2.3.3 Reassembly
To reassemble, follow the disassembly sequence in
reverse. Also follow the instructions given below.
(1) Clean metal parts with volatile cleaning oil, and
blow them completely dry with compressed air.
(2) Apply a thin coat of rubber grease exclusively
designed for brake components or brake fluid to
the cylinder bore and piston cups.
(3) Be careful not to damage the lips of the cups.
(4) Make sure that the cups face the correct direc-
tions when reassembled.
(5) Tighten the bleeder screw to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
5.9 to 8.8
Tightening torque (0.6 to 0.9)
[4.3 to 6.5]

9-13
BRAKE SYSTEM

3. Inspection and Adjustment

3.1 Automatic Adjuster Test
(1) With the clearance A between the lining and drum
being set to specification, pull the cable with
attached spring using a finger as shown. The
lever should turn the adjusting screw wheel by
one notch and, when the cable is released, return A
to the original position.

Unit: mm (in.)
Truck type
Items 2 ton class
1 ton class 213760
3 ton class
Drum inside
254 (10.0) 310 (12.2)
diameter
Drum-to-lining 0.25 to 0.5 0.1 to 0.35
clearance A (0.01 to 0.02) (0.004 to 0.014)

(2) If the lever fails, or turning the adjusting screw

wheel is slow, check the position of the lever rela-
tive to the toothed wheel. The lever's actuating tip
should touch the toothed wheel at approximately
7 to 9 mm (0.28 to 0.35 in.) below the center line
of the screw. If the lever contact is out of range,
the lever will not correctly engage with the toothed
wheel, and the lever will either fail or the wheel will
turn slowly.
213761

(3) If the automatic adjuster fails to operate correctly,

take the following actions.
(a) Ensure that the adjusting spring is correctly
hooked to the primary shoe.
(b) Replace the fitting cable.
(c) Replace the lever.
(d) Replace the adjusting screw.

3.2 Manual Adjustment

Using a screwdriver through a hole on the back of the
backing plate, adjust the drum-to-lining clearance to
specification by rotating the adjusting screw wheel.
Note: Turning the wheel by one tooth corresponds to
a change of 0.03 mm (0.0012 in.) in shoe diam-
eter.

213762

9-14
 BRAKE SYSTEM

3.3 Parking Brake Cable Adjustment

(1) Install the parking brake cable to the parking
brake lever as shown. Set the lever "free" (the
lever resting on the inner surface of the shoe, as
indicated by the chain (double-dashed line)).
(2) With the lever set "free," pull the cable until the
shoe just starts to work on the drum. The amount
of cable pulled A should meet the specification
listed below. A, B

(3) From (1) position, move the parking lever to reach

the neutral position B. In the neutral position, the Shoe
inner cable length C should be as specified below. 213763

Unit: mm (in.)
Truck type
Items 2 ton class
1 ton class
3 ton class
Cable pull A before 10 (0.39) 14.3 (0.56)
shoe works on drum or less or less
C
Distance B to reach
3 (0.12) 5 (0.20)
neutral position
Inner cable length C 44 ± 4 (1.73 ± 0.16)
213764

9-15
BRAKE SYSTEM

3.4 Brake Pedal Adjustment

(1) Using the stop bolt, adjust the installed height A of
the brake pedal (from the floor to the top of the
pad). After adjustment, lock the stop bolt.
(2) To adjust the clearance between the push rod and Stopper bolt
piston of brake master cylinder to 1.0 mm (0.04
in.), turn the push rod clockwise until it contacts
the piston, then turn it back counterclockwise for
approx. 0.8 turns and finally secure the clevis with
nut.
(3) After this adjustment, check the brake pedal play
C.
213765
Note: 1. Ensure that the clevis pin between the brake
pedal and push rod is firmly in place as illus-
trated.
2. Ensure that the snap pin is firmly engaged.
3. Ensure that the brake pedal operates C
smoothly without binding or other problems.
Unit: mm (in.)
Truck type A
Items 2 ton class
1 ton class
3 ton class
Pedal height A
191.6 (7.54)
from floor
Push rod to piston
1 (0.04) 1 (0.04)
clearance Master cylinder 213766
Pedal play C 7 (0.28) 7 (0.28)

9-16
 BRAKE SYSTEM

3.5 Brake Lines Bleeding

Bleeding the brake lines is a two person operation.
After any portion of the brake fluid lines has been dis-
assembled for repair or service, or if the brake pedal
feels spongy, bleed the lines as follows:
(1) Install one end of a transparent vinyl tube onto the
bleeder screw of the right-hand wheel cylinder,
which is located farther from the master cylinder
than the left hand wheel cylinder. Put the loose
end of the tube into a container filled with brake
fluid.
(2) Check the brake fluid level in the reservoir tank. 213767
Fill up as necessary.
(3) After cycling the pedal several times, depress the
pedal and keep it depressed. With the pedal
depressed, loosen the bleeder screw. While the
brake fluid is flowing through the tube, tighten the
bleeder screw.
(4) Repeat the previous step until the fluid flowing
through the tube is free of air bubbles. Repeat the
same procedures for the left-hand wheel cylinder.
With the brake lines free of air, fill brake fluid into
the reservoir tank to the specified level.

Note: 1. Take care to maintain the brake fluid in the

reservoir tank at sufficient levels while the
bleeding operation is in progress.
2. Use only the brake fluid of specified brand
and grade. Avoid mixing different types of flu-
ids.

3.6 Braking Performance Test

With all of the required adjustments completed after
disassembly/reassembly, check the braking force at a
speed of 10 km/h (6.2 mph). Readjust as necessary by
referring to "Manual Adjustment."

9-17
BRAKE SYSTEM

3.7 Parking Brake Lever

Applied

3
Released

1
2

213768

1 Lever support pin 3 Parking brake lever assembly

2 Adjusting screw 4 Parking brake switch

3.7.1 Inspection and Repair

(1) If the lever support pin and/or the pin hole in the
lever are badly worn, replace the worn part(s).
(2) Replace the parking brake cable if it is stretched,
damaged or rusted.
3.7.2 Reassembly
With the parking brake cable and lever connected, the
effort required to pull the lever should be adjusted into
the following range.
Unit: N (kgf) [lbf]
Truck type
Items
1 ton class 2 ton class 3 ton class
Parking brake 150 to 200 200 to 250 230 to 250
lever operat- (15 to 20) (20 to 25) (23 to 25)
ing effort [34 to 45] [45 to 56] [52 to 56]

9-18
 BRAKE SYSTEM

4. Troubleshooting

Oil leaking past primary cup in master *Replace piston cup(s) if cylinder is
cylinder free from unacceptable wear. Replace
the cup(s) and fluid with genuine parts
Oil leaking past cups in wheel cylinder if the cup(s) is distorted.
Lack of braking force Retighten, or replace pipe and con-
Oil leaking from oil pipe connection
nector.
Shoe linings worn Replace.
Shoe linings dirty with oil or grease Clean or replace.
Bleed air at master and wheel
Air trapped in brake fluid lines
cylinders.
Piston cup defective in master cylinder Replace.
Not enough fluid in reservoir tank Refill.
Excessive pedal Push rod to piston clearance too large in
Adjust.
stroke master cylinder
Brake fluid leakage Refer to * above.
Ensure that cable guide and adjusting
spring are correctly installed. If still
Automatic adjuster inoperative
inoperative, replace cable, spring,
lever and adjusting screw.
Foot
Brake Lining or drum dirty with oil or grease in less Clean with cleaner. If lining still dirty,
Uneven braking effective brake replace.
(wheel brake is more
Wobbly or loose-mounted drum in less Replace drum. If loose, readjust and
effective on one side
effective brake retighten.
than on the other)
Wheel tires inflated unequally Reinflate to specification.
Lining glazed Sand.
Worn linings Replace shoe and lining assemblies.
Brake squeals Backing plate securing bolts loose Retighten.
Wheel bearings loose Readjust preload and retighten.
Brake drum dirty Clean with cleaning solvent.
Anchored ends of shoes rattling on anchor Repair or replace.
Brake squeals
Shoe ledges badly worn Replace backing plate.
(clicking)
Pistons badly worn in wheel cylinder Replace wheel cylinder.
Abnormal noise dur- Lining to drum clearance too small Adjust.
ing traveling Brake drum badly distorted Repair or replace.
Linings worn to the service limit Replace.
Will not apply
Lining to drum clearance too large Adjust.
Lever stroke is too
Lining to drum clearance too small Adjust.
small
Parking Check lining to drum clearance. If
Parking brake cable longer than specifica-
brake brake will still not apply, readjust cable
Will not apply tion
length.
Lever lacks operating force Adjust.

9-19
BRAKE SYSTEM

5. Service Data
Unit: mm (in.)
Truck type
Item
1 ton class 2-3 ton class
Master Inside diameter of cylinder body 1 A 19.05 (0.75)
cylinder
Diameter of piston 2 A 19.05 (0.75)
A 0.020 to 0.105 (0.00079 to 0.00413)
Clearance between piston and cylinder
B 0.15 (0.0059)
A 1.0 (0.039)
Primary cup tightness 3 0.4 (0.016)
B
(Replace every year or whenever overhauling)
A 1.1 (0.043)
Secondary cup tightness 4 0.4 (0.016)
B
(Replace every year or whenever overhauling)
A 59.2 (2.3)
Free length of return spring 5 53.9 (2.1)
B
(Replace every year or whenever overhauling)

4 2 5

1 3

213769

A: Standard value B: Repair or service limit

9-20
 BRAKE SYSTEM

Unit: mm (in.)
Truck type
Item
1 ton class 2-3 ton class
Wheel Brake A 254.0 (10.00) 310 (12.20)
Inside diameter of brake drum 1
B 256 (10.08) 312 (12.28)
A 4.87 (0.19) 5.7 (0.224)
Thickness of lining 2
B 1 (0.039 1 (0.039)
0.5 to 1.0 0.2 to 0.7
Clearance between drum and lining 3 (Total) A
(0.02 to 0.04) (0.008 to 0.02)
Primary: 120 (4.72)
Free length A 102 (4.02)
Secondary: 139.3 (5.48)
Primary: 226 ± 23/134
Return spring 4 (23 ± 2.3/134)
Set force/ 157 ± 16/111 [51 ± 5.2/0.44]
N (kgf)
Length under set A (16 ± 1.6/111)
[lbf] Secondary: 226 ± 23/145.4
force [3.5 ± 3.6/0.36]
(23 ± 2.4/145.4)
[51 ± 5.2/0.48]
Free length A 98.4 (3.87) 126 (4.96)
Adjusting spring 5 Set force/ 58.8 ± 5.9 78 ± 8
N (kgf)
Length under set A (6 ± 0.6) (8 ± 0.8)
[lbf]
force [43.4 ± 4.3] [17.5 ± 1.8]
N 145.9 ± 14.6 212.7 ± 21.3
Tightening torque for backing plate
(kgf) A (14.9 ± 1.5) (21.7 ± 2.2)
mounting bolt 6
[lbf] [107.6 ± 10.8] [156.9 ± 15.7]

4
2

4 secondary spring

Free length
213770

A: Standard value B: Repair or service limit

9-21