Workshop Manual: No - LGBRK-WE-1111

2011MY
2011MY
WORKSHOP MANUAL BRAKES
WORKSHOP MANUAL
BRAKES
No.LGBRK-WE-1111
LGBRK-WE-1111_Maegaki 11.7.25 2:17 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A GENERAL INFORMATION
0B MAINTENANCE AND LUBRICATION
1 HEATING AND AIR CONDITIONING 00 SERVICE INFORMATION
1A HEATING AND VENTILATION
2 FRAME AND CAB 00 SERVICE INFORMATION
2 CAB AND FRAME
3 STEERING, SUSPENSION, WHEELS 00 SERVICE INFORMATION
AND TIRES 3A FRONT END ALIGNMENT
3B1 POWER STEERING
3B2 MANUAL STEERING
3B3 STEERING LINKAGE
3B4 STEERING COLUMN
3C FRONT SUSPENSION
3D REAR SUSPENSION
3E WHEELS AND TIRES
4 PROPELLER SHAFT AND AXLE 00 SERVICE INFORMATION
4A PROPELLER SHAFT
4B REAR AXLE
4C FRONT AXLE
5 BRAKES 00 SERVICE INFORMATION
5A HYDRAULIC BRAKES
5C PARKING BRAKES
5E EXHAUST BRAKE
6 ENGINE 00 SERVICE INFORMATION
6A GENERAL ENGINE MECHANICAL
6A1 4JB1/4JB1-TC-ENGINE
6B ENGINE COOLING
6C ENGINE FUEL
6D ENGINE ELECTRICAL
6E EXHAUST GAS RECIRCULATION (EGR) SYSTEM
6F ENGINE EXHAUST
6G TURBOCHARGER
7 MANUAL TRANSMISSION AND CLUTCH 00 SERVICE INFORMATION
7B MANUAL TRANSMISSION
7C CLUTCH
8 CAB AND CHASSIS ELECTRICAL 8 CAB AND CHASSIS ELECTRICAL
(LEFT HAND DRIVE MODEL)
8 CAB AND CHASSIS ELECTRICAL 8 CAB AND CHASSIS ELECTRICAL
(RIGHT HAND DRIVE MODEL)
9 SEAT BELT, SRS AIRBAG 9A SEAT BELT
LGBRK-WE-1111_Maegaki 11.7.25 2:17 PM ページ 2
LGBRK-WE-1111.book 1 ページ２０１１年７月２７日　水曜日　午前１０時４６分
SERVICE INFORMATION 00-1
BRAKES
SECTION 00
SERVICE INFORMATION
Contents
TROUBLESHOOTING .......................................... 00-2
Brake System .................................................... 00-2
Brake Lining....................................................... 00-7
Brake Drum ....................................................... 00-8
Exhaust Brake ................................................... 00-8
Parking Brakes .................................................. 00-9
MAIN DATA AND SPECIFICATIONS ................. 00-10
SERVICE STANDARD........................................ 00-12
SERVICING ........................................................ 00-13
Service Brakes ................................................ 00-13
Parking Brake .................................................. 00-16
FIXING TORQUE................................................ 00-18
SPECIAL TOOLS................................................ 00-23
Hydraulic Brakes ............................................. 00-23
Parking Brakes ................................................ 00-23
00-2 SERVICE INFORMATION
TROUBLESHOOTING
Brake System
PROBLEM POSSIBLE CAUSE CORRECTION

No Brakes 1. Restricted tubing or hose. 1. Replace defective parts.
2. Brakes out of adjustment. 2. Adjust.
3. No fluid. 3. Fill the reservoir with brake fluid.
Insufficient Brakes 1. Pedal improperly adjusted. 1. Adjust.
2. Worn linings or drum. 2. Replace as necessary.
3. Plugged, crimped, restricted lines or 3. Repair or replace.
hoses.
Slow Brake Application 1. Pedal binding. 1. Lubricate pivot pin, clean-check for for-
eign objects.
2. Wheel cylinder piston sticking. 2. Repair the wheel cylinder.
3. Restriction in the lines. 3. Remove the restriction or replace the
line.
4. Worn linings or drums. 4. Replace as necessary.
Uneven Braking 1. Damaged hydraulic lines. 1. Repair or replace.
(Front or Rear Brakes
2. No brake fluid at the master cylinder. 2. Check for plugged, kinked or damaged
not Working)
hose to the reservoir.
Wet Weather: 1. Linings too sensitive to water. 1. Replace in axle sets.
Brakes Grab or won't 2. Dirty brakes. 2. Clean out.
Hold
3. Bent mounting plate - opening. 3. Replace.
4. Scored drums. 4. Machine in pairs. Replace if necessary.
Brakes Squeak 1. Mounting plate bent or shoes twisted. 1. Replace damaged parts.
2. Metallic particles or dust imbedded in 2. Replace the linings in axle sets.
the lining.
3. Lining rivets loose or lining not held 3. Replace the rivets and/or tighten the lin-
tightly against the shoe at the ends. ing by riveting.
4. Drums distorted tampered, or not 4. Machine or replace drums.
Square.
5. Incorrect lining. 5. Replace the linings in axle sets.
6. Mixed size linings. 6. Use all standard or oversize linings in a
brake.
7. Weak or broken return spring. 7. Replace the return spring.
8. Loose wheel bearings. 8. Tighten to the proper setting.
9. Loose mounting plate, drum, wheel cyl- 9. Tighten.
inder.
10. Linings located wrong on the shoes. 10. Install the linings correctly.
11. Linings worn out. 11. Reline the brakes.
12. Lining glazed. 12. Replace.
13. Cracked or threaded drums. 13. Replace in axle pairs.

Brakes Chatter 1. Incorrect lining to drum clearance. 1. Adjust to specification.
2. Loose mounting plate. 2. Tighten securely.
3. Grease, fluid, road dust on the lining. 3. Clean or reline.
4. Weak or broken return spring. 4. Replace the return spring.
5. Loose wheel bearings. 5. Readjust.
6. Drums out-of-round. 6. Machine the drums in axle sets.
7. Cocked or distorted shoes. 7. Straighten or replace.
8. Distorted, tapered, or barrel- shaped 8. Machine drums in pairs. Replace if nec-
drums. essary.
9. Incorrect lining material. 9. Reline with correct linings.
10. Linings worn out. 10. Reline the brake.
11. Lining loose on the shoes. 11. Rerivet the linings to the shoes.
Replace if necessary. Check for dam-
aged or distorted shoes.
12. Foreign material imbedded in the lin- 12. Replace the linings in axle sets.
ings.
13. Cracked or threaded drums. 13. Replace in axle pairs.
Shoe Click 1. Return spring weak. 1. Replace the spring.
2. Shoe bent. 2. Straighten or replace.
Noise and Chatter 1. Bent, damaged or incorrect shoes. 1. Replace with the correct shoes and lin-
Squealing, clicking, or ing. Always replace in axle sets.
scraping sound upon 2. Worn out lining. 2. Replace the shoes and lining in axle
brake application sets.
3. Foreign material embedded in the lin- 3. Replace the shoes and lining in axle
ing. sets.
4. Broken shoe return spring. 4. Replace the return spring.
5. Cracked or threaded drums (lathe 5. Replace the drums in axle sets.
marks).
Pulls to One Side 1. Grease or fluid soaked lining. 1. Replace in axle sets.
2. Loose wheel bearings, loose (or distort- 2. Adjust the wheel bearing, tighten (or re-
ed) mounting plate on the rear or front place) the mounting plate to the axle
axle or loose spring bolts. and tighten the spring bolts.
3. Linings not of the recommended kind. 3. Install recommended linings.
Install the shoes correctly.
4. Tires not properly or evenly inflated or 4. Inflate the tires to recommended pres-
unequal wear of tread. sures. Rearrange the tires so that a pair
Different tread non-skid design. of non-skid tread surfaces of similar de-
sign and equal wear will be installed on
the front wheels, and an other pair with
like tread will be installed on the rear
wheels.
5. Water, mud, etc., in the brakes. 5. Remove any foreign material from all of
the brake parts and inside of the drums.

Pulls to One Side 6. Wheel cylinder sticking. 6. Repair or replace the wheel cylinder.
(Cont.) 7. Weak or broken shoe return spring. 7. Check the spring-replace distorted,
open coiled, or cracked spring.
8. Out-of-round drums or different sized 8. Refinish or replace the drums in axle
drums on the same axle. pairs.
9. Brake dragging. 9. Check for loose lining. Adjust. (Refer to
“Dragging Brakes”.)
10. Weak chassis springs, loose U-bolts, 10. Replace the spring, tighten the
loose steering gear, etc. U-bolts, adjust the steering gear, etc.
11. Loose steering. 11. Repair and adjust.
12. Unequal camber. 12. Adjust to specifications.
13. Restricted brake line or hose. 13. Check for soft hose or damaged lines.
Replace as necessary.
14. Wheel cylinder size different on oppo- 14. Replace with correct cylinders.
site sides.
15. Loose kingpin. 15. Replace the kingpins or bushing.
16. Distorted, damaged, or scored drum. 16. Refinish the drums in axle pairs.
Replace if necessary.
17. Front end alignment. 17. AIign the front end.
18. Excessively worn lining. 18. Replace in axle sets.
19. Uneven adjustment of brake lining 19. Adjust the brake lining clearance in all
clearance. wheels.
20. Water/wet linings. 20. Apply the brakes a few times while
moving at a slow speed to dry the lin-
ings.
One Wheel Locks 1. Gummy lining. 1. Replace in axle sets.
2. Tire tread slick. 2. Match up tire treads from side to side.
3. Brake adjustment not correct. 3. Adjust the brakes.
4. Restricted brake line or hoses. 4. Check for soft hoses or damaged lines.
5. Incorrect lings. 5. Replace. Linings must be the same on
the axle.
6. Grease or fluid soaked lining. 6. Replace in axle sets.
7. Foreign material in the brakes. 7. Remove the material.
Light Pedal Pressure 1. Brake adjustment not correct. 1. Adjust the brakes.
Brakes too Severe
2. Loose mounting plate on the front axle. 2. Tighten the plates.
(Grabby Brakes)
3. A small amount of grease or fluid on the 3. Replace the linings.
lining.
4. Incorrect lining. 4. Install factory specified linings.
5. Wheel bearings loose. 5. Adjust the wheel bearings.
6. Lining loose on the shoe. 6. Replace the lining or the shoe and lin-
ing.
7. Excessive dust and dirt in the drum. 7. Clean and sand the drums and linings.
8. Out-of-round drum. 8. Turn the drums in pairs or replace.

Low Pedal or Pedal 1. Excessive clearance between the lin- 1. Adjust the brakes.
Goes to Floor ings and drum.
2. Pedal stop not adjusted, or missing. 2. Adjust or install the pedal stop.
3. Weak brake hose. 3. Replace with new hose.
4. Leaking wheel cylinder. 4. Clean and rebuild.
5. Air in the hydraulic system. 5. Bleed the hydraulic system.
6. Improper brake fluid (low boiling point). 6. Flush the system and refill with recom-
mended brake fluid.
7. Low fluid level. 7. Fill the reservoir with brake fluid; check
for leaks and bleed system.
8. Bent or distorted brake shoes. 8. Replace in axle sets.
9. Leaks at hydraulic line connections. 9. Check for hydraulic leaks and repair.
Slow Brake Release 1. Foot pedal binding. 1. Lubricate the pivot pin; clean-check for
foreign objects.
2. Restriction in the line. 2. Remove the restriction or replace line.
3. Weak shoe return spring. 3. Replace the spring.
Poor Assist or Loss of 1. Low brake fluid level. 1. Fill the reservoir to the proper level.
Assist Bleed the system.
2. Air in the hydraulic system. 2. Locate the source of the air leak and re-
pair. Bleed the system.
3. Weak brake hose. 3. Replace.
4. Loss of vacuum. 4. Inspect for vacuum leaks or malfunc-
tioning pump. Repair or replace as nec-
essary.
5. No brake fluid at the master cylinder. 5. Check for plugged, kinked, or damaged
hose to the reservoir.
Brake Fade 1. Incorrect lining. 1. Replace with recommended lining.
2. Poor lining contact. 2. Grind the lining to the proper radius; ad-
just.
3. Thin drum. 3. Replace the drum.
4. Dragging brakes. 4. Adjust.
5. All conditions listed under “Pulls to One 5. All corrections listed under “Pulls to
Side”. One Side”.
All Brakes Drag when 1. Pedal does not return to stop. 1. Lubricate the pedal linkage; adjust the
Adjustment is Known pedal.
to be Correct
2. Improper fluid. 2. Replace rubber parts and fill with the
recommended brake fluid.
3. Use of incorrect rubber parts. 3. Install the proper parts.

One Wheel Drags 1. Weak or broken shoe return spring. 1. Replace the return spring.
2. Brake shoe to drum clearance too 2. Adjust to specification.
small.
3. Loose wheel bearings. 3. Adjust or replace the wheel bearings.
4. Wheel cylinder piston cups swollen and 4. Rebuild the cylinders. Flush the hydrau-
distorted or piston stuck. lic system and fill with recommended
fluid.
5. Pistons sticking in the wheel cylinder. 5. Clean or replace the pistons; clean the
cylinder bore.
6. Drum out-of-round. 6. Machine the drum.
7. Restricted brake line or hose. 7. Check for soft hoses or damaged lines.
8. Distorted shoe. 8. Replace.
9. Defective lining. 9. Replace with the recommended lining.
10. Loose or bent mounting plate. 10. Tighten the fasteners; replace the plate.
11. Loose calipers. 11. Tighten the fasteners.
Dragging Brakes 1. Improper fluid. 1. Flush the hydraulic system and fill with
recommended brake fluid, and replace
rubber components.
2. Brake pedal adjustment incorrect. 2. Adjust the pedal.
3. Incorrect shoe return spring. 3. Replace the shoe return spring.
4. Brake pedal linkage interference or 4. Free the linkage and lubricate.
binding.
5. Incorrect lining. 5. Replace the linings.
6. All conditions listed under “One Wheel 6. All corrections under “One Wheel
Drags”. Drags”.

Brake Lining

Poor Contact at the 1. Bell-mouthed drum. 1-5. Repair or replace as required.
Center of Shoe 2. Distorted mounting plate.
3. Bent brake shoe.
4. Undersize linings.
5. Loose wheel bearing.
Unequal Wear on the 1. Brake linings not a balanced set. 1-2. Repair or replace as required.
Shoes in the Same 2. Sticking wheel cylinder piston.
Brake
Material at the Center 1. Undersize linings. 1-2. Repair or replace as required.
of the Shoe Exces- 2. Oversize drum.
sively Thin
Lining Tapered across 1. Bell-mouthed drum. 1-3. Repair or replace as required.
the Width 2. Bent shoe.
3. Distorted mounting plate.
Lining Worn at One Bent mounting plate. Repair or replace as required.
End
Linings Glazed 1. Grease on lining. 1-2. Repair or replace as required.
2. Wrong type lining for service involved.
Rivets Tear Loose 1. Improper set rivet. 1-3. Repair or replace as required.
2. Improper setting of the rivet.
3. Enlarged rivet holes in the shoe.
Unequal Wear 1. Weak shoe return spring. 1-5. Repair or replace as required.
Opposite Brakes, 2. Obstructed hydraulic line.
Same Axle 3. Stuck wheel cylinder piston.
4. Brake drum surface in poor condition.
Linings at Scored 1. Scored drum. 1-2. Repair or replace as required.
2. Abrasive material between the lining
and drum.
Cracks at Rivet Holes 1. Wrong type rivets. 1-4. Repair or replace as required.
2. Rivets not properly set.
3. Dirt or rust on the shoe table.
4. Wrong size lining.
Elongation of the Rivet 1. Loose rivets. 1-2. Repair or replace as required.
Holes 2. Wrong size rivets.
Wear on the Edge of 1. Wrong width lining. 1-4. Repair or replace as required.
the Lining 2. Holes improperly drilled.
4. Bent shoe.
Groove on the Edge of 1. Lining too wide. 1-2. Repair or replace as required.
the Lining 2. Worn drum.

Brake Drum

Brake Drum Heat 1. Out-of-round brake drum. 1-3. Repair or replace as required.
Checked in Spots 2. Eccentric mounting of the drum.
Drum Uniformly Heat 1. Improper friction materials. 1-3. Repair or replace as required.
Checked 2. Overworked brake.
3. Driver abuse.
Excessive Scoring of 1. Improper friction materials. 1-5. Repair or replace as required.
the Drum 2. Overworked brake.
3. Abrasive material between the lining
and drum.
4. Soft drum.
5. Bent or warped shoe.
Excessive Drum 1. Drive abuse. 1-4. Repair or replace as required.
Cracks 2. Weak drum.
3. Wrong friction material.
4. Overworked brake.
Exhaust Brake

Exhaust Brake does 1. Blown fuse. 1. Replace.
not Operate 2. Improperly adjusted or faulty accelera- 2. Adjust or replace.
tor or clutch switches.
3. Poor connections or corroded terminals 3. Clean or replace.
at switches or control valve.
4. Improperly adjusted or seized exhaust 4. Adjust, or repair.
brake valve.
5. Vacuum lines kinked, restricted, or 5. Repair.
plugged with ice.
6. Seized vacuum chamber. 6. Repair.
7. Valve linkage broken. 7. Repair.
8. Chamber or control valve jammed with 8. Melt ice and drain lines of water.
ice.
9. Faulty control valve. Valve should open 9. Replace.
when approximate battery(s) voltage is
applied to terminals.
10. Faulty vacuum chamber. 10. Replace.
11. Broken wire in wiring harness. 11. Repair.
Exhaust Brake SIow to 1. Tighten exhaust brake valve or linkage. 1. Free up and lubricate.
Operate
2. Improperly adjusted accelerator or 2. Adjust.
clutch switches.

Weak Braking Action 1. Improperly adjusted or tight exhaust 1. Free up and/or adjust. Lubricate as
brake valve. needed.
2. Tight linkage. 2. Free up and lubricate.
3. Vacuum lines kinked or partially 3. Repair.
plugged with ice.
4. Leaking fittings at vacuum lines. 4. Tighten.
5. Leaky vacuum chamber. 5. Replace.
Exhaust Brake will not 1. Seized exhaust brake valve or linkage. 1. Free up and lubricate.
Shut Off (Exhaust
2. Control valve or chamber jammed with 2. Melt ice and drain lines.
Brake Control Switch
ice.
“Off”)
3. Short in wiring harness (approximate 3. Repair.
battery(s) voltage) at control solenoid
regardless of control switch position.
4. Faulty control switch. 4. Replace.
Exhaust Brake “On” 1. Improperly adjusted clutch or accelera- 1. Adjust.
Continuously when tor switches.
Exhaust Brake Control 2. Switches improperly wired. 2. Check wiring against wiring diagram.
Switch is “On” (not Repair as needed.
Controlled by Clutch or
Accelerator Switches) 3. Short in wiring harness. 3. Repair.
Engine Overheats or 1. Engine brake valve stuck partially 1. Free up and lubricate or replace.
Loses Power closed.
2. Engine brake valve adjusted so that it is 2. Adjust.
partially closed.
Parking Brakes
Insufficient Braking Force

Brake lining and drum Clearance between the brake lining and Adjust the brake lining and the brake drum
clearance the brake drum excessive clearance.
Brake lining Brake lining worn out Replace the brake lining.
Camshaft Camshaft worn out Replace the camshaft.
Control wire Control wire stretched Adjust the control wire length or replace
the control wire.
MAIN DATA AND SPECIFICATIONS

Model Designation (Explanation Only)
Q K R 5 5 L E E 5 A Y V T
Driving Position Emission Control
L: LHD VT: Euro-2
U: RHD
Body configuration
ENGINE MODEL Y: Cab chassis
55: 4JB1 Engine series Cab
-: Non tilt single cab
DRIVING SYSTEM A: Tilt single cab
R: 4 X 2
Rear tire
1: Single
GVM Range 5: Dual
K: 3.3-5.5 ton GVM
E: 4.0-4.5ton
H: 5.0-5.5ton
MODEL LINE
Q: LIGHT DUTY TRUCK
Wheelbase
E: 2451-2600mm
H: 3201-3500mm
LNWB50LF000101

Front Brakes (QKR)
— Not available FRONT BRAKE

❍ Standard DRUM BRAKE
❏ Factory option Type WHEEL CYL. DRUM LINING
Non Inside dia. Inside dia. Width
2 (in) (in) (mm)
L
1 3
+ 0 7
/ 0 5
8
No. Models 1 2 3 4
1 QKR55U-EE1 ❍ ❍ ❍ ❍
2 QKR55L-EE1 ❍ ❍ ❍ ❍
3 QKR55U-HH5 ❍ ❍ ❍ ❍
4 QKR55L-HH5 ❍ ❍ ❍ ❍
5 QKR55L-FD5 ❍ ❍ ❍ ❍
Rear Brakes (QKR)
— Not available REAR BRAKE PARKING BRAKE BRAKE CONTROL

❍ Standard DRUM BRAKE
❏ Factory option Type WHEEL CYL. DRUM LINING DRUM LINING MASTER CYL
Non D Inside dia. Inside dia. Width Inside dia. Width Inside dia. E
2 (in) (in) (mm) (in) (mm) (in) X
L H
7 3 1 1
A
/ 1 0 7 7 3 +
(
W/O U
8 0 5 8 5 1
S
/
A T
8
U
T B
O R
A
(
K
E
No. Models 1 2 3 4 5 6 7 8 9
1 QKR55U-EE1 ❍ ❍ — ❍ ❍ ❍ ❍ ❍ ❏
2 QKR55L-EE1 ❍ ❍ — ❍ ❍ ❍ ❍ ❍ ❏
3 QKR55U-HH5 ❍ — ❍ ❍ ❍ ❍ ❍ ❍ ❏
4 QKR55L-HH5 ❍ — ❍ ❍ ❍ ❍ ❍ ❍ ❏
5 QKR55L-FD5 ❍ — ❍ ❍ ❍ ❍ ❍ ❍ ❏
SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT

FRONT DRUM BRAKE ASSEMBLY
Brake Drum Inside Diameter mm (in) 300.0 (11.81) 301.5 (11.87)
Brake Drum Run-out mm (in) 0.13 (0.005) or less —
Brake Lining Thickness or Rivet Depth mm (in) — 1.0 (0.039)
Wheel Cylinder and Piston Clearance mm (in) — 0.15 (0.006)
REAR DRUM BRAKE ASSEMBLY
Brake Lining Thickness or Rivet Depth mm (in) — 1.0 (0.039)
Wheel Cylinder and Piston Clearance mm (in) — 0.15 (0.006)
BRAKE PEDAL AND CONTROL
Master Cylinder and Piston Clearance mm (in) 0.11 — 0.195 0.22 (0.009)
(0.004 — 0.008)
PARKING BRAKE
Brake Lining Thickness mm (in) — 1.0 (0.039)
EXHAUST BRAKE
Butterfly Valve and Body Clearance mm (in) 0.1 — 0.2 (0.004 — 0.008) —
SERVICING
Service Brakes D2L
Wheel Brake Adjustment

Brake Lining Clearance Adjustment (2L and D2L)
Without auto-adjuster type
1. Chock the wheels not being adjusted.
2. Jack up the axle until the wheels can be turned
freely.
3. Manually shake the wheel to check for excessive
play.
4. Remove the grommet fitted to one of the brake
drum cover adjuster holes.
5. Insert a screwdriver into the adjuster hole.
Manually rotate the wheel while turning the adjust-
er (A) in the direction of the arrow (1) until resis-
tance is felt at the wheel.
6. Back off the adjuster (A) in the direction of the ar-
row (2) the specified number of notches.
N5A0002E
Specified Notches
7. Install the grommet to the adjuster hole.
Front 8. Repeat Steps 4 through 7 on the other wheels.
5-6
Rear
9. Lower the vehicle to the ground.
2L
Brake Pedal Adjustment
Brake Pedal Height and Free Play Adjustment
Vacuum Booster (Master Vac) Type:
The height of push rod should be adjusted so that the
distance from its master cylinder mounting surface to
end measures 18.2 mm (0.717 in).
N5A0001E
N5A0005E
For push rod length adjustment, the distance from the

center of clevis pin hole to brake pedal bracket mounting
surface should be set at 109 mm (4.291 in); without
spacer.
When fixed under this condition, there is no need to ad-
just the height of brake pedal from floor and free play.

Brake Bleeding
Notice:
• As vacuum booster (Master Vac) is undetachable Brake Bleeding Precautions
type, it should be replaced as an assembly if it Air in the brake hydraulic circuit will result in dangerous
does not work well. reduced braking efficiency.
• Be sure to adjust the stop light switch. The brake hydraulic circuit must be bled whenever the
vehicle has been operated with the reservoir brake fluid
level at an excessively low level or any time the brake
pipes have been disconnected in the course of brake
servicing.
The brake bleeding procedure requires the cooperative
action of two men.
N5A0006E
Brake Pedal Free Play and Allowance

Standard value
1. Free play: 4 to 7 mm (0.16 to 0.28 in)
N5A0012E
2. Allowance mm (in)
Front Brake Bleeding Procedure
Drum Less than Bleed the brake hydraulic circuit in the following se-
QKR 60 (2.36)
Brake GVM 6.5 ton quence.
Model LHD
Right-hand rear wheel → Right-hand front wheel → Left-
(When depressed with force of the 490 N (50 kg / 110 hand front wheel
lbs).) RHD
Right-hand rear wheel → Left-hand front wheel → Right-
hand front wheel
N5A0008E
N5A0013E

1. Check to make sure that the service area is well
ventilated and allow it to run until the vacuum pres-
sure rise sufficiently.
Apply the parking brake firmly. Start the engine and
allow it to run until the vacuum pressure rise suffi-
ciently.
Notice:
Brake booster (master-vac) will be adversely effected if
bleeding operation is performed without running engine.
2. Fill the brake fluid reservoir (1) up to the “MAX” lev-
el with clean brake fluid.
It may be necessary to replenish the brake fluid
reservoir several times during the bleeding proce-
dure to maintain the required level of brake fluid.
N5A0017E
7. Loosen the bleeder screw (4) approximately 1/2 of

a turn.
This will release the brake fluid with air bubbles into
the transparent container (5).
N5A0016E
Notice:
Pour the brake fluid carefully so as not to produce air
bubbles.
3. Remove the right hand rear wheel cylinder bleeder
screw rubber cap and wipe it clean.
4. Connect one end of a vinyl tube (2) to the bleeder N5A0018E
screw.
5. Insert the other end of the vinyl tube into a trans- 8. When the brake fluid being released into the trans-
parent container approximately 1/3 full of brake flu- parent container is completely free of air bubbles,
id. retighten the bleeder screw (4).
6. Depress the brake pedal (3) slowly 3 times and 9. Slowly release the brake pedal.
hold it depressed. 10. Replace the bleeder screw rubber cap.
Notice:
In order to bleed the air completely from the brake line,
repeat the above procedures.
Bleeding of the brake fluid circuit should be performed
for front wheel 10 times or more, for rear wheel 15 times
or more.
11. Repeat Steps 3 through 10 for each bleeder
screws as mentioned before.
12. After the air bleeding procedure is finished in all
wheels, depress the brake pedal, and verify wheth-

er there is no abnormality in operation of the brake Parking Brake Lining Clearance Adjustment
system. 1. Jack up the rear axle until the wheels can be turned
13. After the air bleeding procedure for individual freely.
wheel is completed, inspect the fluid level of the
reservoir tank. If it is insufficient, replenish brake
fluid. Do not overfill above “MAX” level.
14. Stop the engine.
Parking Brake
Parking Brake Adjustment
Before beginning to adjust the parking brake, park the
vehicle on a level surface, chock all of the wheels, and
place the parking brake lever in the released (off) posi-
tion.
Then loosen the parking brake control wire lock nut (1),
and turn the adjuster (2) to completely loosen the park-
ing brake control wire.
N5A0021E
2. Remove one of the two check hole covers from the

parking brake drum.
3. Rotate the brake drum to align the check hole with
the adjusting screw.
4. Move the camshaft lever from side to side several
times to center the brake shoes.
5. Insert a screwdriver into the check hole and rotate
the adjusting screw by pushing it upward.
Continue doing this until the brake shoes begin to
drag on the drum.
N5A0020E
N5A0022E
N5A0024E

6. Back off the adjusting screw the specified number 3. Turn the adjuster (2) to adjust the lever travel to the
of notches. specified notches.
Adjusting Screw Notches and Clearance Parking brake lever travel at 147 N (15 kg / 33 lbs)
Brake Type mm (in) Notches Clearance mm (in) notches
6 to 8
178 (7.008) 30 0.75 (0.029)
N5A0024E
N5A0023E
4. Retighten the control wire lock nut (1).

Legend 5. Check the parking brake lever travel (measured in
1. Screwdriver notches).
2. Adjusting screw
3. Brake drum
4. Brake shoe
5. Clearance
6. Direction of brake shoe expansion (for 178
mm)
7. Reinstall the check hole cover.

8. Lower the rear wheels to the floor.
Parking Brake Lever Travel Adjustment
1. Fully set the parking brake lever and release it sev-
eral times.
Leave the parking brake lever in the released posi-
tion.
2. Loosen the parking brake control wire lock nut (1).
FIXING TORQUE
Brake Pipe Flare Nuts
Brake Pipe Joint 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)

Brake Pipe to 4 / 5 / 6 Way 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
Front Wheel Brake
LNWB50MF000101

Rear Wheel Brake
LNWB50LF000201
Legend
A. Without auto-adjuster

Brake Pedal and Control (Vacuum Booster Type)
LNWB50LF000301

Parking Brake
113 (11.5/83.3)
25 (2.6/18.4)
226 (23.0/166.7)
LNWB5ALF000401

Exhaust Brake
N5A0465E
Legend
A. 4J engine without turbocharger B. 4J engine with turbocharger
SPECIAL TOOLS
Hydraulic Brakes Parking Brakes
Tool Number / Tool Number /
Illustration Illustration
Description / Remarks Description / Remarks
5-8840-2371-0 / Master 5-8840-2043-0 / Flange

cylinder support plate holder
5884023710 5884020430
5-8840-2369-0 / Wrench
(Cylinder inside diame-
ter 28.5 mm)
5884023690
5-8840-2215-0 /
Remover: steering wheel
5884022150
5-8840-2190-0 / Pres-
sure gauge: brake fluid
5884021900
MEMO
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HYDRAULIC BRAKES 5A-1
BRAKES
SECTION 5A
HYDRAULIC BRAKES
Contents
GENERAL DESCRIPTION ................................... 5A-2
Hydraulic Brake System .................................... 5A-2
Front Drum Brake .............................................. 5A-3
Rear Drum Brake (Manual Adjuster Type) ........ 5A-4
ON-VEHICLE SERVICE ....................................... 5A-5
Front Drum Brake Assembly (Two Leading) ..... 5A-5
Rear Drum Brake Assembly ............................ 5A-10
Brake Pedal and Control ................................. 5A-15
UNIT REPAIR ..................................................... 5A-22
Wheel Cylinder Assembly
(without Auto-adjuster) .................................... 5A-22
Master Cylinder Assembly............................... 5A-25
5A-2 HYDRAULIC BRAKES
GENERAL DESCRIPTION
Hydraulic Brake System
N5A0044E
The brake system has dual hydraulic circuit with vacuum

booster (Master-vac).
The master cylinders and the wheel cylinders at the front
and rear of the vehicle are connected by steel piping and
flexible hoses.
The vacuum booster is connected to the vacuum pump
through the vacuum tank. This provides the most effec-
tive vacuum assist.

Front Drum Brake
Drum Inside Diameter
LNWB5ASF000101

Rear Drum Brake (Manual Adjuster Type)
Drum Inside Diameter
LNWB5ASF000201
The dual two leading shoe type brake eliminates the

problem of weaker braking force on reverse stops com-
mon to two leading shoe type brakes while maintaining
the many advantages of this type of brake.
This combination of two leading shoes provides nearly
equal braking force. This prevents an uneven load dis-
tribution on the wheel hub bearings.
This type of brakes is widely used on the rear wheels of
many vehicles.
ON-VEHICLE SERVICE
Front Drum Brake Assembly (Two Leading)
Two Leading Type (2L Type)
N5A0126E
Legend
1. Shoe holding spring, cup and pin 4. Wheel cylinder assembly
2. Brake shoe and return spring 5. Back plate and oil shield cover
3. Brake flexible hose and pipe

Removal
If the brake drum has step wear or the brake drum edge
is corroded, it will be difficult to remove the brake drum.
The following procedure will make brake drum removal
easier.
LNW94BSH000801
N5A0128E
Legend
1. Corroded portion
1. Remove the rubber cover from the brake lining

clearance adjusting hole.
LNW94BSH001001
3. Shoe Holding Spring, Cup and Pin

4. Brake Shoe and Return Spring
5. Brake flexible Hose and Pipe
1) Place a tray beneath the flexible hose to re-
ceive the brake fluid.
2) Loosen the union nut (1).
LNWB5ASH000301
Legend
1. Adjuster lever release hole cover
2. Put the slotted screwdriver (2). Turn the adjust

gear (1).
Brake Drum Inside Diameter mm (in)

Drum size Standard Limit
300.0 300.0 (11.81) 301.5 (11.87)
Out of round:
• Limit: 0.13 mm (0.005 in)
N5A0136E
3) Remove the clip (2) and loosen the hose end

(3) from the pipe to remove the flexible hose.
Notice:
Take care not to twist the piping and the flexible hose.
N5A0138E
Brake Lining Thickness Measurement

Use a vernier caliper to measure the brake lining thick-
ness or the rivet depth.
If the measured value is less than the specified limit, the
brake shoe assembly and/or the lining must be re-
placed.
Brake Lining Thickness

mm (in)
Limit 1.0 (0.039)
N5A0137E
6. Wheel Cylinder Assembly

7. Back Plate and Oil Shield Cover
Store all of the removed parts in a clean part tray.
Inspection and Repair

Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
Brake Drum Inside Diameter
Visually inspect the brake drum for excessive wear and
scoring.
If the brake drum is scored or worn, lathed to the speci-
fied limit. LNWB5ASH000401
Use a vernier caliper to measure the brake drum inside
diameter. Legend
1. Adhesion type

Brake Lining and Drum Contact 2. Wheel Cylinder Assembly
1. Apply chalk powder to the entire inside brake drum Tighten the wheel cylinder assembly bolts to the
surface. specified torque.
2. Place the brake shoe assembly in the inside brake
drum. Wheel Cylinder Assembly Bolt Torque
3. Move the brake shoe assembly around the inside N⋅m (kg⋅m/lb⋅ft)
brake drum. Drum Inside Dia. mm (in) Lining Width mm (in)
Check for uniform contact between the brake lining
and the brake drum. 300.0 (11.81) 75 (2.95)
N5A0142E
N5A0146E
4. Correct any areas having poor contact with sand- 3. Brake Flexible Hose and Pipe
paper. Tighten the brake pipe flare nuts to the specified
5. Repeat Steps 1 through 4 until the contact between torque.
the brake lining and the brake drum is perfect.
Tighten:
Installation Brake pipe flare nuts to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
1. Back Plate
Tighten the back plate bolts to the specified torque. Notice:
Take care not to twist the piping and the flexible hose.
Tighten:
Back plate bolts to
88 N⋅m (9.0 kg⋅m / 65 lb⋅ft)
N5A0147E
N5A0145E

4. Brake Shoe and Return Spring (Two Leading 4) Install the brake shoes and the return springs to
Type) the wheel cylinders.
1) Before setting the brake shoes, apply a thin Keep the lining surface clean.
coat of molybdenum disulfide grease to the 5. Shoe Holding Spring, Cup and Pin
back plate portions (1) contacting the brake 1) Before installing the holding pin, apply a coat of
shoe edge as shown in the illustrations. molybdenum disulfide grease to the holding
2) Apply a coat of molybdenum disulfide grease to cup seating faces (1) contacting the brake
the wheel cylinder parts contacting the shoe shoe.
(2).
N5A0152E
N5A0148E
2) After installation of the pins, cups and the
3) Set the brake shoe assembly to the cylinder ad- springs, make sure the pin (2) seats to the cup
justing screw at the brake shoe small angle (3) properly.
end. After assembly, adjust the lining clearance and air
Do not install it at the round end to the adjusting bleeding the brake, referring to “SERVING” in Sec-
screw. tion 00 of this section.
Notice:
Do not install the rear brake shoe to the front brake be-
cause front brake shoe and rear brake shoe are differ-
ent.
N5A0149E

Rear Drum Brake Assembly
3
3
1
2
LNW84BLF000201
Legend
1. Shoe holding spring, cup and pin 4. Wheel cylinder assembly
2. Brake shoe and return spring 5. Back plate
3. Brake pipe
Removal
1. Shoe Holding Spring, Cup and Pin
2. Brake Shoe Return Spring
3. Brake Pipe
5. Back Plate
N5A0128E LNW94BSH000801
Legend
1. Corroded portion
1. Remove the rubber cover from the brake lining

clearance adjusting hole.
LNW94BSH001001

during inspection.
LNWB5ASH000301 Brake Drum Inside Diameter
Visually inspect the brake drum for excessive wear and
Legend scoring.
1. Adjuster lever release hole cover If the brake drum is scored or worn, lathed to the speci-
fied limit.
2. Put the flathead screwdriver (2). Turn the adjuster Use a vernier caliper to measure the brake drum inside
gear (1). diameter.

Drum size Standard Limit
300 300.0 (11.81) 301.5 (11.87)
Out of round
• Limit: 0.13 mm (0.005 in)
N5A0138E N5A0140E
Brake Lining Thickness Measurement 3. Inspect the brake shoe for cracking.
Use a vernier caliper to measure the brake lining thick- Brake Lining Installation (Riveted Type)
ness or the rivet depth. 1. Install the brake lining and the rivets to the brake
If the measured value is less than the specified limit, the shoe.
brake shoe assembly and/or the lining must be re- 2. Place the brake shoe assembly in the air hydraulic
placed. riveter.
Brake Lining Rivet Depth mm (in) 3. Use the air hydraulic riveter to set and caulk each
of the rivets.
Limit 1.0 (0.039)
N5A0141E
LNWB5ASH000501
4. Start riveting at the center of lining and work to-
wards the ends.
Legend Brake Lining and Drum Contact
1. Riveted type 1. Apply chalk powder to the entire inside brake drum
surface.
Brake Lining Removal (Riveted Type)
2. Place the brake shoe assembly in the inside brake
1. Remove the rivet caulking portions with a hammer drum.
and chisel.
3. Move the brake shoe assembly around the inside
2. Remove the rivets with a hammer and punch. brake drum.
Check for uniform contact between the brake lining
and the brake drum.
Wheel Cylinder Assembly Bolt Torque

N⋅m (kg⋅m/lb⋅ft)
Drum Inside Lining
—
Dia. mm (in) Width mm (in)
300.0 (11.81) 75 (2.95) 34 (3.5/25)
N5A0142E
4. Correct any areas having poor contact with sand-

paper.
5. Repeat Steps 1 through 4 until the contact between
the brake lining and the brake drum is perfect.
Installation
1. Back Plate N5A0146E
Tighten the back plate bolts to the specified torque.
3. Brake Pipe
Back Plate Bolt Torque N⋅m (kg⋅m/lb⋅ft) Tighten the brake pipe flare nuts to the specified
torque.
Drum Inside Lining
—
Dia. mm (in) Width mm (in) Tighten:
300.0 (11.81) 75 (2.95) 67 (6.8/49) Brake pipe flare nuts to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
Notice:
Take care not to twist the piping.
N5A0173E

N5A0147E
Tighten the wheel cylinder assembly bolts to the
specified torque. 4. Brake Shoe and Return Spring
1) Before setting the brake shoes, apply a thin
coat of molybdenum disulfide grease to the

back plate portions (1) contacting the brake 5. Shoe Holding Spring, Cup and Pin
shoe edge as shown in the illustrations. 1) Before installing the holding pin.
2) Apply a coat of molybdenum disulfide grease to Apply a coat of molybdenum disulfide grease to
the wheel cylinder parts contacting the brake the holding cup seating faces (1) contacting the
shoe (2). brake shoe.
2) After installation of the pins, cups and the
springs, make sure the pin (2) seats to the cup
(3) properly.
N5A0150E
3) Set the brake shoe assembly to the cylinder ad-

justing screw at the brake shoe small angle N5A0152E
end.
Do not install it at the round end. 6. After installation of brake drum, be sure to perform
the preload adjustment of hub bearing.
Notice:
Do not install the front brake shoe to the rear brake be- 7. Bleed the air from brake.
cause front brake shoe and rear brake shoe are differ- Adjustment
ent.
Turn the adjuster until the brake drum stops rotating.
Depress the brake pedal several times and turn the ad-
juster furthermore. When the brake drum stops rotating
completely, turn the adjuster back for 5 to 6 notches.
N5A0151E
4) Install the brake shoes and the return springs to

the wheel cylinders.
Keep the brake lining clean.

Brake Pedal and Control
Brake Vacuum Booster and Brake Pedal Assembly
LNWB5ALF000301
Legend
1. Instrument panel 5. Windshield washer tank
2. Stay 6. Steering cowl assembly
3. Defroster nozzle and vent duct 7. Vacuum booster and brake pedal assembly
4. Brake and clutch fluid reservoir
Removal
1. Instrument Panel
2. Stay
3. Defroster Nozzle and Vent Duct
4. Brake and Clutch Fluid Reservoir
5. Windshield Washer Tank
For the removal procedure for above, refer to Sec-
tion 2 CAB AND FRAME.
6. Steering Cowl Assembly
Wheel remover: 5-8840-2215-0

7. Vacuum Booster and Brake Pedal Assembly
1) Disconnect the brake pipes and hoses.
N5A0182E
Remove the tilt lever and steering cowl.

N5A0185E
2) Plug or cover the brake rubber hoses, pipes

and the master cylinder brake fluid ports to pre-
vent brake fluid spillage.
If brake fluid spillage occurs, wipe it up immedi-
ately.
3) Remove the brake pedal bracket fixing bolts
and vacuum booster and brake pedal assem-
bly.
LNWB5ASH000601
Disconnect the wire harness connectors.
N5A0186E
N5A0184E
N5A0187E N5A0189E
4) Remove the brake pedal and master cylinder. Installation

1. Vacuum Booster and Brake Pedal Assembly
1) Vacuum booster cannot be overhauled. If it is
found faulty, replace its assembly with a new
one.
2) Make necessary adjustment, so that distance
between end of push rod and flange face is ad-
justed to 18.2 mm (0.717 in) in condition of vac-
uum applying.
N5A0188E
5) Remove the vacuum booster assembly from

brake pedal assembly.
N5A0005E
3) Push rod length (A) is measured from the cen-

ter of the clevis pin hole to the mounting surface
of the brake pedal bracket. Adjusted to 109 mm
(4.291 in); without spacer, 129 mm (5.079 in);
with spacer and tighten the lock nut. When
fixed under this condition, there is no need to
adjust the height of brake pedal from floor and
free play.
N5A0006E N5A0195E
4) Install the vacuum booster to brake pedal as- 8) Install the vacuum booster and brake pedal as-
sembly. sembly.
• Adjust the clearance between the tip of thread- Tighten:
ed portion of the stop light switch and the pedal Vacuum booster and brake pedal assembly bolts to 42
arm to 0.5 — 1.0 mm (0.02 — 0.04 in). N⋅m (4.3 kg⋅m / 32 lb⋅ft)
N5A0189E
N5A0186E
5) Tighten the vacuum booster bolts to the speci- 9) Connect the brake hoses and pipes.
fied torque.
Tighten:
Vacuum booster bolts to 14 N⋅m (1.4 kg⋅m / 122 lb⋅in)
6) Install the master cylinder assembly to vacuum
booster or brake pedal assembly.
7) Tighten the master cylinder nut to the specified
torque.
Tighten:
Master cylinder nut to 14 N⋅m (1.4 kg⋅m / 122 lb⋅in)
N5A0185E N5A0199E
2. Steering Cowl Assembly 3. Windshield Washer Tank

1) Connect the wire harness connectors. 4. Brake and Clutch Fluid Reservoir
2) Install the steering cowl. 5. Defroster Nozzle and Vent Duct
Tighten: 6. Stay
Steering cowl bolt to 14 N⋅m (1.4 kg⋅m / 122 lb⋅in) 7. Instrument Panel
For the installation procedure for above, refer to
Section 2 CAB AND FRAME.
LNWB5ASH000601
3) Install the tilt lever.

Tighten:
Tilt lever bolt to 45 N⋅m (4.6 kg⋅m / 33 lb⋅ft)
4) Install the steering wheel.
Tighten:
Steering wheel nut to 49 N⋅m (5.0 kg⋅m / 36 lb⋅ft)

Master Cylinder Assembly
LNWB5ALF000501
Legend
1. Meter cluster 3. Brake pipe
2. Master cylinder

Removal
1. Meter CIuster
2. Switch connector
For the removal procedure for above, refer to Sec-
tion 2 CAB AND FRAME.
3. Brake Pipe
N5A0203E
Installation
1. Master Cylinder
1) Install the master cylinder assembly to the vac-
uum booster or brake pedal assembly.
N5A0201E
4. Brake Hose
1) Disconnect the brake pipes and hoses.
2) Plug or cover the brake rubber hoses, pipes
and the master cylinder brake fluid ports to pre-
vent brake fluid spillage.
If brake fluid spillage occurs, wipe it up immedi-
ately.
N5A0205E
2) Tighten the nuts to the specified torque.

Tighten:
Master cylinder assembly nuts to 14 N⋅m (1.4 kg⋅m / 122
lb⋅in)
2. Brake Hose
3. Brake Pipe
4. Switch Connector
N5A0185E
5. Meter Cluster
5. Master Cylinder
UNIT REPAIR
Wheel Cylinder Assembly (without Auto-adjuster)
N5A0231E
Legend
A. 2L type 3. Piston and cup assembly
B. D2L type 4. Boot
1. Adjusting screw 5. Wheel cylinder body
2. Lock plate 6. Bleeder screw

Disassembly 3. Calculate the clearance between the wheel cylin-
2L Type der and the piston.
If the clearance exceeds the specified limit, the pis-
ton and/or wheel cylinder body must be replaced.
Wheel Cylinder and Piston Clearance

mm (in)
Wheel Cylinder size Limit
22.22 (0.875)
25.40 (1.000) 0.15 (0.006)
28.57 (1.125)
When the wheel cylinder disassembled, the repair

kit (piston cup and boot) must be replaced.
N5A0232E
D2L Type
N5A0234E
Reassembly
1. Bleeder Screw
2. Wheel Cylinder Body
1) Apply a coat of rubber grease to the cylinder
body bore (1) and the grooves for the boots (2).
N5A0233E 2) Fit the boot edge securely into the mating
groove of the cylinder body.
1. Adjusting Screw
2. Lock Plate
3. Piston and cup Assembly
4. Boot
5. Wheel Cylinder Body
6. Bleeder Screw

during inspection.
Wheel Cylinder Assembly
Wheel Cylinder and Piston Clearance
1. Use a micrometer to measure the piston diameter.
2. Use an inside dial indicator to measure the cylinder
bore.
Legend
1. Piston cup
2. Edge
3. Boot
D2L Type
N5A0236E
Legend
1. Cylinder body bore
2. Groove
3. Boot
N5A0238E
3. Boot
4. Piston Assembly
Legend
1) Apply a coat of rubber grease to the piston cups
1. Piston cup
and the pistons.
Be sure to lubricate the entire cylinder body 2. Piston
bore with the rubber grease. 3. Boot
2) Install the piston assembly to the cylinder. 4. Grease
Notice: 1. Lock Plate

After installation of the piston assembly into the cylinder 2. Adjusting Screw
body bore, fit the boot edge securely into the mating Apply a coat of molybdenum disulfide grease to the
groove of the piston. adjusting screw slit and threads.
Make sure that the two boot edges firmly sealed into the
grooves.
Be careful not to damage the piston cups and the boots.
2L Type
N5A0237E

Master Cylinder Assembly
N5A0275E
Legend
1. Holder plate 13. Primary piston
2. Hose joint 14. Plug and O-ring
3. O-ring 15. Supporter
4. Primary piston assembly 16. Secondary piston assembly
5. Plug and O-ring 17. Primary cup
6. Secondary cup 18. Bushing
7. Bushing 19. O-ring
8. Primary cup 20. Secondary cup
9. Supporter 21. Screw
10. Screw 22. Spring retainer
11. Spring retainer 23. Secondary piston spring
12. Primary piston spring 24. Secondary piston

Disassembly 11. Spring Retainer
1. Holder Plate 12. Primary Piston Spring
2. Hose Joint 13. Primary Piston
3. O-ring 14. Plug and O-ring
4. Primary Piston Assembly Install master cylinder on a support plate (1), fix the
Draw out Piston by hand so that it may not be dam- support in a vice, and loosen plug using a wrench
aged. (2).
Support plate : 5-8840-2371-0
Wrench : 5-8840-2369-0
(Master cylinder inside diameter 28.5 mm)
N5A0276E
5. Plug and O-ring

Install master cylinder on a support plate (1), fix the N5A0278E
support in a vice, and loosen plug using a wrench
(2). 15. Supporter
Support plate : 5-8840-2371-0 16. Secondary Piston Assembly
Wrench : 5-8840-2369-0 17. Primary Cup
(Master cylinder inside diameter 28.5 mm) 18. Bushing
19. O-ring
20. Secondary Cup
21. Screw
22. Spring Retainer
23. Secondary Piston Spring
24. Secondary Piston

during inspection.
Cup and O-ring
1. Wash each part with brake oil and check for wear,
deterioration, and damage.
2. Replace the cups and O-rings.
Reassembly
N5A0277E
1. Secondary Piston
6. Secondary Cup 2. Secondary Piston Spring
7. Bushing 3. Spring Retainer
8. Primary Cup 4. Screw
9. Supporter 5. Secondary Cup
10. Screw 6. Bushing

Combine secondary cup and bushing with second- Support plate : 5-8840-2371-0
ary piston as indicated as arrows, and push the as- Wrench : 5-8840-2369-0
sembly in until bushing comes into contact with (Master cylinder inside diameter 28.5 mm)
cylinder body step.
7. O-ring Notice:
Install the O-ring to the bushing. If plug tightened to specified torque is found floating
from cylinder body, plug should be disassembled again
and check for abnormal parts fitting. Then reassemble.
N5A0281E
8. Primary Cup N5A0283E

9. Supporter
11. Primary Piston
10. Plug and O-ring
Combine primary cup and supporter with plug as 12. Primary Piston Spring
indicated by arrows. 13. Spring Retainer
14. Screw
15. Supporter
16. Primary Cup
17. Bushing
1) Combined the parts of primary piston as indi-
cated by arrows.
Then push the assembly in until bushing comes
into contact with the step in cylinder body.
N5A0282E
Then tighten plug to specified tightening torque.
Plug Torque N⋅m (kg⋅m/lb⋅ft)

Master Cylinder
Inside diameter 28.5 40 (4.1/30)
(mm)
N5A0284E

2) Draw out primary piston alone taking care not
to be let bushing get out of the step.
18. Secondary Cup
19. Plug and O-ring
Combine secondary cup with plug as indicated by
arrow, and tighten to specified tightening torque.
N5A0285E
Plug Torque N⋅m (kg⋅m/lb⋅ft)

Master Cylinder
Inside diameter 28.5 40 (4.1/30)
(mm)
Support plate : 5-8840-2371-0

Wrench : 5-8840-2369-0
(Master cylinder inside diameter 28.5 mm)
Notice:
If plug tightened to specified torque is found floating
from cylinder body, plug should be disassembled again
and check for abnormal parts fitting. Then reassemble.
20. O-ring
21. Hose Joint
22. Holder Plate
PARKING BRAKES 5C-1
BRAKES
SECTION 5C
PARKING BRAKES
Contents
GENERAL DESCRIPTION ...................................5C-2
PARKING BRAKE ASSEMBLY,
PARKING BRAKE LEVER ....................................5C-3
UNIT REPAIR [178 mm TYPE] .............................5C-7
5C-2 PARKING BRAKES
GENERAL DESCRIPTION
Parking Brake Assembly
178 mm Type
LNWB5CSF000101
The parking brake is a mechanically operated internal-

expanding type drum brake. It is mounted on the rear of
the transmission case.
The control cable is routed into the vehicle cab where it
is connected to the parking brake lever.
PARKING BRAKES 5C-3
PARKING BRAKE ASSEMBLY, PARKING BRAKE LEVER

Components
4
5
LNWB5CLF000601
Legend
1. Parking brake lever assembly 4. Coupling driver
2. Parking brake cable 5. Parking brake drum
3. Parking brake assembly
Removal • Apply the parking brake, completely raise the latch

1. Jack up the body, and support the frame with the of the lock nut for the coupling driver, and loosen
stand. the lock nut. Then, release the parking brake.
Refer to “LIFTING INSTRUCTION” in Section 0A 4. Disconnect the parking brake cable.
GENERAL INFORMATION. • 178 mm TYPE
2. Remove the rear propeller shaft. – Remove the parking brake drum.
• Disconnect the propeller shaft from the transmis- – Disconnect the cable from the lever of the park-
sion. ing brake assembly.
• Remove the center bearing bracket as well in the
case of the long type.
3. Loosen the coupling driver lock nut.
5C-4 PARKING BRAKES
N5A0341E N5A0343E
5. Remove the coupling driver. Drum inside diameter

• Remove the lock nut that was loosened in step 3, 178 mm (7.00 in) type parking brake
and remove the coupling driver using a universal Standard value = 178 mm (7.00 in), limit = 179 mm (7.05
puller. in)
6. Remove the parking brake assembly. Notice:
7. Remove the parking brake lever assembly. Correct the drum inside diameter by grinding to the ap-
• Loosen the adjusting nut, and disconnect the park- propriate limit.
ing brake cable from the lever.
Installation
• Disconnect the connector.
1. Mount the parking brake lever assembly.
• Loosen the retaining nut, and remove the parking
• Mount the parking brake lever assembly, connect
brake lever assembly.
the parking brake cable, and properly tighten the
adjusting nut.
N5A0342E
8. Inspect the parking brake drum. N5A0342E
• Inspect the parking brake drum for damage, wear, 2. Mount the parking brake assembly.
step wear, or cracking. If any defect is found, cor-
• 178 mm type parking brake
rect or replace the parking brake drum with a new
one. Tighten:
• Measure the inside diameter of the parking brake M12 nut to 113 N⋅m (11.5 kg⋅m/83.3 lb⋅ft)
drum. M8 bolt to 25 N⋅m (2.6 kg⋅m/18.4 lb⋅ft)
PARKING BRAKES 5C-5

3. Connect the parking brake cable.
Notice:
• Connect the parking brake cable to the lever of the • Use a new lock nut because it is a caulking type.
parking brake assembly (178 mm TYPE). Apply oil to the seating face before attaching the
Notice: lock nut.
Confirm that the portion indicated by the arrow is prop- • Use a new O-ring. Apply a thin coat of lubricating
erly connected. oil to the O-ring before attaching it.
• Attach the conical washer (JC52 only) with the
identification groove facing the lock nut (rear side).
N5A0341E
4. Mount the coupling driver.

N5A0347E
• Attach the coupling driver to the main shaft, and
fasten it with an O-ring, a conical washer (JC52 5. Caulk the lock nut.
only), and a lock nut. • Align the lip of the lock nut with the V-grooves cut
Tighten the lock nut while holding the coupling driv- in the tip of the main shaft, and securely caulk the
er with a handle 5-8840-2043-0. lock nut at two points so that the caulking length
will be 5 mm (0.2 in) or more and the clearance be-
Tightening torque N⋅m (kg⋅m/lb⋅ft)
tween the lower V-groove in the main shaft and the
JC52 type transmission 226 (23.0/166.7) lock nut lip will be 1.5 mm (0.06 in) or less.
Notice:
After the caulking of the lock nut, check the caulked
points for cracking. If there is any crack, replace the lock
nut with a new one, and caulk it.
N5A0346E
5C-6 PARKING BRAKES

Number of notches by which the adjuster must be
turned back 30 notches
N5A0350E
• Adjust the pulling allowance of the parking brake

lever by tightening the adjusting nut so that the al-
lowance at a handle operating force of 147 N (15.0
kg / 33 lb) will be six to eight notches.
• Confirm that the brake does not drag.
N5A0348E • Mount the adjusting cover over the parking brake
drum.
6. Mount the parking brake drum.
7. Adjust the pulling allowance of the parking brake.
• Turn the adjuster until the parking brake drum
stops turning.
• Turn back the adjuster by the specified number of
notches.
N5A0349E
PARKING BRAKES 5C-7
UNIT REPAIR [178 mm TYPE]

Parking Brake Assembly
N5A0353E
Legend
1. Holding spring 5. Secondary brake shoe assembly with lever
2. Return spring 6. Primary brake shoe assembly
3. Adjuster assembly 7. Strut
4. Spring; adjuster 8. Parking cable
Disassembly • Brake lining

1. Holding Spring • Return spring
2. Return Spring • Parking brake lever assembly
3. Adjuster Assembly • Parking brake inner cable
4. Spring; Adjuster Brake Drum
5. Secondary Brake Shoe Assembly Use a vernier caliper to measure the brake drum inside
diameter.
6. Primary Brake Shoe Assembly
If the measured value exceeds the specified limit, the
7. Strut brake drum must be replaced.
8. Parking Cable
Standard Limit
placements if excessive wear or damage is discovered Inside diameter 178 (7.01) 179 (7.05)
during inspection. Out of round:
Visual Check
• Limit: 0.05 mm (0.0020 in) or less
Inspect the following parts for wear, corrosion, scuffs,
scratches, deterioration or other abnormal conditions.
• Brake drum
5C-8 PARKING BRAKES
N5A0138E N5A0357E
Return Spring
Use a spring balancer to measure the return spring set Legend
load. A. Length
If the variation exceeds 10% of the specified value, the
Brake Lining Thickness
return spring must be replaced.
Use a vernier caliper to measure the brake lining thick-
Drum inside dia. mm (in) ness.
If the measured value is less than the specified limit, the
178 (7.01) brake shoe assembly must be replaced.
Free length: Primary 62 (2.44)
Brake Lining Thickness mm (in)
mm (in) Secondary 49 (1.93)
Limit 1.0 (0.039)
Set length: Primary 70 (2.76)
mm (in) Secondary 57 (2.24)
105.9 — 129.5
Primary (10.8 — 13.2/23.8 —
Set load; 29.1)
N (kg/lb) 88.3 — 107.8
Secondary (9.0 — 11.0/19.8 —
24.3)
N5A0358E
N5A0356E
PARKING BRAKES 5C-9

Reassembly
1. Parking Cable Rear
2. Strut
3. Primary Brake Shoe Assembly
4. Secondary Brake Shoe Assembly
Install the brake shoes by fitting them properly into
slot in the adjuster and strut.
5. Spring; Adjuster
6. Adjuster Assembly
7. Return Spring
Drum inside diameter 178 mm
Attach the return spring bauing fewer windings at the pri-
mary side as illustrated.
N5A0360E
Legend
1. Fewer windings
2. Much windings
8. Holding Spring
MEMO
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EXHAUST BRAKE 5E-1
BRAKES
SECTION 5E
EXHAUST BRAKE
Contents
GENERAL DESCRIPTION ................................... 5E-2
ON-VEHICLE SERVICE ....................................... 5E-3
UNIT REPAIR ....................................................... 5E-5
5E-2 EXHAUST BRAKE
GENERAL DESCRIPTION
N5A0369E
EXHAUST BRAKE 5E-3
ON-VEHICLE SERVICE
Exhaust Brake Assembly
N5A0370E
Legend
A. 4J engine without turbocharger 2. Flange nut
B. 4J engine with turbocharger 3. Exhaust pipe
1. Vacuum hose and clip 4. Exhaust brake unit
Removal
Tighten:
1. Vacuum Hose and Clip Exhaust brake unit fixing nuts and bolts to
2. Nut 4J engine without turbocharger: 37 N⋅m (3.8 kg⋅m / 27
3. Exhaust Pipe lb⋅ft)
4. Exhaust Brake Unit 4J engine with turbocharger: 17 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
Installation
1. Exhaust Brake Unit
Tighten the brake unit fixing nuts and/or bolts to the
specified torque.
5E-4 EXHAUST BRAKE
N5A0372E
Legend
A. 4J engine without turbocharger
B. 4J engine with turbocharger
2. Exhaust Pipe
3. Flange Nut
Tighten the exhaust pipe flange nuts for the ex-
haust manifold to the specified torque.
Tighten:
Flange nuts to
4J engine without turbocharger: 37 N⋅m (3.8 kg⋅m / 27
lb⋅ft)
4J engine with turbocharger: 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
N5A0373E
Legend
A. 4J engine without turbocharger
B. 4J engine with turbocharger
4. Vacuum Hose and Clip

EXHAUST BRAKE 5E-5
UNIT REPAIR
Exhaust Brake Unit
N5A0466E
Legend
1. Exhaust brake valve connector 4. Clevis joint
2. Cotter pin 5. Power chamber
3. Lock nut 6. Exhaust valve assembly
Disassembly
1. Exhaust Brake Valve Connector
2. Cotter Pin
3. Lock Nut
4. Clevis Joint
5. Power Chamber
6. Exhaust Valve Assembly

during inspection.
Visual Inspection
Visually inspect the following parts for excessive wear
and damage.
If excessive wear or damage is discovered during in-
spection, the part(s) must be replaced. N5A0375E
• Exhaust brake valve
Power Chamber
• Exhaust brake shaft
(1) The exhaust brake valve should operate smoothly
• Butterfly valve when the negative pressure (400 mmHg to 700 mmHg)
• Bushings is applied to the power chamber via the vacuum pump.
• Power chamber
5E-6 EXHAUST BRAKE

Reassembly
1. Exhaust Valve Assembly
2. Power Chamber
Tighten:
Power chamber fixing nut to 14 N⋅m (1.4 kg⋅m / 122 lb⋅in)
N5A0376E
(2) At the points (A) and (B), the average clearance be-
tween the valve and the vehicle body should be as men-
tioned in the following table when the negative pressure
(650 mmHg to 700 mmHg) is applied to the power
chamber via the vacuum pump.
N5A0379E
Clearance Between Valve And Body mm (in)
3. Lock Nut
Standard
Tighten:
0.4 — 0.6 (0.016 — 0.024) Lock nut to 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
0.1 — 0.2 (0.004 — 0.008)
N5A0380E
N5A0377E 4. Clevis Joint

5. Cotter Pin
Legend 6. Exhaust Brake Valve Connector
1. Power chamber
Tighten:
2. Adjust bolt
More than 9.8 N⋅m (1.0 kg⋅m / 7.2 lb⋅ft)
3. Valve
LGBRK-WE-1111_奥付_68650 2011.7.12 4:25 PM ページ 1
Published: Jul., 2011 All rights reserved.

First Edition
WORKSHOP MANUAL
BRAKES
Issued by ISUZU MOTORS LIMITED

E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
LGBRK-WE-1111_奥付_68650 2011.7.12 4:25 PM ページ 2
2011MY
2011MY
WORKSHOP MANUAL BRAKES
WORKSHOP MANUAL
BRAKES
No.LGBRK-WE-1111

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2011MY

SERVICE INFORMATION 00-1

00-2 SERVICE INFORMATION

PROBLEM POSSIBLE CAUSE CORRECTION

SERVICE INFORMATION 00-3

PROBLEM POSSIBLE CAUSE CORRECTION

00-4 SERVICE INFORMATION

PROBLEM POSSIBLE CAUSE CORRECTION

SERVICE INFORMATION 00-5

PROBLEM POSSIBLE CAUSE CORRECTION

00-6 SERVICE INFORMATION

PROBLEM POSSIBLE CAUSE CORRECTION

SERVICE INFORMATION 00-7

PROBLEM POSSIBLE CAUSE CORRECTION

00-8 SERVICE INFORMATION

PROBLEM POSSIBLE CAUSE CORRECTION

PROBLEM POSSIBLE CAUSE CORRECTION

SERVICE INFORMATION 00-9

PROBLEM POSSIBLE CAUSE CORRECTION

PROBLEM POSSIBLE CAUSE CORRECTION

00-10 SERVICE INFORMATION

MAIN DATA AND SPECIFICATIONS

Driving Position Emission Control

L: LHD VT: Euro-2

ENGINE MODEL Y: Cab chassis

55: 4JB1 Engine series Cab

-: Non tilt single cab

DRIVING SYSTEM A: Tilt single cab

GVM Range 5: Dual

K: 3.3-5.5 ton GVM

Q: LIGHT DUTY TRUCK

SERVICE INFORMATION 00-11

— Not available FRONT BRAKE

Rear Brakes (QKR)

— Not available REAR BRAKE PARKING BRAKE BRAKE CONTROL

00-12 SERVICE INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

SERVICE INFORMATION 00-13

Wheel Brake Adjustment

For push rod length adjustment, the distance from the

00-14 SERVICE INFORMATION

Brake Pedal Free Play and Allowance

SERVICE INFORMATION 00-15

7. Loosen the bleeder screw (4) approximately 1/2 of

00-16 SERVICE INFORMATION

2. Remove one of the two check hole covers from the

SERVICE INFORMATION 00-17

4. Retighten the control wire lock nut (1).

7. Reinstall the check hole cover.

00-18 SERVICE INFORMATION

Brake Pipe Joint 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)

Front Wheel Brake

SERVICE INFORMATION 00-19

00-20 SERVICE INFORMATION

SERVICE INFORMATION 00-21

00-22 SERVICE INFORMATION

SERVICE INFORMATION 00-23

5-8840-2371-0 / Master 5-8840-2043-0 / Flange