Chapter 11 BRAKE SYSTEM

1. Structure ................................................................................................ 11-1

1.1 Brake System ........................................................................................................ 11-1
1.2 Hydraulic Circuit Diagram (Standard).................................................................... 11-2
1.3 Hydraulic Circuit Diagram (Optional) ..................................................................... 11-3
2. Disassembly and Reassembly............................................................. 11-4
2.1 Main Tank.............................................................................................................. 11-4
2.2 Gear Pump-related ................................................................................................ 11-5
2.3 Brake Valves ....................................................................................................... 11-11
2.4 Parking Brake Valve ............................................................................................ 11-18
2.5 Shuttle Valve, Connector..................................................................................... 11-21
2.6 Oil Filter ............................................................................................................... 11-22
3. Measurement of Hydraulic Pressure................................................. 11-23
4. Forcible Release of Parking Brake .................................................... 11-24
4.1 Release by Turning Bolt ...................................................................................... 11-24
4.2 Release by the External Hydraulic Pressure ....................................................... 11-25
5. Troubleshooting.................................................................................. 11-26

11
 BRAKE SYSTEM

Chapter 11 BRAKE SYSTEM

1. Structure
1.1 Brake System

Main tank
Gear pump
Auto-deceleration valve
(optional)

Oil filter
Pedal assembly

Parking brake valve

Connector

Shuttle valve
(optional)
Wet disc brake
assembly
Brake valve

215946

The wheel brake structure has one set of multi-disc The parking brake is operated mechanically by the
brake (negative brake) installed on each side of the spring force in the wet disc brake assembly. Hydraulic
front axle. pressure from the brake valve is used to release it.
The brake oil used has different specifications from If hydraulic pressure is not generated, the parking
conventional brake fluid and is stored in a dedicated brake is held by the spring force of the wet disc brake
tank. assembly. The lift truck will not move.
The brake system gear pump applies pressure to the To release the parking brake, one port for forcible can-
brake oil which operates the wheel brake. cellation is provided on the parking brake valve and
This foot brake will operate the multi-disc brake with one bolt for forcible cancellation is provided on the wet
hydraulic pressure from the brake valve or auto-decel- disc brake assembly.
eration valve.

11-1
11-2
IN LINE FILTER
BRAKE SYSTEM

LEVEL GAUGE

PARKING BRAKE VALVE

EMERGENCY PORT
PARKING BRAKE VALVE ASSY

OIL TANK (MAX 3.9 L)

A P PKB [MAX 237.99 cu·in]

T
Φ0.8 mm [0.031 in]
CONNECTOR BRAKE VALVE
6 MPa
1.2 Hydraulic Circuit Diagram (Standard)

BR T ENGINE

COOLER
PARKING P GEAR PUMP
SERVICE

BRAKE UNIT (RH)

SERVICE CONNECTOR

PARKING
COOLER

BRAKE UNIT (LH)

215795
 IN LINE FILTER

LEVEL GAUGE

P T PARKING BRAKE VALVE

PROPORTIONAL EMERGENCY PORT
SOLENOID VALVE PARKING BRAKE VALVE ASSY
(OPTIONAL)

B OIL TANK (MAX 3.9 L)

A2 A1 A P PKB [MAX 237.99 cu·in]

B T
SHUTTLE VALVE Φ0.8 mm [0.031 in]
(OPTIONAL)
1.3 Hydraulic Circuit Diagram (Optional)

CONNECTOR
BRAKE VALVE 6 MPa

BR T ENGINE

ONLY CONTROLLED ROLLBACK

COOLER
PARKING 2.3 MPa PRESSURE SWITCH P GEAR PUMP
(OPTIONAL)
SERVICE

BRAKE UNIT (RH)

SERVICE CONNECTOR

PARKING
COOLER

BRAKE UNIT (LH)

215796
BRAKE SYSTEM

11-3
BRAKE SYSTEM

2. Disassembly and Reassembly

2.1 Main Tank

2
4
A 3
A
5

2
1 Front of truck

6
5 3 Gauge,Oil level
Valve,auto decelaration

215737
Sequence
1 Drain plug 5 Hose
2 Connector 6 Main tank mounting bolt
3 Hose 7 Main tank
4 Brake pipe

Procedure for removal

Before starting the removal, loosen the drain plug 1 to
drain oil from the main tank.
Procedure for reinstallation
Reinstall in the reverse order of removal.
After reinstalling the main tank, carry out air bleeding
and flushing.
Note: For the procedure, refer to the section of “1.2.5
Air bleeding of wet disc brake” in “Chapter 5
Power Train.”
Oil for use: Manufacturer's recommended oil
Amount of oil 2 ton class 3 ton class
Gasoline engine 10.9 L 12.8 L
model (665.16 cu.·in.) (781.10 cu.·in.)
Diesel engine 10.4 L 12.3 L
model (634.65 cu.·in.) (750.59 cu.·in.)

11-4
 BRAKE SYSTEM

2.2 Gear Pump-related

2.2.1 Removal (Gasoline-engine models)

Tightening torque
2 10 33.3 ± 3.3 N·m
(3.4 ± 0.3 kgf·m) Tightening torque
[24.6 ± 2.4 lbf·ft] 6.9 ± 0.7 N·m
7 (0.7 ± 0.07 kgf·m)
4
[5.1 ± 0.5 lbf·ft]
1
9
8 5
3 6

Tightening torque
49 ± 4.9 N·m
11
(5.0 ± 0.5 kgf·m)
16
[36.1 ± 3.6 lbf·ft]

Tightening torque
33.3 ± 3.3 N·m
(3.4 ± 0.3 kgf·m)
[24.6 ± 2.4 lbf·ft]
15

14 13
Tightening torque
17
59.8 ± 6 N·m
12 (6.1 ± 0.6 kgf·m)
[44.1 ± 4.4 lbf·ft]
215727
Sequence
1 V-belt 7 Driven pulley 13 Tensioner assembly
2 Suction hose 8 Snap ring 14 Engine mount mounting bolt
3 Delivery pipe 9 Ball bearing 15 Engine mount bracket mounting bolt
4 Wheel mounting bolt 10 Gear pump mounting bolt 16 Engine mount bracket
5 Wheel 11 Gear pump 17 Engine mount
6 Snap ring 12 Tensioner assembly mounting bolt
Procedure for removal
(1) Remove the under cover and left-side rear cover. (5) Remove the snap ring 6, then remove the driven
(2) Loosen the adjustment bolt of the tensioner pulley 7, snap ring 8, and ball bearing 9 together.
assembly 13 to remove the V-belt 1. (6) Remove the snap ring 8 from the driven pulley 7,
(3) Disconnect the suction hose 2 and delivery pipe 3. then remove the ball bearing 9.
(4) Remove the wheel mounting bolt 4 (3 places), (7) Remove the gear pump mounting bolt 10 to
then remove the wheel 5. remove the gear pump 11.

11-5
BRAKE SYSTEM

2.2.2 Removal (Diesel-engine models)

Tightening torque
33.3 ± 3.3 N·m
(3.4 ± 0.3 kgf·m)
10
[24.6 ± 2.4 lbf·ft] Tightening torque
11 49 ± 4.9 N·m
3 (5.0 ± 0.5 kgf·m)
[36.1 ± 3.6 lbf·ft]

2
Tightening torque
12
Tightening torque 59.8 ± 6 N·m
1 6.9 ± 0.7 N·m (6.1 ± 0.6 kgf·m)
(0.7 ± 0.07 kgf·m) 15 [44.1 ± 4.4 lbf·ft]
[5.1 ± 0.5 lbf·ft]
4

14
9 7
6 8
Tightening torque 13
5
59.8 ± 6 N·m
(6.1 ± 0.6 kgf·m)
[44.1 ± 4.4 lbf·ft] 215730
Sequence
1 V-belt 6 Snap ring 11 Gear pump
2 Suction hose 7 Driven pulley 12 Engine mount mounting bolt
3 Delivery pipe 8 Snap ring 13 Engine mount bracket mounting bolt
4 Wheel mounting bolt 9 Ball bearing 14 Engine mount bracket
5 Wheel 10 Gear pump mounting bolt 15 Engine mount

Procedure for removal

(1) Remove the under cover and right-side rear (5) Remove the snap ring 6, then remove the driven
cover. pulley 7, snap ring 8, and ball bearing 9 together.
(2) Loosen the adjustment bolt of the tensioner (6) Remove the snap ring 8 from the driven pulley 7,
assembly to remove the V-belt 1. then remove the ball bearing 9.
(3) Disconnect the suction hose 2 and delivery pipe 3. (7) Remove the gear pump mounting bolt 10 to
(4) Remove the wheel mounting bolt 4 (3 places), remove the gear pump 11.
then remove the wheel 5.

11-6
 BRAKE SYSTEM

2.2.3 Reinstallation (Gasoline-engine models)

Reinstall in the reverse order of removal, noting the
following points.

Deflection amount

Tightening torque
26.5 ± 2.65 N·m
(2.7 ± 0.27 kgf·m)
[19.5 ± 1.95 lbf·ft]

215728

(1) Check the following points before reinstalling the

V-belt:
(a) Check the belt for contamination with oil,
grease and dust, etc., and replace it, if neces-
sary. If the contamination is not significant,
clean with a rag or paper towel. Do not use
gasoline, oil or any other solvent to clean the
belt.
(b) If the belt is damaged, replace it with a new
one.
(2) During the inspection of bearings, confirm that
each bearing rotates smoothly and generates no
abnormal noises.
(3) Make sure that the V-belt is not twisted. Adjust it,
to obtain the deflection shown in the table. Use
the tension adjustment belt and nut on the tension
assembly.
Deflection amount Pressing force
0
14-2 mm
New part 0
(0.55-0.08 in.) 98 N
(10 kgf)
0
16-2 mm [22 lbf]
Reinstalled part 0
(0.62-0.08 in.)

(4) After reinstalling the gear pump, make sure there

are no oil leaks.

11-7
BRAKE SYSTEM

2.2.4 Reinstallation (Diesel-engine models)

Reinstall in the reverse order of removal, noting the
following points.

Tightening torque
26.5 ± 2.65 N·m
(2.7 ± 0.27 kgf·m)
[19.5 ± 1.95 lbf·ft]

Deflection amount

215731

(1) Check the following points before reinstalling the

V-belt:
(a) Check the belt for contamination with oil,
grease and dust, etc., and replace it, if neces-
sary. If the contamination is not significant,
clean with a rag or paper towel. Do not use
gasoline, oil or any other solvent to clean the
belt.
(b) If the belt is damaged, replace it with a new
one.
(2) During the inspection of bearings, confirm that
each bearing rotates smoothly and generates no
abnormal noises.
(3) Make sure that the V-belt is not twisted. Adjust it,
to obtain the deflection shown in the table. Use
the tension adjustment bolt and nut on the tension
assembly.
Deflection amount Pressing force
0
14-2 mm
New part 0
(0.55-0.08 in.) 98 N
(10 kgf)
0
16-2 mm [22 lbf]
Reinstalled part 0
(0.62-0.08 in.)

(4) After reinstalling the gear pump, make sure there

are no oil leaks.

11-8
 BRAKE SYSTEM

2.2.5 Disassembling the gear pump

8
10
7
6 1

5 12
2

11

4
5
3
7
8

216006

1 Bolt 5 Bushing 9 Gear drive

2 Front cover 6 Gasket 10 Gear driven
3 Retainer ring 7 Gasket (3-shaped) 11 Steel ball
4 Oil seal 8 Side plate 12 Body

Note: a) The gear pump should be disassembled, re-

paired and assembled by the manufacturer. If
this has to be done in the field, carefully note
the following points. Remember, doing this
procedure in the field will invalidate the manu-
facturer's guarantee
b) The oil seal 4 and bushing 5 do not need to
be disassembled, unless a fault is found.
Procedure for disassembly
As the front cover 2 is made of aluminum alloy and is
easily scratched, do not forcibly tap them with a ham-
mer, etc. Use a wooden hammer or plastic hammer.
When disassembling, do not remove the body, gear
and bushing, etc. by forcibly tapping them with a ham-
mer etc.
Place the disassembled parts in an orderly sequence
on a clean workbench.
Do not mix up the relative position of the gear and
bushing side plate.

11-9
BRAKE SYSTEM

2.2.6 Reassembling the gear pump

RETAINER RING
GASKET
OIL SEAL
GASKET
(3-SHAPED)

215964

Procedure for reassembly

To reassemble, follow the sequence of disassembly in
the reverse order while noting the following points.
(1) Replace the seal kit parts, marked by a * in the fig-
ure, with new ones.
Seal kit 91K46-00018

(2) Completely remove oil or grease on the mating

surfaces of the front cover, body, etc.
(3) Wash all parts, visually check all parts for cleanli-
ness, wear and damage. Apply brake oil to the
inside surface of the body before reassembly.
(4) Apply grease to the lip of the oil seal.
(5) Be careful not to damage the lip of the shaft seal
by the spline edges of the drive gear.
(6) Tighten the bolts evenly and progressively.
(7) After reassembly, check that the pump shaft can
be easily rotated by hand with a pipe wrench fitted
on the pump shaft.
(8) After reinstalling the pump, bleed the air from the
brake system and check that it operates normally.
Note: For the procedure, refer to section “1.1.5 Wet
disc brake air bleeding procedure.”

11-10
 BRAKE SYSTEM

2.3 Brake Valves

2.3.1 Removal

Brake pedal assembly

1
4

2
3

215947
Sequence
1 Snap pin, washer 3 Brake valve mounting bolt
2 Clevis pin 4 Brake valve

2.3.2 Reinstallation
Reinstall in the reverse order of removal.
After reinstallation, carry out air bleeding of the brake
system.
Note: For the procedure, refer to the section “1.1.5
Wet disc brake air bleeding procedure.

11-11
BRAKE SYSTEM

2.3.3 Disassembly
Precautions on this operation
(1) Since the performance of the brake valve assem- (3) Since the cylinder and spool are combined so as
bly will greatly deteriorate if foreign matter such as to have the optimum clearance, do not replace the
dirt and dust gets inside, it cannot be disassem- cylinder unit by itself, nor attempt to modify the
bled except for the boot and push rod. combination of parts.
(2) Perform disassembly and reassembly in a clean (4) For cleaning parts and O-rings, use mineral-oil
place. type hydraulic fluid.
Note: There must be only a small clearance between (5) Do not reuse the R-cup once it has been removed
the cylinder and spool. If any matter becomes from the piston.
trapped between them, the clearance may be-
come too large, interfering with spool operation.

14.7 – 34.3 N·m

(1.5 – 3.5 kgf·m)
[10.8 – 25.3 lbf·ft]
10 8 9 3 2

18 19 13 14 16 17 20 15 7 6 5 11 12 4 1 58.8 – 78.4 N·m

(6.0 – 8.0 kgf·m)
14.7 – 34.3 N·m [43.4 – 57.9 lbf·ft]
(1.5 – 3.5 kgf·m)
[10.8 – 25.3 lbf·ft]
215948
Sequence
1 End plug 8 Spring 15 Stop wire
2 O-ring 9 spring 16 Piston
3 Bolt 10 Retainer 17 R-cup
4 S cylinder 11 Spool 18 Clevis pin
5 O-ring 12 Spring 19 Lock nut
6 Holder 13 Push rod 20 Flange
7 Rod 14 Boot

11-12
 BRAKE SYSTEM

Procedure for disassembly

Tightening bolt
(1) Remove the end plug from the S cylinder. Do not let the spool fall off.

(2) Unfasten each tightening bolt of the flange and S

cylinder to remove them, then remove the S cylin-
der. Do not allow the spool to fall off while doing
this.

End plug
Flange
S cylinder
215949

(3) Pull out the spool from the S cylinder.

Take care not to
let this fall.

215950

(4) Remove the holder, rod, spring, and retainer

together from the flange.

Flange
215951

(5) Disassemble the holder, rod, spring, and retainer

which have been removed. When drawing out the Retainer Spring Holder Rod
rod through the oval hole of the holder, do not
allow the spring to fly out.

Be careful. The springs will jump off

when the rod is released.

215952

11-13
BRAKE SYSTEM

(6) Remove the push rod from the flange.

(7) Remove the boot. Boot

Push rod

215953

(8) Remove the stop wire from the piston, then

remove the piston.
(9) Remove the R-cup from the piston.

Pull out.

R-cup Stop wire

215954

11-14
 BRAKE SYSTEM

2.3.4 Inspection after disassembly

(1) S cylinder and spool (6) Push rod
Check whether the spool slides smoothly by hand, Replace the push rod if it is bent or deformed.
and if you can feel any interference, replace it as a
set. (7) Boot

(2) Flange (a) Check for any cracks, damages, or crevices,

Check the piston sliding area of the flange for any and replace the boot if it appears to be abnor-
fault, wear, or other damage. If there is any, mal.
replace the flange. (b) Check the interference area of the cylinder and
(3) Piston rod, and replace any part whose interference
Check the flange sliding area of the piston for any size is too small or none.
fault, wear, or other damage. If there is any, (8) Bolt, Nut, End plug
replace the piston. Check for any damage and wear, and confirm its
Unit: mm (in.) smooth operation.
0.016 – 0.095
A
Clearance between (0.0006 – 0.0037)
flange and piston 0.15
B
(0.0059)
A: Standard value B: Repair/Service limit

(4) R-cup
(a) Replace the R-cup, even if it has a minimal
fault in the lip area.
(b) Check the interference of the R-cup, and
replace the cup if the size is smaller than the
service limit using the repair kit.
Unit: mm (in.)
A -
Cup interference size 0.4
B
(0.015)
A: Standard value B: Repair/Service limit

(5) Spring
(a) Check for any fault, wear, or fatigue. Replace
any spring that has a severe fault, etc.
(b) Measure the free length of the spring, and
replace any which exceeds the service limit.
Unit: mm (in.)
48.0
Major diameter of A
(1.89)
control spool
Spring free length 47.5
B
(1.87)
Minor diameter of 50.5
A
control spool (1.99)
Spring free length B -
24.8
Spool return spring A
(0.98)
free length
B -
A: Standard value B: Repair/Service limit

11-15
BRAKE SYSTEM

2.3.5 Reassembly
Procedure for reassembly
To reassemble, follow the sequence of disassembly in
the reverse order while noting the following points.
(1) Install the R-cup to the piston without damaging it.
(2) Install the piston to the flange.
Note: a) Apply lithium grease to the piston circumfer- Flange
ence area and R-cup. Piston
b) When installing the piston to the flange, do
not damage the R-cup.

R-cup

215955

(3) Install the stop wire to the piston.

Piston

Stop wire

215956

(4) Assemble the holder, rod, spring and retainer

together. Retainer Spring Holder Rod

Hook in the oval hole.

215957

(5) Attach the holder, rod, spring, and retainer which

have been assembled together to the flange in the
direction shown in the figure on the right.
(6) Install the O-ring to the S cylinder.

O-ring
Flange S cylinder

215958

11-16
 BRAKE SYSTEM

(7) While aligning the direction of each port, install the

S cylinder and the flange. T P

A Tightening torque
14.7 – 34.3 N·m
Direction of port (1.5 – 3.5 kgf·m)
[10.8 – 25.3 lbf·ft]
215959

(8) Apply oil to the cylinder's inside surfaces and

install the spool and spring in the direction shown
in the figure on the right. Spring
(9) Install the O-ring to the end plug. Spool O-ring

(10)Install the end plug to the S cylinder.

Tightening torque End plug

58.8 – 78.4 N·m
(6.0 – 8.0 kgf·m)
[43.4 – 57.9 lbf·ft] 216035

(11)Install the boot and push rod to the flange.

Note: a) Install the boot with the hole facing the T-port
side. Boot hole
T P
b) Apply lithium grease to the tip of the push rod.
c) When replacing the end plug, take a note of
serial number engraved on the original end
plug.

215960

11-17
BRAKE SYSTEM

2.4 Parking Brake Valve

2.4.1 Removal (Gasoline-engine models)

Tightening torque
49 ± 4.9 N·m
(5.0 ± 0.5 kgf·m)
[36.1 ± 3.6 lbf·ft]
4 7
Port for forcible release Port for forcible release

1 Tightening torque
Front side 6 15.5 ± 2.5 N·m
4 (1.6 ± 0.2 kgf·m)
[11.4 ± 1.8 lbf·ft]

3
Tightening torque Front side
2
49 ± 4.9 N·m
(5.0 ± 0.5 kgf·m)
[36.1 ± 3.6 lbf·ft]
5 Tightening torque
49 ± 4.9 N·m
(5.0 ± 0.5 kgf·m)
[36.1 ± 3.6 lbf·ft]

215872
Sequence
1 Brake pipes 5 Connector
2 Hose (between parking brake valve and connector) 6 Bolt
3 Hose (between parking brake valve and brake valve) 7 Parking brake valve
4 Hose (between gear pump and parking brake valve)

2.4.2 Reinstallation (Gasoline-engine models)

Reinstall in the reverse order of removal.

11-18
 BRAKE SYSTEM

2.4.3 Removal (Diesel-engine models)

Tightening torque
49 ± 4.9 N·m
(5.0 ± 0.5 kgf·m)
[36.1 ± 3.6 lbf·ft] 7 6
4 Port for forcible release

Port for forcible release Front side 5 Tightening torque

1
15.5 ± 2.5 N·m
(1.6 ± 0.2 kgf·m)
4 [11.4 ± 1.8 lbf·ft]

3
2 Tightening torque
49 ± 4.9 N·m
Tightening torque (5.0 ± 0.5 kgf·m)
49 ± 4.9 N·m [36.1 ± 3.6 lbf·ft]
5 (5.0 ± 0.5 kgf·m) Front side
[36.1 ± 3.6 lbf·ft]

215873
Sequence
1 Brake pipes 5 Connector
2 Hose (between parking brake valve and connector) 6 Bolt
3 Hose (between parking brake valve and brake valve) 7 Parking brake valve
4 Hose (between gear pump and parking brake valve)

2.4.4 Reinstallation (Diesel-engine models)

Reinstall in the reverse order of removal.

11-19
BRAKE SYSTEM

2.4.5 Disassembling parking brake valve

Tightening torque 9
19.6 N·m 5 Tightening torque
(2.0 kgf·m) 10 20.3 N·m
[14.4 lbf·ft] (2.1 kgf·m)
[15.0 lbf·ft]

MG
BE
Tightening torque 6 PK

39.2 ± 3.9 N·m

(4.0 ± 0.4 kgf·m) 3 Tightening torque
T
[28.9 ± 2.8 lbf·ft] 39.2 ± 3.9 N·m
P

BR
(4.0 ± 0.4 kgf·m)
[28.9 ± 2.8 lbf·ft]
Tightening torque 11 12
39.2 N·m 4 Tightening torque
(4.0 kgf·m) 39.2 ± 3.9 N·m
[29.0 lbf·ft] (4.0 ± 0.4 kgf·m)
[28.9 ± 2.8 lbf·ft]
2
7 Tightening torque
Tightening torque 8 19.6 N·m
19.6 N·m (2.0 kgf·m)
(2.0 kgf·m) [14.4 lbf·ft]
[14.4 lbf·ft]
1 Tightening torque
34 N·m
(3.5 kgf·m)
[25.1 lbf·ft]
215961

Sequence
1 Valve, solenoid 8 Plug, O-ring type
2 Orifice 9 Plug, O-ring type
3 Elbow 10 Plug, O-ring type
4 Elbow 11 Plug, O-ring type
5 Valve, relief 12 Strainer
6 Connector 13 Plug, O-ring type
7 Plug, O-ring type

Procedure for reinstallation

When reinstalling the elbow, pay attention to the posi-
tion of the angle as shown in the figure on the right. 45

215742

11-20
 BRAKE SYSTEM

2.5 Shuttle Valve, Connector

Connector
90
°
A

Front of truck

Front of truck

View A

Option
Pro-shift
STD Auto-decelerate & Pro-shift
& Auto-decelerate &
Controlled-rollback & Auto-decelerate
Controlled-rollback

Valve,Shuttle
Valve,Shuttle Switch,Pressure
Valve,Shuttle

Connector

Connector
Elbow
Tightening torque:
Elbow Elbow
39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m)
Tightening torque: Tightening torque:
[28.9 ± 2.8 lbf·ft]
39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) 39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m)
[28.9 ± 2.8 lbf·ft] [28.9 ± 2.8 lbf·ft]
215736

11-21
BRAKE SYSTEM

2.6 Oil Filter

Elbow Screw Oil filter assy

20°
A
IN

OUT

Oil filter cover

Elbow

Oil filter bracket

A
Front of truck

215749

Procedure for reinstallation

After thoroughly cleaning the mounting surface at the
filter bracket side, apply a thin coat of brake oil to the
O-ring of the filter, then fully hand-tighten the filter. Bracket side
Note: Do not tighten the filter using a wrench, etc.
Apply oil.

216004

11-22
 BRAKE SYSTEM

3. Measurement of Hydraulic Pressure

(1) Block the wheels with wood blocks.
Hydraulic pressure gauge
(2) Attach a hydraulic pressure gauge to the specific
port of the parking brake valve.
Front side
(3) Use the hydraulic pressure measuring tool in the
table shown below.

Relief valve G1/8

(4) Hydraulic pressure measurement

Start the engine and set all the levers in the neu-
tral position, pull the parking brake switch, mea- 216003
sure the hydraulic pressure required to open the
valve using a hydraulic pressure gauge.

Engine speed Low idling

6.0 – 7.0 MPa
Hydraulic pressure (61.18 – 71.38 kgf/cm2)
[870.32 – 1015.37 psi]

(5) If the hydraulic pressure at the relief valve is dif-

ferent from the standard value, stop the engine,
loosen the lock nut of the relief valve, then turn the
screw with a screwdriver to tighten the lock nut.
Start the engine again and measure the hydraulic
pressure.
When the hydraulic pressure reaches the stan-
dard value, firmly tighten the lock nut.

11-23
BRAKE SYSTEM

4. Forcible Release of Parking Brake

(1) If the parking brake can not be released for some (2) Block the wheel with wood blocks.
reason, perform the required operation as follows.

4.1 Release by Turning Bolt

(1) Remove the tapered plug (4 places) attached to
Tapered plug
the back of the wet disc brake assembly, then
screw in each bolt with a washer (for both right
and left).
Bolt 92071-01300
Washer F1035-10050

Tapered plug
215965

(2) The required amount of turning in is approxi-

mately one turn after the bolt and washer come
into light contact with the seat surface. Do not
overtighten.

Bolt for
forcibly releasing
parking brake

216005

11-24
 BRAKE SYSTEM

4.2 Release by the External Hydraulic Pressure

(1) Remove the plug (G 1/8) for forcible release of the
Connector
parking brake valve. Port plug for
Nut
forcible release
(2) Install the connector attached with the nut, washer Washer
and O-ring to the respective port. O-ring O-ring

Connector for forcible Port for

91K67-00200 forcible release
release
Nut 91K67-00300
Washer F2500-10000
O-ring 05500-24014
215962

(3) Screw in the connector for forcible release until it

is completely in contact with the sealing surface of
the parking brake valve. At that position tighten
the nut to the specified torque.
19.6 N·m
Tightening torque (2.0 kgf·m)
[14.5 lbf·ft]

(4) Connect an external hydraulic source to the con-

nector (G 1/4) for forcible release, and generate a External hydraulic
pressure source
sufficient hydraulic pressure to release the park-
ing brake.
6 – 7 MPa
Allowable range of
(61.18 – 71.38 kgf/cm2)
hydraulic pressure
[870.32 – 1015.37 psi]

215963

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BRAKE SYSTEM

5. Troubleshooting
Unit Situation Description Remedy
Service brake Brake does not func- Leak from the hydraulic system, or Repair leak and add brake oil.
tion. main tank oil level is too low.
Air mixed in the hydraulic system Bleeding air from brake oil line.
Brake piston seal worn or damaged Replace
Friction plate worn or facing dam- Replace
aged
Mating plate worn Replace
Uneven brake effect Uneven tire pneumatic pressures Adjust to the correct pneumatic pressure.
Friction plate worn or facing dam- Replace
aged
Mating plate worn Replace
Brake return failure Piston return spring deteriorated Replace
Spring guide bent Replace
Brake squeaks Inappropriate brake oil Replace with the specified brake oil.
Poor contact between friction plate Replace
and mating plate
Parking brake Brake does not func- Brake spring deteriorated Replace
tion.
Oil line is sealed up. After draining oil from the port to forcibly
release the parking brake valve, disassem-
ble and check the parking brake valve.
Brake can not be Insufficient oil line pressure Measure the hydraulic pressure of the
released. relief valve in the parking brake valve, and
adjust it.
Parking brake valve failure Replace
Electric wiring damaged Check the wiring continuity.

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