Load Sensing Proportioning and By-Pass Valve (LSP & BV) : Components

BR–64
BRAKE SYSTEM – Load Sensing Proportioning and By–Pass Valve (LSP & BV)
LOAD SENSING PROPORTIONING

AND BY–PASS VALVE (LSP & BV)
COMPONENTS
CHECK AND ADJUSTMENT OF FLUID PRESSURE

1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight):
2WD 1 ton, C & C (SRW) 900 kg (1,984 Ib)
1/2 ton 700 kg (1,543 Ib)
C & C (DRW) 1,150 kg (2,535 Ib)
4WD 800 kg (1,764 Ib)
HINT: (For C & C)
If the vehicle unladen weight exceeds the specification
above, set the rear axle load to the specification shown
below. (See step 4 on page BR–65)
Rear axle load (includes vehicle weight):
SRW 1,678 kg (3,699 Ib)
DRW 1,996 kg (4,400 Ib)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709–29017
BR–65
BRAKE SYSTEM – Load Sensing Proportioning and By–Pass Valve (LSP & 13V)
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80
kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRES–
SURE
Rear brake pressure:
2WD 1 ton, C & C (SRW) 4,413±490 kPa
(45±5kgf/cm 2, 640±71 psi)
1/2 ton 4,315 t 490 kPa
(44±5 kgf/cm 2, 626 ± 71 psi)
C & C (DRS) 4,707 ± 490 kPa
(48±5 kgf/cm 2, 683 ± 71 psi )
4WD Regular cab 3,923±490 kPa
(40±5 kgf/cm 2, 569±71 psi )
Extra cab 4,315±490 kPa
(43±5 kgf/cm 2, 626±71 psi)
HINT: The brake pedal should not be depressed twice
and/or returned while setting to the specified pressure.
Read the value of rear brake pressure two seconds after
adjusting the specified fluid pressure.
If the brake pressure is incorrect, adjust the fluid pres–
sure.
4. (C&C)
RAISE FRONT BRAKE PRESSURE TO 11,768 kPa (120
kgf/cm2, 1,707 psi) AND CHECK REAR BRAKE PRES–
SURE
Rear brake pressure:
SRW 9,709 ± 588 kPa
(99 ± 6 kgf/cm2, 1,408 ± 85 psi)
DRW 8,336 ± 588 kPa
(85 ± 6 kgf/cm2, 1,209 ± 85 psi)
5. IF NECESSARY, ADJUST FLUID PRESSURE

(a) Adjust the length of the No.2 shackle.
Low pressure Lengthen A
High pressure Shorten A
Initial set:
2WD 78 mm (3.07 in.)
4WD 120 mm (4.72 in.)
Adjusting range:
2WD 72 – 84 mm (2.83 – 3.31 in.)
4WD 114 – 126 mm (4.49 – 4.96 in.)
HINT: One turn of the nut changes the fluid pressure as
shown in the table below.
Rear brake pressure
1/2 ton, C & C (SRW )
2WD
1 ton, C & C (DRW)
4WD
BR–66
(b) In event the pressure cannot be adjusted by the

No. 1 shackle, raise or lower the valve body.
Low pressure – Lower
High pressure – Raise
(c) Torque the nuts.
Torque: 13 N–m (130 kgf–cm, 9 ft–lbf)
(d) Adjust the length of the No. 1 shackle again.
If it cannot be adjusted, inspect the valve housing.
6. IF NECESSARY, CHECK VALVE BODY

(a) Assemble the valve body in the uppermost position.
HINT: When the brakes are applied, the piston will
move down about 1 mm (0.04 in.). Even at this time, the
piston should not make contact with or move the load
sensing spring.
(b) In this position, check the rear brake pressure.

2WD (SRW)
4WD (DRW)
4WD (Regular cab)
4WD (Extra cab)
If the measured value is not within standard, replace

the valve body.
BR–67
REMOVAL OF LSP & BV OR LSPV

(See page BR–64)
1. DISCONNECT SHACKLE NO.2 FROM BRACKET
2. REMOVE LSP & BV (LSPV) ASSEMBLY

(a) Using SST, disconnect the brake tube from the
valve body.
SST 09751–36011
(b) Remove the valve bracket mounting bolts and re–
move the LSP & BV (LSPV ) assembly.
DISASSEMBLY OF LSP & BV OR LSPV ASSEMBLY

1. REMOVE VALVE BRACKET
(a) Remove the nut and bolt as shown.
(b) Remove the two nuts, and remove the bracket and
set plate from the valve body.
2. DISCONNECT SPRING FROM VALVE

Using pliers, remove the clip, and remove the spring from
the valve.
3. REMOVE SHACKLE NO. 1 AND NO.2

Remove the nut and bolt, and then remove the shackle
No.1 and No.2, and two plate washers from the load
sensing spring assembly.
BR–68
4. DISASSEMBLE LOAD SENSING SPRING

Disassemble the following parts.
(a) Bushings
(b) Collars
(c) Rubber plates
(d) Load sensing valve boot
(e) Load sensing spring boot
INSPECTION OF LSP & BV OR LSPV

INSPECT VALVE PISTON PIN AND LOAD SENSING
CONTACT SURFACE FOR WEAR
Wear limit: 0.7 mm (0.028 in.)
ASSEMBLY OF LSP & BV OR LSPV

(See page BR–64)
1. ASSEMBLE FOLLOWING PARTS TO LOAD SENSING
SPRING:
(a) Load sensing valve boot
(b) Load sensing spring boot
(c) Bushings
(d) Rubber plates
(e) Collars
HINT: Apply lithium soap glycol grease to all rubbing ar–
eas.
Do not mistake the valve side for the shackle side of the
load sensing spring.
2. ASSEMBLE VALVE BODY TO BRACKET

Assemble the valve body to the valve body bracket.
HINT: Finger tighten the valve body mounting nuts.
BR–69
3. CONNECT VALVE BODY AND NO. 1 SHACKLE TO LOAD

SENSING SPRING
CAUTION: When connecting the shackle to the load
sensing spring with a bolt and nut, insert the bolt from
the front side of vehicle.
INSTALLATION OF LSPV & BV OR LSPV

1. INSTALL LSP & BV (LSPV) ASSEMBLY TO FRAME
Torque: 19 N–m (195 kgf –cm, 14 ft–lbf)
2. CONNECT BRAKE TUBE

Using SST, connect the brake tubes.
Torque: 15 N–m (155 kgf–cm, 11 ft–lbf)
SST 09751–36011
3. CONNECT SHACKLE NO.2 BRACKET

(a) Install the shackle No.2 to the load sensing spring.
(b) Set dimension A.
Initial set: 2WD 78 mm (3.07 in.)
4WD 120 mm (4.72 in.)
(c) Connect the shackle No.2 to the shackle bracket.
4. SET REAR AXLE LOAD (See page BR–64)
5. SET VALVE BODY

(a) When pulling down the load sensing spring, confirm
that. the valve piston moves down smoothly.
(b) Position the valve body so that the valve piston
lightly contacts load sensing spring.
(c) Tighten the valve body mounting nuts.
6. BLEED BRAKE LINE (See page BR–8)
7. CHECK AND ADJUST LSP & BV OR (LSPV) FLUID

PRESSURE
(See page BR–64)
8. APPLY SEALANT TO SHACKLE NO.2
Apply sealant to the top portion of the shackle No.2 bolt
threads not to lose the upper lock nut.
Sealant: Part No. 08833–00070, THREE BOND 1324 or
equivalent

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BR–64

LOAD SENSING PROPORTIONING

CHECK AND ADJUSTMENT OF FLUID PRESSURE

5. IF NECESSARY, ADJUST FLUID PRESSURE

(b) In event the pressure cannot be adjusted by the

6. IF NECESSARY, CHECK VALVE BODY

(b) In this position, check the rear brake pressure.

4WD (Regular cab)

4WD (Extra cab)

If the measured value is not within standard, replace

REMOVAL OF LSP & BV OR LSPV

2. REMOVE LSP & BV (LSPV) ASSEMBLY

DISASSEMBLY OF LSP & BV OR LSPV ASSEMBLY

2. DISCONNECT SPRING FROM VALVE

3. REMOVE SHACKLE NO. 1 AND NO.2

4. DISASSEMBLE LOAD SENSING SPRING

INSPECTION OF LSP & BV OR LSPV

ASSEMBLY OF LSP & BV OR LSPV

2. ASSEMBLE VALVE BODY TO BRACKET

3. CONNECT VALVE BODY AND NO. 1 SHACKLE TO LOAD

INSTALLATION OF LSPV & BV OR LSPV

2. CONNECT BRAKE TUBE

3. CONNECT SHACKLE NO.2 BRACKET

4. SET REAR AXLE LOAD (See page BR–64)

5. SET VALVE BODY

7. CHECK AND ADJUST LSP & BV OR (LSPV) FLUID

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