BRAKE SYSTEM

Structure .................................................................................................... 9 – 1
Brake System ............................................................................................ 9 – 1
Disassembly and Reassembly ............................................................ 9 – 2
Master Cylinder ......................................................................................... 9 – 2
Disassembly .......................................................................................... 9 – 2
Reassembly ........................................................................................... 9 – 3
Wheel Brakes ............................................................................................ 9 – 4
Disassembly .......................................................................................... 9 – 6
Reassembly ........................................................................................... 9 – 9
Wheel Cylinder .......................................................................................... 9 – 12
Disassembly .......................................................................................... 9 – 12
Reassembly ........................................................................................... 9 – 13
Inspection and Adjustment .................................................................. 9 – 14
Automatic Adjuster Test ............................................................................ 9 – 14
Manual Adjustment ................................................................................... 9 – 14
Parking Brake Cable Adjustment .............................................................. 9 – 15
Brake Pedal Adjustment ............................................................................ 9 – 16 9
Bleeding Brake Lines ................................................................................ 9 – 17
Braking Performance Test ......................................................................... 9 – 17
Parking Brake Lever .................................................................................. 9 – 18
Troubleshooting ....................................................................................... 9 – 19
Service Data ............................................................................................. 9 – 21
 BRAKE SYSTEM

Structure

Brake System

Parking brake lever

Reservoir tank

Brake pedal

Stop lamp switch

Parking brake
cable

Wheel
cylinder
Master cylinder

Wheel brake

209782

9-1
BRAKE SYSTEM

Disassembly and Reassembly

Master Cylinder
Disassembly

3
1
2 ❋

9
✩

8
✩

4 5 6

❋ ❋ ❋ 7

209783

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 (❋) and (✩) to be changed periodically are included in the Repair Kit.

9-2
 BRAKE SYSTEM

Inspection after disassembly

1. Cylinder
(1) Check the cylinder bore for rusting, erosion, abnormal
wear, or scoring.
(2) Check the inlet and relief ports for restriction. Check
the threads on each joint for damage. Also, check the
boot and other parts for damage.
2. Piston
Check the piston for damage. Replace if it is damaged.
Insert the piston into the cylinder, and measure the piston-
to-cylinder clearance. If the clearance is in excess of the
service limit, replace the cylinder and piston.
A: Standard value B: Service limit
0.020 to 0.105 mm
Clearance between A
(0.00079 to 0.00413 in.)
cylinder and piston
B 0.15 mm (0.0059 in.)

3. Return spring
Replace the spring if it is severely damaged or its free
length is at or less than the service limit.

A: Standard value B: Service limit

A 59.2 mm (2.3 in.)
Spring free length
B 53.9 mm (2.1 in.)

4. Cups in piston assembly

Check the rubber parts for damage or swelling. If the lips
are damaged even slightly, the base is bitten, or abnormal
fatigue, wear or swelling is evident, replace the piston
assembly. If the cup tightness is 0.4 mm (0.0157 in.) or
less, replace the piston assembly.
Note: The cups must be replaced periodically. It is a safe
and good practice to replace them whenever the
master cylinder is disassembled.

Reassembly
To reassemble, follow the disassembly procedure in
reverse, paying attention to the following points.
(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

Wheel Brakes (1 ton class)

4 3 6 11 9 1 2 7 12 5
A

10

Drum rotating Adjusting screw

direction during rotating direction
forward movemnt to expand shoes
15 A 13
14 Section A – A

The illustration shows a left-hand wheel brake.

208523

1 Wheel cylinder 9 Shoe guide plate

2 Backing plate 10 Cable with spring
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

9-4
 BRAKE SYSTEM

Wheel Brakes (2, 3 ton classes)

3 A 11
14
6
9
13
7

5
Drum 8
rotating
direction
during
forward
movement 10

10 10

12
4
Adjusting screw
rotating direction
1 to expand shoes

15
Section A – A
17 2 A
16

The illustration shows a left-hand wheel brake.

209784

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

2 Parking brake cable, Snap ring 11 Shoe guide plate
3 Wheel cylinder 12 Cable with spring
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

9-5
BRAKE SYSTEM

Wheel Brakes
Disassembly

10 9
9

12
1

11 ❋ 5

8 7

❋ 2

5 4
207208

Sequence
1 Return spring 7 Strap, Anti-rattle spring
2 Cable with spring 8 Shoe and lining (primary), Parking brake lever,
3 Hold-down spring, Cup, Pin Retainer, Spring washer
4 Adjusting lever, Adjusting spring, Return 9 Wheel cylinder
spring 10 Parking brake cable
5 Cable guide, Sheave, Adjusting screw, Pin, 11 Mounting bolt, Spring washer
Washer 12 Backing plate
6 Shoe guide plate, Shoe and lining (secondary)

Note: The part (❋) to be changed periodically are included

in the Brake Repair Kit.

Start by:
(a) Remove the front wheel.
(b) Remove the wheel hub and brake drum.
(c) Separate the parking brake lever and cable at the
bottom of wheel brake.
(d) 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

200271

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

200272

Inspection after Disassembly

1. Backing plate
(1) Check the backing plate for cracks.
2. Shoes and lining
(1) Check each shoe and lining for cracks.
(2) Replace the lining if it is heavily fouled with grease,
burnt or otherwise deteriorated.
(3) Measure the thickness of the lining. Replace if it is
worn to less than the service limit.
A: Standard value B: Service limit
Truck Model 1 ton 2, 3 ton
Item class classes

4.87 mm 5.7 mm
A
Thickness of (0.19 in.) (0.22 in.)
lining 1.0 mm 1.0 mm 203005
B
(0.04 in.) (0.04 in.)

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 service limit.

A: Standard value B: Service limit

Truck Model 1 ton 2, 3 ton
Item class classes
254 mm 310 mm
A
Inside diameter (10.0 in.) (12.2 in.)
of brake drum 256 mm 312 mm
B
(10.1 in.) (12.3 in.)

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

200274

5. Parking brake cable

Replace a cable if it shows stretching, rust or damage.

6 Other parts
(1) Check the shoe return springs for cracks or fatigue.
(2) Check the adjusting springs for cracks or fatigue.
(3) Check the cable with spring for stretching.

9-8
 BRAKE SYSTEM

Reassembly
1 ton class

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

11

14 Section A – A
A

203586

Sequence
1 Wheel cylinder 9 Hold-down spring, Cup, Pin
2 Backing plate 10 Shoe guide plate
3 Shoe and lining (primary) 11 Cable with spring
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, Adjusting
7 Strap spring
8 Anti-rattle spring

9-9
BRAKE SYSTEM

2, 3 ton classes

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.

209784

Sequence
1 Backing plate assembly 9 Strut, Anti-rattling spring
2 Parking brake cable, Snap ring 10 Pin, Hold-down spring, Cup
3 Wheel cylinder 11 Shoe guide plate
Prepare Parts 4, 5 and 6 in assembly beforehand. 12 Cable with spring
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
Prepare Parts 7 and 8 in assembly beforehand. 16 Adjusting screw
7 Pin, Sheave, Washer 17 Return spring
8 Secondary shoe and lining assembly

9-10
 BRAKE SYSTEM

Suggestions for Reassembly

1. Wheel cylinder installation
Apply liquid packing to the mounting face of the wheel
cylinder before installing it. Tighten to the specified
torque.

Truck Model 1 ton 2, 3 ton

Item class classes

8 to 12 N·m 18 to 26 N·m
Tightening torque (0.8 to 1.2 kgf·m) (1.8 to 2.7 kgf·m)
200275
[6 to 9 lbf·ft] [13 to 20 lbf·ft]

2. Greasing
Apply a thin coat of the specified brake grease to the
following areas.
(1) Shoe ledges (6 locations)
The ledges are those portions of the backing plate in
contact with the shoe.
(2) Anchor pin surface in contact with the shoe ends
3. Shoe and lining installation
Ensure that each connector link of the wheel cylinder has
been correctly inserted into the shoe web.
4. Return spring installation
Use a special tool to install the return springs to the
backing plate pins.
Special tool needed

Spring installer 65309 - 15413 200276

5. Automatic adjuster installation

(1) 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 the screw is hard to turn, replace it with a new one.
(2) Identification of adjusting screws and levers

Left-half parts
Plated in whitish color 200277
(right-hand thread)
Right-half parts
Plated in yellowish color
(left-hand thread)

Note: After reassembly, bleed air out of the brake lines.

(Refer to “Inspection and Adjustment.”)

9-11
BRAKE SYSTEM

Wheel Cylinder
Disassembly

2
3

5
6
❋
7

4
3

2
1

200278

200279

Sequence
1 Connector link 5 Return spring
2 Boot 6 Bleeder screw, Cap
3 Piston 7 Cylinder body
4 Piston cup

Note: The part (❋) to be changed periodically are included

in the Brake Repair Kit.

9-12
 BRAKE SYSTEM

Inspection and Repair

(1) Cylinder body
(a) Check the bore for rusting, erosion or scoring.
(b) Check the threads of bleeder screw and oil pipe for
damage.
(2) Pistons
(a) Check the sliding surface for rusting or scratching.
(b) With the piston installed in the cylinder body,
measure the piston-to-cylinder clearance. Replace
if the clearance is in excess of the service limit.
A: Standard value B: Service limit
0.020 to 0.105 mm
Clearance between piston A
(0.00079 to 0.00413 in.)
and cylinder 200280
B 0.15 mm (0.0059 in.)

(3) Piston cups

Check for swelling, damage or other defects. Replace the
cup if defective even slightly.
A: Standard value B: Service limit

Tightness between piston A 1.85 mm (0.07 in.)

cup and cylinder body B 0.65 mm (0.025 in.)
(4) Boots
Replace the boots if they show damage or aged
deterioration. In any event, the boots must be replaced
every year.

Reassembly
To reassemble, follow the disassembly procedure in
reverse, paying attention to the following points.
(1) Wash all metal parts clean 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 and piston cups.
(3) Be careful not to damage the lips of the cups.
(4) Make sure that the cups face the correct directions
when reassembled.
(5) Tighten the bleeder screw to the specified torque.

5.9 to 8.8 N·m

Tightening torque (0.6 to 0.9 kfg·m)
[4.3 to 6.5 lbf·ft]

9-13
BRAKE SYSTEM

Inspection and Adjustment

Automatic Adjuster Test

(1) With clearance A between the lining and drum, set
approximate to specification, pull the cable with
attached spring using a finger as shown. The lever
should turn the adjusting screw wheel by one notch A
and, when the cable is released, return to the original
position. Unit: mm (in.)
Truck Model 1 ton 2, 3 ton
Item class classes
202816
Drum inside diameter 254 (10.1) 310 (12.2)
Drum-to-lining 0.5 to 0.5 0.1 to 0.35
clearance A (0.010 to 0.020) (0.004 to 0.014)

(2) If the lever fails, or is slow to turn the adjusting screw

wheel, check the position of the lever relative 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 centerline of the screw. If the lever
contact is out of the range, the lever will not correctly 7 to 9 mm
engage with the toothed wheel, therefore failing or (0.28 to 0.35 in.)
slow to turn the wheel.
200282
(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.

Manual Adjustment
Using a screwdriver through the slotted 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 (0.001 in.) in shoe diameter.

200283

9-14
 BRAKE SYSTEM

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) Move the parking brake lever by the amount specified
below. This is the neutral position. In the neutral Shoe
position, the inner cable length C should be as 209785
specified below.

Unit: mm (in.)
Truck Model 1 ton 2, 3 ton
Item class classes

Cable pull A before 10 (0.39) 14.3 (0.56)

shoe works on drum maximum maximum
Distance B to reach C
3 (0.12) 5 (0.20)
neutral
Inner cable length C 44 ± 4 (1.73 ± 0.16)
209786

9-15
BRAKE SYSTEM

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 Stop bolt
adjustment, lock the stop bolt.
(2) Adjust the push rod length of the master cylinder.
• Truck with powershift transmission
With the push rod-to-piston clearance removed,
adjust the clearance B to specification by turning the
push rod. After adjustment, lock the clevis with the
nut.

209787

(3) Ensure that the pedal play is to specification.

C
Note: (a) Ensure that the clevis pin between the brake
pedal and push rod is firmly in place as
illustrated.
A
(b) Ensure that the snap pin is firmly engaged.
B
(c) Ensure that the brake pedal operates smoothly
without obstruction or other problems.
Unit: mm (in.)
Truck Model 1 ton 2, 3 ton
Item class classes

Pedal height from floor A 182 to 200 (7.16 to 7.87) Master cylinder 209788
0.2 to 1.0 0.2 to 0.8
Clearance B
(0.008 to 0.039) (0.008 to 0.031)
Push rod-to-piston
0 (0) 0 (0)
clearance Clearance B

1.5 to 6.5 1.5 to 5.5

Pedal play C
(0.059 to 0.256) (0.059 to 0.217)

Detail B 209789

9-16
 BRAKE SYSTEM

Bleeding Brake Lines

After any portion of the brake fluid lines has been
disassembled for repair or service, or if the brake pedal
feels spongy, bleed the brake 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.
200285
(2) Check the brake fluid level in the reservoir tank. 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 Step (3) 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: (a) Take care to maintain the brake fluid in the

reservoir tank at sufficient levels while the
bleeding operation is in progress.
(b) Use only the brake fluid of specified brand and
grade. Avoid mixing different types of fluids.

Braking Performance Test

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

9-17
BRAKE SYSTEM

Parking Brake Lever

Applied

Released

1
2

209790

1 Lever support pin 3 Parking brake lever assembly

2 Adjusting screw 4 Parking brake switch

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.

Reassembly
With the parking brake cable and lever connected, the force
required to pull the lever should be 245 to 295 N (25 to 30
kfg) [55 to 66 lbf].

9-18
 BRAKE SYSTEM

Troubleshooting

Oil leaking past primary cup in master *Replace piston cup(s) if cylinder
cylinder is free from unacceptable wear.
Replace the cup(s) and fluid
Oil leaking past cups in wheel cylinder with genuine parts if the cup(s)
Lack of braking is distorted.
force Oil leaking from oil pipe connection Retighten, or replace pipe and
connector.
Shoe lining worn Replace.
Shoe lining dirty with oil or grease Clean or replace.

Air trapped in brake fluid lines Bleed air at master and

wheel cylinders.
Piston cup defective in master cylinder Replace.
Excessive pedal Not enough fluid in reservoir tank Refill.
stroke Push rod to piston clearance too large in Readjust.
master cylinder
Brake fluid leakage Refer to * above.
Automatic adjuster inoperative Ensure that cable guide and
adjusting spring are correctly
installed. If still inoperative,
replace cable with spring, lever,
Foot and adjusting screw.
brakes
Lining or drum dirty with oil or grease Clean with gasoline. If lining
Uneven braking
in less effective brake still dirty, replace.
(wheel brake is
more effective on Wobbly or loose-mounted drum in less Replace drum. If loose, readjust
one side than on effective brake and retighten.
the other)
Wheel tires inflated unequally Reinflate to specification.

Lining glazed Sand.

Worn lining 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 Repair or replace.

Brake chatters on anchor
or clatters Shoe ledges badly worn Replace backing plate.
Pistons badly worn in wheel cylinder Replace wheel cylinder.

9-19
BRAKE SYSTEM

Lever stroke is
Lining to drum clearance too small Readjust.
too small

Will squeal Lining to drum clearance too small Readjust.

Parking during traveling Brake drum badly distorted Repair or replace.
brake

Parking brake cable longer than Check lining to drum clearance.

specification If brake will still not apply,
readjust cable length.
Will not apply lining worn to the service limit Replace shoe and lining
assemblies.
Lining to drum clearance too large Readjust.
Lever lacks operating force Readjust to specification.

9-20
 BRAKE SYSTEM

Service Data
A: Standard value B: Service limit
Unit: mm (in.)
Truck Models
1 ton class 2, 3 ton classes
Items

Cylinder bore size 1 A 19.05 (0.7500)

Diameter of piston 2 A 19.05 (0.7500)

A 0.020 to 0.105 (0.00079 to 0.00413)

Clearance between cylinder and piston
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)
Master B
(Replace every year or whenever overhauling)
cylinder

4 2 5

1 3

209791

9-21
BRAKE SYSTEM

A: Standard value B: Service limit

Unit: mm (in.)
Truck Models
1 ton class 2, 3 ton classes
Items
A 254.0 (10.00) 310 (12.20)
Inside diameter of brake drum1
B 256 (10.08) 312 (12.28)
A 4.87 (0.19) 6 (0.24)
Thickness of lining 2
B 1 (0.039) 3 (0.118) or less
Clearance between drum and lining 3
A 0.5 to 1.0 (0.02 to 0.04) 0.2 to 0.7 (0.01 to 0.03)
(Total)
Primary: 120 (4.72)
Free length A 102 (4.02)
Secondary: 139.3 (5.48)
Primary: 134 (5.3)
Length under set force A 111 (4.4)
Return Secondary: 145.5 (5.8)
spring 4 Primary:
Set force A 157 ± 16 (16 ± 1.6) 226 ± 23 (23 ± 2.3) [51 ± 5.2]
N (kgf) [lbf] [35 ± 3.6] Secondary:
226 ± 23 (23 ± 2.3) [51 ± 5.2]
Free length A 79 (3.11) 104.5 (4.11)

Adjusting Length under set force A 98.5 (3.9) 122 (4.8)

spring 5 Set force 137 ± 14 (14 ± 1.4) 78 ± 8 (8 ± 0.8)
A
N (kgf) [lbf] [31 ± 3.1] [18 ± 1.8]
Wheel Tightening torque for backing plate
A 215 (21.9) [158] 215 (21.9) [158]
brakes bolt 6 N·m (kgf·m) [lbf·ft]

4
2

4 secondary spirng

Free length
204962

9-22