BR(Brake System)

BRAKE

GENERAL ........................................................................... BRa - 2

SPECIFICATIONS ............................................................... BRa - 14

SERVICE STANDARDS ...................................................... BRa - 15

TIGHTENING TORQUE ....................................................... BRa - 18

SERVICE PROCEDURES

Air Compressor ............................................................ BRa - 20

Dual Brake Valve ........................................................... BRa - 28

Relay Valve .................................................................... BRa - 37

Front Wheel Brake ........................................................ BRa - 43

Rear Wheel Brake ......................................................... BRa - 47

Disk Brake ..................................................................... BRa - 52

Brake Chamber ............................................................. BRa - 59

Exhaust Brake System ................................................. BRa - 66

Intarder System............................................................. BRa - 76

Air Drier ......................................................................... BRa-107

Auto Slack Adjuster ...................................................... BRa-126

TROUBLESHOOTING ........................................................ BRa-140

BRa-2 BRAKE

GENERALFull Air Brake

[WITHOUT ABS SYSTEM]

1 2

3

8

6 5

7

12

4

17

5

7

10 19

15

119

14

20

RR

PARK’G(15)

Door

(35)

FR(25)

Supply

Air suspension

1. Air compressor2. Air dryer

3. Purge tank4. PR-4 protection valve5. Air reservoir

6. Safety valve

7. Drain valve8. Air gauge

9. Dual brake valve10. Parking brake valve11. R-12 relay valve

12. Check valve

13. Double check valve14. Brake chamber

15. Spring brake chamber16. Magnetic valve17. Low air pressure switch

18. Exhaust brake valve

19. QR1C vlave20. Quick release valve

KMABR003

HOSE

BRa-5

Air CompressorThe air compressor is driven with revolutions of half the number of

engine revolutions by injection pump gear that is in mesh with the

timing gear on engine. The cylinder head of the air compressor is

provided with the suction valve, delivery valve, and unloader valve

allowing the system to accomplish the suction discharge and ex-

haust operation.

Service BrakeService brake is full air type brake of complete two systems where

one side system is secured even if a case occur that air leaks by

plate damage of other side, etc. Leading trailing type is used for

both front and rear of wheel brake.

In air system, air pressure is generated in air compressor, which

air is sent to air dryer from which the dried air is then supplied to air

tank and air pressure is maintained in a certain range by air pres-

sure governor.

And air is exhausted by operation of safety valve attached to air

tank if air pressure in air tank rises above specified pressure.

1. Suction stroke

Air intake is by negative pressure in cylinder when piston goes

down.

Air is introduced into cylinder because suction valve that has

been intercepting the inlet opens the inlet by compressing the

valve spring if negative pressure is large in cylinder.

But suction valve is again pushed down by valve spring so as

to intercept air inlet of valve seat if piston goes up to the rising

reciprocation step.

Cylinder

head

Delivery valve

From the air pressure governor

to air tank

From the aircleaner

Unloader valve

Suction valve

Piston

Injection pump

gear

Crank case

JMS58A-005

Crank shaft

Cyliner

liner

Air inlet

Suction valveValve spring

JMS58A-006Piston

GENERAL

BRa-6 BRAKE

2. Delivery stroke

As piston moves upward on its compression stroke, discharge

side valve spring causes suction valve to close. Pressure of

air being compressed in cylinder overcomes delivery valve

spring tension pushing the delivery valve open to send air to

air tank under high pressure. If piston goes down the recipro-

cation step, delivery valve being pushed again by valve spring

closes air exhaust exit of valve seat.

3. When unloader valve is actuated

When air pressure inside the air tank exceeds predetermined

level, air pressure governor is actuated.

Then air pressure governor sends compressed air to unloader

valve, which causes unloader valve to be pushed down. At the

same time, governor maintains suction valve in open position;

as a result, no air is compressed and air compressor runs

under no load. As air pressure in air tank drops below prede-

termined level, air pressure governor is again actuated to dis-

charge compressed air above unloader valve. This results in

unloader valve being returned to its original position by unloader

valve spring, thus actuating the suction valve.

Dual break valveDual brake valve is control unit that (dis)connects and regulates

compressed air from air tank so as to operate, release and control

the brakes.

1. When pedal is depressed

Piston is pushed down by plunger to force inner valve to open.

Compressed air from air tank passes inner valve to actuate

relay valve or quick relay valve.

2. When pedal is released

Piston and inner valve are returned to their original positions

by return spring to cut off compressed air supply. At the same

time, compressed air supplied in air line escapes from exhaust

valve to atmosphere.

Air tank

Delivery valve

springDelivery valve

JMS58A-007

Unloader valve compressed air

(from air pressure governor)

Unloader valve

spring

Suction valve

JMS58A-008

Compressed air

Compressed air

Front brake

chamber

Rear brake

chamber

JMS58A-009

Compressed air

Compressed air

Exhaust gasJMS58A-010

BRa-7

G

Pressure protection valve1. Function

This acts to interrupt air flow until the set pressure is made up.

This is brake system safety function unit to prevent air pres-

sure drop so that brake power is influenced mainly by exces-

sive use of auxiliary equipment or any other cause.

This is used after installed between the two tanks so that pri-

mary tank for use in brake be filled before air is filled in auxil-

iary secondary tank.

This valve would also be installed at emergency line of tractor

to protect tractor system.

2. How to operate

(1) Pressure is made up at piston B until force of control spring A

is overcome if air enters supply inlet G. Whence valve stem C

is raised according to piston rise so as to open the suction

valve D. Accordingly air passes the exhaust outlet E.

(2) If air pressure drops down (supply inlet side or exhaust

outlet side), piston goes down by force of control spring A

so that suction valve is shut. Accordingly air flow is

interrupted.

Quick release valve1. Function

It is to quickly exhaust air pressure through this valve when

brake is released, which air has been accumulated in chamber.

2. How to operate

(1) Air pushes diaphragm down to shut the exhaust outlet when

brake is operated. At the same time the air pressure is sup-

plied to chamber as diaphragm brim is pushed down.

(2) If air pressure at upper and lower parts of diaphragm equals

each other, diaphragm brim closes body seat and exhaust

outlet is yet closed at diaphragm center part.

A

B

CD

E

MS58A-017

JMS58A-019

JMS58A-020

JMS58A-019

Air

GENERAL

BRa-8 BRAKE

(3) If brake is released, air at upper part of diaphragm is ex-

hausted through dual brake valve and diaphragm is raised

to open the exhaust outlet so that air of chamber side quickly

goes out.

Quick release check valve1. Function

This valve has functions of traditional double check valve and

quick release valve together. Firstly it acts as quick release

valve that supplies air to emergency side of spring brake and

secondly it plays anti-compound function. Double check valve

prevents simultaneous operation of service and emergency

side.

JMS58A-021

JMS58A-022

2. How to operate

(1) When spring brake is released

Air that has passed quick release check valve from gradual

valve makes the double check and quick release diaphragm

to be flexed so as to close the balance and the exhaust

outlet. Accordingly parking is accomplished as air enters

emergency inlet of spring brake through exhaust outlet.

(2) When spring brake operates

Air supplied to valve is depleted through gradual valve. Air

pressure makes the the double check and quick release

diaphragm to be flexed in opposite direction so as to open

the exhaust outlet of balance. Parking is accomplished as

chamber air pressure is depleted through exhaust while air

between two diaphragms is expelled through relay valve

and brake valve.

(3) Anti-compounding

When service brake is operated while spring brake is be-

ing operated, air enters the balance opening and then the

air passing through valve closes the supply inlet and the

exhaust outlet by making the double check diaphragm and

the quick release diaphragm to be flexed. So air passes

delivery opening so that air in spring brake is depleted to

accomplish parking. This prevents service and spring

brakes to be simultaneously held.

BRa-9

Check valveCheck valves at entrance of each layer of air tank are preventing

reverse flow of air pressure being sent from air compressor to air

tank.

Air switch (Stop lamp switch)Air switch installed at air piping between dual brake valve and air

tank senses the air pressure generated by treading dual brake

valve and turns on the brake lamp.

Low air pressure switchThis switch turns on the warning lamp in meter cluster so as to

notify air pressure drop when air pressure in air tank is decreased

below designated value.

Spring Valve Body

Air supply

inlet

Air exhaust outletJMS58A-028

Air switch

Seal is coated in case of

reuse material JMS58A-032

JMS58A-033

Double check valveWhen air enters from either side, this valve interrupts the other

side. Namely in case when air supply is from air inlet A, check

valve moves to B side so that A side and C side are passable. On

other hand in case when air supply is from air inlet B, check valve

moves to A side so that B side and C side are passable.

ConnectorCheck valve

Air supply

inlet BAir supply

inlet A

Air exhaust outlet C JMS58A-037

GENERAL

BRa-10 BRAKE

Room A

Relay valve (Parking)1. When operating

If indicated pressure is introduced from hand control valve,

piston moves down and sit on inlet valve so that gas exhaust

channel (room F) is shut. Then inlet valve pressing the spring

is pushed down and gap between inlet valve and air supply

valve P of body is opened. Accordingly the air pressure of

room B is introduced in room A and the pressure released of

parking brake from discharge exit is supplied.

2. Brake pressure stabilized

If indicated pressure from hand control valve is maintained in

definite pressure, air pressure from discharge exit is also sta-

bilized by the indicated pressure. Air pressure of room A passes

channel C to be applied to piston bottom surface so that pis-

ton and inlet valve are pushed up while these are closely at-

tached together. If inlet valve touches air supply valve P of

body then air supply from air tank is stopped and the rising air

pressure for release of parking brake is interrupted to be stable.

3. Releasing the brake pressure

If indicated pressure from hand control valve becomes naught,

piston is pushed up by spring and air pressure of discharge

exit side (pressure of room A) so that air supply valve S at

piston bottom is separated from inlet valve. Accordingly air

pressure of discharge side is exhausted to atmosphere from

room F of central exhaust gas channel.

Indicated pressure (from hand control valve)

Piston

Air

supply

valve “P”

Inlet valve

Room FSpring

Supply inlet

(from air tank)

Room B

Dischargeexit (tobrakechamber)

Room A

JMS58A-034

Indicated pressure (from hand control valve)

Piston

Air

supply

valve “P”

Inlet valve

Room B

Supply

inlet (from

air tank)

Room A

Channel “C”

JMS58A-035

Piston

Spring

Air supply

valve “S”

Room FExhaust gas JMS58A-036

Supply

inlet (from

air tank)

Dis-chargeexit

BRa-11

JMS419A

Wheel brake1. Drum brake

If brake pedal is trodden, force transmitted through chamber

makes S cam to rotate so that brake shoe assembly is ex-

panded to brake drum to decelerate or stop the car. Brake shoe

assembly is supported by pin at anchor bracket and plays role

in contraction of piston of wheel cylinder and brake shoe as-

sembly when releasing the brake by return spring installed at

shoe.

Parking brake (Gradual parking)This is used in controlling pressure of emergency brake and hand

control parking brake. Precise and gradual air pressure is supplied

to this valve so as to operate emergency brake and parking brake

through spring brake chamber. Spring brake chamber is directly

controlled according to volume by relay valve or hand control valve.

Brake chamber

Front brake assembly

Slack adjuster

JMS58A-161

GENERAL

BRa-12 BRAKE

Exhaust brake system

Exhaust brake switchTo battery relay

Fuse

Air tank

Magnet valve

Control cylinder

Exhaust brake valveIntake silencer valve

Microswitch

Power relayClutch switchMeter cluster

Exhaust brake

To

tachometer

Control cylinder

JMS58A-040

This system is auxiliary brake of foot brake and is composed of an

exhaust brake unit of butterfly valve type and an intake silencer to

reduce air suction noise generated at exhaust brake operation.

If exhaust brake switch is turned on, 3-way magnet valve is driven

to send the air pressure of air tank to control cylinder in exhaust

brake unit and to close the exhaust brake valve so that exhaust

brake is operated.

At the same time air pressure is also sent to control cylinder of

intake silencer so that intake silencer valve is also closed. And if

clutch pedal or accelerator pedal is trodden, the electric circuit is

temporarily turned off and the exhaust brake system is released.

The pressure in exhaust pipe is raised by closing exhaust pipe;

and so as for exhaust brake the pressure at exhaust reciprocation

stroke acts as force to push back the piston, which becomes brake

force.

Exhaust strokeExhaustbrake valve

Exhaust pipe

JMS58A-041

BRa-13

Intarder SystemThe driver can drive at high speed as increasing the vehicle weight, high efficient engine, and improved road condition.

Due to the above conditions, the heat created by brake power has increased in service brake system. Because of brake

fade phenomenon caused by the increased heat, it is difficult to cope with the emergency situation.

To improve these conditions, intarder has been studied as the third brake with retarder.

Intarder, differently to retarder system, has the rotor and stator installed inside of transmission to derease the rotating

power of thrust shaft by hydraulic pressure.

As the result, intarder controls the vehicle’s speed with high-performanced brake effect. Intarder has been applied to the

transmission of express bus.

(Model : ZF ECOMID 6S 1600 TM)

Z000001A

GENERAL

Helical gear

Stator

Rotor

Heat exchangerOil reservoir

Flange output

PTO connection

BRa-14 BRAKE

Type Water-cooling, 2 cylinder

Cylinder I.D×Strokes×No. of cylinder 85×50×2 mm

Cylinder displacement 502cc

Max. Revolution 1150rpm

Max. Allowable output 8.5kg/cm2

30+24+23 liters

SPECIFICATIONS

Heater capacity (for car where heater is installed)

Switch operation range for ON-OFF

(for car where heater is installed)

Valve operation pressure

Purge chamber capacity

Regeneration time of desicants

I.D. of Brake drum

(Limit)

Brake lining

(Width x thickness (Limit))

Clearance between brake

shoe and brake chamber

in push rod stroke

(Limit value)

Dimensions related

to drum

Clearance between drum and lining

Brake type

Brake line system

Air dryer

model

Dual brake valve type

Safety valve working pressure

Wheel

brake

Brake type

Maximum push rod stroke

Exhaust brake system

Front

Rear

Front

Rear

Front

Rear

Diameter

Roundness

Angularity

Concentricity

Front

Rear

Front

Rear

Control method

Valve type

Compressed air actuated, internal expansion-leadingtrailing

shoe brakes acting on all wheels (With spring brake)

Dual system (Dual brake)

DR-5

24V-100W

4°±4°C~20°C or less

5~9.8 kg.cm2

2.7 liters

40~50 sec.

Treadle type (dual)

8.5~11.5±0.4 kg/cm2

156 x 19 (6.3) mm

220 x 19 (6.3) mm

25~30 (45) mm

25~30 (50) mm

410 + 0.3 mm

0.05 mm

0.05 mm

0.05 mm

0.3~0.5 mm

#24

#30 Spring brakes

57 mm

63.5 mm

Combination method of air pressure and electro magnetic valve

Butterfly valve

410 (414) mm

Specified value descriptionItems

Air compressor

Air tank capacity

BRa-15

SERVICE STANDARDS

Dual brake

valve

Pressure pro-

tection valve

(PR-4 valve)

Quick

release

check

valve

(QR-1C

vlave)

Brake pedal

play

Pressure

stroke

Full stroke

Setting

pressure

Operation

test

Depressing angle

Depressing angle

Depressing angle

Depressing angle

General

For air suspension

When pressure of

supply inlet side is

zero

When pressurized

12.8 kg/cm2

Norminal value

(Basic diameter[ ])

4°±1.5°

12°

16.5°

18±1.5°

5.96 kgf/cm2

3.16 kgf/cm2

Exhaust outlet side

pressure

0.035kg/cm2 or more

Pressure difference

between supply inlet

and exhaust outlet

0.07 kg/cm2

Standard value

±0.35kg/cm2

1.35kg/10.3

2.4kg/15.7

Adjust air susction pressure

by adjusting screw

Air pressure

2.3±0.4 kg/cm2

Air pressure

4±0.5 kg/cm2

Air pressure

7kg/cm2

Periodically check per

40,000km

Periodically disassemble

and check per year

Air

suction

pressure

7kg/cm2

Check items Limit value Remedy and Remarks

SERVICE STANDARDS

Working pressure

Air leaks at any position of the drier

when air outlet is completely

closed and an air pressure of

0.5~9kg/cm2 is applied to air inlet

Air leaks at valve under the same

condition as above

Air leaks any position when an

air pressure of 9kg/cm2 is applied

to control port

Inlet and outlet pressure difference

8.5-11.5±4

-

Less then 20cc/min

-

0.28±0.149 kgf/cm2

or less

1.65 kg/10.3

3.0 kg/15.7

Replace

Replace valve spring and

valve complete

Replace

Correct or replace

Replace

Safety valve

Air drier

Relay

valvePiston spring

Inlet valve spring

Load/

installed length

BRa-16 BRAKE

Quick

release valve

Check

valve

Supply

valve

Cab control

valve

Brake

drum

Brake shoe

return spring

Brake

shoe

Operating pressure

Valve opening pressure

Valve closing pressure

Working pressure (Return

pressure of depressed knob)

Inner diameter

Cylindricity

Brake lining thickness

Clearance between bushing and

anchor pin

Clearance between bushing and

cam shaft

Pressure difference

Inlet and outlet pressure difference

for service brake

2.89kg/cm2

0.079kg/cm2 or less

0.3 kg/cm2

3.2~3.8 kg/cm2

3.0~3.4 kg/cm2

1.8~2.5 kg/cm2

[410]

0.05

43 kg/255

19 for all car models

[35] 0.05~0.14

for all car models

[40] 0.16~0.21

for all car models

414

0.2

Any gap between

coil loops or between

coils and cover

Abrasion limit : 6.3

Replace

Replace

Replace

Correct or replace

Correct or replace

Replace ¡Ú¡Ú¡Ú¡Ú¡Ú with I.D.

when over size is used.

Correct

Replace

Replace lining

Replace bushing

Front


0.3

0.5

Unit : mm

Load/

installed length Rear 55 kg/255

Nominal value

(Basic diameter[ ])

BRa-17


Exhaust Exhaust Spindle to bushing clearance [12]0.25~0.35 Replace

brake brake Clearance between A, B 0.1 or less

system butterfly valve andA+B

and body at/2

0.1~0.4Adjust

operating position

Control cylinder Load/Return spring installed 8.3kg/106 7.1kg/106 Replace

load length

Intake Valve shaft to bushing clearance [16]0.03~0.11 Replace

silencer1 or less

Adjust

B+BDL 2~3DC 4~5

Control cylinder Load/

Return spring installed 7.3kg/109 6.2kg/109 Replace

load length

Magnet Air When outlet port is

valve leak plugged and air at pres-To be free of airsure of 3~10kg/cm2

leaksis applied to inlet port

and valve operated. Replace

When air at a pres-

sure of 10kg/cm2

20V or lessis applied to inletport.

Air com- Suction valve springLoad/ 0.45kg/5 0.36kg/5pressor bending

installed ReplaceDelivery valve springlength

bending0.46kg/9.5 0.37kg/9.5

Piston ring to fitting- 1.0clearance (measured in Replace piston ring set

cylinder liner) - 1.0

Piston ring to piston- 0.1 Replace piston ring set

groove clearance

Fit clearance between piston pin and piston [16] 0.08 Replace

Piston pin to connecting rod small end part[16] 0.07 Replace connecting rodclearance

Fit clearance between Top side [80] 0.28Replacepiston cylinder and liner Skirt side [80] 0.18

Crank shaft to connecting rod bearing[34] 0.1 Replace bearingclearance

End play of crank shaft - 1.0 Replace crankshaft

Unit : mm

End play of connecting rod - 1.0 Replace crankshaft or

connecting rod

Minimum

operating

voltage

Load/

installed length

Suction valve

spring bending

Delivery valve

spring bending

SERVICE STANDARDS

Clearance between

butterfly valve and

coupler or air duct at

operating position

Compression

ring

Oil ring

Compression

ring

Nominal value

(Basci diameter[ ])

BRa-18 BRAKE

Delivery

brake

valve

Air drier

Air

compressor

Check itemsScrew size Tightening torque

(O.D.×pitch) Nm(kgf·m)

Brake pipe flare nut

Cylinder head mounting nut

Piston plate mounting nut

Tightening retainer

Injection pump gear mounting nut

Tightening switch assembly

Tightening plug

Bearing holder mounting bolt

Connecting rod cap mounting nut

Tightening unloader valve guide or unloader connector

Tightening delivery valve holder

Cylinder shell and cylinder body mounting bolt

Tightening suction valve holder

Case cover mounting nut

Case cover screw

Oil filter mounting nut

Valve complete mounting bolt

Tightening heater

Thermostat complete mounting screw

Bracket tightening nut

Tightening

Board mounting bolt

Piston part bolt

Tightening sleeve

Tightening screw

Plate assembly bolt

Cover mounting bolt

Tightening lock nut of adjusting screw side

6.35

10

12

15

8DC

8DC

8DC

8DC

M16x1.5

M20x1.5

M22x1.5

M10x1.25

-

-

M24x1.5

M14x1.5

-

M8x1.25

M8x1.25

M28x1.5

M36x1.5

M10x1.25

M45x1.5

-

-

-

-

-

-

-

PT 3/8

M10x1.25

-

-

-

-

-

-

M12x1.5M12x1.0 21~26 (2.1~2.6)

51~60 (5.1~6.0)

77~90 (7.7~9.0)

85~100 (8.5~10)

23~28 (2.3~2.8)

20~30 (2.0~3.0)

8.0~20 (0.8~2.0)

220 (22)

25~35 (2.5~3.5)

7.0~13 (0.7~1.3)

19~26 (1.9~2.6)

23~26 (2.3~2.6)

100~120 (10~12)

100~120 (10~12)

20~30 (2.0~3.0)

100~120 (10~12)

4.0~7.0 (0.4~0.7)

4.0~7.0 (0.4~0.7)

4.0~7.0 (0.4~0.7)

4.0~7.0 (0.4~0.7)

20~30 (2.0~3.0)

1.5~2.5 (0.15~0.25)

50~60 (0.5~0.6)

30~40 (3.0~4.0)

30~120 (3.0~12)

15~25 (1.5~2.5)

12~19 (1.2~1.9)

1.0~3.0 (0.1~0.3)

5.0~8.0 (0.5~0.8)

12~19 (1.2~1.9)

5.0~8.0 (0.5~0.8)

5.0~8.0 (0.5~0.8)

TIGHTENING TORQUE

BRa-19

Screw size

(O.D. x pitch)

-

-

M10x1.25

M10x1.25

M16x1.5

M10x1.25

M10x1.25

M10x1.0

M10x1.25

M14x1.25

M10x1.25

-

M8x1.25

M6x1.25

-

M8x1.25

M12x1.25

-

-

Tightening torque

Nm (kgf·m)

4.0~7.0 (0.4~0.7)

45~50 (4.5~5.5)

21~32 (2.1~3.2)

16~24 (1.6~2.4)

190~260 (18.7~25.3)

16~24 (1.6~2.4)

21~32 (2.1~3.2)

12~16 (1.2~1.6)

16~24 (1.6~2.4)

110~180 (10.3~17.3)

16~24 (1.6~2.4)

21~26 (2.1~2.6)

10~16 (1.0~1.6)

5.0~7.0 (0.5~0.7)

10~16 (1.0~1.6)

9.0~12 (0.9~1.2)

38~46 (3.8~4.6)

20~24 (2.0~2.4)

10~16 (1.0~1.6)

Lock nut tightening

Plate mounting nut

Cover mounting nut

Plate mounting nut

Cover mounting bolt

Brake hose

Tightening back plate mounting bolt

Tightening anchor bracket mounting nut

Anchor pin lock plate mounting bolt

Tightening brake hose

Tightening oil pipe plate

Tightening back plate mounting bolt

Tightening anchor bracket mounting nut

Anchor pin lock plate mounting bolt

Exhaust

brake

valve

Intake

silencer

Control cylinder mounting bolt

Lever mounting nut

Stopper plate adjusting bolt lock nut

Control cylinder

Plate mounting bolt

Lever mounting bolt

Lock plate mounting bolt

Control cylinder

Front wheel

brake

Rear wheel

brake

Exhaust brake

system

Air pressure governor

Check valve cap

Check items

SERVICE STANDARDS

BRa-20 BRAKE

SERVICE PROCEDURES1. Tightening torque of brake pipe

2. Sealant coating

When reusing air line air hose or connector, fasten it after coat-

ing sealant except part of one or two threads at slanting end

side of screw surface after removing water, grease, oil, seal-

ant etc. remained after disassembling.

Air compressorRemoval and installation1. Remove the injection pump assembly.

2. Disconnect all connections

3. 8DC engine

1) Set No.1 cylinder piston of crank the engine at the top dead

center on the compression stroke.

When the pointer on the flywheel housing is aligned with

the line 1, 4 on the flywheel pulley, the pistons in No. 1 and

No. 4 cylinders are at TDC. At this time, the piston in the

cylinder whose push rod is no pushing up the rocker, is at

TDC on its compression stroke.

NOTE :

· Whenever the engine is to be cranked, crank it by

hand 180° in the direction of normal rotation.

JMS58A-049

Sealant is applied onslanting end side ofscrew surface exceptone or two threads.

Slanting screw

surface

Sealant is not

applied on plain

screw surface.

Suction air pipe

Water outlet pipe

Unloader pipe

Water inlet pipe

Water inlet pipe

Air outlet pipeUnloader pipe JMS58A-050

JMS58A-050

Connector shape Pipe diameter (mm)

6.35

10

12

15

Screw diameter (mm)

12

16

20

22

Pitch (mm)

1.0

1.5

1.5

1.5

1.5

Tightening torque Nm (kgf·m)

19~25 (1.9~2.6)

39~50 (4.0~5.1)

59~78 (6~8)

69~93 (7.0~9.5)

BRa-21

2) Insert the air compressor in the hole provided in flywheel

housing until its gear end makes contact with the end sur-

faces of both injection pump gear and cam shaft gear. Align

the inscribed lines on the rear plate and injection pump

gear and push the air compressor inward.

3) Remove tachometer sensor from flywheel housing.Make sure that the sensor plate projection is positioned atthe center of the sensor mounting tapped hole, then secureair compressor.

4) If the projection is out of position, pull out the air compres-

sor and perform step (b) again.

NOTE :

••••• If the injection pump gear is in mesh with cam shaft

gear one tooth off the specified tooth, about a half

portion of the sensor plate projection disappears

from the tapped hole.

5) Mounting the tachometer sensor

Apply sealant to the threads of the sensor and screw and

tighten the screw until its hexagonal part bottoms.

Rear plate

Flywheel housingAlign inscribed lines

JMS58A-053

Tachometer sensor

Sensor plate projection JMS58A-054

Apply sealant to threads(THREEBOND 1211 or1212 or equivalent)

Hexagonal part

JMS58A-055

SERVICE PROCEDURES

BRa-22 BRAKE

28

Crankshaft end play L 1.0 mm

MA580190

14

19

20

< D6A ENGINE >

Cracks,scratch

5

67

4

2123

2221

Cracks, wear ofbushing, cloggedoil hole

26

Damage ofcircle, wear

20

1918

141516

Wear,damageSettling

SettlingWear, damage

17

Settling10111213

9

Cracks,wear

123

30Damage ofcircle, wear

3228

27

29312425

Wear, damage

Disassembly sequence1. Sensor plate

2. Injection pump gear3. Collar4. Cylinder head

5. Snap ring6. Unloader valve7. Valve spring

8. Valve guide9. Valve holder10. Spring holder

11. Delivery valve spring

12. Delivery valve

13. Delivery valve seatSuction valve holder

15. Suction valve spring

16. Suction valve17. Suction valve seat18. Cylinder liner

Compression ringOil ring

21. Snap ring

22. Piston pin

23. Piston

24. Bearing holder25. Oil seal26. Connecting rod

27. Connecting rod cap28. Connecting rod bearing29. Crankshaft

30. Crankcase31. Bearing32. Bearing

For parts with an encircled number, refer to disassembly procedure

that follows.

BRa-23

Suction valve tool

Disassembly procedure1. Removal of suction valve

NOTE :

· Since the suction valve holder is staked by punching,

do not attempt disassembly unless trouble is evident.

2. Removal of piston ring

NOTE :

· When a piston ring is removed, do not widen the open

ends of the piston ring more than 26mm.

MA580210

Suction valve tool

MA580220

SERVICE PROCEDURES

BRa-24 BRAKE

< D6A ENGINE >

Deterioration load/installed length NV 4.5N (0.46 kgf)/9.5 mm L 3.6N (0.37 kgf)/9.5 mm

Deteriorationload/installed length NV 4.4N (0.45 kgf)/5 mm L 3.5N (0.36 kgf)/5 mmClearance

BD 16 mm L 0.08 mm

Clearance BD 16 mm L 0.07 mm

Connectingrod endplayL 0.5 mm

Crankshaft end play L 1.0 mm



BD ... Basic DiameterNV ... Nominal ValueL ... Limit

MA580230

Clearance between piston ringto piston ring groove L 0.1 mm

Piston ring end gap L 1.0 mm

Inspection and correction

Clearance BD 80 mm L Top 0.3 mm

Skirt 0.2 mm

BRa-25SERVICE PROCEDURES

< D6A ENGINE >

Apply 0.2 to 0.3 cc ofTHREBOND Thread Lock Cement1323B or equivalent to three threads

98 to 115 Nm(10 to 12 kgf·m)

25 to 29 Nm(2.5 to 3.0 kgf·m)

98 to 115 Nm(10 to 12 kgf·m)

Apply engineoil to lips

Dowel pin

23 to 25 Nm(2.3 to 2.6 kgf·m)

Reassembly sequence30 � 32 � 31 � 29 � 24 � 25 � 28 � 27 � 26 � 23 � 22 � 21 � 20 � 19 � 18 � 4 � 3 � 2 � 1

13 � 12 � 11 � 10 � 9 � 17 � 16 � 15 � 14

7 � 6 � 5

For parts with an encircled number, refer to reassembly procedure that follows.

MA580250

18

2322

15 to 20 Nm(1.5 to 2.0 kgf·m)

21

31

2524

14 to 18 Nm(1.4 to 1.8 kgf·m)

26 27 28 29 30 32 3 2 1

Bend lock washer

215 Nm(22 kgf·m)

20

19

39 to 49 Nm(4 to 5 kgf·m)

4

98 to 115 Nm(10 to 12 kgf·m)

9

10

11

12

13

17

16

1514

7

6

5

8

BRa-26 BEAKE

Connecting rod cap

Suction valve tool

MA580300

< D8A >

Reassembly Procedure 1. Assembly of connecting rod

Assemble the connecting rod with the matchmarks on the con-

necting rod and connecting rod cap at the same side.

2. Installation of piston rings

Make sure that the correct piston rings are installed at the cor-

rect positions and their sides with letters stamped faced up.

Keep the compression ring ends 120° apart from one another;

place the oil ring ends at the center between the ends of com-

pression rings; place the side ring ends 45° further away to the

right and left from the oil ring ends.

3. Installation of suction valve holder.

Connecting rod

Nut23 to 25 Nm(2.3 to 2.6 kgfm)

Bend lock washer

Match marks

Face the cut side ofbolt gead inside

MA580270

Piston ring tool

MA580280

Face side with lettersstamped up

1st compressionring

2nd, 3rd compressionring

Side ringOil ringSide ring

< D8A >

2nd compressionring ends

Approx. 120°

3rd compressionring ends

Approx. 120°

1st compressionring ends

Side ring endsOil ring < D8A >

MA580290

Side ring ends

Approx.45°

Approx.45°


4. Installation of injection pump gear

Install the injection pump gear, sensor plate, and nut as shown

above.

Face thisside to gear

Stake the cylinder head at three places shown over the suction

valve holder.Punch at three places,except the head gasketsurface

Cylinder head

Suction valveholder

MA580310

Align "O" mark with "U" mark

Align notch in sensor platewith "O" mark in gear

Injection pump gear

Align catch with notchin sensor plate MA580320

Nut

BRa-28 BEAKE

JMS58A-158

Dual brake valveRemoval and installation

NOTE :

1. Plug the ends of the removed air pipes and the open parts

of the dual brake valve.

2. Check for air leakage after installation.

Brake pedal assembly

40~51 Nm(4.0~5.1kgf·m)

60~80Nm(6~8kgf·m)

30~40 Nm(3~4kgf·m)

Dual brake valve

30~40 Nm(3~4kgf·m)

60~80Nm(6~8kgf·m)

40~51 Nm(4.0~5.1kgf·m)


Roller contact surface wear

Slide surface damage or jaw wear

Disassembly and inspection

Spindle hole I.D.

BD9.5

L 9.68

Straight pin O.D.

Roller mounting

BD 9.5 L 9.44

Pedal mounting

BD 9.5 L 9.45

Spring deterioration

Load kg/Installed length

L 22/12.6



L 21.8/26.5



L 6.1/19.1



L 9.9/17



L 4.8/12.8



L 3.8/14.3



L 4.8/12.9

FJR58A-042

Internal surface damage, wear,

corrosion

Deterioration

Corrosion, damage

Straight pin hole O.D.

BD9.5

L 9.68

Bushing I.D.

BD20

L 20.08

Plunger O.D.

BD19.9

L 19.8

Roller I.D.

BD19.9

Roller I.D.

BD18.3

L 18.5

BD ... Basic diameter

NV ... Nominal value

L ... Limit value

Unit :mm

6

2 32

101123

24

25

262122

27

2829

38

20

37

36353433

3130

32

61

4

78

14

121315

16

17

18

19

39

49

48

47

46

454443

42

41

40

BRa-30 BEAKE

10

12

13

14

22

28

30

33

Disassembly sequence

1. Spring pin

2. Straight pin3. L-pin4. Roller

5). Pedal cover6. Pedal assembly7. Boot

8. Plunger9. Plate assembly . Retaining ring

11. Spring . Relay piston . O-ring

. O-ring15. Sleeve16. Washer

17. Sleeve outer spring

18. Sleeve inner spring19. Screw

20. Relay piston spring21. Bushing . O-ring

23. Self-locking bolt24. Spring seat25. Primary piston outer spring

26. Primary piston inner spring27. Primary piston . O-ring

29. Primary piston spring . Retaining ring31. Primary inlet valve retainer

32. O-ring . O-ring

34. Washer35. Primary inlet valve spring36. Washer

37. Primary inlet valve38. Body . O-ring

. Retaining ring41. Exhaust cover assembly42. Washer

. O-ring . O-ring45. Secondary inlet valve retainer

46. Secondary inlet valve spring47. Valve retainer48. Secondary inlet valve

49. Cover

39

40

43

44

NOTE :

1. Before disassembly, remove dust, dirt, and other foreign

matter from the surface. During the procedure, use utmost

care to prevent entry of any foreign object.

2. Display arranged mark at each connection part before

disassembling.

3. Wipe or wash the disassembled parts using the following

procedure.

(1) Rubber parts : For rubber parts seeming intact, wipe

surfaces clean of deposits with a soft cloth dampened

with alcohol or light oil.

(2) Metallic parts : Clean metal parts in light oil except plate

then blow air to dry. Dry it by blowing compressed air

in order to completely remove the cleaning solution.

Disassembly procedure1. Alignment marks

Put alignment marks on each joint before disassembly.

Part A : Plate assembly and body

Part B : Body and cover

2. Removal of relay piston

Clamp socket wrench (width across flats 14mm) in a vise. Se-

cure the body so that the piston bolt is aligned with socket

wrench. Then, gradually loosen the screw.

NOTE :

· When the screw is loosened, the tension of the spring

in the body may cause the piston and spring to jump

out. Be sure to hold down the body, together with the

relay piston, when loosening the screw.

Part APlate assembly

Body

Part B

Cover

JJR58-032

Philips screwdriverRelay piston

Screw

Socketwrench

JJR58-033


JJR58-038

3. Removal of O-ring

1) Using the Needle, remove the O-rings from the relay piston.

a. Using a pliers, remove the retaining rings from the inlet

valve.

In relay pistonNeedle

O-ringRelay piston

O-ring

JJR58-034

At piston

O-ring

Piston

Needle

JJR58-036

At bushing

Bushing

O-ring

Needle

JJR58-035

In coverNeedle

O-ring

Cover

JJR58-037

At inlet valvePliersRetaining ring

2) Remove the O-ring from the piston.

3) Remove the O-ring from the bushing.

4) Remove the O-ring from the cover.

BRa-32 BEAKE

At exhaust cover assembly

Pliers

Retaining

ring

JJR58-039

b. Using a pliers, remove the retaining ring from the ex-

haust cover assembly.


MA580430

Reassembly

562

Section A-A

Apply multipurpose type grease (NLGI No. 2) Li soap to slidingsurfaces of parts marked with *

Reassembly sequence

49 � 48 � 47 � 46 � 42 � 41 � 40 � 39

� � 45 � 44 � 43

27 � 28 � 21 � 22

38 � 37 � 36 � 35 � 34 30 � 29 26 � 25 � 24 � 23 � 20 � � 11 � 10 � 9 � 8 � 7 � 6 � 4

31 � 32 � 33 5 � 1 � 3 � 2 �

19 � 18 � 17 � 16 � 15 � 12 � 14 � 13

For parts with an encircled number, refer to reassembly procedure that follows.

Apply multipurposetype grease (NLGINo. 2) Li soap.

3

Adjusting screw

4.9 to 7.8 Nm(0.5 to 0.8 kgf·m)

4.9 to 7.8 Nm(0.5 to 0.8 kgf·m)23

2421

* 27252629

* 37

35

20

13 34 39 12 33 32 45 42 48 *0.6 to 1.2 Nm(6 to 12 kgf·m)

41 44 43 40 46 47 491430311918361716153828229

1 to 2.9 Nm(0.1 to 0.3 kgf·m)

111078

2 1 412 to 19 Nm(1.2 to 1.9 kgf·m)

4.9 to 7.8 Nm(0.5 to 0.8 kgf·m)

4.9 to 7.8 Nm(0.5 to 0.8 kgf·m)

Apply multipurpose type grease(NLGI No. 2) Li soap to O-ring atinstallation

A

A

BRa-34 BEAKE

Inspection and adjustment after installation1. Installation pressure gauge [capable of measuring 980 kPa (10

kgf/cm²) or more] to the primary outlet port of the dual brake

valve. Fit foot pressure gauge to the brake pedal. Increase the

air tank pressure to 685 kPa (7 kgf/cm²) and check parts for

possible air leaks.

MA580480

1. Installation of retaining ring

1) Exhaust cover assembly

Using a pliers, install the retaining ring to the exhaust cover

assembly.

2) Inlet valve

Using a pliers, install the retaining ring to the inlet valve

assembly.

2. Installation of relay piston O-ring

Pliers

Retaining ring

MA580440

Pliers

Retaining ring

MA580450

Insert tool

O-ring

Relaypiston

MA580460

Retainer

MA580470

Foot pressuregauge

Pressuregauge

3. Locking of piston

After inserting the piston into the body, install the retainer to

prevent the piston from jumping out.


3. Use the adjusting screw to adjust the play at the tip of the

pedal.

2. Tighten the push rod in the dual brake valve and set the screw

on the pedal to adjust the brake pedal angle so that the follow-

ing characteristic diagram can be met.

G7BR0800

G7BR0810

3° to 5°, 12 to 20 mm (play)

Adjusted with adjusting screw

Air pressure setup

¨Í̈Í¨Í̈Í¨Í 12°¨Î̈Î¨Î̈Î¨Î 12° ± 1.5 °

¨ç̈ç¨ç̈ç¨ç 22±4.0 kpa (2.2±0.4 kgf·cm2)¨è̈è¨è̈è¨è 70 kpa (7kgf·cm2)

¨ç̈ç¨ç̈ç¨ç ¨è̈è¨è̈è¨è

¨Í̈Í¨Í̈Í¨Í ¨Î̈Î¨Î̈Î¨Î

DecreasePlay Increase

Adjusting screw

Turn clockwise to decreaseplay and turn counterclockwise to increase paly

BRa-36 BEAKE

MA5805103.5° ± 1.5°

Prim

ary

outp

ut p

ress

ure

(kgf

/cm

²)

PEDAL DEPRESSING ANGLE

DE

PR

ES

SIN

G F

OR

CE

(kg

f)

Full stroke : 30° ± 3°19.5° ± 1.5° (at output pressure 7 kgf/cm²)

2.2 ± 0.4 kgf·cm²

Outputpressure

Foot pressure :26 ± 2 kgf

10.0 ± 2.0 kgf (at 2.2 kgf/cm²)

2° 4° 6° 8° 10° 12° 14° 16° 18° 20° 22° 0

Air brake valve characteristic diagram

8

7

6

5

4

3

1

0

2


Spring deteriorationLoad/installed lengthNV 16 N (1.65 kgf)/10.3 mmL 13 N (1.35 kgf)/10.3 mm

Spring deteriorationLoad/installed lengthNV 29 N (3.0 kgf)/15.7 mmL 24 N (2.4 kgf)/15.7 mm

1012 to 19 Nm(1.2 to 1.9 kgf·m)

Reassembly sequence

16 � 9 � 8 � 7 � 6 � 5 � 4 � 3 � 2 � 1 � 15 � 10

12 � 14 � 13

MA580530

Relay valveDisassembly, inspection and correction


1. Retaining ring

2. Exhaust cover assembly

3. Retaining ring

4. Valve guide

5. O-ring

6. O-ring

7. Spring

8. Valve retainer

9. Inlet valve assembly

10. Cover

11. O-ring

12. Piston

13. O-ring

14. O-ring

15. Spring

16. Body

NOTE :1. Wash the disassembled metallic parts in a cleaning solu-

tion and work carefully to prevent ingress of metal chips,dust, etc.

2. Never wash rubber parts in a cleaning solution.

1311

15

5

4

2 1

3

6

789

14

16

13

12

NV ... Nominal ValueL ... Limit

15

7

10

12

14

13

11

16

9

8

6

5

3

4

21

MA580520

BRa-38 BEAKE

Inspection after pressure gauge reassemblyApply air pressure to the inlet and control port after installing air

pressure gauge in a piping circuit as in right figure. Difference

between pressures at control port and outlet port shall not exceed

0.28kg/cm². If it is above this specific value then replace spring or

assembly.

Air pressurePressure gauge(control port pressure)

Pressure gauge(delivery portpressure)

Air supply

Outputpressure(kg/cm2)

Gauge pressure(kg/cm2)

JMS58A-084


Pressure protection valve

JMS58A-086

How to test1. Operation test

1) Install drain valve and air gauge at supply and delivery sides.

2) Stop the engine after filling air to maximum.

3) Deplete air from delivery side until cut-out pressure is reached.

4) Confirm whether pressure after valve closure is in range of standard value ± 0.35kg/cm2(5PSI).

5) Supply side gauge stops at set pressure level while delivery side shows continuous decrease.

2. Leak test

1) Stop the engine after filling air to maximum.

2) Check for air leakage after applying soap suds around cap.

3) Deplete air from delivery port but do not connect air line.

4) Check for air leakage after applying soap suds at delivery port.

3. Durability

There shall be no abnormality after 50,000 operations with air pressure 8.4kg/cm2(12PSI).

Setting pressure (kg/cm 2)

Caution items at (dis)mounting1. It shall be installed in vertical direction and a sufficient space shall be secured for upper part to enable pressure

adjustment.

2. Usable temperature range : -49°C~93°C

Maintenance items1. Set pressure value shall be checked per 40,000 km period. If pressure value is beyond ±0.35kg/cm2 check the pres-

sure or confirm whether there is any parts abnormality.

2. Disassemble per cycle of each year and perform checking and cleaning where metallic parts shall be cleansed using

mineral oil.

3. Rubber parts shall be replaced per cycle of each year.

Pressure

5.96 (85PSI)

3.16 (45PSI)

Remark

For use in air suspension

BRa-40 BEAKE

JMS58A-022

Quick release check valve (QR-1C VALVE)

How to testCar must be parked by means of other than brake.

1. Leak test

1) Release from parking by locating gradual valve at release position.

2) Check for air leakage after applying soap suds at exhaust balance ports after removing air line connected to QR-

1C balance port.

3) Operate the parking brake after connecting the balance line.

4) When suds are applied around supply port, body and cover pause under condition where service brake is oper-

ated after removing air line connected to supply port, soap bubble within 1'' in 5sec is allowable at supply port

while interface between body and cover allows no leakage.

2. Operation test

1) Delivery side pressure shall not exceed 0.035kg/cm2 when supply side pressure drops to zero.

2) Pressure difference between supply and delivery shall be within 0.07kg/cm2 when pressure is applied 2.8kg/cm2.

3. Durability

There shall be no abnormality in each part after 1,000,000 cycle operations with supplied air pressure 0~8.45kg/cm2.

Caution items at (dis)mounting1. Usable temperature : -40°C~93.3°C

2. Maximum appliable pressure : 10.5kg/cm2

3. Two spring brake actuators are used while tube connection method is as follows:

1) Delivery port is connected to spring brake emergency port.

2) Balance port is connected to delivery port of relay valve or brake valve. (It is not service or signal side in case

where relay valve is mounted.)

3) Supply port is connected to gradual valve delivery port.

Maintenance method1. Disassemble per cycle of 3,600hr with 160,000km per year and perform checking and cleaning.

2. Metallic parts shall be cleansed using mineral oil.

3. Rubber parts shall be replaced per cycle of each year.

4. Check wear and damage of all parts.


JJR58-050

Check valve1. Removal, inspection, correction, assembling and installation

1) Cap

2) O-ring

3) Valve

4) Valve spring

5) Valve body

NOTE :

1. O-ring shall be replaced at time of removal or per

each year.

2. When assembling, take heed to arrow mark direc-

tion on valve body that indicates air flow direction

so as not to err in assembling direction.

3. When installing valve horizontally, position can be

rightly taken by what is indicated by top and bot-

tom marks.

Double check valveDisassembly

Body

Suttle guide

Suttle valve

O-ringCap

Bolt 58~92 (5.8~9.2kgf·m)

Disassembly sequence1. Bolt2. Cap

3. Suttle guide4. O-ring5. Suttle valve

6. O-ring

JMS58A-087

(Check valve removal)

45~55 Nm(4.5~5.5kgf·m)

Deterioration

Damage, deformationJJR58-051

Air inflow

from air

compressor

To air tank

Valve body

Valve springValve Cap(Assembling)

Description Standard value

Pressure difference between

intake and exhaust port3.0 Nm (0.3kgf/cm2) or less

BRa-42 BEAKE

* Gradual valve does not need special check.

Gradual valve

Brake operation position Steering position

Release sleeve Locker arm

Piston

rod

Gradual position

Inlet

Valve body

Outlet

Com-pressionspring

JMS58A-089

Suttle guide

Body

Cap

3-PT 3/8-19

Suttle valve[NOTE]

Installation shall be done so that shuttle valve may be moved horizontally.

O-ring

JMS58A-088

Safety valve

Category Standard value

CUT 10.5±0.4kg/cm2

CUT OUT 8.5kg/cm2 or more

Adjuster nut Lock nut Spring Valve Body

Release pinSpring caseRivet

JJR58-053

Reassembly


2. Wheel brake.

Front wheel brakeRemoval and installation1. Brake hose

Remove the brake hose of the frame side first.

At reassembly, install it to the wheel brake end first.

NOTE :

Make sure that the brake hose is not twisted during

installation.

40~45 Nm(4.0~4.5kgf·m)

Brakehose

JMS58A-160

Brake chamber

Front brake assembly

Slack adjuster

JMS58A-161

BRa-44 BEAKE

JMS58A-162

1

4

6

Disassembly, inspection and correction

BD......Basic diameterNV......Nominal valueL ...... Limit value

Lining thickness

NV 19 mm

L 6.3 mm

Bushing to cam shaft

clearance

BD 41 mm

NV 0.16~0.21 mm

L 0.5 mm

Load/installation length

NV 43kg/25.5 mm

L Deficiency in between coil

and cover or in coil distance

Anchor pin to bushing clearance

BD 35 mm

NV 0.05~0.04 mm

L 0.3 mm

Brake drum I.D.

BD 410 mm

L 414 mm

Roundness

NV 0.05 mm

L 0.2 mmInner wall side scratch

Uneven wearDisassembly sequence

. Return spring2. Anchor pin lock washer3. Anchor pin lock plate

. Anchor pin5. Bushing . Brake shoe assembly

7. Roller pin

8. Roller9. Return spring pin10. Snap ring

11. Washer12. Slack adjuster13. Spacer14. Cam shaft

15. Dust cover16. Oil seal17. Dust seal

18. Bushing19. Anchor bracket

* Refer to the next disassembling method for disassembling of circle marked parts.

Disassembly procedure1. Removal of return spring

2. Removal of anchor pin

Return spring setter JMS58A-163

Anchor pin pullerJMS58A-164

1011 12

13 1718

15

19 17 16 14

8

6

9 7

5 4

1

6


JJR58-058

3. Replacement of brake lining

1) Removal of the rivet

When drilling out the brake lining rivets, use care not to

enlarge or damage the brake shoe hole by the drill.

2) Installation of the rivet

¨ç̈ç¨ç̈ç¨ç Riveting of lining from the center portion and working

toward the ends. Make sure that no gap is produced

between the shoe and lining.

¨è̈è¨è̈è¨è Stake the rivets to 1700 to1900kgf

¨é̈é¨é̈é¨é Select the lining according to the operating conditions

of the vehicles. Use linings of the same size and paint

color on right and left wheels of the same axle.

¨ê̈ê¨ê̈ê¨ê After relining, check contact with the drum inside and

correct poor contact if any. Correct the lining as incor-

porated into the wheel and brake assembly.

4. Correction of drum

If the drum has a cylindricity of 0.2mm or less scratching, cor-

rect to the repair limit value. After machining, use an oversize

lining.

NOTE :

· Correct the brake drum with the wheel hub installed.

5. Assembly is worked in reverse order of disassembly.

Brake drum I.D.

410 mm

Repair limit value

412 mm

Limit value

414 mm

BRa-46 BEAKE

JMS58A-165

Reassembly

Install oil seal to be flush with surface. Make sure of the

bushing inserting direction printed on its outside surface

and press-fit it to be flush with this surfaces.

(((((Apply wheel grease to bushing inside

surface after press-fitting it.)

Make sure of the bushing inserting direction

printed on its outside surface and press-fit to

be flush with this surfaces.

Install dust seal to be flush with this surface.

Direction of drum

rotation for forward

direction

(Bend securely after tightening bolt)

1.6~2.4kgf·m

(Apply wheel grease to bushing inside surfaceafter press-fitting it.)

1.6~2.4kgf·m

Reassembly sequence

19→18→17→16→15→14→13→12→11→10→4→3→2→1

6→5→8→7→9

NOTE :1. Use 2mm thick washer in the slack adjuster only when 1.2mm thick washer cannot be used.2. Keep the drum inside and lining surface free of grease and oil.

1618

17

14 11 12

13 10

187

6

9

32 15

Reassembly procedureInstallation of return spring.

Return spring setterJMS58A-166


JMS58A-167

Rear wheel brakeRemoval and installation1. Brake hose

Remove brake hose from the connector. Connect brake cham-

ber side at first when installing.

NOTE :

Take heed brake hose is not twisted when installing.

2. Wheel brake.

JMS52-023

4

8

12

14

13

1210

11

9

87

65

43

2

1


1. Rear axle shaft

2. Bolt washer assembly

3. Lock plate

. Lock nut

5. Lock washer

6. Outer bearing

7. Wheel bolt

. Rear wheel hub

9. Rear brake drum

10. Oil seal

11. Inner bearing

..... Oil seal ring

13. Rear brake assembly

14. Oil seal

* For parts with an encircled number, refer to the disassembling method.

Wear or damaged of lip

Wear or damaged of lip

Rust, damage

Wear, rustCondition of rotation

Stepwise wear of spline

BRa-48 BEAKE

JMS58A-169

1

4

6

Disassembly, inspection and correction

Bushing to cam shaft

clearance

BD 40 mm

NV 0.16~0.21 mm

L 0.5 mm


Load/Installed length

NV 55kg/25.5 mm

L Defect in coil hanger

Inner wall scratch

Uneven wear

BD 410 mm

L 414 mm

Roundness

NV 0.05 mm

L 0.2 mm

Bushing to anchor pin

clearance

BD 35 mm

NV 0.05~0.14 mm

L 0.3 mm Lining thickness

NV 19 mm

L 6.3 mm

BD ... Basic diameter

NV ... Nominal value

L ... Limit value

Disassembly sequence . Return spring2. Anchor pin lock washer

3. Anchor pin lock plate . Anchor pin5. Bushing . Brake shoe assembly

7. Roller pin8. Roller

9. Return spring pin10. Brake chamber11. Snap ring

12. Washer13. Slack adjuster14. Spacer

15. Cam shaft

16. Chamber bracket

17. Oil seal18. Bushing19. Dust seal

20. Bushing21. Dust cover22. Anchor bracket

111213141718

16

10

21

22

4

5 69

7

8

1

6

201915

32

Brake drum

JMS58A-171

Disassembly procedure1. Removal of return spring

2. Removal of anchor pin

Return spring setter

Return spring

JMS58A-170

Anchor pin puller


JMS58A-172

Reassembly

Install oil seal aligning withthis surface

Install bushing aligning with this surface,noting correct direction of installation (printmark on bushing outside)

Install dust sealaligning with thissurface

Apply multi-purpose typegrease

This side up when installedon vehicle

Direction of drum rotationwhen vehicle moves for-ward(Bend securely after tight-ening bolt) Apply multi-purpose type grease to

the inside surface.

Reassembly sequence

22→21→16→20→17→18→19→15→14→13→12→11→4→3→2→1

6→5→8→7→9

NOTE :1. Use 1.2mm thick washer at the slack adjuster only when 2mm thick washer cannot be installed.2. Install bushing on the anchor bracket side of the cam shaft after installation of the chamber bracket.3. Keep the drum inside and lining surface free from oil and grease.

61

7 8

10

9

3 2

15

22

45 21

16 14 1211

13

16

17

20 1819

Reassembly procedure1. Installation of return spring.

JMS58A-173Return spring setter

Return spring

BRa-50 BEAKE

JJR58-058

2. Replacement of brake lining

1) When drilling out the brake lining rivets, use care not to

enlarge or damage the brake shoe hole by the drill.

2) In case of rivet

¨ç̈ç¨ç̈ç¨ç Rivet starting from the center and working toward the

ends. Make sure that no gap is produced between the

shoe and lining.

¨è̈è¨è̈è¨è Stake the rivets : 1700 to1900kgf

¨é̈é¨é̈é¨é Select the lining according to the operating conditions

of the vehicle.

¨ê̈ê¨ê̈ê¨ê Use linings of the same size and paint color on right

and left wheels of the same axle.

¨ë̈ë¨ë̈ë¨ë After installing of lining, check contact with the drum

inside and correct poor contact if any. Correct the lin-

ing as incorporated into the wheel and brake assembly.

3. Correction of drum

If the drum has a damage of 0.2mm or less correct to the repair

limit. After correcting, use an oversize lining.

NOTE :

· Correct the brake drum with the wheel hub installed.

Brake drum I.D

410 mm

Repair limit value

412 mm

Limit value

414 mm


JMS58A-096

Adjustment of brake shoe clearanceInspection before adjustment1. Perform the following checks after removing the clevis pin of

brake chamber push rod.

Turn the worm shaft in the direction of arrow as shown in illus-

tration to make sure that the turning torque is 0.5kg·m or more.

2. If the torque is smaller than the specified, replace the spring

and set screw of slack adjuster with new ones. Adjust the set

screw to obtain a turning torque of 0.6 to 1.5kgf·m, then lock

the screw by staking it at two points.

3. Turn the slack adjuster to right and left to check for looseness.

If the slack adjuster moves beyond the limits value shown in

illustration, replace it.

Adjustment1. Connect the push rod and check the air line for leaks and the

push rod for smooth movement.

2. Increase the air pressure to 8kg/cm² and check that the fall of

the air pressure gauge reading in 30 minutes does not exceed

0.8kg/cm². Also check that compressed air is working to the

spring brake side of the spring brake chamber and high air

pressure is working to the main brake.

To increase shoeclearance

Worm shaftJMS58A-092

Stake (Punch)

Set screw

Spring

JMS58A-093

Looseness : Less than 4 mm

JMS58A-094

<Front, #24, Brake chamber>

Push rodstroke

JMS58A-095

BRa-52 BEAKE

JMS58A-097

3. To adjust the brake shoe clearance, press the brake shoes

against the brake drum by turning the worm shaft of the slack

adjuster until it does not move any further. With the brake pedal

fully depressed, release the worm shaft to adjust the brake

chamber push rod stroke to the standard value (25mm front

tire, 30mm rear tire) and now the correct clearance is obtained.

4. When the brake chamber push rod stroke has reached the limit

(40mm front tire, 50mm rear tire), readjust by the slack adjuster.

NOTE :

· The brake chamber push rod length should be set at

the standard value at reassembly.

· When the brake shoe clearance is adjusted, make sure

that there is a air pressure of 7.0 to 8.0g/cm² in the air

tank.

AA58006A

Disk brakeAssembled status of single part materials and each part nomenclature

CarrierPad

Bus

Housing

Lever

Operating shaft

Fixed pamp Guide pin

Adjuster wheel

Thrust race

WasherNeedle race

Plate

Adjuster

Tapper

Pad

Bridge

Rotor

Component


Disassembly and Reassembly

1

2

4

5

6

7

913

14

15

10

12

11

8

3

<Disassembly sequence>1. Clevis pin

2. Chamber assembly3. Operating lever4. Pad retainer plate

5. Pad spring6. Pad7. Bridge

8. Housing

9. Carrier10. Long guide pin

11. Short guide pin12. Guide pin dust cover13. Terminal cap

14. Terminal cover15. Dust cover

<Reassembly sequence>Reassembly is reverse procedure of disassembly.

AA58049A

BRa-54 BEAKE

AA58008A

AA58009A

AA58200A

AA58015A

L

Pad replacement procedureWhen pad is remained 5mm from the back plate after abrasion or pad wear alarm unit is operated so that ( ) sign is

displayed on steering instrument panel, it tells that pad is in complete weared condition so that immediate replacement

should be done.

Pad wear condition shall be inspected per 5,000km or per week.

Minimum air pressure 6kg/cm2 should be maintained at pad replacement work which shall be performed under state

where parking brake has been released.

1. Pad disassembly sequence

1) Disassemble bolt pad retainer by tool.

2) Remove by lifting the pad retainer plate.

3) How to return pad

¨ç̈ç¨ç̈ç¨ç Manually dismantle step cover 3.

¨è̈è¨è̈è¨è Unfasten lock nut 5 unto 4 adjuster step end stage.

¨é̈é¨é̈é¨é Push 4 adjuster stem to connect in 6 adjuster wheel

groove.

¨ê̈ê¨ê̈ê¨ê Return pad by turning 4 adjuster stem (about 12 turns).

¨ë̈ë¨ë̈ë¨ë Disassemble by hand.

NOTE :

· Clean by vacuum cleaner if necessary and do not

use compressed air because if foreign substance

of disk brake would be removed by compressed

air then it will clog oil passage.

123

4

5

6


AA58010A

AA58011A

AA58012A

AA58013A

AA58014A

2) Assemble a new pad and push the brake in opposite direc-

tion as in right figure.

4) Separate the pad from the disk brake.

NOTE :

· Perform procedure 3) and 4) under state of push-

ing the spreader plate as in right figure for spreader

plate not to be separated at time of pad return.

If tappet pin and spreader plate are separated from

each other, pad return work is not normally

performed.

The work must be by hand and air tool shall not be

used. Tappet head part shall not be turned because

of worry about adjuster stem damage.

When working the pad return, spreader plate should

be in close contact with tappet as in right figure.

Confirm whether or not of each part after pad

separation.

2. Pad assembly sequence

1) When the disk brake is pushed and pulled by hand and the

force at time of sliding is measured, then if the force is found

to be over 20kg, the sliding pin part should be checked.

Pull brake by hand as in right figure.

Disk brakePad

BRa-56 BEAKE

AA58015A

AA58016A

AA58017A

AA58008A

AA58018A

D

CAB

E

F

3) Assemble inner pad.

If pad cannot be correctly assembled, it is because spreader

plate has not been completely pushed back. so reassemble

pad after returning referring to pad return method of the

preceding section.

* How to adjust pad clearance

¨ç̈ç¨ç̈ç¨ç Turn adjuster stem for pad to be in close contact with

rotor.

¨è̈è¨è̈è¨è Turn adjuster stem 3/4 in opposite direction.

4) Take off adjuster stem using a driver and then fix by turning

the lock nut.

(Tightening torque : 1~1.5kgm)

NOTE :

· The above work is a must because if the above work

has not been performed, pad clearance adjustment

function cannot be done.

After the above work, mount the stem cover.

5) Mount spring on top of spreader plater, both pads.

- Disk rotor thickness shall be 45mm if it is a new stuff.

It can be used until abrasion limit of 35mm.

- If disk rotor is a new stuff, pad shall be used with pad

back plate thickness of 8mm.

- If disk rotor thickness has been weared out over 3mm

on one side, pad shall be used having pad back plate

thickness of 10mm.

6) Mount pad retainer, then fix with bolt.

3. Pad and disk brake abrasion limits

1) Disk thickness : 45mm (A)

2) Disk use limit : 37mm (B)

3) Pad and back plate thickness : 30mm (C)

4) Back plate : 9mm (D)

5) Pad wear limit : 5mm (E)

6) Pad and back plate wear limit : 13mm (F)


AA58919A

AA58921A

Disassembly of brass bushing in brake housing1. Disassembly

Before disassembling mark the alignment marks on housing and brass bushing using a punch etc.

AA58918A

2. Reassembly

Press-fit the brass bushing in housing using a special tool.

50mm

40mm

40mm

31.7mm

50mm

40mm

10mm

50mm

31.7mm

35.7mm

BRa-58 BEAKE

AA58923A

Guide pinassembly

AA58916A

(Dis)assembly of long and short guide pins1. Removal

Remove guide pin out of carrier using a plastic hammer.

2. Reassembly

Mount dust cover and terminal cap to guide pin and then mount it on carrier.

Terminal cap

Guide pin

Dust cover

Terminal cap

3.5mm

Guide pin

Dust cover

Guide pin sleeve


Brake chamberOutlineBrake chamber is a unit that converts air pressure to mechanical

force when braking. There are many kinds of brake chamber be-

cause each brake requires different force than others.

Brake chamber is classified by number according to size which

number indicates effective area of diaphragm. For example cham-

ber of type 24 signifies that effective area of diaphragm of brake

chamber is 24in2 while force acting on push rod by brake chamber

is value obtained by multiplying this area with air pressure.

OperationIf brake pedal is depressed, compressed air enters brake chamber

through supply port at pressure plate so that air pushes diaphragm.

Diaphragm is supported by push plate to push forward the push

rod. Push rod is connected to slack adjuster which moves forward

to rotate cam shaft so as to brake. When air pressure is discharged

from brake chamber, push rod return spring acts simultaneously

with brake shoe return spring so as to return the push rod assembly,

the slack adjuster and the cam shaft to their respective original

positions of state when brake was not applied.

Tightening torque15~20 Nm (1.5~2kgf·m) Diaphragm

Pressureplate

Clamp ringReturn spring

Push rod

Frombrake valve

Nut tightening nut24′′ 45~67 Nm (4.5~6.7kgf·m )

JMS58A-101

RemovalNOTE :

· Replace diaphragm and return spring as respective sets

for each axle.

· Mark the coincidence marks on cylinder assembly (in case

of car furnished with spring brake), pressure plate and

clamp ring before disassembling.

BRa-60 BEAKE

Remember that push rod stroke must be as short as possible when braking. Excessive push rod stroke drops

down brake efficiency, shortens diaphragm life, retards brake reaction and increases air consumption.

2. Check the push rod in slack adjuster operation stroke arrangement and whether the push rod is operated

without interference. And check angle formed by slack adjuster arm and push rod. The angle must be larger

than 90° under state of brake release and the readjusted maximum stroke should be near 90°.

3. Check if mounting nut is fastened tightly and confirm that cotter pin is installed at proper location.

4. Each year after driving 150,000km or 3,600hr, maintain as follows.

(1) Disassemble brake chamber and cleanly polish every part.

(2) Replace spring and push rod if they are corroded, worn or distorted and replace diaphragm.

(3) When replacing diaphragm or spring, it should be replaced by same thing as in other chamber in same

axle part.

DisassemblyUnfasten support part of brake chamber, separate air hose, and separate push rod from slack adjuster. Remove brake

chamber by unfastening installation nut.

1. Clearly cleanse outside of brake chamber using methanol. At this cleansing you must not polish with gasoline, diesel,

or water solution etc. And before disassembly firstly mark upon brake chamber the original assembly locations of

clamping ring and plate for time of reassembly.

· When replacing diaphragm or spring in car without removing non-pressure plate of brake chamber, return spring

pressure should be removed by unfastening slack adjuster.

Maintenance1. Each month after driving 12,000km or 300hr, check the stroke of push rod and adjust slack adjuster stroke.

1. Brake chamber (#24, #30)

1) Removal, inspection and correction

NOTE :

· Before disassembly, pull out the push rod and fix

completely.

· Work it cautiously preventing the return spring from

bouncing out.

1. Clamp ring2. Pressure plate

3. Diaphragm4. Push rod complete5. Return spring

6. Dust cover7. Non-pressure plate complete

67

15

43

2

JMS58A-102

Type of chamber

24

Adjustment limit

45 mm

Remark

5.6 kgf/cm2 or less


JMS58A-103

Spring brake chamberOutlineSpring brake chamber is designed so that brake function might be

exerted in emergency and parking. And when pressure in air sys-

tem is reduced, braking is automatically applied by pressure re-

duction amount.

Spring brake is not only emergency brake but also substitutes gen-

eral hand brake by manually operating gradual valve installed at

driver's position.

1 2 3 4 5 6 7 8 9 10 11

12131415161718

1. Clevis assembly2. Service brake housing3. Service brake diaphragm return spring

4. Push rod5. Connecting clamp of adapter and service brake

chamber

6. Service brake diaphragm7. Push rod plate8. Adapter

9. Connecting clamp of parking brake chamber andadapter

10. Pressure plate11. Compressor spring12. Release stud excess plug

13. Parking brake diaphragm14. Adapter push rod15. Parking brake diaphragm

16. Release stud assembly17. O-ring18. Nylon screw

BRa-62 BEAKE

Normal driving

Parking brake chamberParking brake

chamber

JMS58A-104

It holds spring compressed to allow driving (so that parking or emergency operation may be feasible).

* Spring of parking brake consistently maintains state as above during driving.

Main brake (Service brake)

JMS58A-107

Spring brake is not operated under condition of normal main brake operation. It is held in by air pressure. If brake is

depressed, air is supplied to main brake chamber as in the above figure so that braking is accomplished.


Parking valve (gradual valve) operation discharges air from spring brake so that force that has been holding the spring is

removed, and so oppositely main brake is operated through push rod by spring force so as to brake.

· Emergency brake : if air pressure drops below spring pressure, main brake is automatically operated by spring force

so as to brake.

Release of main brake

Exhaustgas

JMS58A-106

If brake pedal is released, air in line is exhausted through brake valve bottom and air in main brake chamber is quickly

discharged through quick release valve.

Parking brake (spring brake)

JMS58A-107

BRa-64 BEAKE

Mechanical release or maintenance1. Fix wheel and remove cap from spring chamber. Unfasten re-

lease bolt from side pocket.

2. Put release bolt in location where cap has been removed and

then insert pressure plate.

3. Turn the release bolt clockwise by 1/4 round so that cross pin

is fixed at pressure plate.

4. Assemble nut and washer at the release bolt.

5. Tighten the release bolt tightening nut by wrench until com-

pression spring is completely compressed.

Check by adjustment that push rod goes back while tightening.

Tightening torque : 6.8kgf·m

· Because strong spring has been compressed in spring

chamber, it may cause fatal injury if clamping is unfastened

without controlling the spring.

Chamber diaphragm replacementIf to replace diaphragm of parking brake or main brake without

removing car brake it shall be performed as follows.

· Diaphragm shall be replaced per six months or about 80,000km

run.

Cap

JMS58A-108

JMS58A-109

Turn clockwise.

JMS58A-110

JMS58A-111

JMS58A-112


1. Parking brake

[Disassembly]

1) Compress the parking brake spring as in right figure. Re-

move the spring brake clamp so as to replace spring brake

diaphragm.

2) Take off the diaphragm by pushing off the parking brake

chamber from adaptor.

3) Replace the diaphragm removed from the chamber to new

diaphragm. Cleanly polish inside of adaptor with clear sol-

vent and again with suds.

[Reassembly]

1) Lay the new diaphragm plainly in adaptor housing. Place

the parking brake housing, the spring and the pressure plate

on the adaptor housing and install clamp.

Fasten by 2.6 to 3.4kgf·m with clamp bolt.

2) Applying the air into chamber to check for air leakage.

3) Unfasten the parking brake release bolt to install at side

pocket and then install plug at parking brake chamber.

[Main brake]

1) Unfasten main brake bottom clamp after manually holding

the parking brake spring.

2) Replace main brake diaphragm after pulling off chamber.

3) Polish inside of adaptor housing with clear solvent.

4) Check push rod, spring, housing, and push rod and plate

adaptor.

5) Replace worn or damaged parts.

6) Install the diaphragm, place the clamp so as to be suitably

mounted, and fasten the clamp bolt by 25~33Nm. Apply

pressure to the spring and the main chamber and check

the clamp with suds to confirm if leak occurs. Leak out only

the air of main brake. Remeasure clamp torque.

JMS58A-113

JMS58A-114

JMS58A-115

BRa-66 BEAKE

Sealing

How to disassemble1. Removal of the spindle

Remove control cylinder plate cover lamp.

Put bar at spindle and strike with hammer so that spindle comes

out. Make body only clean after removing the spindle.

NOTE :

At this removing, valve and spindle shall be replaced by

new ones.

Spindle(Lever side)

ValveHammer

Bushing(cover side)

Spindle

FJR58A-151

Bushing

JMS58A-116

Exhaust brake systemExhaust brake system1. Disassembly and inspection

10

9 8

6

4

1

32

5

7

Disassembly sequence1. Snap pin2. Pin

3. Clevis4. Lever5. Control cylinder

6. Stopper plate7. Seal ring (small)

8. Seal ring (large)9. Bushing10. Valve and body assembly

NOTE :If valve lever side bushing and spindle are defective, do not disassemble but re-place by assembly.


Reassembly sequence

10 � 9 � 8 � 7 � � 4 � 3 � 2 � 1

6 � 5

NOTE :To install the control cylinder, place the valve at full openposition, pull out the control cylinder shaft 2 mm or more fromthe free state and connect it with the clevis.

MA580850

Valve body

Clearance between valve and bodywhen valve is closedNV A, B 0.1 mm or more

(A+B)/2 0.1 to 0.4 mm

2. Reassembly and adjustment

<D6A Engine>

Turn adjusting screw so that thebutterfly valve runs parallel with thevalve body when it is opened andclearances A and B are up tospecification when it is closed.

Fullyopened

30°

9

2

7

8

1

64

Fullyclosed30°

21 to 25 Nm(2.1 to 2.6 kgf·m)

5 3 9.8 to 16 Nm(1.0 to 1.6 kgf·m)

4.9 to 6.9 Nm(0.5 to 0.7 kgf·m)

10

NV ... Nominal Value

A

B

Valve

BRa-68 BEAKE

Reassembly ProcedureInstallation of the spindle

1. Support with spindle after taking close contact with inner wall

of body centerline while taking A and B of valve by hand.

2. Firstly insert spindle lever side into inside of body using a press-

fitting tool. Strike press-fitting tool end by hammer so that in-

stall spindle at valve. Install cover side spindle in same manner.

6

5

2

1

3

4

Fully opened

44.5°

30.5°

Fully closed

1.0~1.6kgf·m

Adjusting bolt

0.5~0.7kgf·m

2.1~2.6kgf·m

1.0~1.6kgf·m 10

Turn adjusting screw sothat the butterfly valveruns parallel with thevalve body when it isopened and clearances Aand B are up to specificationwhen it is closed.Clearance between valveand body when valve isclosedNV A,B 0.1 mm or more

A+B/2 0.1~0.4 mm

89

7NV : Nomianl value

JMS58A-119

Body

Valve

FJR58-154

Press-fitting tool

Machining surface toinstall lever

Spindle(Lever side)

Valve Spindle(Cover side)

Press-fittingtool

BodyFJR58-154


3. Insert until jawed surface of press-fitting tool comes contact

with body.

4. Install short bushing at lever side spindle and long bushing at

cover side spindle.

Install the sealing on the spindle as in right figure.

Control cylinder1. Disassembly and inspection

Machining surface to install lever

Press-fitting tool

SpacerPress-fitting tool

JMS58A-156

Long bushing(Cover side)

Short bushing(Lever side)

JMS58A-157

Deterioration,uneven wear

Damage, rust, wearin inner surface

Spring deterioration load/installed lengthNV 8.3kg/106 mmL 7.1kg/106 mm

NV ... Nominal valueL .......Limit value

Disassembly sequence1. Cover

2. Retainer3. Packing4. Plate

5. Wear ring6. Shaft assembly7. Spring

8. Dust seal9. Cylinder JMS58A-120

8

97

12

3456

BRa-70 BEAKE

JMS58A-120

2. Reassembly

10~16 Nm (1.0~1.6kgf·m)10~16 Nm (1.0~1.6kgf·m)

Reassembly sequence

9→7→6→3→2→1→8

4→5

NOTE :1. Apply grease 2cc to inner surfaces of the cylinder.

Apply the grease also to f12 section of shaft assembly.2. Apply sealant to the area in the shaft assembly to which the plate is fitted.

FJR58A-071

9 61

87453

2

Air intake silencer1. Disassembly and inspection

89

5

11

Seizure

Clearance

(Replace bushing)

BD 16 mm

NV 0.03~0.11 mm

Crack12

1110

Wear

6

7. Bracket8. Plate

9. Valve shaft10. Oil seal11. Bushing

12. Silencer coupler


1. Snap pin2. Pin3. Clevis pin

4. Control cylinder5. Valve6. Lever

Wear, damage

3

2

1

7

4

BD...Basic diameter

NV...Nominal value


MA580910

Reassembly sequence

12 � 11 � 10 � � � 8� 7 � 6 � 4� 3 � 2 � 1

9 � 5

8

B

Butterfly valve to coupler clearanceNV A,B 1 mm or more

(A+B) 2 to 3 mm

Replace lock washer

Bend lock washer

Replace O-ring

Replace gasket

8.8 to 12 Nm(0.9 to 1.2 kgf·m)

20 to 24 Nm(2.0 to 2.4 kgf·m)

Apply sealant to threads(LOCTITE No. 271 or equivalent)

Identificationmark O


37 to 45 Nm(3.8 to 4.6 kgf·m)

NOTE :To install the control cylinder, place the valve at full openposition, pull out the control cylinder shaft 2 mm or morefrom the free state and connect it with the clevis.


2. Reassembly and adjustment

Opened

80°

Closed


7

4

3

1

2

6

10 9

11

5

Pack grease (JT-6grease or equivalent

A

12

BRa-72 BEAKE

MA580930


L ... Limit

3. Control cylinder

1) Disassembly and inspection

Lost tension load/installed lengthNV 72 N (7.3 kgf)/109 mmL 61 N (6.2 kgf)/1.9 mm

Disassembly sequence1. Cover

2. O-ring3. Retainer4. Packing

5. Plate6. Wear ring

7. Shaft assembly

8. Spring9. Dust seal10. Retaining ring

11. Filter12. Cylinder

12

8

9

11

10

7

6

5

4

3

2

1


MA580950

Reassembly sequence

12 � 11 � 10 � 8 � � 2 � 1 � 9

7 4 � 3

5 � 6

NOTE :1. Apply grease (NICHIMOLY L2 by Nichinoly Century System

Eye Co. or equivalent) 2 cc to inner surfaces of the cylinder.Apply the grease also to ø12 section of shaft assembly.

2. Apply sealant (HERMETIC GA by Sanno Kogyo or equivalent)to the area in the shaft assembly to which the plate is fitted.

3

9.8 to 16 Nm(1.0 to 1.6 kgf·m)

2) Reassembly

1 9.8 to 16 Nm(1.0 to 1.6 kgf·m)

12 10 11

98756

2

4

MA580940

Exhaust brake control1. Removal and installation

1) Remove the 3-way magnet valve

NOTE :

1. At installation air pipe and hose, making sure that

they do not the interfere with other parts.

2. Do not twist or bend the hose excessively; keep

them in natural position.

2) Remove the Clutch switch.

3) Remove the Combination switch.

3-way magnetvalve

Air pipe (Ø 6.35)19 to 25 Nm(1.9 to 2.6 kgf·m)

BRa-74 BEAKE

ON

OFF

Output "4"

2. Inspection

1) 3-way magnet valve

(1) Airtightness check

With output "2" completely plugged and with a 295 to

980 kPa (3 to 10 kgf/cm²) air pressure applied from

input "1", apply and shut down alternately a 24V volt-

age to check for possible leaks.

PortVoltage Input "1" Output "2"

MA580960

Output "2"

Input "1"295 to 980 kPa(3 to 10 kgf/cm²)

Output "4"(plugged)

0.75B

0.75R

MA580980

(2) Operation check

With a 980 kPa (10 kg/cm²) air pressure applied to in-

put "1", apply voltage, gradually increasing from 0V.

Then, make sure that the voltage at which the valve is

actuated is up to specification.

Nominal value 20 V or less

2) Clutch switch continuity check

Check to see if there is no continuity when the push rod in

the advanced position and there is continuity when the push

rod is retracted.

3) Combination switch continuity check.

Output "2"

Input "1"295 to 980 kPa(3 to 10 kgf/cm²)

Output "4"(plugged)

0.75B

0.75R

MA580960

Push rod

ONOFF


Adjustment and inspection after installation1. Adjusting of microswitch

With the engine running at about 1000 rpm under no load, turn

ON the exhaust brake switch. Slowly release the accelerator

pedal and adjust with the adjusting screw so that the exhaust

brake operated when the engine speed reaches 600 to 700

rpm.

2. Exhaust brake system operation check

Start the engine and turn ON the exhaust brake switch. Then,

make sure that the exhaust brake valve and intake silencer

valve are operated.

Make also sure that the exhaust brake and intake silencer de-

activate when the clutch pedal and accelerator pedal are

depressed.

Adjusting screw

Microswitch

MA580990

Micro switch Adjusting screw

Micro switchAdjusting screw

Injection pump

MA581000

BRa-76 BEAKE

Intarder SystemStructure

Z000001A

PTO connection

Stator

Rotor

Flange output

Helical gear

Oil reservoir

Heat exchanger

21

22

23

4

30

50


Intarder Chracteristercs1. High braking power.

2. Shared oil circuit with the transmission.

3. Integrated transmission cooling system.

4. Unchanged transmission installation length up to the output

flange.

5. Compact construction due to the integration in the transmission.

6. Low weight.

7. Compatible with ABS braking system.

8. Integrated emergency steering pump (on request).

9. Bremsomat mode.

10. Bremsomatic mode.

Z000002A

Comp. air

Water line

Electrical cable

30 57

20 21

34

32

31

4090

33

98

91

95

99

How the intarder works

The oil in the Intarder is used to create a brakin effect.

You can operate the ZF Intarder using the electronic braking level selector (91).

Depending on the position of the braking level selector, the intarder fills with the required quantity of oil in order to produce

the desired braking troque.

The desired braking torque is readhed in 0.75s after switch-on.

Reduction of the torque, e.g. with ABS, takes about 0.3s from switch-off of the intarder.

A step-up gear set on the transmission output shaft accelerates a rotor (23).

As the rotor turns, its blades push oil into the stationary blades of the turbine wheel (Stator [22]) where the oil is slowed.

This converts the braking energy into heat energy.

The braking torque achieved is applied to the vehicle driveline through a helical gear set (21). The heat created is

dissipated through the direct-mounted oil/water heat exchanger to the vehicle’s engine cooling water circuit (30).

Schematic diagram of the ZF intarder system in the vehicle.

BRa-78 BEAKE

Intarder pilot lampThe Intarder pilot lamp gives the driver a continuous survey of the current Intarder condition. The pilot lamp comes on

when the Intarder master switch is switched on and the Intarder is activated by moving the braking level selector.

NOTE :

When the Intarder is switched on, the Intarder pilot lamp flashes continuously if there is any fault in the electrical

system.

Electronic Control Unit ESTThe Intarder is controlled by the electronic control unit.

This unit receives and processes various signals;

1. The signal from the braking level selector activates the accumulator solenoid vlave and the proportional solenoid

valve. This activates the oil resevoir and the Intarder hydraulic control system. The oil contained in the resevoir is

immediately fed into the Intarder circuits.

2. The ABS signal siwtches the Intarder off automatically.

As soon as the ABS system allows the Intarder to operate again, the Intarder is automatically switched back on. In this

case braking torque rises smoothly to the level currently set according to a specified characteristic curve.

3. The signal from the electronic pulse sensor for Intarder speed limits the Intarder braking power and is used to enable

Bremsomat operation.4. The signal for the cooling water temperature allows the electronic control unit to control the Intarder power reduction

function. this prevents the cooling water temperature exceeding a specified maximum value (standard value 105°C).

5. The Bremsomat or Bremsomatic signal allows the driver to select and maintain his speed when descending hills. The

Intarder electronics automatically set the braking torque needed.

NOTE :

If the vehicle has an engine brake, this can be controlled

by the Intarder as well.

Intarder master switchThe master switch controls the power supply to the intarder’s electronic system.

A master switch is recommended to switch the Intarder on and off. It is to be fitted to the dashboard and easily accessible.

If your vehicle does not have ABS, we recommend use of the master switch since this prevents the interder engaging if the

driver accidentally moves the braking level selector (e.g. on a slippery road surface).


Fail-Safe FunctionsThe electronic control unit comprised additional safty functions which ensure limited Intarder operation if any electrical

component should fail (short circuit, interruption).

1. Fault in braking level selector or interruption of braking level signals.

The highest braking level selectable is the level corresponding to the number of intact braking level signals. If the

signal for braking level 1 fails, the Intarder is switched off.

2. Fault in the speed and/or temperature sensor

The electronic control unit reduces maximum braking power to braking lever 2 (even if a higher braking level is

engaged). This ensures the Intarder still functions, although with reduced braking torque.

3. Fault the speed and/or temperature sensor

The electronic control unit reduces maximum braking power to braking level 2 (even if a higher braking level is

engaged). This ensures the Intarder still functions, although with reduced braking torque.

4. Fault in the proportional solenoid valve

The Intarder is automatically switched off.

5. Fault in the accumulator solenoid vlave

No reduction in braking power. The Intarder takes longer to respond.

Fault recognitionThe Intarder pilot lamp indicates Intarder function and also assists fault recognition.

The Intarder pilot lamp lights for 3 sec, when the ignition is switched on (lamp check).

In the unlikely event of a failure of an electrical component of the Intarder, this is indicated by the lamp flashing continuously.

This informs you that only a limited braking effect or no braking effect at all is available from the Intarder.

Error diagnosisThe Intarder electronic control system is capable of diagnostic functions. Errors recognized by the Intarder electronic

control unit are stored in an error memory.

During vehicle inspection, the information stored can help you to indentify any faults quickly and clearly.

You can call up this information as follows :

BRa-80 BEAKE

Hydraulic diagram

Z010143A

Brake light acc. tolocal regulations

Mainswitch

EST Braking level selector

0B

12

34

5

in cabin

IntarderControl lamp

Pressure reliefvalve 12 bar

Pump

Reversing valve

Impulse sensor

Intarder

Sump

FilterTemperature sensor

Oil tank/reservoirCompr.air

Preload valve

Pressureelevation valve

Regulatingvalve

Control valve Safety valve

Proport.solenoidvalve

Main oil flow

Control circuit

Electr. line


Spring table

Order No.

0732 042 402

0732 042 470

0732 042 471

0732 041 247

0732 042 348

0732 042 403

0732 042 406

Location

Intarder control unit

(cooler changeover valve)


(pressure relief valve)


(pressure relief valve)


(safety valve)


(pressure increase valve)

Intarder

(preload valve)

Intarder

(drain valve)

No. of

coils

52.5

7.5

11.5

7.5

8.5

14.5

16.5

Wire dia.

in mm

3.0

1.9

1.6

1.4

1.5

1.6

1.7

Spring dia.

in mm

16.5

15.8

10.8

9.4

18.3

17.6

15.6

Untensioned

length in mm

238.0

31.2

32.6

19.6

52.4

85.0

72.0

Adjustment data

Description

Oil pump

Impeller Axial play

Stator-Rotor

Axial play of taper roller bearing

Dimension spec.

0.03-0.05 mm

0.05-0.1 mm

Measuring device

Dial gauge

Fixture and dial gauge

Remarks

-

Preload (pressure)

BRa-82 BEAKE

Special tool

Tool (Number and Name)

1x89 122 292

Hydraulic spindle

1x56 138 045

Centring dis

1x56 138 046

Adjustment fixture

1x56 138 047

Extraction fixture

1x56 138 050

Ring

1x56 137 124

Tool

1x56 137 974

Tool

Use

Pressing out rotor and stator

(use with 1x56 138 047)

Guide when installing stator

and rotor

Installation of taper roller bearing

on stato and rotor

Pressing out stator and rotor

Installation of spur gear when

assembling inner race of taper

roller bearing

Installation of shaft seal

(use with 1x56 138 038)

Driving in inner race of

taper roller bearing

ZF00001A

ZF00002A

ZF00003A

ZF00004A

ZF00005A

ZF00006A

ZF00007A

Illustration



1x56 137 975

Tool

1x56 138 038

Tool

1X56 138 049

Ring

1x56 136 471

Tool

1x56 138 048

Tool

1x56 138 054

Calibration mandrel

1x56 138 055

Calibration mandrel

Use

Installing needle sleeve in

control housing and pump

housing

Installation of shaft seal

(Use with 1x56 137 124)

Pressing out stator and rotor

(Use with spindle press or hydraulic

press)

Driving retaining plate into output

flange

Installation of shaft seal on output

flange.

Bore-pressure relief valve/

control valve

Bore-pressure increase valve

Illustration

ZF00008A

ZF00009A

ZF00010A

ZF00011A

ZF00014A

ZF00016A

ZF00015A

BRa-84 BEAKE


1X56 138 056

Calibration mandrel

1X56 138 057

1x56 138 068

Measuring plugs

1P01 138 069

Test unit

1P01 138 070

Test unit

Use

Bore-cooler changeover valve

Bore-pilot valve

Intarder housing/control

housing for intarder outlet

pressure or intard or temperature

Test on test bench

Testing electric speedometor

Illustration

ZF00017A

ZF00018A

ZF00019A

ZF00020A

ZF00021A


Disassembly1. Remove oil filter (1).

1) Remove M8x20 retaining screw (1) and washer from oil

filter.

2) Pull filter from filter neck using a pliers.

Remove oil filter from Intarder housing

CAUTION :

Beware of escaping oil.

Catch escaping oil in suitable container.

3) Remove filter cover from oil filter.

2 = Remove filter cover from oil filter.

3 = O-ring filter

4 = Magnetic disc

CAUTION :

Always renew filter. Cleaning oil filter is not sufficient.

ZF000534A

ZF000529A

ZF000552A

2 3 4ZF004467A

1

1

BRa-86 BEAKE

1) Unfasten nuts (1) (wat 18) on stud bolts and unscrew.

Unscrew and remove on M8x115 (4) hex nut from oil connection flange on heat exchanger.

2) Remove heat exchanger and reservoir.

3) Remove heat exchanger and reservoir.

4) Remove two O-rings (2) from heat exchanger oil ducts in control unit housing.

5) Unscrew and remove retaining screws (12) from solenoid valve, remove valve from reservoir.

6) Unscrew and remove retaining screws (14 or 15) from angle plate and on reservoir connection flange (7), remove

reservoir.

7) Remove O-ring (6) from annular groove in reservoir.

8) Unscrew and remove temperature sensor (17) from heat exchanger.

2. Remove heat exchanger, solenoid valve, reservoir, and tem-

perature sensor.

1. Nut (M12)2. O-ring

3. Stud bolt4. Hex screw (M8x1.15)5. Screw plug

6. O-ring7. Hex screw (M8)8. Line connection - solenoid valve

9. Screw plug

10. O-ring11. Solenoid valve12. Hex screw (M8)

13. Reservoir14. Retaining screw15. Retaining screw

16. Screw plug17. Temperature sensor (M18x1.5)18. Angle plate

8

13

12

6

5

17

18 14

10

9

723 Nm (2.5kgf·m)

23 Nm (2.5kgf·m)

35 Nm (3.8kgf·m)

23 Nm (2.5kgf·m)

35 Nm (3.8kgf·m)

40 Nm (4.4kgf·m) 62 Nm (6.8kgf·m)

18 Nm (2.5kgf·m)

23 Nm (2.5kgf·m)

62 Nm (6.8kgf·m)

15

1

3

2

3

1

4

16

ZF001229A


1. Retaining plate2. Hex screw (TT=60 Nm depen. on version, 120 Nm)3. Washer4. O-ring (68x4)5. Output flange6. Ring7. Shaft seal8. Hex screw (M10x35 / 8.8)9. Hex screw10. Hex scrw11. Hex screw12. Hex screw

13. Hex screw (M10x215)14. Hex screw for cardan shaft15. *Hex scrw

(head with bore for wire retainer)16. Hex screw17. Hex screw18. Shim (thickness 1.6 to 0.9 mm, 0.1 mm steps)19. Shim (thickness 0.6, 0.5, 0.4, 0.3, 0.2 mm)20. GasketA = Sealing face of Intarder housingB = Contact face for output shaft ball bearingC = Contact face for stator

846 Nm (5kgf·m)

950 Nm (5.5kgf·m)

1250 Nm (5.5kgf·m)

1050 Nm (5.5kgf·m)

11

76

19

A

B

18

20

16

15

17

14 13

54

32 1

50 Nm (5.5kgf·m)

50 Nm (5.5kgf·m)

50 Nm (5.5kgf·m)

50 Nm (5.5kgf·m)

50 Nm (5.5kgf·m)

A

C

ZF001202A

3. Removal of intarder from main transmission.

1) Release output flange (5), remove shim (3) and O-ring (4), extract flange with two-leg puller.

2) Remove ring (6) or, instead of ring (6), remove ring gear (not shown in drawing) from output flange.

CAUTION :

In the following procedure, the Intarder becomes free

and may fall.

Secure Intarder to prevent it from falling.

3) Remove hex screws (8, 9, 10, 11, 12, 13, 15, 16 and 17) from Intarder, remove Intarder.

4) Remove gasket (20) and shims (18 and 19).

BRa-88 BEAKE

4. Oil pump removal

1) Unscrew and remove screws (8 and 9).

2) Remove pump, pressing off with pry lever if necessary un-

til dowel pin (10) comes free.

3) Remove O-rings (1 and 6) from control unit housing.

4) Remove shaft (3) and ring gear (2) from pump housing.

Check the following :

Axial play on ring gear : 0.03 - 0.05 mm

No scoring permitted on ring gear, shaft and ring gear bore in

housing.

Check that pump pinion (3) is firmly located on shaft.

8 23 Nm (2.5kgf·m)

23 Nm (2.5kgf·m)9

7

6

10

11

11

5

4

3

2

1

ZF001202A

1. O-ring2. Ring gear3. Shaft

4. V-ring5. Needle sleeve6. O-ring

7. Pump housing8. Hex screw, (x4) (M8x80) TT = 23Nm9. Hex screw, (x1) (M8x30) TT = 23Nm

10. Dowel pins (x2)11. Mark on ring gear (ease of assembly)


5. Control unit housing and vlave removal

15

15.115.2

16.116.2

16.3

16

16

15.3

2.5

1.3 2.5

3

5

4

6

173.1

14

16.3

3.3

2.42.3

22.22.1

13

7.2

7.1

8.3 8.2

10.3

10.2

10

12

11

11.511.4

11.311.2

11.1

10.1

8

8.1

97.3

7

1.2

1

1.1

16.2

16.1 ZF004275A

ZF004127A

8

10

11

3

2

11

1

BRa-90 BEAKE

1. Cooler changeover valve1.1 Screw plug (M48) with seal1.2 Compression spring, e.g. 0732 042 402

1.3 Piston

2. Pressure relief valve (12 bar)

2.1 Screw plug (M26) with seal2.2 Piston2.3 Compression spring, e.g. 0732 042 470

Compression spring, e.g. 0732 042 4712.5 Piston

3 = Safety valve (14, 5 bar)3.1 = Screw plug M12x1.5 with seal3.2 = Compression spring. e.g. 0732 041 247

3.3 = Ball

4 = Screw plug M26 with seal

5 = Screw plug M12 (pump pressure) with seal6 = Screw plug M12 (control pressure) with seal7 = Cover

7.1 = Gasket7.2 = Hex screw7.3 = Hex screw

8 = Proportional solenoid with control valve8.1 = Cylindrical screw8.2 = O-ring

8.3 = Piston (control valve)

9 = Hex screw (M10)10 = Pressure valve

10.1 = Screw plug (M30x1.5)10.2 = Compression spring.10.3 = Piston

11 = Control valve11.1 = Sealing cover11.2 = Adjusting screw

11.3 = Piston11.4 = Compression spring11.5 = Piston

12 = Hex screws13 = Screw plug (M24x1.5) with seal14 = Screw plug (M24x1.5) with seal

15 = Preload vlave (1.5 bar)15.1 = Screw plug (1.5 bar) M26x1.5 with seal and re-

cess for compression spring.

15.2 = Compression spring.15.3 = Piston16 = Drain valve

16.1 = Screw plug (M22x1.5) with seal16.2 = Compression spring.16.3 = Piston

17 = Needle sleeve and V-ring (for pump shaft).

1) Remove Intarder control unit.

2) Remove gasket (14).

NOTE :

When removing the vlaves, ensure that the removed

pistons and piston guides are not damaged.

3) Remove the valves shown in this diagram.

Clean Loctite residue from thread on screw plugs and

threads for screw plugs.

CAUTION :

Proportional solenoid (8) must not be subjected to 24V

power source. Check solenoid using terminal tester

only.

Technical data - proportional solenoid (8)

Stroke

Limit current

Resistance at 20°C

Activation time

2 + 2 mm

0.5 A

25.0 ±6% §Ù§Ù§Ù§Ù§Ù

100 %


6. Stator and rotor removal

1 = Retaining ring

2 = Circlips3 = Spindle (or press) 1X56 122 2924 = Pressing-out fixture 1X56 138 047

5 = Pressure piece (in-house manufacrure,refer to tools, item 15)

6 = Rotor

7 = Stator8 = Baseplate or ring (ring 1X56 138 049 when

using press)

9 = Shaft seal

1) Release retaining ring (1) and remove (strike with chisel).

2) Remove circlips (2).

3) Fit pressing-out fixture (4) with pressure piece (5).

4) Heat housing at points around circumference marked with arrows to between 90 and 100°C using hot air blower.

NOTE :

When using fixture (4) with spindle (3), an appropriate height of baseplate can be inserted instead of item

8 (ring).

When using a press, item 8 (ring) 1X56 138 049 must be used.

If no baseplate is used, housing may become distorted or damaged.

5) Press out shaft with stator and rotor from housing.

6) Press out shaft seal (9) from housing.

9

8

7

6

5

4

3

21

ZF004276A

BRa-92 BEAKE

7. Input spur gear removal

1) Clamp shaft in vice using soft chucks.

2) Remove hex screw (1) and shim (2).

3) Remove spur gear (3) using three-leg puller and pressure

piece.

1. Special hex screw

2. Shim3. Spur gear4. Inner race of taper roller bearing

5. Outer race of taper roller bearing6. Stator

7. Ring (not fitted to all versions)

8. Rotor9. Rectangular ring (piston ring)10. Baseplate or ring

11. Three-leg puller12. Pressure piece

1

2

10

9

8

7

654

3

12

11

ZF004277A


Stator removal

1. Three-leg puller2. Pressure piece

3. Inner race of taper roller bearing4. Stator housing pocker

5. O-ring6. Stator7. Ring (not fitted to all versions)

8. Rotor

9. Rectangular ring10. Ring (or baseplate)11. Inpulse sensor

1) Place rotor (8) on baseplate, remove stator using three-leg

puller.

2) Remove inner race of taper roller bearing.

3) Remove ring (7)

4) Remove O-ring (5) from stator.

5) Remove outer race of taper roller bearing from stator (6)

7) Remove rectangular rings (9) from rotor (8).

8) Remove impulse sensor (11).

Technical data - impulse sensor (11)

Operating voltage Ub

Current intake

Tightening torque

Air cap sensor/impulse wheel

ZF operating voltage

max 6 -15V

max. 18 mA

40 Nm

1.4 mm

8V

1

56

9

7

10

8

2

3

4

ZF004278A

ZF004278A11

BRa-94 BEAKE

7. Heat spur gear (3) to approx. 85°C place correctly on rotor.

8. Fit shm (2).

9. Screw in special hex screw (1), tighten provisionally.

When cooled down, tighten to 95 Nm (10.4 kgf·m)

10. Place O-ring (7) in stator and coat lightly using grease.

Reassembly

Stator and rotor assembly

NOTE :

Clean all parts. Lightly coat all moving parts with oil.

1. Coat rectangular rings (9) with oil, insert in annular grooves of rotor.

2. Heat stator bore for outer race of taper roller bearing (5) to approx. 80°C, install outer race of bearing in stator, facing

in correct direction.

3. Slide ring (8) onto stator (6).

4. Place rotor on bench (end of shaft) as shown in diagram.

5. Fit stator with ring onto rotor.

6. Heat inner race of taper roller bearing (4) to approx.

100°C, slide correctly onto rotor shaft (contact face for inner race of taper roller bearing protrudes, i.e. inner race of

bearing faces rotor). Apply light coat of oil to inner, race of taper roller bearing.

1. Hex screw M12x80 Powerlock (95 Nm)2. Shim3. Spur gear

4. Inner race of taper roller bearing5. Outer race of taper roller bearing

6. Stator7. O-ring

8. Ring (not fitted to all versions)9. Rectangular ring (piston ring)10. Rotor

1

2

3

4

6

78

9

10

5

ZF004280A


Stator and rotor installation

1. Apply light coat of oil to rectangular ring (piston ring) and align centrally.

2. Fit centring disc (8) to Intarder housing.

3. Heat Intarder housing (4) to approx. 90 to 100°C (in heating chamber at 100°C for approx. 15 mins., if possible)

NOTE :

Ensure no scoring occurs inside housing when fitting.

4. Firmly install stator (1) and rotor (5) in Intarder housing until tips of arrows on cam surface of Intarder housing and

stator are precisely aligned with one another. Maximum tolerance 1mm.

Using manual press lever, apply pressure to stator and rotor for approx. 5 minutes until stator locates firmly in housing

recess.

NOTE :

When correctly installed, stator must be located lower than the groove on the Sealing face (corresponds

to plate (7) supporting face.

5. Press shaft seal (depending on version) to correct depth using suitable tool (refer to list of tools).

6. Screw 1.5 bar preload valve (refer to control unit), spring, seal pulg (with recess for spring) and seal into Intarder

housing.

1. Stator2. O-ring3. Rectangular ring (piston ring)

4. Intarder housing

5. Rotor6. Shaft seal7. Plate (in-house manufacture, refer to tools, item 16)

8. Centring disc (1X56 138 045)

5

8

1

2

4

3

6 7

ZF004281A

BRa-96 BEAKE

Fitting of taper roller bearing to rotor and taper roller bearing adjustment

1. Fit Intarder and spur gear to ring 1X56 138 050 as shown in diagram.

2. Heat inner race of taper roller bearing (4) to approx. 85°C, fit correctly on rotor shaft.

3. Apply light coat of oil to inner race (4) of taper roller bearing.

4. Allow bearing to cool. Remove ring (5). Place Intarder housing on baseplates (6). This enables spur gear (9) to rotate

freely.

5. Fit adjusting fixture (3), preload inner race of taper roller bearing until spin torque reaches 2±0.5 (22 ± 5 kgf·cm)

6. Using feeler gauge (8), measure gap “A” and note dimension.

Circlip is supplied in 0.05 mm grades from 2.9 to 3.7 mm

Taper roller bearing must have pressure of 0.05 to 0.1 mm. This is assured if a circlip with thickness equivalent to gap

“A” is fitted. At a spin torque of 2Nm, circlip with next possible dimension can be installed.

7. Fit retaining ring (1) and peen onto baseplate at 3 points (120° apart).

1. Retaining ring2. Circlip3. Adjusting fixture (1X56 138 046)

4. Inner race of taper roller bearing5. Ring (for assembly of item 4) (1X56 138 050)6. Baseplate

7. Tightening torque to spin point [2±0.5 Nm (22±5 kgf·cm)]

8. Feeler gauge9. Spur gear10. Rotor shaft

A = Gap [measure at spin torque 2 ± 0.5 Nm. (22±5 kgf·cm)Taper roller bearing must have preload of 0.05 to 0.1mm]

ZF004281A

1

2

3

7

4

5

10

8A

9

66


Valve assembly and fitting of control unit housing

15

15.115.2

16.116.2

16.3

16

16

15.3

2.5

1.3 2.5

3

5

4

6

173.1

14

16.3

3.3

2.42.3

22.22.1

13

7.2

7.1

8.3 8.2

10.3

10.2

10

12

11

11.511.4

11.311.2

11.1

10.1

8

8.1

97.3

7

1.2

1

1.1

16.2

16.1ZF004275A

8

25 Nm (2.7 kgf·m)35

10

11

3

2

1

36

37

38

39

40

42

45

46

4723 Nm (2.5kgf·m)

23 Nm (2.5kgf·m)

25 Nm (2.7kgf·m)

25 Nm (2.7kgf·m)

70 Nm (7.8kgf·m)

70 Nm (7.8kgf·m)

150 Nm (16.5kgf·m)

60Nm (6.6 kgf·m)

100 Nm (11kgf·m)

70 Nm (7.8kgf·m) 44

ZF004127

BRa-98 BEAKE

NOTE :

Check compression springs against spring table.

Apply light coat of oil to moving parts.

Calibrate bores for valve pistons using calibration mandrel

In all cases, check piston for ease of movement in piston bore.

1. Install appropriate piston and compression springs in control housing.

Apply light coat of Loctite 574 to seal plug threads and screw in with new sealing ring. Tighten to required torque.

2. Fit proportional solenoid (8) with O-ring (8.2) and piston (8.3).

3. Fit control unit with gasket (14).

Tighten retaining screws to required torque.

1. = Cooler changeover valve1.1= Screw plug (M48) with seal1.2 = Compression spring, e.g. 0732 042 402

1.3 = Piston

2. = Pressure relief valve (12 bar)

2.1= Screw plug (M26) with seal2.2 = Piston2.3 = Compression spring, e.g. 0732 042 470

2.4 = Compression spring, e.g. 0732 042 4712.5 = Piston

3. = Safety valve (14.5 bar)3.1 = Screw plug M12x1.5 with seal3.2 = Compression spring. e.g. 0732 041 247

3.3 = Ball

4. Screw pulg M26

5. Screw plug M12 (pump pressure) with seal6. Screw plug M12 (control pressure) with seal7. Cover

7.1 Gasket7.2 Hex screw7.3 Hex screw

8. Proportional solenoid with control valve8.1 Cylindrical screw8.2 O-ring

8.3 Piston (control valve)

9 = Hex screw M10x21510 = Pressure valve

10.1 = Screw plug (M30x1.5) with seal10.2 = Compression spring. e.g. 0732 042 34810.3 = Piston

11 = Control valve11.1 = Sealing cover

11.2 = Adjusting screw11.3 = Piston11.4 = Compression spring

11.5 = Piston

12 = Hex screws

13 = Screw plug (M24x1.5) with seal (entry to heat exchanger, oil temperature)

14 = Gsket (on sheet metal version, do not bend)15 = Preload vlave (1.5 bar)15.1 = Screw plug (1.5 bar) M26x1.5 with seal and re

cess for compression spring.15.2 = Compression spring. e.g. 0732 042 40315.3 = Piston

16 = Drain valve (not on all versions)16.1 = Screw plug (M22x1.5) with seal16.2 = Compression spring. e.g. 0732 042 40616.3 = Piston

17 = Needle sleeve and V-ring (for pump shaft). (Install needle sleeve so that thick collar faces pressing-in side)

Technical data proportional solenoid (8)

Stroke

Limit current

Resistance at 20°C

Activation time

2 + 2 mm

0.5 A

25.0 ± 6%§Ù§Ù§Ù§Ù§Ù

100 %


Mounting bolts on control housingControl housing Items 1 to 33

Item no.

2

1, 3, 4

5

6, 7, 8, 9, 10

11

12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24

25, 26, 27, 28, 29, 30, 31

32, 33

Tightening torque

Nm (kgf·m)

62 (6.8)

62 (6.8)

23 (2.5)

23 (2.5)

50 (5.5)

23 (2.5)

23 (2.5)

23 (2.5)

Screw size

O.D x pitch (mm)

M12 x 115

M2 x 120

M8 x 115

M8 x 30

M10 x 215

M8 x 80

M8 x 105

M8 x 30

2

11

14

7

1

2928

6

10

5

15

16

12

13

171819203 4

33

27

30

32

26

253189

23

22

21

O2 O2

O1

O1

24

ZF004098A

BRa-100 BEAKE

Oil pum Reassembly and mounting

NOTE :

Apply light coat of oil to moving parts.

Once needle sleeve and V-ring have been removed from pump housing or control unit housing, heat housing to

approx. 40°C and install needle sleeve correctly using tool 1X56 137 975 (thick collar facing pressing-on side).

Note that mark (dot) on ring gear (11) points upwards.

This ensures that the lug on the ring gear external diameter points towards pump housing.

1. Install shaft (3) with internal rotor and ring gear (2) in pump housing.

2. Install O-ring (6 and 1) in control unit housing.

3. Fit pump housing, avoiding damage to drive spigot on shaft (3). Drive in dowel pins (10). Tighten screws to required

torque.

1. O-ring2. Ring gear

3. Shaft with internal rotor4. V-ring5. Needle sleeve

6. O-ring

7. Pump housing8. Hex screws. (x4)

9. Hex screw. (x1)10. Dowel pins (x2)11. Mark on ring gear (for ease of assembly)

8 23 Nm (2.3kgf·m)

23 Nm (2.3kgf·m)9

7

6

10

11

11

5

4

3

2

1

ZF001227A


Axial paly measurement (stator and grooved ball bearing on main transmission)

1. Retaining plate

2. Hex screw (depending on version)3. Shim4. O-ring (68x4)

5. Output flange6. Ring (ring or ring gear)7. Shaft seal (possibly already fitted)

8. Hex screw (M10x35/8.8)9. Hex screw10. Hex screw

11. Hex screw12. Hex screw13. * Hex screw (M10x215) TA = 50Nm

14. Hex screw for universal shaft15. * Hex screw (head with bore for wire retainer

to secure with impulse sensor)

16. Hex screw17. Hex screw

18. Shim (thickness 1.6 to 0.9 mm. available in 0.1 mm steps)

19. Shim (thickness 0.6, 0.5, 0.4, 0.3, 0.2 mm)20. Gasket

A = Sealing face of Intarder housingB = Contact face for ball bearing on output shaftC = Gap between bearing and

D = Gap between bearing and sealing face of basic housingGAP A - C e.g. 1.1 mmGAP A - B e.g. 10.5 mm

Gap D e.g. 10.0 mm

Axial play :

Axial play of stator must be 0 ± 0.05 mmAxial play of output flange bearing must be 0 to 0.1 mm.

8 5kgf·m

9 5.5kgf·m

12 5.5kgf·m

10 5.5kgf·m11

76

19

A

B

18

20

16

15

17

14 13

54

32 1

5.5kgf·m

5.5kgf·m

5.5kgf·m

5.5kgf·m

A

C

ZF001202A

BRa-102 BEAKE

NOTE :

Various versions of the gasket between Intarder and main trans-

mission are in circulation.

1. Paper gasket.

2. Paper gasket and gasket bead.

3. Steel plate gasket (with corrugated strip).

When measuring this part, do not include gasket bead or corru-

gated strip.

When being measured, the paper gaskets are placed on the Intarder

housing. The steel plate gasket is measured separately.

D = Gap between sealing face of basic transmissionand face end of grooved ball bearing.

A-B = Gap between sealing face of Intarder housingand face end of grooved ball bearing - must be0 to 0.1 mm larger than dimension “D”

A-C = Gap between sealing face of Intarder housing and faceend of stator must be 0 ± 0.05 mm

E = Impulsgeber

AA

E

C

D

B

ZF004284A


1. Meausre shim (19)Shim must have play of 0 to 0.1 mmMeasure dimension “A”-”B” from sealing face (A) with paper gasket fitted to contact face (B), note dimension e.g. 10.5 mm(On version with steel plate gasket, dimension “A”-”B” is thinner by the thickness of the gasket. In this case, thicknessof steel plate gasket without corrugated strip must be added to dimension “A”-”B”). “A”-”B”.Measure dimension “D” from outer race of ball bearing to sealing face of main transmission, note dimension, e.g. 10.0 mm

E.G. Dimension A-B

- Gap D

Gap =

- Axial play

Thickness of shim (19)

10.5 mm

10.0 mm

0.5 mm

0.1 mm

0.4 mm

Fitting of Intarder

1. Measure shim (18). Shim must be adjusted to 0.05 mm pressure and 0.05 mm paly.Measure dimension “A”-”C” from sealing face (A) with fitted paper gasket to contact face (C), note dimension, e.g. 1.1 mm.(On version with steel plate gasket, dimension “A”-”C” is thinner by the thickness of the gasket. In this case, thethickness of the steel plate gasket without corrugated strip must be added to dimension “A”-”C”).

E.g. Dimension A-C

+ Pressure

Thickness of shim (18)

1.10 mm

0.05 mm

1.15 mm

2. Attach corrected shms (18 and 19) to contact faces “C” and “B” with grease.3. Fit gasket (20) to basic transmission. On version with gasket bead or corrugated strip, raised portion of bead (corrugated

strip) points towards Intarder housing.Secure the gasket by inserting as many hex screws as possible to the basic transmission and by screwing in longenough stud bolts. Fit stud bolts at the points where through bores exist on the Intarder housing. The stud bolts alsoserve as dowels when fitting the Intarder.

4. Carefully fit Intarder to basic transmission and screw down. Note tightening torques.5. Slide ring (6) onto output flange.6. Correctly install retaining screws for cardan shaft in output flange.

(screws cannot be inserted when flange is fitted).7. Fit output flange (5) without heating.8. Fit O-ring (4) and shim (3).9. Screw in hex screws (2), tighten to correct torque and secure with retaining plate (1) using tool (refer to transmission).10. Screw in impulse sensor, tightening torque 40Nm. (4.4kgf·m)

Technical data - impulse sensor (11)

Operating voltage Ub

Current intake

Tightening torque

Air gap between sensor/impulse gear

ZF operating voltage

max 6 - 15V

max. 18 mA

40 Nm (4.4 kgf·m)

1.4 mm

8V11

ZF004279A

BRa-104 BEAKE

Fitting of reservoir and temperature sensor to heat exchanger1. Install O-ring (3) in annular groove of reservoir.

Fit reservoir to heat exchanger.

Technical data - Temperature sensor

at 20°C

at 91°C

at 100°C

at 110°C

at 140°C

approx. 50000§Ù§Ù§Ù§Ù§Ù





1

3

54

2

6

ZF001226A

2

1 ZF001225A

2. Screw temperature sensor (1) into heat exchanger, tighten.

Max. tightening torque 40 Nm (4.4 kgf·m)


Fitting of heat exchanger1. Install new O-rings (3) in annular grooves of control unit housing.

2. Screw stud bolts (1) into heat exchanger with Loctite 574.

3. Apply thin coat of Loctite 574 to designated surfaces (*) of heat

exchanger.

Fit heat exchanger to control unit housing, insert and tighten

hex nuts using Loctite 574.

Tightening torque 62Nm (6.8 kgf·m)

4. Screw in one M8 hex screw (2) and tighten.

1. Retaining nut (waf 18)

(* coat with Loctite 574)2. Hex screw (M8)3. O-ring

1

1

1

3

3

1*

62 Nm (6.8 kgf·m)

62 Nm (6.8 kgf·m)

23 Nm (2.5 kgf·m)

62 Nm (6.8 kgf·m)

BRa-106 BEAKE

Fitting of oil filter to Intarder1. Install new O-rings in filter cover and filter cartridge.

2. Fit filter cartridge to filter cover.

3. Fit magnet from old filter cartridge to face of new cartridge. If

magnet disc is missing, obtain a new one and fit.

4. Install filter cover with cartridge in housing, secure with hex

screw and washer.

2 = O-ring in filter cover

3 = O-ring in filter cartridge

4 = Magnet disc

Fitting of solenoid valve to reservoir1. Slide retaining screw (2) into solenoid valve.

Install O-ring (4) in groove. Fit solenoid vlave.

Tightening torque for screws (2) is 23Nm (2.5 kgf·m)

Technical data - solenoid valve

Operating voltage

Coil resistance

24V

Approx. 55.6 §Ù§Ù§Ù§Ù§Ù(23°C)

2 3 4ZF004467A

ZF000534A


No. Item Specification Remarks

1 Flowing material Air

2 Max. used pressure 9.8kg/cm2

3 Max. air pressure 5~9kg/cm2

4 Relative humidity 30% or less Discharge 160§¤§¤§¤§¤§¤/min., Operation ratio 20%,

Inlet air temperature approx. 40°C,

Pressure 6.0-7.5kg/cm2, Tank capacity 69§¤§¤§¤§¤§¤,

Air consumption approx. 27§¤§¤§¤§¤§¤/min(standard)

5 Time lag 40~50 seconds Pressure drop 8.2Õ0kg/cm2

6 Applicable compressor Actual discharge

1200§¤§¤§¤§¤§¤/min or less

7 Air consumption 36§¤§¤§¤§¤§¤/min or less

8 Operating temperature range -4°C~+70°C Without heater

-30°C~+70°C Within heater

9 Heater capacity 24V 100W 50W×2

10 Thermostat operation On at 4°C±4°C,

temperature Off at 20°C or less

11 Weight Approx. 8.6kg

12 Drying agent weight Approx. 1.5kg or more

Air DrierGeneralCompressed air is used in vehicles for various purposes, and is

condensed and drained in the reservoir or is used in the piping line

to affect the devices.

For example, the compressed air may flush off the lubricant(grease)

from moving parts to interrupt smooth operation or stimulate corro-

sion by impurities contained in the drain and lower the service life.

In addition the drain may freeze in wintertime or cold areas to dis-

able operation of various devices including the brake system. There-

fore the air drier is installed to remove moisture and impurities con-

tained in the compressed air in the compressor and protect vari-

ous devices in the air line

Specifications

BRa-108 BEAKE

Components

28 34 2726

25

29

31

30

24

22

23

14

35

16

21

8

9

131110711232

4

5

6

31

30

37

36

32

33

15

17

18

22

2019

JJMS58C-002

A


JMS58C-002

1. Body2~10 Valve body assembly3. Valve body

3. O-ring4. O-ring5. Piston

6. O-ring7. Valve compressor8. Valve spring

9. Spring washer10. Bolt11. Exhaust body

12. O-ring13. Retaining ring14~31 Cartridge

14. Case15. Oil filter assembly16. Gasket ring

17. Gasket ring18. Filter plate19. Bolt

20. O-ring21. Spacer

22. Filter23. Desiccant24. Filter plate(2)

25. O-ring26. Set spring27. Case cover

28. Check valve29. Bolt30. Spring washer

31. Nut32. O-ring33. Screw and washer

34. Purge pump35. Plug36. O-ring

37. Stopper ring38. Bolt and washer39. Stopper plate(1)

40. Stopper plate(2)

41~46. Thermostat (A)41. Thermostat (B)

42. Cord cover43. Heater boot44. Terminal

45. Terminal cover46. Terminal47. Heater

48. Gasket49. FT screw50. Cord clamp

51. Rolling screw52. Bracket53. Bolt

54. Spring washer55. Nut56. Terminal and cord

57. Rolling screw58. Bolt

4038

49

51

50

46

45

42

57

56 52 5855 54 53 41

39

47

48

43

44

BRa-110 BEAKE

JMS58C-003

Outline

Purge

chamber

Check valve

Drier

Body

Air drier

Compressor

Governor

Check valve

Main tank

Drying mechanismAt the compressor duty cycle, air in the drier goes into the air drier

inlet and cooled at the body wall surface, and then moisture and oil

vapor precipitate down in the body. The air will again go through

the assembled (with the oil coated separator) oil filter, where oil

particulates and dust will be removed. Thereafter the air will flow

up from bottom in the drier cylinder contacting the drier, to reduce

moisture and become dry at the top of the drier cylinder. The dried

air will go through the check valve and the purge chamber to the

main tank.

Check valve

Purge

chamberDrier

Case

Body

Oil filter

JMS58C-004


JMS58C-005

Drier

Removal and installation

Purge

chamber

Check valveOrifice

Desiccant

Drain valve

Air drier

Outlet

Control lineCompressor

Governer

Check valve

Main pump

Recovery mechanismWhen the air pressure in the system reaches the maximum value,

the governor makes the compressor idle without load, and the com-

pressed air in the air tank flows back to the air drier. At the same

time the air pressure governor opens the valve located below the

air drier to rapidly drain the compressed air.

Then the rapid opening of the valve generates pressure in the drier

cylinder, that cleans the oil filter and drain moisture and oil precipi-

tates to ambient air. After the drastic pressure reduction, dry air in

the purge chamber will pass through the orifice expending and re-

ducing pressure to make ultimately dry air, that will pass in reverse

through the drier cylinder, absorb and discharge moisture from the

drier, and recover the drier.

During running, air in the air tank is consumed and pressure in the

air tank reaches the minimum pressure adjusted by the governor,

and then the drain valve in the air drier is closed to remove moisture.

Orifice,

Purgechamber

Case

Oil filter

High pressurefrom the airtank checkvalve

Exhaust

Valve

JMS58C-006

BRa-112 BEAKE

InspectionInspection items after every three months or 15,000km1. In order to check normal operation of the air drier, open the drain cock and check air drain. (However, if the tempera-

ture drop around the tank is above 17°C , only a little drain may occur.)

2. Watch the drain out of the air drier outlet. If oil is drained excessively, check the compressor and remedy the exces-

sive oil drain.

3. If the drain is too low at normal operating condition, check correct adjustment of the governor pressure. If the governor

is normal disassemble the air drier and check the drier for precipitated oil and impurities. If the precipitation is above

one fifth of the drier, replace the drier.

NOTE :

· When replacing the drier, replace the oil filter and filter together.

Inspection items after every one year or 100,000km1. Disassemble the air drier and replace the drier, the oil filter, filter, and all rubber parts.

2. As for metal parts, replace only rusted parts.

3. If aluminum bodies or purge chamber is damaged, replace the air drier with a new one.

4. Check piping and wiring for defects.


JMS58C-007

JMS58C-008

Removal And Disassembly

Disassembly procedure

1. Bracket2. Cord3. Stopper plate

4. Stopper ring5. Purge chamber6. Case

7. Case cover8. Check valve9. O-ring

10. Spring11. Filter plate12. Filter

13. Desiccant14. Filter15. Filter plate16. Gasket ring

17. Oil filter18. Gasket ring19. O-ring

20. Spacer21. O-ring22. O-ring

23. Retaining ring24. Nipple

25. O-ring26. Valve

27. Piston28. O-ring29. Valve spring

30. Valve body31. O-ring32. O-ring

33. Thermostat complet34. Heater35. Body

36. Elbow

NOTE :In order to remove stained materials, cleanse the disassembled parts using de-tergent oil and dry them (Except rubber parts, drier, oil filter).

Removal1. Secure the vehicle without using the air brake.

2. Throughly drain air from the brake line.

3. Remove the thermostat wiring.

4. Remove the whole piping from the air drier.

5. Remove the air drier mounting bolt.

70~95 Nm(7.0~9.5kgf·m)

19~26 Nm(1.9~2.6kgf·m)

70~95 Nm(7.0~9.5kgf·m)

Air drier

1

2

5

4

7910

8

361

11

12

1314

15

1617181920

6

21

22

35

3

28272932303126

2423

25

3433

34

BRa-114 BEAKE

JMS58C-012

JMS58C-013

JMS58C-010

JMS58C-011

Disassembly of the cartridge1. Disconnect the ground wire from the bracket and the bolt, and

remove the stopper plate releasing the hexagonal bolt of 10mm.

2. Disconnect the stopper ring from the purge chamber using a

(-) screwdriver.

On removing insert the screwdriver into the purge chamber

groove and lift up the stopper ring, and then it will be easily

removed.

3. Putting out the body to outside of the purge chamber, and re-

lease the four screws and washers that hold the cartridge us-

ing a (+) screwdriver.

4. Remove the cartridge from the body release the six nuts hold-

ing the cover using a 10mm spanner.

On removal, press the case cover using a vice, etc, and re-

lease all nuts.

JMS58C-009


JMS58C-014

JMS58C-017

JMS58C-018

JMS58C-015

JMS58C-016

5. Disassemble from above in the order of the set screw, the filter

plate, the wheel, the desiccant, filter.

6. Reverse the case and hold the center hexagonal bolt in a vice

using a 12mm socket.

Release nut of the case from the top using a 10mm double

ended wrench or a socket wrench. and then disassemble filter

plate, gasket ring, oil filter compressor, spacer, O-ring.

BRa-116 BEAKE

JMS58C-019

JMS58C-021

JMS58C-022

JMS58C-020

1) From the upper left

case, desiccant, filter

2) From the mid left

case cover, set spring and O-ring, filter plate

3) From the lower left

filter plate, gasket ring, check valve, oil filter compressor

Disassembly of body1. Put the heater connection assembled on the exhaust body face

upward, and prise out the retaining ring using a C type retain-

ing ring pliers, and disassemble the exhaust body and the O-

ring.

2. Hold the hexagonal bolt head using a pliers, and disassemble

the valve body complete.

a

d

fg h

f

cb

[Cartridge components]

a : Case

b : Desiccant

c : Filter

d : Case cover

e : Set spring and O-ring

f : Filter plate

g : Gasket ring

h : Check valve and oil filter compressor


JMS58C-023

JMS58C-024

JMS58C-025

3. Secure the piston in the valve body using a 10mm hexagonal

wrench, and release the valve complete connecting bolt, and

disassemble the piston, valve spring, valve complete.

(Body components)

a : Retaining ring

b : Exhaust body

c : O-ring

d : Valve body complete

e : Body, Heater, Thermostat complete A

(Valve body complete components)

a : Piston

b : Valve spring

c : Valve body

d : Valve compressor

e : Spring washer and bolt

f : O-ring

ab e

c d

ca b d e

f

SERVICE PROCEDURES

BRa-118 BEAKE

JMS58C-026

NOTE :1. Apply grease on the slip surface between the O-ring and the piston.2. Install the filter facing the soft area toward desiccant.

ReassemblyClean all disassembled parts using clean detergent oil excert rub-

ber parts and desiccant, and blow off all stained materials to dry.

Replace damaged or worn parts with new ones, if any. For reusing

a rubber part, clean the part using soft rag.

Replace desiccant with new one.

Outlet

Control hole

1.5~2.5 Nm(0.15~0.25kgf·m) Inlet

5~6 Nm(0.5~0.6kgf·m)

4~7 Nm(0.4~0.7kg·m)

4~7 Nm(0.4~0.7kg·m)

8 5 7 10 9

11

12

13

6

36

1820 17

29

2730

35

2324262531

3234

334

2221

1615

14

192

1

3

28

A

B

4~7 Nm(0.4~0.7kg·m)

4~7 Nm(0.4~0.7kg·m)


JMS58C-027

JMS58C-030

JMS58C-031

JMS58C-028

JMS58C-029

Reassembly of the cartridge1. Insert the O-ring at the spacer groove and install the gasket

ring.

2. Press the spacer, O-ring, and gasket ring toward the oil filter

complete rugged area to contact. Put the filter plate and the

gasket ring together on the opposite side, and insert the bolt

from the filter plate side.

Put the filter plate center protrusion face toward the oil filter.

3. Insert the bolt into the case center hole, and tighten the spacer,

O-ring, gasket ring, oil filter complete, gasket ring, filter plate

from above using the spring washer and the nut.

BRa-120 BEAKE

JMS58C-032

JMS58C-035

JMS58C-036

JMS58C-033

JMS58C-034

5. For charging the desiccant well, turning the case lightly tap the

cylindrical part using a plastic hammer, and then fill the second

filter. (call it ‘tapping’)

For the second charge put the soft area of the filter layer face

downward.

4. Put the filter pressed to the case bottom with the soft layer

facing upward, and put desiccant in the case.

Charge approx. 1.15kg of desiccant, or the whole desiccant in

the case if provided as a repair kit.


JMS58C-037

JMS58C-040

JMS58C-041

JMS58C-038

JMS58C-039

6. Insert the O-ring and the check valve on the case cover.

Apply grease on the check valve center protrusion, then it will

be inserted easily.

7. Put the filter plate and the set spring at the center of the case in

which desiccant is contained, and the case cover on them, and

pressing the cover with a special tool tighten them using the

bolt, the spring washer, and the nut. Be careful to the spring

tension that reaches 74kg on setting in the assembly procedure.

Tightening torque : 4~7 Nm (40~70kg·cm)

Reassembly of body1. Apply grease on the O-ring and install the O-ring on the piston.

Use specified silicone type grease only.

2. Apply grease on the valve body’s O-ring moving part and pis-

ton guide part, and insert the valve spring into the valve body.

Then at the opposite direction that the valve spring is installed,

holding the piston assembled with the O-ring as it is, tighten

the valve complete using the spring washer and the bolt.

Tightening torque: 4~7 Nm (40~70kg·cm)

BRa-122 BEAKE

JMS58C-042

JMS58C-045

JMS58C-046

JMS58C-043

JMS58C-044

3. Insert the valve body complete and the O-ring in order, and in-

stall on the retaining body groove. On inserting the valve body

complete in the valve body, be careful not to make the O-ring

caught at the body’s cut area.

3. Install the body and the cartridge on the purge chamber, and

the stopper ring on the purge chamber groove, then pressing

one part of the body press-fit them into the purge chamber

groove using two hands.

4. Connect the stopper plate using bolts and washers. Connect

the stopper plate that is vertically bent with the purge chamber

rugged area using a bolts

Reassembly of the main body1. Apply grease on the O-ring and install the O-ring in the body

groove.

2. Install the cartridge in the body guide area, and tighten the

cartridge using the screw and the washer. (tightening torque

40~70kgf·cm)


JMS58C-047

JMS58C-050

JMS58C-051

JMS58C-048

JMS58C-049

5. Connect the heater on the gasket.

Tightening torque : 20~25 Nm (200~250kgf·cm)

6. Fix the thermostat complete using screws, connect the termi-

nals to the heater, and install the terminal cover.

7. Fix one end of the terminal & cord(smaller connecting hole side

of the pressed terminal) using screws.


8. Install and fix the bracket on the purge chamber, insert the

bolts in the bracket bolt hole, install the spring washer and nut,

tighten the bolts head using a 12mm spanner, and tighten the

nuts using a impact wrench.

Tightening torque : 8.5~9.5 Nm (85~95kgf·cm)

BRa-124 BEAKE

JMS58C-052

9. Insert the other end of the terminal & cordon the thread part of

the bolts that connects the bracket and tighten it.


Inspection after mounting on the vehicle1. Operate the engine. When the pressure reaches the maximum

pressure, it turns from loaded condition to unloaded condition.

Then check leak at the air drier outlet. (The draining air is high

at first, and no sound will be generated after approx. three

seconds. Recovery time is approx. 40~50 seconds.)

2. When the air pressure decreases up to the minimum pressure

and turned from unloaded to loaded condition, check leak at

the drier outlet. If leaks, the leak shall be 20cc/min. (the air

bubble size shall be f15 in six seconds)

3. Check each piping connection for leak.


Troubleshooting

Symptom Probable causes Remedy

Drain from the

main tank

No drain from thedrain valve

Drain from the

main tank

Air leak from the

drain valve

Abnormally low

main tank pres-

sure

Drain until the completely dry condition

Adjust the use of air to enable the recovery,

and check the drier installation condition.

Adjust the governor cut-in pressure to 5kg/cm2 or more.

Adjust the inlet temperature to 60°C of less.

(Make the distance between the air drier and

the compressor as far as possible.)

Replace the desiccant kit every one year or100,000km.

If the heater is failed replace the heater.

If the thermostat is failed replace the thermostat.

Adjust the governor cut-in pressure to the

specified pressure, 5kg/cm2.

Overhaul the valve and replace the valve kit.

Change the air drier installation position or

install a windshield.

Check the heater for circuit-break using a tester,and replace the heater in case of a circuit-break.

Check the thermostat operation:

1) Check the continuity using a tester at 0°C

or less, and;

2) Press the thermostat with palm and check

if it switches off.* If the thermostat does not operate replace

the thermostat.

Check the heater and the thermostat wiring.

Remove theice caring not to damdge the heater

wiring, and change the drier installation position.Overhaul the valve part, and replace the valve

or the valve body if the valve body sealed

surface is damaged.

Overhaul the check valve between the main

tank and the air drier and replace the check

valve if required.

• Time is required to dry from saturatedcondition when additionally install the drier

after modification

• Excessive air consumption to override the

air drier recovery.

• The governor (pressure regulator) cut-in

pressure is decreased(to 5kg/cm2 or less)and the drain valve does not open.

• The air drier and the compressor is too

close to make the inlet temperature high,

and dehumidifying ability is low.

• Desiccant and the oil filter is overused

beyond the replacement frequency.• The heater does not operatee and the

drier does not freeze.

• The governor cut-in pressure is low (to

5kg/cm2 or less) and the drain valve does

not open.

• Foreign material is in the drain valve, andthe valve does not operate.

• The air drier installation condition is

abnormal, and the temperature decreases

to –30°C or less during driving.

• The heater has circuit-break, no heatreservation.

• The thermostat does not operate and the

heater does not operate either.

• The heater thermostat wiring is disconnected

and the heater does not operate.

• Ice is frozen at the air drier drain outlet, and

the recovery procedure is not effective.• Foreign material is in the valve, and the

valve does not seat completely.

• The check valve does not operate effectively

between the main tank and the drier when

the compressor is load-free, and the air inthe air tank flows in reverse and drains from

the drier.

BRa-126 BEAKE

Time

Auto Slack AdjusterGeneral

As for brake lining, because gap between drum and lining gows larger according to use, control is necessary to maintain

adequate lining gap through its adjustment when lining gap is adjusted by slack adjuster in case of full air S-cam brake.

But if it is not adjusted in due period cycle, brake performance is deteriorated because brake chamber stroke is length-

ened owing to excessive lining gap when braking so that brake shove phenomenon arises.

The reaseon is that it has characteristics to decrease the brake power in region where brake chamber stroke is larger than

about 80% of maximum stroke. Therefore because lining gap adjustment is a very important maintenance service item in

S-cam brake, auto slack adjuster herein

1. Pursue stability by securing always stable brake performance by automatically adjusting and maintaining the lining

with adequate gap and maintaining the adequate chamber stroke.

2. Reduces maintenance service time because there comes no need of lining gap adjustment by hand after installation

until complete wear-out.

GapIn case when adjusted manually

In case when adjusted automatically

The effect of Auto-Slack-Adjuster(compared to “By-Hand-Adjust”)

JMS58B-001


Component

1 . Housing 2 . Bushing 3.4.Worm gear

5 . O-ring 6 . Bearing 7 . Oneway clutch

8 . Needle bearing 9 . Cover10. Cotrol unit

CYBR007A

20. Screw21. Nipple

22. Gasket23. O-ring24. Rivet

25. Plug

11. Rack12. Return spring13. Plug

14. Coil spring15. Thrust washer16. Cover

17. Control disc18. Clutch spring19. Gear wheel

24

7

1819

1

2

3

456

89

10

11

12

13

141516

17

20

2122

23

24

25

24

23

BRa-128 BEAKE

Screw

1. Housing is cast in nodular iron and tenifer treated to give a low

coefficient of friction and high wear resistance.

2. Worm gear transmits force from housing to the S-cam shaft.

The tooth profile of the gear is asymmetrical, and both parts

are made of specially treated high-grade steel.

3. Rack converts the rotation of control disc to a reciprocating

liner action. Return spring keep the rack in contact with the

lower flank of the recess in the control disc when one way clutch

and is disengaged.

4. Control unit supplies the motion required for the compensatory

action of the adjuster. The unit consists of control disc, control

arm and cover. The control arm and disc are rigidly joined to

each other and can rotate freely as a unit in the cover.

JMS58B-005

JMS58B-006

JMS58B-004

JMS58B-003

O-ring O-ringWormgear

Worm gear

Bushing

Housing

Return springRack

Plug

GasketCover

Control unit

Control disc

Control arm


Operation PrincipleMaintaining gap is secured by gap A between the rack rotating

together with slack adjuster and the control disc in control unit fixed

at anchor bracket etc. as shown in right figure.

Namely it is not adjusted until rack end comes in touch with control

disc when slack adjuster rotates in direction at time of braking

whence gap is adjusted in the afterward region.

5. Needle bearing, thrust washer and screw cover control the

thrust from coil spring. Coil spring is held by four springs to be

in touch with clutch ring; rivet lets cover to be fixed at proper

position and also allows it to be easily dismounted.

6. One-way clutch converts the linear motion of the rack to rotary

motion. The clutch consists of gear wheel, clutch spring and

clutch ring.

1. When brake is operated with excessive gap between drum and

brake lining, slack adjuster slope may be divided into the fol-

lowing factors:

1) Clearance angle C: normal gap.

2) Excessive clearance angle(δ) : for excessive gap that is

made by wear of brake lining etc.

3) Elasticity angle E: determined by elasticity of component

parts transmitting between wheel brake, brake cylinder,

brake drum and lining.JMS58B-010

JMS58B-009

JMS58B-008

JMS58B-007

one-way clutch

CoverNeedle bearing

Thrust washerCoil spring

Cover

Clutch ringClutch spring

Gear wheel

Bearing

Slack adjuster

Control

disc

Control disc

BRa-130 BEAKE

JMS58B-011

JMS58B-012

Rack

JMS58B-013

13Rack

21

78

13Control disc

2. The working cycle of the brake adjuster can be divided into the

following stages:

1) Starting position

Slack adjuster control arm is located so that the rack is at

the bottom of its travel and its tooth is in contact with the

upper flank of the recess in the control disc. Angle A (clear-

ance angle) between the lower flank of the recess in the

control disc and the tooth of the rack determines the nor-

mal angle that will be obtained between brake lining and

brake drum.

2) Application of brake with excessive clearance

� Movement through clearance angle (C)

The slack adjuster moves through angle A until the toe

of the rack pushes against the lower flank of the re-

cess in the control disc.

The brake shoes expand, but not enough to touch the

brake drum. Thus normal clearance (C) corresponds

to the clearance angle (A).

� Movement through excess clearance angle (Ce)

The control disc pushes the rack upwards so that it

turns the gear wheel(7) of the one-way clutch(7, 8, 9).

The one-way clutch is disengaged in this sense of rota-

tion. At the same time the S-cam shaft expands the

brake shoes until the linings are in contact with the brake

drum.

13

21Controldisc

Rack

21Control disc

Gear wheelClutch spring

Clutch ring 9

A


4

9

17

94

13

21

94

� Movement into elasticity zone (E)

The worm screw is displaced axilally and compresses

the coil spring so that the cone clutch between screw

and (9) is disengaged.

This happens when the torque on the S-cam shaft rises

rapidly as a result of the brake linings being pressed

with increasing force against the brake drum.

� Movement through elasticity angle (E)

The control disc continues to push the rack upward.

Now, however, the rack turns the whole one-way clutch

assembly (7-8-9) because the cone clutch and 9 is dis-

engaged.

3) Release of brake with excess clearance

� Movement through elasticity angle (E)

The return springs 14 and 15 hold the tooth of the rack

13 against the lower flank of the recess in the control

disc 21. The rack 13 turns the one-way clutch because

the cone clutch 4 and 9 is disengaged.

JMS58B-014

Wormscrew

JMS58B-015

7

JMS58B-016

2113

8

8

7

Coil spring

Clutch ring

BRa-132 BEAKE

13

1

987

14,154

31321

� Movement into clearance zone (C)

The cone clutch 4 and 9 engages when the torque on

the S-cam shaft falls to a level at which the coil spring

17 can push the worm screw 4 into contact with the

clutch ring 9.

� Movement through clearance angle (C)

The force exerted by the return spring 14 and 15 on

the rack 13 is not enough to turn the one-way clutch 7-

8-9 when the cone clutch is in engagement. As a re-

sult contact between the tooth of the rack and the re-

cess in the control disc shifts from the lower to the

upper flank (angle A).

The control disc 21 pushes the rack down to its bottom position in

the housing 1. As both clutchs are now in engagement the worm

screw 4 is turned by the rack and the wheel 3 and the S-cam shaft

turn with it.

The net result is an automatic adjustment which keeps the clear-

ance between the brake shoes and the drum at a constant value.

If the clearance is abnormally large, e.g. after the slack adjuster

has been removed in connection with repairs, the brake will have

to be applied many times to adjust the slack adjuster to its normal

stroke. Alternatively the excess clearance can be taken up manu-

ally by turning hut clockwise. The takeup of the slack adjuster per

stroke is determined by the gear ratio.

49

17

21

JMS58B-017

JMS58B-018

21

JMS58B-019


4) Braking at normal clearance

Working cycle in this case is generally same as described

above but there is difference as follows. In case when brake

was applied with normal clearance, lining is installed in drum

just after slack adjuster rotated through angle A. Result is

as B� and B� when brake was applied forcibly.

When brake is released, slack adjuster is operated as ex-

plained in C� and the following action takes place.

Slack adjuster moves through clearance angle A. Rack

tooth is in contact with top part in recess of control disc 21

and at the same time rack is in touch with housing bottom

so that slack move upward no more.

Special Tools

Maintenance items Nominal value Limit value Remark

Chamber strokeFront 45 mm max.

Rear 50 mm max.

Worm screw slip torque (anticlockwise) 1.8 kgf.m or more

Worm screw in axle direction play 0.15~0.6mm 0.6mm 0.6mm

Conical clutch (serration portion) 0.08mm 0.08mm

Coil spring tension 380~20kg

Tool name Part number Shape Application

Spanner

Distant tube

Extension piece D.T1

76025

76026

76034

JMS58B-022

JMS58B-021

JMS58B-020

Service Standards

BRa-134 BEAKE

Tool name

Spanner

Lubricating tool

Holder

Mandrel

Spline key

1�″-10C

Part number

76035

76843

76591

76493

76494

Shape

JMS58B-023

JMS58B-024

JMS58B-025

JMS58B-026

JMS58B-027

Application


JMS58B-028

Reassembly1. Place the worm wheel with the two O-rings in the housing with

flange uppermost. Fit the worm screw against the recess in

the housing. At that time, hexagonal head part should be lo-

cated toward the arrow position of the housing.

NOTE:

Before reassembly all part materials are to be begun ad-

justment after coating grease of lithium series.

2. Fit the bearing over the worm screw and press it into the hous-

ing by means of mandrel(76493).

NOTE:

Ensure that the bearing is correctly seated against its re-

cess in the housing, and that fit the bearing to the hexago-

nal head side of worm screw and check the worm wheel

turn aroud the worm screw one time.

4. Remove the front screw cover using the spanner(76025) andtake out the needle bearing, O-ring and the one way clutch.

5. Remove the worm screw and bearing using the mandrel(76493)and distance tube(76126).NOTE:If remove, remove the same direction of the arrow in thehousing

6. Remove the worm wheel with its O-rings.7. Replace the following parts without fail in case auto slack ad-

juster assembly has been disassembled:1) O-ring2) One-way clutch3) Clutch4) Rivet

5) Plug

Service ProceduresDisassembly1. Release the screw and remove the control unit and the gasket.

After that disassemble the rack, plug and the return spring.

2. Remove rear screw cover with a hexagon wrench, and remove

the spring and the thrust washer.

3. Check the worm screw play. If the axial play is beyond 0,6mm,

the housing is worn and replace auto slack adjuster assembly

without removal check.

Worm screw travel in axle direction 0.6mm or less

JMS58B-032

JMS58B-031

JMS58B-030

JMS58B-029

BRa-136 BEAKE

JMS58B-033

JMS58B-034

JMS58B-035

3. Mount clutch ring, clutch spring and gear wheel of one-way

clutch and confirm the contact state of gear wheel surface with

clutch ring.

4. Fit the O-ring on the worm screw.

5. Assemble the front screw cover with the needle bearing.

6. Tighten the front screw cover against recess in housing with a

torque of (5.1kgf·m).

Recheck that the worm screw train revolves easily.

7. Recheck worm screw play in axle direction using the splinekey (76494) and the holder (76591) that are special tools of

dial gauge.

NOTE:If worm screw travel in axle direction that is axial play ofworm screw “ worm movement ” is outside tolerance thensubstitute a new one and at this time also if adjuster limitvalue is exceeded then change auto slack adjusterassembly.

8. Compress the two return springs with the spring inserter fit

rack. Check that the rack sits correctly in its slot, and that the

springs are correctly placed on the abutment of the rack.

10. Measure serration part height of conical clutch using special

tools of holder (76591), spline key (76594) and 18mm spanner.

If below limit value, a new worm screw is required.

NOTE:

During measuring, the rack must be kept in position by

using the thumb. Please see picture.


9. Place a new welch plug in the recess of the hole for the two

return springs with the convex surface outwards. Lock by punch-

ing it in the centre.


11. Lock the front cover using rivet.

12. Place the thrust washer into the housing with its bearing sphere

foword the worm screw. Insert the coil spring against the thrust

washer.

13. Screw the rear cover by means of a hexagon wrench about 4

turns against the coil spring.


15. Place a new gasket on the control unit place the control unit in

the housing ensuring that the toe of the rack enters the cut out

in the control disc. Tighten six screws.

16. Adjust the spring force by means of an end load tester(76035)

to (380-20kg).

NOTE:

Spring force adjustment shall be precise because it plays

important role in auto slack adjuster function.

14. Fit the lubricating tool(76593).

Fill the adjuster with prescribed grease and dismantle the lu-

brication tool.

1) To ensure proper function of the auto slack adjuster, the

force of the coil spring has to be adjusted to 380~20kg.

This force is reached when the gauge pointer is inside the

red area.

NOTE:

The minimum gap of the vice must be 215mm.

JMS58B-036

JMS58B-037

JMS58B-038

JMS58B-039

2) Place the auto slack adjuster in the tool so that the hexa-

gon wrench in the hexagon of the rear screw cover and

that the hexagon on the worm screw is fitted into the lock-

ing plate.

3) Load the adjuster until the pressure gauge is about half-

way to the red area. Rotate the control arm clockwise so

that the rack of the adjuster is moved fully up in its slot.

Then rotate the control arm backwards over the control

angle A.

BRa-138 BEAKE

JMS58B-040

4) Load the adjuster until the gauge pointer is whin the red

area. The control arm should then return to its starting point

due to the release of the conical clutch. If the control unit

should only move slowly it may be necessary to press it

lightly by hand to return it to the normal position.

NOTE:

The gauge must be read at the same time as the con-

trol arm begins to return to its starting position.

5) (Un)fasten rear screw cover by spanner to control tensile

force if control arm starts to return when gauge pointer is

before or beyond red area.

6) Sufficiently return the vice so that adjuster will receive no

load.

7) The above � ~� must be repeated until accurate spring

force is got.

17. Lock rear screw cover using a rivet.


Nominal torque ¡Ã¡Ã¡Ã¡Ã¡Ã1.8kgf⋅m

3. The above reverse adjustment torque shall be measured more

than three times and then if one-way clutch slips below nomi-

nal torque then auto slack adjuster function is abnormal.

NOTE:

Take heed that phenomenon is frequent that mainly one-

way clutch spring is broken.

Wear Limit

Periodical CheckOperation Status Check1. Check per drive distance 20,000 km whether chamber push

rod stroke is within nominal value.

2. If the stroke is beyond nominal value then confirm whether it is

auto slack adjuster abnormality or other parts abnormality by

means of reverse adjustment torque checking.

Reverse Adjustment Torque Check1. Reverse adjustment torque shall be checked per six months.

2. Check if slip occurs below nominal torque of one-way clutch by

measuring the torque by turning the worm screw hexagon head

anticlockwise.

≤ 45mm

≤ 50mm

≤ 45mm

≤ 50mm

Chamber push rod

Stroke(mm)

Min ∅61.87mm

Min

∅15

.90m

m

Max

∅16

.15m

m

Max

∅62

.2m

m

Max 9.4(Nom 9.0)mmA

A

CYBR007B

BRa-140 BEAKE

TROUBLESHOOTING1. Wheel brakes

Loose connectors

Leaky primary and secondary valves of

dual brake valve

Damaged dual brake valve O-ring

Loose connectors

Leaky primary and secondary valves of

dual brake valve

Air leak

Air pressure governor improperly adjusted

Air compressor malfunctioning

Oil or grease on brake lining

Hardened lining surface

Excessive brake shoe clearance

Improper return motion of the primary or

secondary valve of the dual brake valve, or

exhaust port being plugged with foreign

matter

Small brake shoe clearance

Weak or broken brake shoe return spring

Rusty anchor pin makes brake shoes un-

able to return

Air pressure brake chamber not released

Rusty camshaft

Spring brake is activated

Symptom Probable cause Remedy Ref. group

Poor

braking

action

Brake

drum

overheats

Air leaks when

brake pedal is de-

pressed

Air leaks when

brake pedal is re-

leased

Low air pressure

No air leaks

The brake shoes

are not moving

away from the

brake drum when

the brake pedal is

released

(brake dragging)

Tighten connectors

Disassemble dual brake

valve to remove foreign mat-

ter or replace inlet valve


valve and replace O-ring

Tighten connectors


valve to remove foreign mat-

ter or replace inlet valve

Check air line and correct

air leaks

Adjust air pressure

governor

Overhaul air compressor

Wash deposits off the sur-

face or replace brake lining

Machine brake lining surface

or replace lining

Adjust shoe clearance re-

place brake lining if it has

worn to limit

Disassemble, check, and

clean dual brake valve and

correct problem or replace

Adjust shoe clearance

Replace return spring

Remove anchor pin and re-

move rust

Check dual brake valve and

quick release valve

Correct

Find the cause and release

spring brake

BRa-141

Brake lining worn to allow rivet head to be

exposed

Hardened brake lining

Unevenly worn brake drum inner surface

Brake shoe not in tight contact with brake

lining

Brake drum left loose

Anchor pin left loose

Improper brake shoe clearance or brake

lining in poor contact

Oil or grease on brake lining and brake

drum inner surface

Brake drum runout, or left loose

Uneven right and left inflation pressures

Different brake lining materials used

Weak or broken brake shoe return spring

Chassis spring U-bolt left loose

Air pressure to each brake chamber

uneven

Small brake shoe clearance


Brakes are noisy when pedal is

depressed

Vehicle pulls to one side when

brake pedal is depressed

Abrupt braking action of wheel

brakes

Replace brake lining


Machine or replace drum


Retighten

Tighten anchor pin lock nut

to specification

Adjust shoe clearance cor-

rect poor contact or reline

brake lining

Completely remove depos-

its or reline brake lining

Correct runout retighten

Adjust to specified inflation

pressure

Reline brake lining or pad of

the same material

Replace return spring

Retighten

Check piping to brake cham-

bers for leaks or check oper-

ation of each components

Adjust shoe clearance

TROUBLESHOOTING

BRa-142 BEAKE

2. Air drier

Desiccant becoming ineffective

Heater fails to operate and air drive is

frozen

Valve inoperative due to foreign matter

trapped

Heater circuit is open

Heater inoperative due to defective ther-

mostat

Snow or ice on air drier, abnormally lower-

ing its temperature

Heater inoperative due to heater and ther-

mostat wires left disconnected

Valve fails to seat properly due to foreign

matter

When check valve on air tank side is not

functioning properly in unloading cycle of

air compressor, backward flow of dry air

from air tank occurs.

Oil working up in air compressor


Air tank drain cock

drains

Exhaust port does

not drain

Air drier interior is

frozen

Air leaks from exhaust

port

Excessively low air

tank pressure

Replace desiccant, oil filter,

and filter

Replace heater if defective

replace thermostat if defec-

tive

Disassemble and check

valve and replace valve

complete as necessary

Check heater for continuity

with a tester and replace

heater if there is an open

circuit

Use following procedure to

check thermostat and re-

place if found defective

o Leave thermostat under

environment 0°C or be-

low and check for conti-

nuity using a multimeter

using a multimeter

o Heat thermostat to make

sure that it turns OFF at

temperature between

0°C and 20°C

Remove snow or ice with

care not to damage air driv-

er and heater wires

Connect heater and ther-

mostat wires properly

Disassemble and check

valve and replace valve

complete or replace valve

body, if its sliding surface is

damaged

Replace check valve be-

tween air tank and air driver

Replace piston rings and

cylinder liner

Air drier

Engine oil is discharged

from exhaust port

BRa-143

3. Exhaust brake

Abnormal air pressure

Faulty electrical circuit

Air piping crushed

3-way magnet valve inoperative

Exhaust brake valve inoperative

Exhaust brake valve shaft sticking

Control cylinder inoperative

3-way magnet valve inoperative

Exhaust brake valve inoperative

Exhaust brake valve shaft sticking

Faulty electrical circuit


Exhaust

brake

ineffective

Exhaust brake

cannot be

released

Check for air compressor

performance and piping

and correct as required

Check and repair clutch

switch, microswitch, and

exhaust brake harness

Replace

Replace

Clean

Replace

Disassemble control cylin-

der and replace defective

parts

Replace

Clean

Replace

Check and repair clutch

switch, microswitch, and

exhaust brake harness

Exhaust

brake

TROUBLESHOOTING

Documents

BR(Brake System)