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
Check items Limit value Remedy and Remarks
0.3
0.5
Unit : mm
Load/
installed length Rear 55 kg/255
Nominal value
(Basic diameter[ ])
BRa-17
Check items Limit value Remedy and Remarks
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
Clearance BD 34 mm L 0.1 mm
Clearance BD 42 mm L 0.1 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°
BRa-27SERVICE PROCEDURES
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)
BRa-29SERVICE PROCEDURES
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
Spring deterioration
Load kg/Installed length
L 21.8/26.5
Spring deterioration
Load kg/Installed length
L 6.1/19.1
Spring deterioration
Load kg/Installed length
L 9.9/17
Spring deterioration
Load kg/Installed length
L 4.8/12.8
Spring deterioration
Load kg/Installed length
L 3.8/14.3
Spring deterioration
Load kg/Installed length
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
BRa-31SERVICE PROCEDURES
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.
BRa-33SERVICE PROCEDURES
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.
BRa-35SERVICE PROCEDURES
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
¨Í̈ͨÍ̈Í¨Í 12°¨Î̈ΨÎ̈ΨΠ12° ± 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
¨Í̈ͨÍ̈Í¨Í ¨Î̈ΨÎ̈ΨÎ
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
BRa-37SERVICE PROCEDURES
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
Disassembly sequence
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
BRa-39SERVICE PROCEDURES
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.
BRa-41SERVICE PROCEDURES
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
BRa-43SERVICE PROCEDURES
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
BRa-45SERVICE PROCEDURES
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
BRa-47SERVICE PROCEDURES
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
Disassembly sequence
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
Spring deterioration
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
BRa-49SERVICE PROCEDURES
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
BRa-51SERVICE PROCEDURES
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
BRa-53SERVICE PROCEDURES
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
BRa-55SERVICE PROCEDURES
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)
BRa-57SERVICE PROCEDURES
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
BRa-59SERVICE PROCEDURES
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
BRa-61SERVICE PROCEDURES
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.
BRa-63SERVICE PROCEDURES
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
BRa-65SERVICE PROCEDURES
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.
BRa-67SERVICE PROCEDURES
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
BRa-69SERVICE PROCEDURES
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
Disassembly sequence
1. Snap pin2. Pin3. Clevis pin
4. Control cylinder5. Valve6. Lever
Wear, damage
3
2
1
7
4
BD...Basic diameter
NV...Nominal value
BRa-71SERVICE PROCEDURES
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
Apply sealant to threads(LOCTITE No. 271 or equivalent)
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.
NV ... Nominal Value
2. Reassembly and adjustment
Opened
80°
Closed
Apply sealant to threads(LOCTITE No. 271 or equivalent)
7
4
3
1
2
6
10 9
11
5
Pack grease (JT-6grease or equivalent
A
12
BRa-72 BEAKE
MA580930
NV ... Nominal Value
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
BRa-73SERVICE PROCEDURES
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
BRa-75SERVICE PROCEDURES
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
BRa-77SERVICE PROCEDURES
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).
BRa-79SERVICE PROCEDURES
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
BRa-81SERVICE PROCEDURES
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)
Intarder control unit
(pressure relief valve)
Intarder control unit
(pressure relief valve)
Intarder control unit
(safety valve)
Intarder control unit
(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
BRa-83SERVICE PROCEDURES
Tool (Number and Name)
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
Tool (Number and Name)
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
BRa-85SERVICE PROCEDURES
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
BRa-87SERVICE PROCEDURES
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)
BRa-89SERVICE PROCEDURES
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 %
BRa-91SERVICE PROCEDURES
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
BRa-93SERVICE PROCEDURES
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
BRa-95SERVICE PROCEDURES
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
BRa-97SERVICE PROCEDURES
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 %
BRa-99SERVICE PROCEDURES
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
BRa-101SERVICE PROCEDURES
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
BRa-103SERVICE PROCEDURES
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
approx. 2380§Ù§Ù§Ù§Ù§Ù
approx. 1830§Ù§Ù§Ù§Ù§Ù
approx. 1340§Ù§Ù§Ù§Ù§Ù
approx. 573§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)
BRa-105SERVICE PROCEDURES
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
BRa-107SERVICE PROCEDURES
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
BRa-109SERVICE PROCEDURES
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
BRa-111SERVICE PROCEDURES
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.
BRa-113SERVICE PROCEDURES
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
BRa-115SERVICE PROCEDURES
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
BRa-117SERVICE PROCEDURES
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)
BRa-119SERVICE PROCEDURES
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.
BRa-121SERVICE PROCEDURES
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)
BRa-123SERVICE PROCEDURES
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.
Tightening torque : 2~4 Nm (20~40kgf·cm)
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.
Tightening torque : 5~9 Nm (50~90kgf·cm)
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.
BRa-125SERVICE PROCEDURES
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
BRa-127SERVICE PROCEDURES
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
BRa-129SERVICE PROCEDURES
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
BRa-131SERVICE PROCEDURES
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
BRa-133SERVICE PROCEDURES
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
BRa-135SERVICE PROCEDURES
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.
Worm screw travel in axle direction 0.6mm or less
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.
Worm screw travel in axle direction 0.6mm or less
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.
BRa-137SERVICE PROCEDURES
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.
BRa-139SERVICE PROCEDURES
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
Disassemble dual brake
valve and replace O-ring
Tighten connectors
Disassemble dual brake
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
Symptom Probable cause Remedy Ref. group
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
Replace brake lining
Machine or replace drum
Replace brake lining
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
Symptom Probable cause Remedy Ref. group
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
Symptom Probable cause Remedy Ref. group
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