Brakes: Workshop Manual

WORKSHOP MANUAL
F&G SERIES
BRAKES
FULL AIR TYPE
SECTION 5
International Service & Parts

Tokyo, Japan
NOTICE
Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the
information contained in Section 0A under the headings
“GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS
MANUAL”.
All material contained in this Manual is based on the latest

product information available at the time of publication.
All rights are reserved to make changes at any time without
prior notice.
Applicable Model : FTR, FVR, FVD, FVM, FVL, FVZ, FVY, GVR,
GVD
For the disassembly, reassembly and inspection of MERITOR-

made air brake, refer to the MERITOR brake service manual.
This manual is applicable to 2000 year model and later vehicles.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION NO. CONTENTS

00 Service Information
5A –
5B Air Brakes
5C –
5D Air Compressor and Governor
5E Exhaust Brake
SERVICE INFORMATION 00-1
SECTION 00
SERVICE INFORMATION
CONTENTS
PAGE
Troubleshooting................................................................................................................ 00- 3
Main Data and Specifications.......................................................................................... 00- 13
Service Standard .............................................................................................................. 00- 15
Servicing............................................................................................................................ 00- 17
Fixing Torque..................................................................................................................... 00- 25
Special Tools ..................................................................................................................... 00- 30
00-2 SERVICE INFORMATION
MEMO
TROUBLESHOOTING
CONTENTS
PAGE
Brake System .................................................................................................................... 00- 4
Brake Lining ...................................................................................................................... 00- 6
Brake Drum ....................................................................................................................... 00- 7
Air Dryer ............................................................................................................................ 00- 8
Air Compressor and Governor ........................................................................................ 00- 10
Exhaust Brake ................................................................................................................... 00- 11
BRAKE SYSTEM
PROBLEM POSSIBLE CAUSE CORRECTION
No Brakes 1. No air pressure. 1. Check for leaks, broken lines, broken
compressor, etc. Repair or replace
as necessary.
2. Restricted tubing or hose. 2. Replace defective parts.
3. Defective brake valve. 3. Repair or replace.
4. Ice in system. 4. De-ice and drain system.
5. Slack adjusters out of adjustment. 5. Adjust.
Insufficient Brakes 1. Low brake line pressure. 1. Check for leaks, etc. and repair.
Check governor cutout pressure;
adjust, check safety valve for correct
“pop-off” pressure.
2. Foot control valve linkage 2. Adjust.
improperly adjusted.
3. Worn linings or drums. 3. Replace as necessary.
4. Leakage chamber diaphragm. 4. Replace diaphragm.
5. Too much pushrod travel. 5. Adjust.
(Slack adjusters out of adjustment.)
6. Pushrod travel incorrect. 6. Adjust pushrod to proper length.
7. Plugged, crimped, restricted air lines. 7. Repair or replace.
Slow Brake 1. Low brake line pressure. 1. Check for leaks, etc. and repair.
Application Check governor cutout pressure;
adjust, check safety valve for correct
“pop-off” pressure.
2. Pedal linkage binding. 2. Lubricate linkage, clean, check for
foreign objects.
3. Too much pushrod travel. 3. Adjust slack adjuster.
(Slack adjusters out of adjustment.)
4. Restriction in lines. 4. Remove restriction or replace line.
5. Leaking or malfunctioning brake valve. 5. Repair or replace.
6. Worn linings or drums. 6. Replace as necessary.
7. Leaking chamber diaphragm. 7. Replace diaphragm.
8. Brake shoes binding. 8. Free up, replace or lubricate as
necessary.
9. Foot control valve linkage 9. Adjust.
improperly adjusted.
10. S-cam bushings binding. 10. Lubricate or replace.
Quick Loss of 1. Leaking lines or connections. 1. Repair or replace.

Pressure When 2. Leaking compressor and governor. 2. Repair or replace.
Engine Is Stopped
3. Leaking one-way check valves. 3. Repair or replace.
(Brakes Not Applied)
4. Leaking spring brake hoses or 4. Tighten connection or replace hose.
connections.
5. Leaking brake system valves. 5. Repair or replace.
6. Open or leaking reservoir drain cock. 6. Close, repair or replace.
7. Leaking spring brake chamber 7. Replace diaphragm.
diaphragm.
BRAKE SYSTEM (CONT.)

Quick Loss of 1. Leaking brake chamber. 1. Tighten clamp.
Pressure When 2. Leaking compressor governor. 2. Repair or replace.
Engine Is Stopped
3. Leaking brake system valves. 3. Repair or replace.
(Brakes Fully Applied)
4. Leaking lines or connections. 4. Repair or replace.
5. Leaking chamber hoses or 5. Tighten connections or replace
connections. hose.
6. Leaking brake chamber diaphragm. 6. Replace diaphragm.
Safety Valve 1. Safety valve malfunction. 1. Replace.

“Blows Off” 2. Pressure in the system above normal. 2. Check governor cutout pressure.
BRAKE LINING
Poor Contact at 1. Bell-mouthed drum. 1–6. Repair or replace as required.
Center of Shoe 2. Distorted anchor pin bracket.
3. Bent brake shoe.
4. Worn anchor pin or bushing.
5. Loose wheel bearing.
6. Anchor pins not centered.
Unequal Wear on 1. Brake linings not a balanced set. 1–4. Repair or replace as required.
Shoes in Same Brake 2. Flat spots on cam follower roller.
3. Worn anchor pin or bushings.
4. Worn camshaft or bushings.
Material at Center of Oversize drum. Repair or replace as required.

Shoe Excessively Thin
Lining Worn at One 1. Bent anchor pin bracket. 1–2. Repair or replace as required.
End 2. Worn anchor pins or bushings.
Linings Glazed 1. Grease on lining. 1–2. Repair or replace as required.

2. Wrong type lining for service
involved.
Rivets Tear Loose 1. Improper size rivet. 1–3. Repair or replace as required.
2. Improper seating of rivet.
3. Enlarged rivet holes in shoe.
Unequal Wear 1. Weak shoe retracting springs – one 1–7. Repair or replace as required.
Opposite Brakes, brake.
Same Axle 2. Obstructed air line.
3. Ineffective brake chamber.
4. Frozen or slow acting camshaft.
5. Frozen anchor pin or bushings.
6. Brake drum surface in poor
condition.
Linings Scored 1. Scored drum. 1–2. Repair or replace as required.

2. Abrasive material between lining
and drum.
Cracks at Rivet Holes 1. Wrong type rivets. 1–4. Repair or replace as required.
2. Rivets not properly set.
3. Dirt or rust on shoe table.
4. Wrong size lining.
Elongation of Rivet Loose rivets or bolts. Repair or replace as required.

Holes
BRAKE LINING (CONT.)

Wear on Edge of 1. Wrong width lining. 1–4. Repair or replace as required.
Lining 2. Holes improperly drilled.
4. Bent shoe.
Groove on Edge of 1. Linings too wide. 1–2. Repair or replace as required.

Lining 2. Worn drum.
BRAKE DRUM
Brake Drum Heat 1. Out-of-round brake drum. 1–3. Repair or replace as required.
Checked in Spots 2. Eccentric mounting of drum.
Drum Uniformly Heat 1. Improper friction materials. 1–3. Repair or replace as required.
Checked 2. Overworked brake.
3. Driver abuse.
Excessive Scoring of 1. Improper friction materials. 1–5. Repair or replace as required.

Drum 2. Overworked brake.
3. Abrasive material between lining
and drum.
4. Soft drum.
5. Bent or warped shoe.
Excessive Drum 1. Driver abuse. 1–5. Repair or replace as required.

Cracks 2. Use of service brakes for parking.
3. Weak drum.
4. Wrong friction materials.
5. Overworked brake.
AIR DRYER
1. WATER IN VEHICLE RESERVOIRS
Checkpoint Trouble Cause Countermeasure
NG
Governor Faulty governor Replace governor
OK
NG
Desiccant Desiccant is contaminated Replace desiccant
OK
NG
Purge valve Air dryer not purging Refer to next section
2. AIR DRYER DOES NOT PURGE OR EXHAUST AIR
Test to determine air flows

NG Broken, kinked, plugged,
through purge control line
Purge valve control line frozen or disconnected
when compressor is
purge control line
unloaded
OK
Test electrical circuit

NG Frozen Purge valve (Cold (heater, thermostat, wiring
Purge valve
weather operation only) and fuse), Replace parts as
necessary.
OK
NG Repair or replace purge

Purge valve Faulty Purge valve
valve
3. CONSTANT EXHAUST OF AIR AT PURGE VALVE
NG Repair or replace Purge

Purge valve Faulty Purge valve
valve
4. UNABLE TO BUILD SYSTEM PRESSURE

Checkpoint Trouble Cause Countermeasure
NG Repair or replace faulty

Air line Air leakage
item(s)
OK
NG
Check valve on the cover Faulty check valve Replace check valve
AIR COMPRESSOR AND GOVERNOR

Compressor Not 1. Damaged inlet valve plunger or 1. Replace the cylinder head assembly.
Unloading spring.
2. Intake cavity restrictions. 2. Remove the restriction; clean the
cavity.
3. Malfunctioning governor. 3. Remove the governor.
4. Unloader line or cavity to the 4. Remove the restriction.
governor restricted.
5. Unloader mechanism binding or 5. Replace the cylinder head assembly.
stuck.
Excessive Oil Flowing 1. Excessive wear. 1. Repair or replace.

Through Compressor 2. High inlet vacuum. 2. Clean or repair as necessary.
3. Small oil return line. 3. Install the proper line.
4. Excessive oil pressure. 4. Determine the cause of pressure and
repair.
5. Oil supply or return lines to 5. Determine the cause of condition
compressor flooded. and repair.
6. Damaged oil seal rings in crankcase 6. Replace the seals.
cover.
7. Piston ring not properly installed. 7. Install properly.
8. Back pressure from engine 8. Determine the cause of the pressure
crankcase. and repair.
Noisy Operation 1. Restriction in the cylinder head or 1. Remove the restriction or clean.
discharge line.
2. Worn or burned out bearings. 2. Replace.
3. Compressor not getting the proper 3. Clean and repair or replace
lubrication. malfunctioning parts.
4. Excessive wear. 4. Rebuild or replace.
Compressor Fails to 1. Restriction in the compressor 1. Remove the restriction and clean.
Maintain Sufficient cylinder head intake, discharge
Pressure cavities or in discharge line.
2. Leaking or broken discharge valves. 2. Replace the cylinder head assembly.
3. Excessive wear. 3. Rebuild or replace.
4. Inlet valve stuck open. 4. Replace the cylinder head assembly.
5. Worn inlet valves. 5. Replace the cylinder head assembly.
6. Excessive system leakage or usage. 6. Check and repair.
High or Low Pressure 1. Governor out of adjustment. 1. Replace the governor.

2. Governor leakage. 2. Replace the governor.
3. Compressor leakage. 3. Check the fittings, bolts, and mating
surfaces. Tighten or overhaul.
4. Unloader not functioning. 4. Replace the cylinder head assembly.
5. Defective governor. 5. Replace the governor.
EXHAUST BRAKE
Exhaust Brake Does 1. Blown fuse. 1. Replace.
Not Operate 2. Improperly adjusted or faulty 2. Adjust or replace.
accelerator or clutch switches.
3. Poor connections or corroded 3. Clean or replace.
terminals at switches or control
valve.
4. Improperly adjusted or seized 4. Adjust or repair.
exhaust manifold valve.
5. Air or vacuum lines kinked, 5. Repair. In freezing weather keep air
restricted, or plugged with ice. tanks drained.
6. Seized relay crank. 6. Repair.
7. Broken or missing relay rod. 7. Repair.
8. Air cylinder, vacuum chamber or 8. Melt ice. Drain lines of water. Keep
magnetic valve jammed with ice. air tanks drained in freezing weather.
9. Faulty magnetic valve. 9. Replace.
10. Faulty air cylinder or vacuum 10. Replace.
chamber.
11. Broken wire in wiring harness. 11. Repair.
Exhaust Brake Slow 1. Tight exhaust manifold valve or 1. Free up and lubricate.
to Operate relay crank.
2. Improperly adjusted accelerator or 2. Adjust.
clutch switches.
Weak Braking Action 1. Improperly adjusted or tight exhaust 1. Free up and/or adjust. Lubricate as
manifold valve. needed.
2. Tight relay crank. 2. Free up and lubricate.
3. Air or vacuum lines kinked or 3. Repair. In freezing weather, keep air
partially plugged with ice. tanks drained.
4. Leaking fittings at air lines or 4. Tighten.
vacuum lines.
5. Leaky air cylinder or vacuum 5. Replace.
chamber.
Exhaust Brake Will 1. Seized relay crank or exhaust 1. Free up and lubricate.
Not Shut Off manifold valve.
2. Magnetic valve or air cylinder 2. Melt ice and drain lines. Keep air
jammed with ice. tanks drained in freezing weather.
3. Short in wiring harness. 3. Repair.
4. Faulty control switch. 4. Replace.
Exhaust Brake “ON” 1. Improperly adjusted clutch or 1. Adjust.

Continuously When accelerator switches.
Control Switch Is 2. Switches improperly wired. 2. Check wiring against wiring diagram.
“ON” (Not Controlled Repair as needed.
by Clutch or
3. Short in wiring harness. 3. Repair.
Accelerator Switches)
EXHAUST BRAKE (CONT.)

Engine Overheats or 1. Exhaust manifold valve stuck 1. Free up and lubricate or replace.
Loses Power partially closed.
2. Exhaust manifold valve adjusted so 2. Adjust.
that it is partially closed.
MAIN DATA AND SPECIFICATIONS

Air Brakes
VEHICLE MODEL
ALL MODELS
ITEMS
Drum inside diameter mm (in)
: Front 410 (16.1)
: Rear 410 (16.1)
Lining dimensions mm (in)
(Width x Thickness) : Front 140 x 16 (5.5 x 0.6)
: Rear
Forward 180 x 16 (7.1 x 0.6)
Rearward 180 x 16 (7.1 x 0.6)
Pedal free play RHD/LHD mm (in) 10 – 14 (0.39 – 0.55) / 9 – 14 (0.35 – 0.55) (Reference)
Lining clearance mm (in) 0.3 (0.01)
Power chamber stroke mm (in) 25 – 30 (0.98 – 1.18)
Spring chamber stroke mm (in) 27 – 32 (1.06 – 1.26)
Normal air pressure kPa (kg / cm2 / psi) 735 – 834 (7.5 – 8.5 / 107 – 121)
Low pressure switch
acting pressure kPa (kg / cm2 / psi) 520 (5.3 / 75) or less
Air governor acting
pressure kPa (kg / cm2 / psi) open at 834 (8.5 / 121)
close at 735 (7.5 / 107)
Safety valve opening
pressure kPa (kg / cm2 / psi) 883 (9.0 / 128)
Air Compressor and Governor

ITEMS DESCRIPTION
Type Reciprocating
Cooling method Water
Bore x stroke mm (in) 85 x 60 (3.35 x 2.36)
Number of piston rings Compression: 2 / Oil: 1 or 2
Capacity lit (in3 / rev) 0.34 (20.7)
Drive method Gear
Ratio To 1 0.5
Unloader valve operation
Governor pressure kPa (kg / cm2 / psi ) 735 – 834 (7.5 – 8.5 / 107 – 121)
Exhaust Brake
ENGINE MODEL
6S 6H
ITEMS
Type Electric and air control.
Butterfly valve, with intake shutter.
Location, exhaust brake valve Between exhaust manifold and pipe.
Exhaust brake valve inside diameter mm (in) 80 (3.15) 75 (2.95)
Exhaust brake valve operating angle degree 60
Control cylinder inside diameter mm (in) 30 (1.18)
Control cylinder effective stroke mm (in) 50 (1.97)
SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT
Wheel Brake
Brake Drum Inside Diameter mm (in) 410.0 (16.14) 414.0 (16.30)
Brake Drum Run-Out mm (in) 0.05 (0.00197) or less 0.20 (0.008)
Brake Lining Thickness mm (in) 0.5 (0.0197)
Clearance between Anchor Pin Bushing
Inside Diameter and Anchor Pin
Diameter mm (in) 0.10 (0.0039) 0.25 (0.0098)
Clearance between Camshaft
and Bushing mm (in) 0.05 – 0.11 (0.0020 – 0.0043) 0.6 (0.0236)
Brake Pedal
Clearance between Pin and
Bushing mm (in) 0.015 – 0.086 (0.0006 – 0.0034) 0.4 (0.0157)
Clearance between Roller and Pin mm (in) 0.015 – 0.108 (0.0006 – 0.0043) 0.25 (0.0098)
Clearance between Plunger and
Bushing mm (in) 0.49 (0.0193)
Air Compressor
Cylinder Bore Uneven Wear mm (in) 0.1 (0.004)
Clearance between Cylinder Bore
and Piston mm (in) 0.07 – 0.12 (0.0028 – 0.0047) 0.2 (0.008)
Clearance between Piston and
Piston Pin mm (in) 0.006 – 0.026 (0.0002 – 0.0010) 0.1 (0.004)
Clearance between Piston Ring
and Piston Ring Groove mm (in)
Compression Ring 0.02 – 0.05 (0.0008 – 0.0020) 0.15 (0.0060)
Oil Ring 0.03 – 0.07 (0.0012 – 0.0028) 0.15 (0.0060)
Piston Ring Gap mm (in)
Compression Ring 0.15 – 0.30 (0.006 – 0.012) 1.0 (0.039)
Oil Ring 0.15 – 0.35 (0.006 – 0.014) 1.0 (0.039)
Clearance between Connecting
Rod Small End and Piston Pin mm (in) 0.006 – 0.026 (0.0002 – 0.0010) 0.1 (0.004)
Clearance between Connecting Rod
Big End Bearing and Crankpin mm (in) 0.034 – 0.075 (0.0013 – 0.0030 0.15 (0.006)
MEMO
SERVICING
CONTENTS
PAGE
Air Brakes .......................................................................................................................... 00- 18
Brake Pedal Free Play and Adjustment ...................................................................... 00- 18
Lining Clearance Adjustment and Wear..................................................................... 00- 18
Cleaning of Exhaust Port ............................................................................................. 00- 19
Water Drain ................................................................................................................... 00- 20
Greasing Up for Camshaft and Slack Adjuster.......................................................... 00- 20
Air Dryer ........................................................................................................................ 00- 21
Load Sensing Proportioning Valve (L. S. P. V.) Adjustment (for South Africa only) .... 00- 22
Exhaust Brake ................................................................................................................... 00- 23
Exhaust Brake Adjustment.......................................................................................... 00- 23
SERVICING
AIR BRAKES
Brake Pedal Free Play and Adjustment
Brake Pedal (RHD)

Turn the adjusting screw all the way out, then turn it
in just enough, so that brake pedal free play (stroke of
pedal until a resistance is felt) is adjusted to 12 – 23
mm. Fully tighten the lock nut when a correct
adjustment is obtained.
Pedal Free Play mm (in)
RHD 10 – 14 (0.39 – 0.55)
LHD 9 – 14 (0.35 – 0.55) (Reference)
Lining Clearance Adjustment and Wear

Push Rod
Push Rod Stroke: mm (in)
Standard Limit
25 – 30
Front brake 40 (1.57)
(0.98 – 1.18)
Forward rear 27 – 32
47 (1.85)
Rearward rear (1.06 – 1.26)
Lining Clearance
Lining clearance: 0.3 mm (0.01 in)
By adjusting the push rod stroke, the specified lining
clearance can be obtained.
Lining Wear
The brake lining clearance is adjusted to
approximately 0.3 mm when the standard push-rod
travel is obtained. If the projected portion of the
indicator comes into contact with the stopper when
the worm shaft is turned for adjustment, it is an
indication that the linings have been worn to the limit
and lining replacement should be made.
Remove the check hole rubber cap on the brake

backing plate, and check the brake linings for wear
through the check hole.
If the brake linings are completely worn at their
projected ends, it shows the time to replace them.
Cleaning of Exhaust Port
Brake Valve
Relay Valve
Water Drain
Air Tank
Greasing Up for Camshaft and Slack

Adjuster
Front Wheel Brake
Each wheel 2 points.
Rearward Rear Axle

Each wheel 2 points.
Air Dryer
Maintenance
1. Be sure to check the air drain every three (3)
months or every 20,000 km, whichever comes fast.
Inspect for moisture in the air system by opening
drain valve and checking for presence of water. In
areas where more than approximately a 16˚C
(61˚F) range of temperature is common, small
amounts of water can accumulate in the air brake
system due to condensation. The presence of
small amounts of water due to condensation is
normal and should not be considered as an
indication that the dryer is not performing
properly. The desiccant should be replaced when
it has been determined that the desiccant is
contaminated and does not have adequate water
adsorption capacity.
Excessive oil in the air drain indicates that the air
compressor requires attention.
2. Replace the desiccant, filters and gaskets once
every year or every 100,000 km, whichever comes
fast.
3. Take care to ensure that the drain port is not
blocked or obstructed by foreign material.
Load Sensing Proportioning Valve (L.S.P.V.)

Adjustment
FVR Model (for South Africa only) :
1. Set the specific rear axle load as below.
Model Rear axle set load

FVR23G 26625N / 2715kg / 5985lb
FVR23P 32310N / 3295kg / 7265lb
2. Align the mark (•) on the valve body and the

indicator pointer, by adjusting the length of the link
rod.
FVZ Model (for South Africa only) :

NOTE:
This adjustment should be performed under noload
condition.
1. Adjust the rod length between the forward rear
axle and the rearward rear axle.
The notch of the rod should be flush with the end
face of the joint.
Then tighten the lock nut.
indicator pointer by adjusting the length of the link
rod.
GVR Model (for Australia only) :

indicator pointer by adjusting the length of the link
rod, on the unloaden vehicle.
EXHAUST BRAKE
Exhaust Brake Adjustment
Brake Valve
Adjust it to the value specified below, using the
stopper bolt.
When valve is open:
Parallelness between butterfly valve and tube inner
surface: ± 2 degrees
When valve is completely closed, with lever

contacting with stopper clearances are following.
Clearance mm (in)
For 6HE1 Except 6HE1
The respective
0.3 – 0.5 0.2 – 0.4
clearances of the
(0.012 – 0.020) (0.008 – 0.016)
points A and B
The average clearance 0.3 – 0.4 0.2 – 0.3
of the points A and B (0.012 – 0.016) (0.008 – 0.012)
Accelerator Switch
Adjust the clearance “A” with adjust nut.
Clearance: A mm (in)
Standard 10 – 12 (0.39 – 0.47)
The accelerator switch is installed within the cab and
is interlocked with the accelerator pedal.
Clutch Switch (Mechanical Type)

The clutch switch is installed on the upper part of the
clutch pedal.
Exhaust Brake Switch

Pull the lever type exhaust brake switch on the
steering column and check that the indicator lamp on
the instrument panel operates.
Wiring
A continuity should exist across the switch terminals
when both of the accelerator pedal and clutch pedal
are released, and continuity should not exist when
either of the pedals is depressed.
Accelerator switch should be checked after
completing idling adjustment.
Magnetic Valve
With a circuit tester check for open coil.
FIXING TORQUE
Front Wheel Brake N·m (kg·m / lb·ft)
185 (18.9/137)
515 (52.5/380)
Rear Wheel Brake N·m (kg·m / lb·ft)

Brake Valve (RHD) N·m (kg·m / lb·in)
16 (1.6 / 12 lb·ft)
7 (0.7 / 61)
2 (0.2 / 17) 7 (0.7 / 61)
7 (0.7 / 61)
7 (0.7 / 61)
334MT001
Spring Chamber N·m (kg·m / lb·ft)

Air Compressor N·m (kg·m / lb·ft)

SPECIAL TOOLS
PART NO. SERVICE

ILLUSTRATION PART NAME
ISUZU BRAKE
9-8522-1231-0
Brake shoe spring
(Included kit No. ●
installer
9-8523-1554-0)
Brake shoe spring

1-8523-7002-0 ●
remover
Brake shoe spring

1-8523-7013-0
remover & installer
●
(Leading/Trailing type
9-8523-1560-0
rear wheel only)
Anchor pin puller

9-8521-0095-0 (Leading/Trailing type ●
only)
AIR BRAKES 5B-1
SECTION 5B
AIR BRAKES
CONTENTS
PAGE
General Description.......................................................................................................... 5B- 3
Precautions in Handling the Nylon Tube ........................................................................ 5B- 24
Front Wheel Brake Assembly .......................................................................................... 5B- 26
Disassembly .................................................................................................................. 5B- 26
Inspection and Repair .................................................................................................. 5B- 28
Reassembly ................................................................................................................... 5B- 31
Rear Wheel Brake Assembly............................................................................................ 5B- 34
Disassembly .................................................................................................................. 5B- 34
Reassembly ................................................................................................................... 5B- 40
Brake Valve and Pedal (RHD model) ............................................................................... 5B- 44
Removal......................................................................................................................... 5B- 44
Installation .................................................................................................................... 5B- 45
Brake Valve and Pedal (LHD model) ............................................................................... 5B- 46
Removal and Installation ............................................................................................. 5B- 46
Brake Valve (RHD model) ................................................................................................. 5B- 50
Disassembly .................................................................................................................. 5B- 50
Reassembly ................................................................................................................... 5B- 56
Brake Valve (LHD model) ................................................................................................. 5B- 60
Disassembly .................................................................................................................. 5B- 60
Reassembly ................................................................................................................... 5B- 64
Operation Test .............................................................................................................. 5B- 67
5B-2 AIR BRAKES
PAGE
Power Chamber ................................................................................................................ 5B- 71
Removal......................................................................................................................... 5B- 71
Installation .................................................................................................................... 5B- 72
Disassembly .................................................................................................................. 5B- 73
Reassembly ................................................................................................................... 5B- 75
Spring Chamber................................................................................................................ 5B- 77
Removal......................................................................................................................... 5B- 77
Installation .................................................................................................................... 5B- 78
Disassembly .................................................................................................................. 5B- 80
Reassembly ................................................................................................................... 5B- 84
Air Circuit Parts................................................................................................................. 5B- 88
Air Dryer (DR-5 type) ........................................................................................................ 5B- 95
Disassembly .................................................................................................................. 5B- 95
Reassembly ................................................................................................................... 5B- 99
Operational Tests.......................................................................................................... 5B-102
Air Dryer (DR-7 type) ........................................................................................................ 5B-103
Disassembly .................................................................................................................. 5B-103
Inspection and Repair .................................................................................................. 5B-104
Reassembly ................................................................................................................... 5B-105
Operational Test ........................................................................................................... 5B-108
AIR BRAKES 5B-3
GENERAL DESCRIPTION
Full Air Brake System
FTR
2
1
11
9 10 15
16 3
C D
12 20
17 10
A B
24 9
8 4
PRI
SEC 20
25 7 17
AIR LINE 22
22
22
13 14
17
20 10 10
16 15
9 9
5 6
20 20
ACC LINE
FLEX HOSE 21
1
AIR PIPE (‫ޓ‬6.35) 2
AIR PIPE (‫ޓ‬8) Air Dryer
AIR PIPE (‫ޓ‬10)
AIR PIPE (‫ޓ‬12) CIRCUIT A , B VALVE PRESSURE(OPEN) ; 570kPa
AIR PIPE (‫ޓ‬15) (SHUT) ; 440kPa
NYLON TUBE (12X1.5) CIRCUIT C , D VALVE PRESSURE(OPEN) ; 570kPa
NYLON TUBE ( 8X1.0) (SHUT) ; 440kPa
NYLON TUBE of STANDARD DIN No.12 ; VALVE PRESSURE
NO PART NAME NO PART NAME

1 Air Compressor 16 Power Chamber
2 Air Charge Governor 17 Relay Valve
3 Air Reservoir-Supply (20.0 ) 18
4 Air Reservoir-Service Brake; Prim (20.0 ) 19
5 Air Reservoir-Service Brake; Sec(20.0 ) 20 Test Connector
6 Air Reservoir-Spring(20.0 ) 21 Air Dryer(Option)
7 Dual Brake Valve 22 Quick Release Valve
8 Dual Air Pressure Gauge 23
9 Check Valve 24 Pressure Switch(Prim)
10 Low Pressure Switch (Air Reservoir) 25 Pressure Switch(Sec)
11 Safety Valve 26
12 MULTI Protection Valve(with Check Valve C ‫ޓ‬
,D) 27
13 Parking Brake Control Valve 28
14 Parking Brake Switch 29
15 Power Chamber with Spring Brake
5B-4 AIR BRAKES
FVR (General)
10
11
9 9
6 3
2
15
16 10 9 10
17 4 5
21
24
8
25 7 17
14
AIR SUS
SEAT
(OPTION) 1
22
18
13
16 17 15
23 EXH BRK CYL

FLEX HOSE MINIPACK
AIR PIPE (Ǿ6.35) T/M
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)
AIR PIPE (Ǿ12)
AIR PIPE (Ǿ15)
NYLON TUBE (12X1.5)
NYLON TUBE ( 8X1.0)
NYLON TUBE of DIN STANDARD

1 Air Compressor 15 Power Chamber with Spring Brake
2 Air Charge Governor 16 Power Chamber
3 Air Reservoir-Supply (28.5 ) 17 Relay Valve
4 Air Reservoir-Service Brake; Prim (19.5 ) 18 Duble Check Valve
5 Air Reservoir-Service Brake; Sec (19.5 ) 19
6 Air Reservoir-Spring Brake (11 ) 20
7 Dual Brake Valve 21 Air Dryer (Option)
8 Dual Air Pressure Gauge 22 Quick Release Valve
9 Check Valve 23 Magnetic Valve (Exh Brake)
10 Low Pressure Switch (Air Reservoir) 24 Pressure Switch (Prim)
11 Safety Valve 25 Pressure Switch (Sec)
12
13 Parking Brake Control Valve
14 Parking Brake Switch
AIR BRAKES 5B-5
FVR (ADR Regulation)
10
11
9 9
6 3
2
12 15
16 10 9 10
20
17 4 5
21
8 24
20 20
25 7 17
14
AIR SUS
SEAT 22
1
(OPTION)
22
18 22
13
20
16
19 17 15
23 EXH BRK CYL

FLEX HOSE MINIPACK
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)
AIR PIPE (Ǿ12)
AIR PIPE (Ǿ15)
NYLON TUBE (12X1.5)
NYLON TUBE ( 8X1.0)

5 Air Reservoir-Service Brake; Sec (19.5 ) 19 Load Sensing Proportioning Valve (Option)
6 Air Reservoir-Spring Brake (11 ) 20 Test Connector
7 Dual Brake Valve 21 Air Dryer (Option)
12 1 Way Protection Valve (Set Pressure 480kPa)
14 Parking Brake Switch 㩔
5B-6 AIR BRAKES
FVR ('03MY Australia)
2
1 12
11
9 10 15
16 3 C D
12 20
17 10
A B
24 9
8 4
PRI
SEC 20
25 7 17
AIR LINE 22
22
22
18
13 14
17
20 10 10
16 15
9 9
5 6
20 20
ACC LINE
FLEX HOSE
AIR PIPE ( 6.35)
AIR PIPE ( 8)
AIR PIPE ( 10)
AIR PIPE ( 12) CIRCUIT A , B VALVE PRESSURE(OPEN) ; 570kPa
AIR PIPE ( 15) (SHUT) ; 440kPa

3 Air Reservoir-Supply (20.0 ) 18 Double Check Valve
6 Air Reservoir-Spring(20.0 ) 21 Air Dryer
11 Safety Valve 26
12 MULTI Protection Valve(with Check Valve‫ޓޓ‬
C, D) 27
AIR BRAKES 5B-7
FVR (EC Regulation)

10
11
9 9
6 3
2
20
A B 15
16 10 12
9 10 C D
20
17 4 5
20 9
8 24
20
25 7 17
14
AIR SUS
SEAT
1
(OPTION)
22
18
13
16 20
19 17
20 20 15
23 EXH BRK CYL

FLEX HOSE MINIPACK
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)
AIR PIPE (Ǿ12)
AIR PIPE (Ǿ15) CIRCUIT A , B , VALVE PRESSURE (OPEN) ; 600kPa
NYLON TUBE (12X1.5) (SHUT) ; 450kPa
NYLON TUBE ( 8X1.0) CIRCUIT C , D , VALVE PRESSURE (OPEN) ; 500kPa
(SHUT) ; 400kPa
NO.12;VALVE PRESSURE

5 Air Reservoir-Service Brake; Sec (19.5 ) 19 Load Sensing Proportioning Valve (Option)
6 Air Reservoir-Spring Brake (11 ) 20 Test Connector
7 Dual Brake Valve 21
12 4 Way Protection Valve
5B-8 AIR BRAKES
FVD
2
1
11
9 15
16 3 C D 26 20
12 10
17 A B
24 9
8 4
PRI
SEC 20
25 7 17
AIR LINE 22
22
18 22
13 14
26 17
20 10 10
16 15
9 9
5 6
20 20
ACC LINE
FLEX HOSE 21
1
AIR PIPE (Ǿ6.35) 2
AIR PIPE (Ǿ8)
Air Dryer(option)
AIR PIPE (Ǿ10)
AIR PIPE (Ǿ12) CIRCUIT A , B VALVE PRESSURE(OPEN) ; 570kPa
AIR PIPE (Ǿ15) (SHUT) ; 440kPa

4 Air Reservoir-Service Brake; Prim (19.5 ) 19 Load Sensing Proportional Valve(Option)
5 Air Reservoir-Service Brake; Sec (19.5 ) 20 Test Connector
6 Air Reservoir-Spring (19.5 ) 21 Air Dryer(Option)
11 Safety Valve 26 Levelling Valve
12 C , D ) 27
MULTI Protection Valve(with Check Valve‫ޓޓ‬
AIR BRAKES 5B-9
FVD ('03 MY Australia)
2
1
21
11
9 15
10
16 3 C D
12 20
17 10
A B
24 9
8 4
PRI
SEC 20
25 7 17
AIR LINE 22
22
18 22
13 14
17
20 10 10
16 15
9 9
5 6
20 20
ACC LINE
FLEX HOSE
AIR PIPE (Ǿ6.35)
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)

6 Air Reservoir-Spring (20.0 ) 21 Air Dryer(Option)
11 Safety Valve 26
12 MULTI Protection Valve(with Check Valve ‫ޓޓ‬
C,D ) 27
5B-10 AIR BRAKES
FVM (General)
10
11
9 2
6 3
9
15 15
16
25 14
7 17 4
8
9 9 17
26 5
17
13 17
16
15 15
22 EXH BRK CYL

FLEX HOSE MINIPACK
AIR PIPE (Ǿ6.35)
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)
AIR PIPE (Ǿ12)
AIR PIPE (Ǿ15)
NYLON TUBE (12X1.5)
NYLON TUBE ( 8X1.0)
NYLON TUBE of STANDARD DIN

5 Air Reservoir-Service Brake; Sec (19.5 ) 19
6 Air Reservoir-Spring Brake (11 ) 20
7 Dual Brake Valve 21
8 Dual Air Pressure Gauge 22 Magnetic Valve (Exh Brake)
9 Check Valve 23
10 Low Pressure Switch (Air Reservoir) 24
11 Safety Valve 25 Pressure Switch (Prim)
12 26 Pressure Switch (Sec)
AIR BRAKES 5B-11
FVM,FVZ (ADR Regulation)
10
9 11 20
3 6 9 9
(SUP) (SPR) 5 (SEC)
16 10 C B 15 15
2 14
12
10 20 A D
22 17 22
24 9
PRI
7 4 (PRI) 22 22
8 SEC
25
17
ACC LINE 18
1 17 17
19
22 22 22
13
20 20
16 20 ACC LINE 15 15
FLEX HOSE
1 21
AIR PIPE (Ǿ6.35) 2
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)
AIR PIPE (Ǿ12)
CIRCUIT A , B , VALVE PRESSURE (OPEN) ; 570kPa
AIR PIPE (Ǿ15)
(SHUT) ; 440kPa
NYLON TUBE (12X1.5)
CIRCUIT C , D , VALVE PRESSURE (OPEN) ; 570kPa
NYLON TUBE of STANDARD DIN NO.12;VALVE PRESSURE

4 Air Reservoir-Service Brake; Prim (35.0 ) 19 Load Sensing Proportioning Valve (Option)
6 Air Reservoir-Spring Brake (19.5 ) 21 Air Dryer (Option)
9 Check Valve 24 Pressure Switch (Prim)
10 Low Pressure Switch (Air Reservoir) 25 Pressure Switch (Sec)
11 Safety Valve
12 MULTI Protection Valve
14 Pressure Switch (Parking Brake)
5B-12 AIR BRAKES
FVM('03MY Australia)
10 10
9 11 20
3 6 9 9
(SUP) (SPR) 5 (SEC)
16 15 15
10 C B
2 14
12
10 20 A D
9 22 17 22
24
PRI 4 (PRI) 22 22
8 SEC 7
25 21
17
ACC LINE
1 17 17
22 22 22
13
20 20 20
16 ACC LINE 15 15
FLEX HOSE
AIR PIPE (Ǿ6.35)
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)

3 Air Reservoir-Supply (20.0 ) 18
6 Air Reservoir-Spring(19.5 ) 21 Air Dryer
11 Safety Valve
14 Pressure Switch(Parking Brake)
AIR BRAKES 5B-13
FVZ ('03 MY Australia)
10 10
9 11 20
3 6 9 9
(SUP) (SPR)
16 15 15
10 C D
2 14
12
10 20 A B
9 22225 518.559019 519.108
221l424.323 18.559023 18.559
24
PRI
8 7 22 22
SEC
25 21
18
ACC LINE
1 17 17
22 22 22
13
20 20 20
16 ACC LINE 15 15
FLEX HOSE
AIR PIPE (Ǿ6.35)
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)
AIR PIPE (Ǿ12)
CIRCUIT A , B VALVE PRESSURE(OPEN) ; 570kPa
AIR PIPE (Ǿ15)
(SHUT) ; 440kPa
NYLON TUBE (12X1.5)
CIRCUIT C , D VALVE PRESSURE(OPEN) ; 570kPa

6 Air Reservoir-Spring (19.5 ) 21 Air Dryer
11 Safety Valve
AIR BRAKES 5B-15
FVL, FVY('03MY Australia)
10 10
9 11 20
3 6 9 9
(SUP) (SPR) 5 (SEC)
16 15 15
10 C B
2 14
12
10 20 A D
9 22 17 22
24
PRI 4 (PRI) 22 22
8 SEC 7
25 21
17 16
ACC LINE
1 17 17
22 22 22
13
20 20 20
16 ACC LINE 15 15
FLEX HOSE
AIR PIPE (Ǿ6.35)
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)

11 Safety Valve
AIR BRAKES 5B-15
FVL, FVY('03MY Australia)
10 10
9 11 20
3 6 9 9
(SUP) (SPR) 5 (SEC)
16 15 15
10 C B
2 14
12
10 20 A D
9 22 17 22
24
PRI 4 (PRI) 22 22
8 SEC 7
25 21
17 16
ACC LINE
1 17 17
22 22 22
13
20 20 20
16 ACC LINE 15 15
FLEX HOSE
AIR PIPE (Ǿ6.35)
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)

11 Safety Valve
5B-16 AIR BRAKES
GVR (ADR Regulation)
10 20 9
11
9 9
6 3
2
15
16 10 9 10 C D
12 20
17 4 5 A B
24 9
8 PRI 20 20
SEC
25 7 17
14
CONTROL 1
ACC LINE 28 22
29 22
26 18 27 23 22
28 22
SUPPLY 18
13
20
22 19 17
16 15
ACC LINE
FLEX HOSE
FLEX HOSE 21
1
2
AIR
AIR PIPE PIPE (Ǿ6.35)
(Ǿ6.35)
AIR
AIR PIPE PIPE (Ǿ8)
(Ǿ8) Air Dryer(option)
AIR PIPE (Ǿ10) Ǿ
AIR PIPE (Ǿ12)
CIRCUIT A , B , VALVE PRESSURE (OPEN) ; 570kPa
AIR PIPE (Ǿ15)
(SHUT) ; 440kPa
NYLON TUBE (12X1.5)
CIRCUIT C , D , VALVE PRESSURE (OPEN) ; 570kPa
NO.12;VALVE PRESSURE
NYLON TUBE of STANDARD DIN

4 Air Reservoir-Service Brake; Prim (19.5 ) 19 Load Sensing Proportioning Valve
6 Air Reservoir-Spring & Trailer Brake (19.5 ) 21 Air Dryer (Option)
8 Dual Air Pressure Gauge 23 Pressure Switch (Trailer)
11 Safety Valve 26 Trailer Hand Brake
12 MULTI Protection Valve (with Check Valve C , D) 27 Trailer Control Valve
13 Parking Brake Control Valve 28 Air Cock
14 Parking Brake Switch 29 Trailer Switch
AIR BRAKES 5B-17
GVR('03MY Australia)
10 20 9 10
11
9 9
6 3
2
15
16 10 9 10 C D 21
12 20
17 4 5 A B
24 9
8 PRI 20 20
SEC
25 7 17
14
CONTROL 1
ACC LINE 28 22
29 22 22
26 18 27 23
22
28 22
SUPPLY 18
13
30
20
19 17 15
16
ACC LINE
FLEX HOSE
AIR PIPE (Ǿ6.35)
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)
AIR PIPE (Ǿ12) CIRCUIT A , B , VALVE PRESSURE(OPEN) ; 570KPa
AIR PIPE (Ǿ15) (SHUT) ; 440KPa
NYLON TUBE (121.5) CIRCUIT C , D , VALVE PRESSURE(OPEN) ; 570KPa
NYLON TUBE ( 81.0) (SHUT) ; 440KPa
NYLON TUBE OF STANDARD DIN NO.12 ; VALVE PRESSURE

4 Air Reservoir-Service Brake;Prim (19.5 ) 19 Load Sensing Proportional Valve
5 Air Reservoir-Service Brake;Sec (19.5 ) 20 Test Connector
6 Air Reservoir-Spring&Trailer Brake (19.5 ) 21 Air Dryer
12 MULTI Protection Valve(With Check Valve C , D ) 27 Dual Relay Valve
15 Power Chamber with Spring Brake 30 Synchro Valve
5B-18 AIR BRAKES
GVD
10 20 9
11
9 9
6 3
2
15
16 10 9 10 C D
12 20
17 4 5 A B
24 9
8 PRI 20 20
SEC
25 7 17
14
CONTROL 1
ACC LINE 28 22
29 22 22
26 18 27 23
28 22
SUPPLY 18
13
20
22 19 17 15
16
ACC LINE
FLEX HOSE 21
1
2
AIR PIPE (Ǿ6.35)
AIR PIPE (Ǿ8) Air Dryer(option)
AIR PIPE (Ǿ10)

6 Air Reservoir-Spring&Trailer Brake (19.5 ) 21 Air Dryer (Option)
12 MULTI Protection Valve(With Check Valve C , D ) 27 Trailer Control Valve
AIR BRAKES 5B-19
GVD('03MY Australia)
10 20 9 10
11
9 9
6 3
2
15
16 10 9 10 C D 21 LEVELING
12 20
17 4 5 A B VALVE
24 9
8 PRI 20 20
SEC
25 7 17
14
CONTROL 1
ACC LINE 28 22
29 22 22
26 18 27 23
22
28 22
SUPPLY 18
13
30
20
19 17 15
16
ACC LINE
FLEX HOSE
AIR PIPE (Ǿ6.35)
AIR PIPE (Ǿ8)
AIR PIPE (Ǿ10)
NO PART NAME NO
6 Air Reservoir-Spring&Trailer Brake (19.5 ) 21 Air Dryer
12 MULTI Protection Valve(With Check Valve C , D ) 27 Dual Relay Valve
15 Power Chamber with Spring Brake 30 Synchro Valve
5B-20 AIR BRAKES
Wheel Brake Assembly
Both the front and the rear brakes are leading-trailing This allows the leading- trailing brake to work equally
type and manually adjusted. Leading-trailing brake well in either direction.
has one leading shoe and one trailing shoes. In Lining are riveted to the shoes.
essence, this brake design has one energized and one
Each shoe pivots on an anchor pin.
de-energized shoe regardless of whether it is applied
while the vehicle is traveling forward or in reverses. Each brake shoes has a bushing in the cast shoe
pivots.
AIR BRAKES 5B-21
Brake Valve
RHD RHD LHD

(For SouthAfrica)
334MY00002
The dual brake valve is a single assembly which Secondary Valve

simultaneously controls the brake systems at both The secondary valve senses the pressure being
the front and the rear wheels of the vehicle. This delivered to the primary system and delivers a nearly
ensures vehicle safety at all times. equivalent air pressure to the secondary system relay
Depressing the brake pedal causes the dual brake valve.
valve to supply the appropriate air pressure to the Should the primary control valve become inoperative
relay valve. due to primary system piping damage, the secondary
The dual brake valve consists of the primary and valve will continue to operate in response to the force
secondary control valves. Each of these valves has applied to the brake pedal.
an air supply port to supply air from the air tank and
a discharge port to deliver air to the relay valve.
Primary Valve
The primary valve controls the air pressure being
delivered to the primary system. The amount of air
pressure delivered is directly proportional to the
force applied to the brake pedal.
5B-22 AIR BRAKES
Power Chamber Spring Chamber (JKC made)
Spring Brake Valve (Lever Type) Load Sensing Proportioning Valve
Quick Release Valve Dual Relay Valve

AIR BRAKES 5B-23
Relay Valve Pressure Control Valve
Double Check Valve Synchro Valve
WARNING
WHEN SERVICING WHEEL BRAKE PARTS, DO
NOT CREATE DUST BY GRINDING OR
SANDING BRAKE LININGS OR BY CLEANING
WHEEL BRAKE PARTS WITH A DRY BRUSH OR
WITH COMPRESSED AIR. MANY WHEEL
BRAKE PARTS CONTAIN ASBESTOS FIBERS,
WHICH CAN BECOME AIRBORNE IF DUST IS
CREATED DURING SERVICING. BREATHING
DUST CONTAINING ASBESTOS FIBERS MAY
CAUSE SERIOUS BODILY HARM. A WATER-
DAMPENED CLOTH OR WATER-BASED
SOLUTION SHOULD BE USED TO REMOVE
ANY DUST ON BRAKE PARTS. EQUIPMENT IS
COMMERCIALLY AVAILABLE TO PERFORM
THIS WASHING FUNCTION. THESE WET
METHODS WILL PREVENT ASBESTOS FIBERS
FROM BECOMING AIRBORNE.
5B-24 AIR BRAKES
PRECAUTIONS IN HANDLING
THE NYLON TUBE
1. In body mounting or repair operations, be careful
not to expose the nylon tube to heat higher than
the highest range.
Usable temperature range –40°C to + 100°C
• Before making a hole, welding, soldering or
sanding protect the nylon tube from the heat
source, sparks or dismount it.
• Do not install the clamp of the welding equipment
near the nylon tube.
• When it is expected that the heat may be higher
than the highest range, for example before
painting or drying, dismount the nylon tube.
2. Exercise care so as to keep the nylon tube from
contacting acidic fluid, such as battery electrolyte.
The nylon tube must be replaced if it comes into
contact with acidic fluid.
3. When transporting or storing the nylon tube, roll it
allowing a diameter of at least 600 mm to prevent
fiber deformation due to tight rolling.
4. The nylon tube should be stored so as to prevent
penetration by foreign objects. Before installation,
be sure to clean the inside (using an air blower,
etc.) to eliminate dirt, dust, etc.
Nylon Tube Installation Procedure Configuration

1. Connector body
5 4 3 2 1
2. V-seal (O-ring)
3. Collet
4. Insert
5. Nylon tube
5 4 3 2 1
370HW004
AIR BRAKES 5B-25
Disconnecting the nylon tube

1. Before disconnecting the nylon tube, put the
Mark
setting mark on the nylon tube as figure.
370HW002
2. Push the tip of collet toward the connector body,

and pull the nylon tube.
370HW003
Visual check
Less than 1mm(0.04in) 1. Inspect the tip of nylon tube for burrs, sharp edges
and deform.
2. Inspect the tip of nylon tube squareness.
It must be less than 1mm (0.04in).
370HW006
12mm(0.48in) 3. Inspect the V-seal (0-ring) contact surface as

shown in illustration.
The V-seal (0-ring) contact surface must be free
from damage and foreign matters.
370HW005
Connecting the nylon tube

1. Insert the nylon tube into the connector until
setting mark.
2. Check for air leakage.
If it is found, push the nylon tube toward the
connector.
3. If the leakage still continues, replace the nylon tube
or connector with new items.
370HW001
5B-26 AIR BRAKES
FRONT WHEEL BRAKE ASSEMBLY

DISASSEMBLY
Front Wheel Brake Assembly
Disassembly Steps
1. Return spring 11. Cotter pin, washer and pin
2. Bolt 12. Power chamber
3. Lock washer 13. Snap ring
4. Lock plate 14. Stopper plate
5. Backing plate 15. Spacer
6. Anchor pin 16. Slack adjuster
7. Brake shoe assembly 17. Collar
8. Snap ring 18. Camshaft
9. Pin 19. Anchor pin bracket
10. Roller
AIR BRAKES 5B-27
Disassembly Steps
1. Return Spring
Remover: 1-8523-7002-0
2. Bolt
3. Lock Washer
4. Lock Plate
5. Backing Plate
6. Anchor Pin
The anchor pin can be removed easily by using a
anchor pin puller.
Anchor pin puller; 9-8521-0095-0
7. Brake Shoe Assembly

8. Snap Ring
9. Pin
10. Roller
11. Cotter Pin, Washer and Pin
12. Power Chamber
13. Snap Ring
14. Stopper Plate
15. Spacer
16. Slack Adjuster
17. Collar
18. Camshaft
19. Anchor Pin Bracket
5B-28 AIR BRAKES
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered
during inspection.
Brake Drum
Brake Drum Inside Diameter

Visually inspect the brake drum for excessive wear
and scoring.
If the brake drum is scored or worn, lathe to the
specified limit.
Use a vernier caliper to measure the brake drum
inside diameter.
If the brake drum inside diameter exceeds the
specified limit, it may be increased by 4 mm (0.157 in).
Oversize brake linings are available as service parts.
Brake Drum Inside Diameter mm (in)
Standard Limit
410.0 (16.14) 414.0 (16.30)
Brake Drum Run-Out mm (in)

Standard Limit
0.05 (0.00197) or less 0.20 (0.008)
Brake Lining
Brake Lining Thickness
Use a vernier caliper to measure the brake lining
thickness (rivet depth).
If the measured value is less than the specified limit,
the brake lining must be replaced.
Clearance to Rivet Head (Rivet Depth) mm (in)
Limit 0.5 (0.0197)
1 Rivet depth
2 Lining height
3 Rivet
4 Lining
5 Brake shoe
AIR BRAKES 5B-29
Brake Lining Replacement

Brake Lining Removal
1. Remove the rivet caulking portions with a hammer
and chisel.
2. Remove the rivets with a hammer and punch.
3. Inspect the brake shoe for cracking.
Brake Lining Installation

1. Install the brake lining and the rivets to the brake
shoe.
2. Place the brake shoe assembly in the air hydraulic
riveter.
3. Use the air hydraulic riveter to set and caulk each
of the rivets.
4. Start rivetting at the center of lining and work
towards the ends.
Brake Lining and Drum Contact

1. Apply chalk powder to the entire inside brake drum
surface.
2. Place the brake shoe assembly in the inside brake
drum.
3. Move the brake shoe assembly around the inside
brake drum.
Check for uniform contact between the brake lining
and the brake drum.
4. Correct any areas having poor contact with
sandpaper.
WARNING:
SEE “WARNING” ON PAGE 5B-10 OF THIS SECTION.
5. Repeat Steps 1 through 4 until the contact between
the brake lining and the brake drum is perfect.
Brake Shoe Return Spring

Use the spring balance to measure the return spring
tension.
Return Spring Specifications (for reference)
Rear
Front
Inner Outer
Free length (mm) 191 231 192
Set load / set length
56 / 212 25 / 258 41 / 212
(kg / mm)
5B-30 AIR BRAKES
Brake Shoe
Clearance between anchor pin bushing inside
diameter and anchor pin diameter.
mm (in)
Standard Limit
0.10 (0.0039) 0.25 (0.0098)
Camshaft
Clearance between camshaft and bushing
mm (in)
Standard Limit
0.05 – 0.11
0.6 (0.0236)
(0.0020 – 0.0043)
Slack Adjuster
Clearance between bushing and pin (for reference)
mm (in)
0.1
Standard
(0.0039)
AIR BRAKES 5B-31
REASSEMBLY
Front Wheel Brake Assembly
Reassembly Steps
1. Anchor pin bracket 11. Pin
2. Camshaft 12. Snap ring
3. Collar 13. Brake shoe assembly
4. Power chamber 14. Anchor pin
5. Slack adjuster 15. Backing plate
6. Pin, washer and cotter pin 16. Lock plate
7. Spacer 17. Lock washer
8. Stopper plate 18. Bolt
9. Snap ring 19. Return spring
10. Roller
5B-32 AIR BRAKES
Reassembly Steps
Apply molybdenum disulfide grease to the threads of
lower bolts before tightening.
Bolt Torque N·m (kg·m / lb·ft)
Upper side 185 (18.9 / 137)
Lower side 515 (52.5 / 380)
2. Camshaft
Apply grease to the shaft, and install it, making sure
that the arrow on the end face is outward (in the
forward direction of the vehicle).
3. Collar
4. Power Chamber
Mount the power chamber on the bracket, adjust the
push rod to 152 mm long, direct the jaw joint properly
and tighten the lock nut securely.
5. Slack Adjuster
Mount the slack adjuster on the camshaft in such a
way that the slack adjuster will properly engage the
push rod.
During this operation, do not change the push rod
length or turn the camshaft.
6. Pin, Washer and Cotter Pin
7. Spacer
8. Stopper Plate
Match the arrow on the camshaft end face with the
arrow on the top of the plate, and assemble them.
AIR BRAKES 5B-33
9. Snap ring
10. Roller
11. Pin
12. Snap ring
Fill the anchor pin groove and bushing with grease.
One gram per pin.
Be careful not to mistake the leading shoe for trailing
shoe or vice versa in mounting them.
The trailing shoe has recesses on the surface.
14. Anchor pin

15. Backing plate
16. Lock plate
17. Lock Washer
18. Bolt
After tightening the bolts, bend the lock washers
securely.
19. Return Spring

Remover and installer: 9-8522-1231-0
After assembly, adjust the lining clearance and grease

the brakes, referring to the paragraph on servicing.
5B-34 AIR BRAKES
REAR WHEEL BRAKE ASSEMBLY

DISASSEMBLY
Rear Wheel Brake Assembly
Disassembly Steps
1. Outer return spring 11. Roller
2. Snap ring, pin and inner return 12. Cotter pin, washer and pin
spring 13. Spring chamber
3. Bolt 14. Snap ring
4. Lock washer 15. Stopper plate
5. Lock plate 16. Spacer
6. Backing plate 17. Slack adjuster
7. Anchor pin 18. Collar
8. Brake shoe assembly 19. Bracket
9. Snap ring 20. Camshaft
10. Pin 21. Anchor pin bracket
AIR BRAKES 5B-35
Disassembly Steps
1. Return Spring
Remover; 1-8523-7002-0
2. Snap Ring, Pin and Inner Return Spring

Remover and installer; 1-8523-7013-0
9-8523-1560-0
Hook the arm to the end of the spring from the inner
side and insert the handle to the arm, then turn the
handle to extend the spring and take out the spring.
3. Bolt
4. Lock Washer
5. Lock Plate
6. Backing Plate
7. Anchor Pin
The anchor pin can be removed easily by using a
anchor pin puller.
Anchor pin puller; 9-8521-0095-0

9. Snap Ring
10. Pin
11. Roller
13. Spring Chamber
14. Snap Ring
15. Stopper Plate
16. Spacer
17. Slack Adjuster
18. Collar
19. Bracket (Except Rearward)
5B-36 AIR BRAKES
20. Camshaft
AIR BRAKES 5B-37

during inspection.
Brake Drum
Brake Drum Inside Diameter
Visually inspect the brake drum for excessive wear
and scoring.
If the brake drum is scored or worn, lathed to the
specified limit.
Use a vernier caliper to measure the brake drum
inside diameter.
If the brake drum inside diameter exceeds the
specified limit, it may be increased by 4 mm (0.1575
in).
Oversize brake linings are available as service parts.
Brake Drum Inside Diameter mm (in)
Standard Limit
410.0 (16.14) 414.0 (16.30)
Brake Drum Run-Out mm (in)

Standard Limit
0.05 (0.00197) or less 0.20 (0.008)
Brake Lining
Brake Lining Thickness
Use a vernier caliper to measure the brake lining
thickness (rivet depth).
If the measured value is less than the specified limit,
the brake lining must be replaced.
Clearance to Rivet Head (Rivet Depth) mm (in)
Limit 0.5 (0.0197)
1 Rivet depth
2 Lining height
3 Rivet
4 Lining
5 Brake shoe
5B-38 AIR BRAKES
Brake Lining Replacement

Brake Lining Removal
1. Remove the rivet caulking portions with a hammer
and chisel.
2. Remove the rivets with a hammer and punch.
3. Inspect the brake shoe for cracking.
Brake Lining Installation

1. Install the brake lining and the rivets to the brake
shoe.
2. Place the brake shoe assembly in the air hydraulic
riveter.
3. Use the air hydraulic riveter to set and caulk each
of the rivets.
4. Start rivetting at the center of lining and work
towards the ends.
Brake Lining and Drum Contact

1. Apply chalk powder to the entire inside brake drum
surface.
2. Place the brake shoe assembly in the inside brake
drum.
3. Move the brake shoe assembly around the inside
brake drum.
Check for uniform contact between the brake lining
and the brake drum.
4. Correct any areas having poor contact with
sandpaper.
WARNING:
SEE “WARNING” ON PAGE 5B-10 OF THIS SECTION.
5. Repeat Steps 1 through 4 until the contact between
the brake lining and the brake drum is perfect.
Brake Shoe Return Spring

Use the spring balance to measure the return spring
tension.
Return Spring Specifications (For Reference)
Rear
Front
Inner Outer
Free length (mm) 191 231 192
Set load / set length
56 / 212 25 / 258 41 / 212
(kg / mm)
AIR BRAKES 5B-39
Brake Shoe
Clearance between anchor pin bushing inside
diameter and anchor pin diameter.
mm (in)
Standard Limit
0.10 (0.0039) 0.25 (0.0098)
Camshaft
Clearance between camshaft and bushing
mm (in)
Standard Limit
0.05 – 0.11
0.6 (0.0236)
(0.0020 – 0.0043)
Slack Adjuster
Clearance between bushing and pin (for reference)
mm (in)
0.1
Standard
(0.0039)
5B-40 AIR BRAKES
REASSEMBLY
Rear Wheel Brake Assembly
Reassembly Steps
1. Anchor pin bracket 12. Pin
2. Camshaft 13. Snap ring
3. Bracket (except Rearward) 14. Brake shoe assembly
4. Coller 15. Anchor pin
5. Spring chamber or power 16. Backing plate
chamber 17. Lock plate
6. Slack adjuster 18. Lock washer
7. Pin, washer and cotter pin 19. Bolt
8. Spacer 20. Snap ring, pin and inner return spring
9. Stopper plate 21. Outer return spring
10. Snap ring
11. Roller
AIR BRAKES 5B-41
Reassembly Steps
Tighten the bolts to the specified torque in the
sequence shown in the illustration.
Torque N·m (kg·m / lb·ft)
7T 127 (13.0 / 94)
9T 157 (16.0 / 116)
2. Camshaft
Apply grease to the shaft and the inner surface of the
bushing, and install the camshaft, making sure that
the arrow on the end face points outward.
3. Bracket
137 (14.0 / 101)
Apply grease to the inner surface of the bushing.
4. Collar
5. Spring Chamber or Power Chamber
Mount the chamber on the bracket, adjust the push
rod to the specified length, direct the jaw joint
properly, and tighten the lock nut securely.
Rod Length: mm (in)
100 (3.94)
6. Slack Adjuster
Mount the slack adjuster on the camshaft or shaft in
such a way that the slack adjuster can be properly
mounted on the push rod.
During this operation, do not change the push rod
lenght or turn the shaft.
8. Spacer
5B-42 AIR BRAKES
9. Stopper Plate
Match the arrow on the end face of the shaft with the
arrow on the top of the plate, and assemble them
together.
10. Snap Ring

11. Roller
12. Pin
13. Snap Ring
15. Anchor Pin
Fill the anchor pin groove and the bushing with
grease.
One gram per pin.
Be careful not to mistake the leading shoe for the
trailing shoe or vice versa in mounting them.
The trailing shoe has recesses on the surface.
16. Backing Plate

17. Lock Plate
18. Lock Washer
19. Bolt
After tightening the bolts, bend the lock washers
securely.
20. Snap Ring, Pin and Inner Return Spring

Inner spring installer; 1-8523-7013-0
9-8523-1560-0
AIR BRAKES 5B-43
21. Outer Return Spring

Outer spring installer; 9-8522-1231-0
5B–44 AIR BRAKES
BRAKE VALVE AND PEDAL (RHD MODEL)

REMOVAL
Removal Steps
1. Air Pipe
After tilting the cab, disconnect the four air pipes from
the brake valve at the pipe union nuts.
2. Stop Light Switch Harness
Disconnect the two stop light switch harnesses from
the brake valve at the terminals.
3. Accelerator Pedal
Before removing the accelerator pedal, return the
tilted cab to the original position.
4. Brake Valve
Remove the brake valve together with the pedal and
plate by pulling upward.
AIR BRAKES 5B–45
INSTALLATION
Installation Steps
1. Brake Valve
Apply a sealant to the pedal board seal and install it.
2. Accelerator Pedal
3. Stop Light Switch Harness
After tilting the cab, connect the two stop light switch
harnesses.
4. Air Pipe
5B–46 AIR BRAKES
BRAKE VALVE AND PEDAL (LHD MODEL)

REMOVAL AND INSTALLATION
1
4
310MT007
Removal Steps Installation Steps

1. Brake air pipe 4. Brake valve assembly
2. Center joint and lock nut 3. Brake pedal assembly
3. Brake pedal assembly 2. Center joint and lock nut
4. Brake valve assembly 1. Brake air pipe
AIR BRAKES 5B–47
Removal Steps
1. Brake Air Pipe

After tilting the cab, disconnect brake air pipes from
the brake valve assembly.
377MT001
Center joint 2. Center Joint and Lock Nut

Lock nut
Double nut • Return the tilted cab to the original position.
• Remove the pedal control rod cover.
Brake valve
• Disconnect the brake valve and pedal by loosening
the center joint and lock nut (combination B).
A
310MT004
3. Brake Pedal Assembly

4. Brake Valve Assembly
Installation Steps
4. Brake Valve Assembly

After tilting the cab, install the brake valve assembly
to the bracket.
Brake Valve Bolt Torque N·m (kg·m / lb·ft)
40 (4.1 / 30)
3. Brake Pedal Assembly

• Return the tilted cab to the original position.
• Install the brake pedal assembly to the brake pedal
plate.
Brake Pedal Bolt Torque N·m (kg·m / lb·ft)
M6 bolt 8 (0.8 / 69 lb·in)
M8 bolt 19 (1.9 / 14)
5B–48 AIR BRAKES
2. Center Joint and Lock Nut

1) Fix the brake pedal in a state of being brought in
contact with the stopper on the return side.
310MT002
2) Pull up the push rod in the illustrated direction and

make sure there is free play.
If there is no play, replace with a new brake valve.
Brake Valve Push Rod Free Play mm (in)

0.1 – 0.8 (0.0039 – 0.0315)
Push rod
310MT003
Center joint
3) Install the brake valve to the bracket. After
Lock nut installation of brake valve, pull up and tighten the
Double nut center joint and higher-walled side of double
Brake valve nut.(combination A).
4) Tighten the center joint and the lock nut
(combination B).
Brake Valve Bolt Torque N·m (kg·m / lb·ft)
B 40 (4.1 / 30)
A
310MT004
Center Joint Torque N·m (kg·m / lb·ft)

62 (6.3 / 46)
AIR BRAKES 5B–49
5) After installation of the brake valve, release the

S
brake pedal and check to see there is free play at
the pedal end (S).
NOTE:
Pedal end play (S) is between the brake pedal 's
contact with its return side stopper and the push
rod's contact with the brake valve plunger, not
including the stroke of 1.4 ± 0.3 mm (0.055 ± 0.012 in)
to the delivery of brake pressure.
310MT005
6) Check the pedal end play in accordance with the

table. If the check result is NG, brake valve must
be reinstalled.
Pedal End Play (S) mm (in)
S=0 NG
More than 6.4 (0.252) NG
More than 0, 6.4 (0.252) or less OK
7) Measure the angle of the brake pedal from the

pedal board.
Floor (Pedal boad)
Brake Pedal Angle (θ) degree
ǰ‫ޓ‬
(10.5°)
42 ± 1.5
WL
1. Brake Air Pipe
310MT006
NOTE:
Make sure that there is no brake dragging.
Brake Pedal Free Play Measurement

After installation of brake valve and pedal, measure
the pedal free play.
If the brake valve and pedal were installed certainly as
above procedure, pedal free play could be obtained
properly.
Brake Pedal Free Play (Reference) mm (in)

9.0 – 14.0 (0.35 – 0.55)
310MT011
5B–50 AIR BRAKES
BRAKE VALVE (RHD MODEL)

DISASSEMBLY
13
37
12 38
36
B 14 35 for South Africa
43 34 model only
32 32
44
33 33
46
45
47 31
48
50 27
49 28
30
52 29
3
5 26
53
51 25
4 8
54 22
B
23
21
7 18
6 19
24 20
11 1
10 41
17
2 42 16
9 15
39
40
334MY00004
Disassembly Steps
1. Cotter pin 22. Valve
2. Washer 23. Valve retainer
3. Pin 24. O-ring
4. Lock pin 25. Cover
5. Pedal 26. Screw
6. Cotter pin 27. Sleeve
7. Washer 28. Washer
8. Roller pin 29. Spring
9. Roller 30. Spring
10. Adjusting screw 31. Piston
11. Lock nut 32. O-ring
12. Plunger 33. O-ring
13. Boot 34. Spring
14. Plate 35. Snap ring
15. Snap ring 36. O-ring retainer
16. Exhaust cover 37. O-ring
17. Washer 38. O-ring
18. O-ring retainer 39. Spring
19. O-ring 40. Washer
20. O-ring 41. Valve
21. Spring 42. Valve retainer
AIR BRAKES 5B–51
43. Snap ring 49. Piston

44. Spring 50. O-ring
45. Bolt 51. Spring
46. Spring seat 52. Bushing
48. Spring 54. Body
Disassembly Steps
1. Cotter Pin
2. Washer
3. Pin
4. Lock Pin
5. Pedal
Remove all parts up to the lock nut in Item 11 together
with the pedal.
6. Cotter Pin
7. Washer
8. Roller Pin
9. Roller
10. Adjusting Screw
11. Lock Nut
12. Plunger
13. Boot
14. Plate
15. Snap Ring
16. Exhaust Cover
17. Washer
18. O-ring Retainer
19. O-ring
20. O-ring
21. Spring
22. Valve
23. Valve Retainer
5B–52 AIR BRAKES
24. O-ring
25. Cover
26. Screw
Passage for exhaust gas should not be scratched with
screw driver.
27. Sleeve
28. Washer
29. Spring
30. Spring
31. Piston
32. O-ring
33. O-ring
34. Spring
35. Snap Ring
36. O-ring Retainer
37. O-ring
38. O-ring
39. Spring
40. Washer
41. Valve
42. Valve Retainer
43. Snap Ring
44. Spring
45. Bolt
The bolt should be loosened with the seat spring
pushed downward.
46. Spring Seat

47. Spring
48. Spring
49. Piston
50. O-ring
51. Spring
52. Bushing
53. O-ring
54. Body
AIR BRAKES 5B–53

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are
found through inspection.
Plate
Check that the difference between the maximum and
minimum inside diameters of the pin hole is less than
0.1mm.
Check the bushing that its sliding surface is free from
damage and that the plunger slides smoothly.
Plunger
The plunger must slide smoothly through the hole in
the plate.
External stepped wear must be less than 0.1mm. The
roller contact surface must be free of serious wear.
Body
The O-ring contact surface and inlet valve seat surface
must be free of scars detrimental to airtightness.
For South Africa model only
334HY00006
5B–54 AIR BRAKES
Piston
Must be free of scars which can damage the body.
Relay Piston
Must be free of scars which can damage the body.
For South Africa model only
334HY00005
Cover
Pedal
Clearance between Pin and Bushing mm (in)
Standard Limit
0.015 – 0.086 (0.0006 – 0.0034) 0.4 (0.0157)
AIR BRAKES 5B–55
Clearance between Roller and Pin mm (in)

Standard Limit
0.015 – 0.108 (0.0006 – 0.0043) 0.25 (0.0098)
Clearance between Plunger and Bushing mm (in)

Limit 0.49 (0.0193)
5B–56 AIR BRAKES
REASSEMBLY
42
17
B 43 18
19
41 20 for South Africa
21 model only
12
22 22
11
23 23
9
10
8 24
7
5 28
6 27
26
4 25
52
50 29
3
2 30
51 47
1 33
B
32
34
48
37
49 36
31 35
45
54
44 14
53 38
13
39
46 40
15
16
334MY00005
Reassembly Steps
1. Body 22. O-ring
3. O-ring 24. Piston
4. Bushing 25. Spring
5. O-ring 26. Spring
6. Piston 27. Washer
7. Spring 28. Sleeve
8. Spring 29. Screw
9. Spring seat 30. Cover
10. Bolt 31. O-ring
11. Spring 32. Valve retainer
12. Snap ring 33. Valve
13. Valve retainer 34. Spring
14. Valve 35. O-ring
16. Washer 37. O-ring retainer
17. O-ring 38. Washer
18. O-ring 39. Exhaust cover
19. O-ring retainer 40. Snap ring
20. Snap ring 41. Plate
21. Spring 42. Boot
AIR BRAKES 5B–57
43. Plunger 49. Cotter pin

44. Adjusting screw 50. Pedal
45. Lock nut 51. Lock pin
46. Roller 52. Pin
47. Roller pin 53. Washer
48. Washer 54. Cotter pin
Reassembly Steps
1. Body
Apply Airmaster paste or lithium - base grease to the
O-ring sliding surface, and metal sliding surfaces.
2. Spring
3. O-ring
4. Bushing
5. O-ring
6. Piston
O-ring groove and metal sliding surfaces.
7. Spring
8. Spring
9. Spring Seat
10. Bolt
Tighten bolt to the specified torque.
Bolt Torque N·m (kg·m / lb·in)
7 (0.7 / 61)
11. Spring
12. Snap Ring
13. Valve Retainer
14. Valve
15. Spring
16. Washer
17. O-ring
18. O-ring
19. O-ring Retainer
20. Snap Ring

21. Spring
5B–58 AIR BRAKES
22. O-ring
23. O-ring
24. Piston
25. Spring
26. Spring
27. Washer
28. Sleeve
29. Screw
• Tighten the sleeve to the specified torque.
Sleeve Torque N·m (kg·m / lb·in)

2 (0.2 / 17)
• Apply Airmaster paste or lithium - base grease to

the sleeve.
• Tighten screw to the specified torque.
Screw Torque N·m (kg·m / lb·in)

7 (0.7 / 61)
30. Cover
O-ring groove.
7 (0.7 / 61)
31. O-ring
32. Valve Retainer
33. Valve
34. Spring
35. O-ring
36. O-ring
37. O-ring Retainer
38. Washer
39. Exhaust Cover

40. Snap Ring
AIR BRAKES 5B–59
41. Plate
16 (1.6 / 12)
42. Boot
43. Plunger
Apply MoS2 grease to the pedal pin, roller pin and
plunger. Particularly, seal 1 cc grease between the
boot and plunger.
44. Adjusting Screw

Assemble all the parts from Item 44 to 49 with the
pedal.
45. Lock Nut

46. Roller
47. Roller Pin
48. Washer
49. Cotter Pin
50. Pedal
51. Lock Pin
52. Pin
53. Washer
54. Cotter Pin
Adjustment of Brake Pedal Free Play

After reassembling the brake valve, adjust the pedal
free play by turning the adjusting screw.
Brake Pedal Free Play mm (in)

10 – 14 (0.39 – 0.55)
5B–60 AIR BRAKES
BRAKE VALVE (LHD MODEL)

DISASSEMBLY
1
2
6 22
3 37
36
4 38
5 7
35
8 34
9 39
10 28 33
32
12 53
14 31 52
15 30 51
16 29 50
27
17 49
18 26 45 48
11 25
19 47
46
20
24 44
21 43
23 13 40 42
41
334MT006
Disassembly Steps
1. Nut 22. Upper piston spring
2. Nut 23. O-ring
3. Dust cover 24. Relay piston
4. Plate 25. O-ring
5. Horseshoe washer 26. Relay piston spring
6. Push rod 27. Snap ring
7. Plunger 28. Primary valve assembly
8. E-ring 29. Snap ring
9. Stem plate 30. Special washer
10. Stem spring 31. O-ring
11. Upper piston assembly 32. Retainer
12. Nut 33. Primary valve spring
13. Stem 34. Valve retainer
14. Spring washer 35. Primary valve
15. Washer 36. Bushing; upper body
16. Spring seat 37. O-ring
17. Main spring 38. Upper body
18. Spring seat 39. O-ring
19. Sub spring 40. Exhaust cover assembly
20. Upper piston 41. Screw
21. Sleeve 42. Retaining washer
AIR BRAKES 5B–61
43. Exhaust seat 49. Retainer

44. Exhaust cover 50. Secondary valve assembly
45. Secondary valve assembly 51. Valve retainer
46. Snap ring 52. Secondary valve
47. Washer 53. Lower body
48. O-ring
Disassembly Steps
1. Nut
2. Nut
3. Dust Cover
4. Plate
5. Horseshoe Washer
6. Push Rod
7. Plunger
8. E-ring
Hold the lower side of the stem and the relay piston.
Push the stem plate down to remove the E-ring.
9. Stem Plate
10. Stem Spring
11. Upper Piston Assembly
12. Nut
Loosen the nut to disassemble the upper piston
assembly.
13. Stem
14. Spring Washer
15. Washer
16. Spring Seat
17. Main Spring
18. Spring Seat
19. Sub Spring
20. Upper Piston
21. Sleeve
5B–62 AIR BRAKES
22. Upper Piston Spring

23. O-ring
24. Relay Piston
25. O-ring
26. Relay Piston Spring
27. Snap Ring
Remove the snap ring using a snap ring plier.
28. Primary Valve Assembly

29. Snap Ring
30. Special Washer
31. O-ring
32. Retainer
33. Primary Valve Spring
34. Valve Retainer
35. Primary Valve
36. Bushing; Upper Body
37. O-ring
38. Upper Body
39. O-ring
40. Exhaust Cover Assembly
41. Screw
42. Retaining Washer
43. Exhaust Seat
44. Exhaust Cover
45. Secondary Valve Assembly
46. Snap Ring
47. Washer
48. O-ring
49. Retainer
51. Valve Retainer
52. Secondary Valve
53. Lower Body
AIR BRAKES 5B–63

Make necessary correction or parts replacement if excessive wear, damage or any other abnormal
conditions are found through inspection.
Visual Check
Inspect the following parts for excessive wear,
• O-rings damage or other abnormal conditions.
• Snap ring
• Lower valve
• Upper valve
• Springs
Brake Valve Push Rod Free Play Measurement

Pull up the push rod in the illustrated direction and
make sure there is free play.
If there is no play, replace with a new brake valve.
Brake Valve Push Rod Free Play mm (in)

Push rod 0.1 – 0.8 (0.0039 – 0.0315)
310MT003
5B–64 AIR BRAKES
REASSEMBLY
53 52
48 32
49 17
18
50 16
51 47
19
46 20
45 15
44 26 21
22
41 1
40 23 2
39 24 3
38 25 4
27
37 5
36 28 9 6
42 29
35 7
8
33
30 10
34 11
43 31 14 12
13
334MT007
Reassembly Steps
1. Lower body 22. Retainer
2. Secondary valve 23. O-ring
3. Valve retainer 24. Special washer
4. Secondary valve spring 25. Snap ring
5. Retainer 26. Primary valve assembly
6. O-ring 27. Snap ring
7. Washer 28. Relay piston spring
8. Snap ring 29. O-ring
9. Secondary valve assembly 30. Relay piston
10. Exhaust cover 31. Stem
11. Exhaust seat 32. Upper piston spring
12. Retaining washer 33. Upper piston
13. Screw 34. Sleeve
14. Exhaust cover assembly 35. Sub spring
15. O-ring 36. Spring seat
16. Upper body 37. Main spring
17. O-ring 38. Spring seat
18. Bushing; upper body 39. Washer
19. Primary valve 40. Spring washer
20. Valve retainer 41. Nut
21. Primary valve spring 42. Upper piston assembly
AIR BRAKES 5B–65
43. O-ring 49. Dust cover

44. Stem spring 50. Plate
45. Stem plate 51. Horseshoe washer
46. E-ring 52. Nut
47. Plunger 53. Nut
48. Push rod
Reassembly Steps
Preparation
Lubricate O-rings, O-ring grooves and piston bores
with lithium base grease before reassembling the
brake valve.
1. Lower Body
2. Secondary Valve
3. Valve Retainer
4. Secondary Valve Spring
5. Retainer
6. O-ring
Apply lithium grease to the O-ring and O-ring groove.
7. Washer
8. Snap Ring
10. Exhaust Cover
11. Exhaust Seat
12. Retaining Washer
13. Screw
14. Exhaust Cover Assembly
15. O-ring
16. Upper Body
17. O-ring
18. Bushing; Upper Body
19. Primary Valve
20. Valve Retainer
21. Primary Valve Spring
22. Retainer
23. O-ring
24. Special Washer
25. Snap Ring
26. Primary Valve Assembly
27. Snap Ring
28. Relay Piston Spring
29. O-ring
5B–66 AIR BRAKES
30. Relay Piston

31. Stem
32. Upper Piston Spring
33. Upper Piston
34. Sleeve
35. Sub Spring
36. Spring Seat
37. Main Spring
38. Spring Seat
39. Washer
40. Spring Washer
41. Nut
42. Upper Piston Assembly
43. O-ring
44. Stem Spring
45. Stem Plate
46. E-ring
47. Plunger
48. Push Rod
49. Dust Cover
50. Plate
51. Horseshoe Washer
52. Nut
10.5+20 mm 53. Nut
30mm • Apply liquid gasket (Three Bond 1305B or
equivalent) to nut threads.
• Fix double nut as figure, and tighten them to the
specified torque.
Double Nut Torque N·m (kg·m / lb·ft)
62 (6.3 / 46)
334MT010
AIR BRAKES 5B–67
OPERATION TEST
Simplified Test on Brake Valve
After overhauling the brake valve, a simplified test can
be conducted as follows if necessary. Before
conducting the test, have ready a brake valve mount,
goniometer, air gauges and foot pressure gauge.
1. Set the brake valve on the brake valve mount, and
fasten it with a vice.
2. Conduct an air leak test.
1) Supply compressed air of 686 – 785kPa (7 –
8kg/cm2) to the brake valve through its supply port,
and confirm that the compressed air does not leak
from the delivery port.
2) Mount the air gauges on the brake valve at its
primary and secondary delivery ports.
3) Step on the brake pedal to the half open and full
open adjusting positions, and make sure that the
delivery ports are free of the air leakage.
Check the joints, mounting seats, exhaust port, etc.
that they are also free of air leakage.
5B–68 AIR BRAKES
3. Operate the brake valve, and check if the

characteristics line diagram is satisfied.
The secondary side is the same in performance as
the primary side except that the secondary side
has a slight lower delivery pressure — 3 kPa – 13
kPa (0.03 – 0.13 kg/cm2 / 0.43 – 1.85psi) lower than
on the primary side.
1) Slowly step down on the brake pedal (or push rod),
and measure the angle (or stroke) at which the
pressure begins to build up on the delivery port
side.
For RHD, use the pedal adjusting bolt for this
adjustment.
Pressure Rising Level and Angle (or Stroke)
Less Than 34 kPa
(0.35 kg/cm2 / 5.0psi)
Angle (RHD) 3° – 4°
Stroke (LHD) 1.4±0.3mm (0.055±0.012in)
FSR*····FSR with Heavy Duty Package (RD2)
2)
RHD
Depress the brake pedal to an angle of 8° keep it
there, and check the delivery pressure on the
delivery port side.
Delivery Pressure at 8° kPa (kg/cm2 / psi)
Angle Pressure
8° 127 - 206 (1.3 - 2.1 / 18 - 30)
LHD
Depress the brake valve push rod to stroke of
4.3mm (0.17in) for FRR and FSR, or 3.8mm (0.15in)
for FSR (RD2), FTR and FVR, keep it there, and
check the delivery pressure on the delivery port
side.
Delivery Pressure at 3.8mm (4.3mm) kPa (kg/cm2 / psi)
Model Stroke Pressure
FRR, FSR 4.3 (0.17) 142 - 221 (1.45 - 2.25 / 21 - 32)
FTR, FVR
3.8 (0.15) 177 - 255 (1.80 - 2.60 / 26 - 37)
FSR (RD2)
AIR BRAKES 5B–69
3) Depress the brake pedal (or push rod) further, and

check the angle (or stroke) at which the pressure
on the supply port side is equal to the pressure on
the delivery port side.
Angle or Stroke
Model Angle or Stroke
RHD 15.5° – 18.5°
LHD 5.8 – 6.9mm (0.23 – 0.27in)
5B–70 AIR BRAKES
Brake Valve Characteristic Diagram
For RHD
MPa (Supply Air Pressue 0.7MPa)

0.7
0.6
Delivery Port Pressure

0.4 0.5 N
(Primary)
Delivery Port Pressure
0.4 400
Pedal Force
0.3 300
233
Pedal Force
0.2 200
142
0.17
0.1 100
80
0 0
0 2 4 6 8 10 12 14 16 18 20 22
38
+2.5
3.5r0.5 8 13 16 -0.5
0.034 or less
Pedal Angle (Deg.)
For LHD
+0.9
6.0 -0.2
± 0.8
Full Stroke 8.9
690
Delivery Port Pressure (Primary) kPa
Delivery Port
590
Pressure
4.8
N
490
Plunger Force
390 3.8 1960

r69
±39
392
290 216 1470
150-277N
34 or less
200 980
Plunger
Force
98 ±98
490
530 N at 216kPa
0 0
0 1 2 3 4 5 6 7 8 9 10
1.4 +0.3 Plunger Stroke (mm)
334MT011
AIR BRAKES 5B-71
POWER CHAMBER
REMOVAL
Removal Steps
1. Air hose
2. Cotter pin, washer and pin
3. Nut
Removal Steps
1. Air Hose
3. Nut
5B-72 AIR BRAKES
INSTALLATION
Installation Steps
1. Nut
2. Pin washer and cotter pin
3. Air Hose
Installation Steps
1. Nut
3. Air Hose
After connecting the air hose, check the individual
parts for air leakage.
Check the push rod length when not operating the
brake.
Push Rod Length mm (in)
152 (5.98)
AIR BRAKES 5B-73
DISASSEMBLY
Disassembly Steps
1. Jaw joint 6. Diaphragm
2. Lock nut 7. Piston Plate
3. Clamp ring 8. Spring
4. Retainer 9. Lower cover
5. Upper cover 10. Dust cover
5B-74 AIR BRAKES
Disassembly Steps
Before disassembly, apply setting mark to the upper
cover, clamp ring and lower cover to reassemble into
original position.
Release the vise gradually and remove the parts.
1. Jaw Joint
2. Lock Nut
3. Clamp Ring
4. Retainer
5. Upper Cover
6. Diaphragm
7. Piston Plate
8. Spring
9. Lower Cover
10. Dust Cover

during inspection.
AIR BRAKES 5B-75
REASSEMBLY
Reassembly Steps
1. Dust cover 6. Upper cover
2. Lower cover 7. Retainer
3. Spring 8. Clamp ring
4. Piston plate 9. Lock nut
5. Diaphragm 10. Jaw joint
5B-76 AIR BRAKES
Reassembly Steps
Match the setting marks on the disassembled parts
and reassemble them.
1. Dust Cover
2. Lower Cover
3. Spring
4. Piston Plate
5. Diaphragm
6. Upper Cover
7. Retainer
8. Clamp Ring
27 (2.8 / 20)
9. Lock Nut
10. Jaw Joint
Push Rod Length; L mm (in)
152 (5.98)
Before mounting on the vehicle, supply compressed

air of 98 kPa (1 kg / cm2) to the inlet port, and confirm
that the push rod stroke is between 60 and 65 mm.
(2.4 and 2.6 in.)
When the air is discharged, the push rod must return
to the original position.
Also check for air leakage by supplying compressed
air of normal operating pressure.
AIR BRAKES 5B-77
SPRING CHAMBER
REMOVAL
Removal Steps
1. Air hose or tube
2. Cotter pin, washer and pin
3. Nut
Removal Steps
For easy removal and installation, release the spring
brake, turn the nut on the back of the chamber, and
pull out the bolt by about 70 mm (2.72 in) to compress
the spring and take out pipes.
1. Air Hose or Tube
3. Nut
5B-78 AIR BRAKES
INSTALLATION
Installation Steps
1. Nut
2. Pin, washer and cotter pin
3. Air hose or tube
AIR BRAKES 5B-79
Installation Steps
1. Nut
3. Air Hose or Tube
After mounting the air hose or tube, check the
individual parts for air leakage.
Operate the spring brake valve to release the brake,
and return the bolt that has compressed the spring to
its original position securely.
Check the push rod for length when neither the
service brake nor the spring brake is operated.
mm (in)
Forward rear
100 (3.94)
Rearward rear
5B-80 AIR BRAKES
DISASSEMBLY
AIR BRAKES 5B-81
Disassembly Steps
1. Jaw joint 19. O-ring
2. Lock nut 20. Nut, straight pin and bolt assembly
3. Nut and spring washer 21. Clamp ring
4. Clamp ring 22. Pressure plate
5. Retainer 23. Bracket
6. Lower cover 24. Hose
7. Pipe 25. O-ring
8. Cover 26. O-ring
9. Cover 27. Back up ring
10. Spring 28. Bearing
11. Retainer 29. Piston
12. Rod and plate 30. O-ring
13. Diaphragm 31. Spring seat
14. Snap ring 32. Spring
15. Piston cover 33. Cylinder shell
16. O-ring 34. Pipe
17. Straight pin 35. Exhaust cover
18. Nut
Disassembly Steps
1. Jaw Joint
2. Lock Nut
3. Nut and Spring Washer
4. Clamp Ring
Before removing the parts, draw match marks on the
lower cover, pressure plate, two clamp rings, and
cylinder shell so that they can be easily mounted back
in their original positions.
The lower cover can be easily removed if the clamp
rings are removed after slightly pushing the dust
cover into the chamber.
5. Retainer
6. Lower Cover
7. Pipe
8. Cover
9. Cover
10. Spring
11. Retainer
12. Rod and Plate
13. Diaphragm
14. Snap Ring
15. Piston Cover
16. O-ring
5B-82 AIR BRAKES
17. Straight Pin

Pull out the straight pin in direction opposite to
grooved side of the pin.
18. Nut
19. O-ring
20. Nut, Straight Pin and Bolt Assembly
21. Clamp Ring
Use either a bench press to press the pressure plate or
a special bolt to compress the spring together with the
piston, remove the clamp rings, then gradually release
the spring tension, and remove the other parts.
22. Pressure Plate

23. Bracket
24. Hose
25. O-ring
26. O-ring
27. Back Up Ring
28. Bearing
29. Piston
30. O-ring
31. Spring Seat
32. Spring
33. Cylinder Shell
34. Pipe
35. Exhaust Cover
AIR BRAKES 5B-83

during inspection.
Cylinder Shell
Inspect O-ring sliding face of the cylinder shell for
scuffing, damage or other abnormal conditions.
Piston
Inspect the outer face of piston for scuffing, corrosion
or other abnormal conditions.
Spring
Inspect springs for corrosion, damage or other
abnormal conditions.
5B-84 AIR BRAKES
REASSEMBLY
AIR BRAKES 5B-85
Reassembly Steps
1. Exhaust cover 19. Straight pin
2. Pipe 20. O-ring
3. Cylinder shell 21. Piston Cover
4. Spring 22. Snap ring
5. Spring seat 23. Diaphragm
6. O-ring 24. Rod and plate
7. Piston 25. Retainer
8. Bearing 26. Spring
9. Back up ring 27. Cover
10. O-ring 28. Cover
11. Hose 29. Pipe
12. Bracket 30. Lower cover
13. O-ring 31. Retainer
14. Pressure plate 32. Clamp ring
15. Clamp ring 33. Spring washer and nut
16. Nut, straight pin and bolt assembly 34. Lock nut
17. O-ring 35. Jaw joint
18. Nut
Reassembly Steps
1. Exhaust Cover
20 (2.0 / 14)
Apply a sealant to the threads, and tighten the bolt.

2. Pipe
3. Cylinder Shell
Liberally apply grease to the inner surface in contact
with operating piston.
4. Spring
5. Spring Seat
Mount on the piston side.
5B-86 AIR BRAKES
6. O-ring
7. Piston
Liberally apply grease to the grease groove, O-ring
groove, and outer surfaces of ø173 and ø60.3.
Install the spring together with the piston,
compressing them with a special bolt.
In case of using a bench press, press the pressure
plate with it, and install the clamp ring.
Align the match marks on the cylinder shell, pressure
plate, two clamp rings, and lower cover, and assemble
them.
8. Bearing
Liberally apply grease.
9. Back Up Ring
10. O-ring
11. Hose
12. Bracket
13. O-ring
14. Pressure Plate
Liberally apply grease to the O-ring grooves.
Align the match marks, and install it, exercising care
not to damage the O-ring.
15. Clamp Ring
19 (1.9 / 14)
Remove the special bolt.
16. Nut, Straight Pin and Bolt Assembly
Liberally apply grease between plate, washer and all
threads.
17. O-ring
18. Nut
54 (5.5 / 40)
19. Straight Pin
20. O-ring
21. Piston Cover
49 (5.0 / 36)
Apply grease to prevent the O-ring from breaking
during tightening.
22. Snap Ring
23. Diaphragm
24. Rod and Plate
25. Retainer
AIR BRAKES 5B-87
26. Spring
27. Cover
28. Cover
29. Pipe
30. Lower Cover
Align the match marks and mount the lower cover.
31. Retainer
32. Clamp Ring
Nut Torque N·m (kg·m / lb·ft)
19 (1.9 / 14)
33. Nut
Nut Torque N·m (kg·m / lb·ft)
16 (1.6 / 12)
Stud Torque N·m (kg·m / lb·ft)

20 (2.0 / 14)
34. Lock Nut
35. Jaw Joint
Push rod length mm (in)
Forward rear
100 (3.94)
Rearward rear
Before mounting on the vehicle, supply compressed

air of 588 kPa (6 kg / cm2) to the emergency air port to
compress the spring.
In making the above check supply compressed air of
98 kPa (1 kg / cm2) to the service air port, and confirm
that the push rod has a stroke of 60 mm (2.4 in) or
more.
Also check that the push rod returns to its original
position when the air is discharged.
Then, open the emergency air port, and confirm that
the push rod has a stroke of 60 mm (2.4 in) or more.
Also check that the push rod returns to its original
position when compressed air of 539 kPa (5.5 kg / cm2)
is supplied to the emergency air port.
Check the individual parts that they are free of air
leakage when compressed air is supplied to the
service and emergency air ports.
5B-88 AIR BRAKES
AIR CIRCUIT PARTS

during inspection.
The following air circuit parts cannot be repaired or overhauled.
Faulty parts must be replaced with new ones.
Pressure Protection Valve (Air Valve)

Performance Test
Check that the valve is closed when the air pressure
on the supply port is zero.
Check that, when the air pressure on the supply port
has risen to anywhere between 461 and 500 kPa (4.7
and 5.1 kg / cm2), the valve opens and that the air runs
to the delivery port.
Check the valve body, pipe joints, and delivery port
that they are free of air leakage.
Double Check Valve

Check that, when the delivery port is closed and air is
supplied to either of the supply ports, the other supply
port is free of air leakage.
Check the valve body and pipe joints that they are free
of air leakage.
AIR BRAKES 5B-89
Relay Valve
Performance Test
1. Disconnect the air pipe at the power chamber side
of the relay valve and connect an air gauge.
2. Raise the air pressure within the air tanks to 686
kPa (7 kg / cm2) or higher.
3. Fully depress the brake pedal and hold and check
that the air pressure at the delivery port is almost
equal to that of within the air tank.
4. Release the brake pedal and check that air is
discharged from the exhaust port and reading of
air gauge becomes zero.
5. Depress the brake pedal and check for air leakage
from around the body fitting face of the relay
valve, pipe joints and discharge port.
Dual Relay Valve

Performance Test
1. Disconnect the air pipe at the power chamber side
of the relay valve and connect an air gauge.
2. Raise the air pressure within the air tanks to 686
kPa (7 kg / cm2) or higher.
3. Fully release the parking brake control valve lever
and check that the air pressure at the delivery port
is almost equal to that at the supply port.
4. Pull out while turning counterclockwise the
emergency parking brake release switch and check
that the air pressure at the delivery port is almost
equal to that of within the air tank.
5. Release the spring brake and check for air leakage
from around the body fitting face of the dual relay
valve, pipe joints and discharge port.
5B-90 AIR BRAKES
Parking Brake Control Valve

1. LEAKAGE TEST
1. With the valve handle in the fully applied (parking)
position, connect 785 kPa (8 kgf / cm2) air supply to
the inlet port. Check for exhaust port leakage.
2. With the valve handle in the released position,
connect 785 kPa (8 kgf / cm2) air supply to the inlet
port. Check for exhaust port leakage.
A 15 mm (0.59 in.) soap bubble in 15 seconds is
permissible.
2. INSPECTION
1. Connect 686 kPa (7 kg / cm2) air supply to the inlet
port and a gauge to the delivery port.
2. Move the valve handle slowly to the applied
position. Inspect for the point where the pressure
gauge shows the first rise.
Quick Release Valve

PERFORMANCE TEST
The relationship between supply port pressure and
delivery port pressure is as shown at left. Check the
valve body, pipe joints, and exhaust port that they are
free of air leakage.
AIR BRAKES 5B-91
Air Tank Safety Valve

Operating test
1. Connect the safety valve to a tester.
2. Increase the pressure of air within the tester by
operating the air compressor.
3. The pressure gauge needle will continue to deflect
and begin to dance at a point indicating that the
safety valve is being actuated.
Operating Pressure kPa (kg / cm2 / psi)
912 (9.3 / 132)
Air Check Valve

The valve, spring and stopper are built into the joint
bolt and cannot be disassembled for inspection or
correction.
The entire check valve assembly must be replaced if
air leakage is noticeable.
1. Pressure test
Apply compressed air of 0.3 kg / cm2 into the valve
from the “A” side and feel of air at the “B” side with
hand.
2. Leak test
Connect a pipe to the “A” side of the valve and
submerge the end of the pipe into kerosene.
Apply compressed air of 2.0 kg / cm2 into the valve
from the “B” side and check air leaks at the “A” side.
5B-92 AIR BRAKES
Air Tank Drain Valve

Performance test
Check that, when the ring is pulled horizontally, water
and air can be smoothly discharged.
There must be no air leakage when the ring is
released.
Air Tank Automatic Drain Valve

(If so equipped)
Performance test
Check that water will be smoothly discharged when
the air pressure inside the air tank has lowered due to
the use of air devices.
There must be no air leakage other than when air is
discharged.
AIR BRAKES 5B-93
Multi Protection Valve
Port Name and Piston No.
Secondary Side:B Primary Side:A

B A
Piston No.1
Piston No.3 Outlet Port 23 Outlet Port 21
B room A room
Inlet Port
Piston No.4 Outlet Port 24 Outlet Port 22 Piston No.2
B A
B-B A-A
320MY00004
Performance test
1. Valve opening pressure
(1) Primary
Valve opening pressure shall be as follows:
charging speed. Time Duration 3 ~ 7 sec.
Time for air pressure rising 295→490 (3→5 / 43→71)
kPa (kg / cm2 / psi) under the condition opening air
at outlet 21, 22 saturation pressure of inlet.
(2) Secondary
Valve opening pressure shall be as follows:
charging speed. Time Duration 8 ~ 22 sec.
Time for air pressure rising 295→490 (3→5 / 43→71)
kPa (kg / cm2 / psi) under the condition pressure = 0
at outlet 23, outlet 24.
5B-94 AIR BRAKES
2. Valve closing pressure

Minimum pressure drop shall be as follows:
Pressure drop time: 3sec MAX. Time for drop
pressure to air pressure drop as 590→295 (6→3 / 43→22)
kPa (kg / cm2 / psi) under the condition pressure = 930
(9.5 / 135) kPa (kg / cm2 / psi) at outlet 21, outlet 22,
outlet 23 and outlet 24.
outlet vol is about 0.5L
kPa (kg / cm2 / psi)
Outlet port 21, 22 23, 24
570 570
Valve opening pressure
(5.8 / 82) (5.8 / 82)
440 440
Valve closing pressure
(4.5 / 64) (4.5 / 64)
3. Air tightness
(1) By-pass check valve for primary line
No air leakage at the inlet 1, when applied air
pressure of 49 (0.5 / 7) kPa (kg / cm2 / psi) and 392
(4 / 57) kPa (kg / cm2 / psi) to the inlet 1 from the
outlet 21 and 22.
(2) Center check valve
No air leakage at the outlet 21 and 22, wen applied
air pressure of 49 (0.5 / 7) kPa (kg / cm2 / psi) and
930 (9.5 / 135) kPa (kg / cm2 / psi) to the outlet 21
and 22 from the inspection port.
(3) Check Valve for secondary line
No air leakage at the inspection port, when applied
air pressure of 49 (0.5 / 7) kPa (kg / cm2 / psi) and
930 (9.5 / 135) kPa (kg / cm2 / psi) to the inspection
port from the outlet 23 and 24.
AIR BRAKES 5B-95
AIR DRYER (DR-5 TYPE)

DISASSEMBLY
Disassembly Steps
1. Wire 18. Oil filter
2. Stopper plate and screw 19. Gasket ring
3. Stopper ring 20. Spacer
4. Purge chamber 21. O-ring
5. Screw 22. Case
6. Cartridge 23. Check valve
7. Nut, washer and bolt 24. Snap ring
8. Case cover 25. Exhaust cover
9. O-ring 26. Exhaust body
10. Set spring 27. O-ring
11. Filter plate 28. Valve body assembly
12. Filter 29. Thermostat
13. Desiccant 30. Heater
14. Filter 31. Gasket
15. Nut, washer and bolt 32. O-ring
16. Filter plate 33. O-ring
17. Gasket ring 34. Body
5B-96 AIR BRAKES
Disassembly Steps
1. Wire
2. Stopper Plate and Screw
3. Stopper Ring
Insert the blade of a screwdriver in the notch and
slowly pry out the stopper ring.
4. Purge Chamber
5. Screw
6. Cartridge
7. Nut, Washer and Bolt
1) Using a press tool, press the case cover.
2) Remove the bolts.
WARNING:
USE CARE IN REMOVING CASE COVER BOLTS TO
PREVENT BODILY INJURY BECAUSE THE CASE
COVER IS SPRING LOADED.
8. Case Cover
9. O-ring
10. Set Spring
11. Filter Plate
12. Filter
13. Desiccant
14. Filter
16. Filter Plate
17. Gasket Ring
18. Oil Filter
19. Gasket Ring
20. Spacer
21. O-ring
22. Case
23. Check Valve
24. Snap Ring
25. Exhaust Cover
26. Exhaust Body
27. O-ring
28. Valve Body Assembly
AIR BRAKES 5B-97
29. Thermostat
30. Heater
31. Gasket
32. O-ring
33. O-ring
34. Body
5B-98 AIR BRAKES

during inspection.
Thermostat
1. Cool the thermostat to below 0°C (32°F).
Using an ohmmeter, check the continuity between
the two terminals. If no continuity exists, the
thermostat should be replaced.
2. Warm the thermostat to over 20°C (68°F).
Using an ohmmeter, check the continuity between
the two terminals. If continuity exists, the
thermostat should be replaced.
Heater
Make a continuity test between heater terminal and
body.
If no continuity exists, the heat wire is broken and the
heater should be replaced.
Cover
Check the operation of the check valve.
Desiccant
If the desiccant is contaminated, it should be replaced.
AIR BRAKES 5B-99
REASSEMBLY
Reassembly Steps
1. Body 18. Gasket ring
2. O-ring 19. Filter plate
3. O-ring 20. Nut, washer and bolt
4. Gasket 21. Filter
5. Heater 22. Desiccant
6. Thermostat 23. Filter
7. Valve body assembly 24. Filter plate
8. O-ring 25. Set spring
9. Exhaust body 26. O-ring
10. Exhaust cover 27. Case cover
11. Snap ring 28. Nut, washer and bolt
12. Check valve 29. Cartridge
13. Case 30. Screw
14. O-ring 31. Purge chamber
15. Spacer 32. Stopper ring
16. Gasket ring 33. Stopper plate and screw
17. Oil filter 34. Wire
5B-100 AIR BRAKES
Reassembly Steps
1. Body
2. O-ring
Apply a coat of silicon grease to the O-ring.
3. O-ring
Apply a coat of silicon grease to the O-ring.
4. Gasket
5. Heater
6. Thermostat
7. Valve Body Assembly
Apply a coat of silicon grease to the bore of the body.
8. O-ring
9. Exhaust Body
10. Exhaust Cover
11. Snap Ring
12. Check Valve
13. Case
14. O-ring
15. Spacer
16. Gasket Ring
17. Oil Filter
18. Gasket Ring
19. Filter Plate
Tighten the nut to the specified torque.
Nut Torque N·m (kg·m / lb·in)
6 (0.6 / 52)
21. Filter Plate

The side of soft must be facing up.
AIR BRAKES 5B-101
22. Desiccant
1) Pour the entire package of desiccant material into
the case making sure none is lost.
2) While slowly turning the case, tap the side of the
case with a plastic mallet.
23. Filter
Install the filter, soft side down.
24. Filter Plate
25. Set Spring
26. O-ring
27. Case Cover
Using a press tool, press the case cover.
Tighten the nut to the specified torque.
Nut torque N·m (kg·m / lb·in)
6 (0.6 / 52)
29. Cartridge
30. Screw
Tighten the screw to the specified torque.
Nut torque N·m (kg·m / lb·in)
6 (0.6 / 52)
31. Purge Chamber

32. Stopper Ring
33. Stopper Plate and Screw
34. Wire
5B-102 AIR BRAKES
OPERATIONAL TEST
Air Drying System
1. Check that the purge noise continues for
approximately three(3) seconds when governor
cut-out pressure is reached.
2. After the air compressor has switched from unload
to load state following fall of the air pressure, the
leak from the air dryer exhaust port should be less
than 20 cc in one minute.
(A 15 mm (0.59 in.) soap bubble in 6 seconds is
permissible.)
AIR BRAKES 5B-103
AIR DRYER (DR-7 TYPE)

DISASSEMBLY
2
1 16
15
4 26
5
6
7
21
22
23
8
9 25
3
24
20
19
10 18
17
11
12
13
14
Disassembly Steps
1. Purge chamber 14. Cover
2. Cover and check valve 15. Gasket ring
3. O-ring 16. Gasket ring
4. Set spring 17. Retaining ring
5. Filter plate 18. Exhaust cover
6. Filter 19. Bolt and washer
7. Desiccant 20. Valve
8. Filter 21. Piston
9. Filter plate 22. O-ring
10. Case 23. Valve spring
11. Oil separator filter 24. Valve body
12. O-ring 25. O-ring
13. O-ring 26. Body
5B-104 AIR BRAKES
Disassembly Steps
1. Purge Chamber
2. Cover and Check Valve
Press the cover with one hand, until the four screws
have been removed.
3. O-ring
4. Set Spring
5. Filter Plate
6. Filter
7. Desiccant
8. Filter
9. Filter Plate
10. Case
11. Oil Separator Filter
12. O-ring
13. O-ring
14. Cover
15. Gasket Ring
16. Gasket Ring
17. Retaining Ring
18. Exhaust Cover
19. Bolt and Washer
1. Clamp a 10 mm hexagon wrench in a vise.
2. Set the piston on the hexagon wrench.
3. Use a 8 mm socket wrench to remove the bolt.
Valve body Take care not to scratch the body surface to the
piston.
20. Valve
Allen wrench
21. Piston
22. O-ring
23. Valve Spring
24. Valve Body
25. O-ring
26. Body

during inspection.
See AIR DRYER (DR-5 TYPE) “INSPECTION AND REPAIR”, PAGE 5B-91.
AIR BRAKES 5B-105
REASSEMBLY
25
26 11
12
23 1
22
21
20
6
5
4
19
18 2
24
3
7
8
17 9
10
16
15
14
13
Reassembly Steps
1. Body 14. O-ring
2. O-ring 15. O-ring
3. Valve body 16. Oil separator filter
4 Valve spring 17. Case
5. O-ring 18. Filter plate
6. Piston 19. Filter
7. Valve 20. Desiccant
8. Bolt and washer 21. Filter
9. Exhaust cover 22. Filter plate
10. Retaining ring 23. Set spring
11. Gasket ring 24. O-ring
12. Gasket ring 25. Cover and check valve
13. Cover 26. Purge chamber
5B-106 AIR BRAKES
Reassembly Steps
1. Body
1. Apply a coat of silicon grease to the cylinder of the
body.
2. O-ring
1. Apply a coat of silicon grease to the O-ring.
2. Install the O-ring to the body.
3. Valve Body
4. Valve Spring
5. O-ring
6. Piston
2. Install the O-ring to the piston.
3. Apply a coat of silicon grease to the valve body
bore and the piston metal sliding surface.
7. Valve
8. Bolt and Washer
1. Clamp a 10 mm hexagon wrench in a vise.
2. Set the piston on the hexagon wrench.
3. Tighten the bolt to the specified torque.
6 (0.6 / 52)
9. Exhaust Cover
10. Retaining Ring
11. Gasket Ring
1. Apply a coat of silicon grease to the gasket ring.
2. Install the gasket ring to the body.
12. Gasket Ring
13. Cover
14. O-ring
2. Install the O-ring to the body.
AIR BRAKES 5B-107
15. O-ring
16. Oil Separator Filter
17. Case
3 (0.3 / 26)
18. Filter Plate

19. Filter
20. Desiccant
1. Pour the entire package of desiccant material into
the case making sure none is lost.
2. While slowly turning the case, tap the side of the
case with a plastic mallet.
21. Filter
22. Filter Plate
23. Set Spring
24. O-ring
25. Cover and Check Valve
Tighten the screw to the specified torque.
Screw Torque N·m (kg·m / lb·in)
3 (0.3 / 26)
26. Purge Chamber

1. Install the purge chamber to the body.
2. Tighten the bolt to the specified torque.
23 (2.3 / 17)
5B-108 AIR BRAKES
OPERATIONAL TEST
Operation Test
1. Check that the purge noise continues for
approximately three(3) seconds when governor
cut-out pressure is reached.
2. After the air compressor has switched from unload
to load state following fall of the air pressure, the
leak from the air dryer exhaust port should be less
than 20 cc in one minute. (A 15 mm (0.59 in.) soap
bubble in 6 seconds is permissible.)
AIR COMPRESSOR AND GOVERNOR 5D-1
SECTION 5D
AIR COMPRESSOR AND GOVERNOR
CONTENTS
PAGE
General Description.......................................................................................................... 5D- 2
Air Compressor ................................................................................................................. 5D- 3
Disassembly .................................................................................................................. 5D- 3
Inspection and Repair .................................................................................................. 5D- 9
Reassembly ................................................................................................................... 5D- 15
Air Governor...................................................................................................................... 5D- 22
Inspection and Repair .................................................................................................. 5D- 22
5D-2 AIR COMPRESSOR AND GOVERNOR
GENERAL DESCRIPTION
Unloader
Unloader
Air outlet Air outlet
Air inlet
Air inlet
Inlet valve Delivery valve Inlet valve

Delivery valve
for 6HH1 engine (EURO-2 model) for 6HH1 engine (except EURO-2 model)
or 6SD1 engine
Air outlet Unloader

Unloader Air outlet
Air inlet
Air inlet
Inlet valve
Inlet valve Delivery valve
Delivery valve
for 6HE1-TC engine for 6SD1-TC engine
039MY00007
The air compressor is directly mounted to the cylinder the air pressure is regulated by the air governor.
body rear right side (6S series), or rear left side (6H The compressor unloader is also regulated by the
series). governor.
The air compressor is a reciprocating type driven by The system acts to maintain constant air pressure
the injection pump timing gear. resulting in improved fuel economy.
The air compressor delivers air to the air tank where
AIR COMPRESSOR
DISASSEMBLY
(6HH1 EURO-2 MODEL or 6SD1 MODEL)
10
7
3 8
9‫ޓޓޓޓ‬
6HH1
4 6SD1
11
6
2
12
6SD1 TC
13
14 15
1
12
13
039MY00006
Disassembly Steps
1. Nut or bolt 9. Piston
2. Injection pump timing gear 10. Piston ring
3. Unloader 11. Connecting rod assembly
4. Cylinder head 12. Bearing cover
5. Gasket 13. Crankshaft and bearing
6. Cylinder and O-ring 14. Oil seal
7. Snap ring 15. Crankcase
8. Piston pin
Disassembly Steps
1. Nut or Bolt
2. Injection Pump Timing Gear
1. Clamp the injection pump timing gear in a vise.
Take care not to damage the timing gear.
2. Loosen the nut.
3. Use a remover to remove the injection pump
timing gear.
3. Unloader
4. Cylinder Head
5. Gasket
6. Cylinder and O-ring
7. Snap Ring
Use snap ring pliers to remove the snap ring.
130401-002
8. Piston Pin
9. Piston
10. Piston Ring
Use a piston ring replacer to remove the piston ring.
130401-002
11. Connecting Rod Assembly

1. Straighten the connecting rod nut lock plate tang.
2. Loosen the connecting rod nuts.
3. Remove the connecting rod.
NOTE:
Do not attempt to remove the connecting rod cap
bolts.
130401-003
12. Bearing Cover

13. Crankshaft and Bearing
1. Use a mallet to drive out the crankshaft end.
Take care not to damage the crankshaft .
2. Remove the crankshaft with the bearing cover
from the crankcase.
3. Remove the bearing cover from the crankshaft.
130401-004
14. Oil Seal

15. Crankcase
DISASSEMBLY
(6HH1 EXCEPT EURO-2 MODEL or 6HE1-TC MODEL)
5
4
2 6
8
10
9
3
11
6HH1 9
11
6HE1-TC
039MY00003
Disassembly Steps
1. Unloader 6. Piston
2. Cylinder head assembly and 7. Piston ring assembly
gasket 8. Bearing cover, O-ring and Oil seal
3. Cylinder body and O-ring 9. Bearing
4. Snap ring 10. Connecting rod
5. Piston pin 11. Crankshaft and bearing
Disassembly Steps
1. Unloader
2. Cylinder Head Assembly and Gasket
3. Cylinder Body and O-ring
Remove the four bolts which connect the cylinder with
the crank case.
Tap out the cylinder from the crank case with a
wooden hammer.
4. Snap Ring
5. Piston Pin
Remove the snap ring using a snap ring pliers.
6. Piston
7. Piston Ring Assembly
Remove the piston ring using a piston ring pliers.
8. Bearing Cover, O-ring and Oil Seal

9. Bearing
Remove the bearing using a bearing remover or gear
remover.
10. Connecting Rod

Remove the bearing using a bench press.

during inspection.
Cylinder Head
Cylinder Head
Check the cylinder head for cracking.
If the cylinder head is cracked, it must be replaced.
Inlet Valve (In The Cylinder Head)
Check the valve spring and the valve seat for
excessive wear or damage.
If the inlet valve is excessively worn or damaged, the
entire cylinder head must be replaced.
Delivery Valve (In The Cylinder Head)
Check the valve excessive wear or damage.
If the valve is excessively worn or damaged, the entire
cylinder head must be replaced.
Unloader
1. Remove the unloader valve and spring from the
body.
2. Check the unloader valve for excessive wear or
damage.
If the unloader valve is excessively worn or
damaged, it must be replaced.
130501-001
Cylinder
Cylinder Bore and Piston Clearance
Cylinder Bore Uneven Wear
1. Use a cylinder indicator to measure the cylinder
bore.
If the uneven wear exceeds the specified limit, the
cylinder must be replaced.
Cylinder Bore Uneven Wear Limit mm (in)
0.1 (0.004)
Cylinder Bore (Reference) mm (in)

85.00 – 85.03 (3.346 – 3.348)
130502-002
2. Use a micrometer to measure the piston outside

diameter.
Piston Outside Diameter (Reference) mm (in)
84.91 – 84.93 (3.343 – 3.344)
3. Calculate the cylinder bore and piston clearance.
Cylinder Bore and Piston Clearance Limit mm (in)
0.2 (0.008)
If the clearance exceeds the specified limit, the
130502-003
cylinder and/or the piston must be replaced.
Piston
Piston and Piston Pin Clearance
1. Use a cylinder indicator to measure the piston pin
bore.
Piston Pin Bore (Reference) mm (in)
16.006 – 16.017 (0.630 – 0.631)
130502-005
2. Use a micrometer to measure the piston pin

diameter.
Piston Pin Diameter (Reference) mm (in)
15.991 – 16.000 (0.6296 – 0.6299)
3. Calculate the piston and piston pin clearance.
Piston and Piston Pin Clearance mm (in)
Cylinder bore size Standard Limit
0.006 – 0.026
130502-006
85 (3.347) 0.1 (0.004)
(0.0002 – 0.0010)
If the clearance exceeds the specified limit, the piston
and/or the piston pin must be replaced.
Piston Ring and Piston Ring Groove Clearance

Use a feeler gauge to measure the clearance between
the piston ring and the piston ring groove at several
points around the piston.
Piston Ring and Piston Ring Groove
Clearance mm (in)
Cylinder bore 85 mm type Standard Limit
0.02 – 0.05
Compression Ring
(0.0008 – 0.0020) 0.15
130502-007
0.03 – 0.07 (0.0060)
Oil Ring
(0.0012 – 0.0028)
If the clearance exceeds the specified limit, the piston
ring must be replaced.
Piston Ring Gap

Use a feeler gauge to measure the piston ring gap.
Do not allow the piston ring to slant to one side or the
other. It must be perfectly horizontal.
Piston Ring Gap (Cylinder bore 85 mm type) mm (in)
Standard Limit
0.15 – 0.30
Compression Ring
(0.006 – 0.012)
1.0 (0.039)
130502-004 0.15 – 0.35
Oil Ring
(0.006 – 0.014)
If the measured value exceeds the specified limit, the
piston ring must be replaced.
Connecting Rod
Connecting Rod Small End and Piston Pin clearance
1. Use a cylinder indicator to measure the connecting
rod small end inside diameter.
Connecting Rod Small End Inside Diameter
(Reference) mm (in)
Standard
16.006 – 16.017 (0.6300 – 0.6305)
2. Use a micrometer to measure the piston pin
130502-008 diameter.
Piston Pin Diameter (Reference) mm (in)
15.991 – 16.000 (0.6296 – 0.6299)
3. Calculate the connecting rod small end and piston
pin clearance.
Connecting Rod Small End and Piston Pin
Clearance mm (in)
Cylinder bore size Standard Limit
85 (3.347) 0.006 – 0.026 0.1 (0.004)
(0.0002 – 0.0010)
connecting rod and/or the piston pin must be
replaced.
Connecting Rod Big End Bearing and Crankpin Clearance

1. Use a cylinder indicator to measure the connecting
rod big end inside diameter.
Connecting Rod Big End Inside Diameter
(Reference) mm (in)
Cylinder bore size Engine Standard
40.009 – 40.034
6H series
(1.5751 – 1.5761)
85 (3.347)
130502-009 35.009 – 35.034
6S series
(1.3783 – 1.3793)
130502-020
2. Use a micrometer to measure the crankpin

diameter.
Crankpin Diameter (Reference) mm (in)
Cylinder bore size Engine Standard
39.959 – 39.975
6H series
(1.5732 – 1.5738)
85 (3.347)
34.959 – 34.975
6S series
(1.3763 – 1.3770)
3. Calculate the clearance between the connecting

rod big end and the crankpin.
Connecting Rod Big End Bearing and
Crankpin Clearance mm (in)
Cylinder bore
Engine Standard Limit
size
6H 0.034 – 0.075 0.15
85 (3.347)
6S (0.0013 – 0.0030) (0.006)

connecting rod and/or the crankshaft must be
replaced.
Crankshaft
Crankshaft and Ball Bearing
1. Check the oil seal fitting faces for excessive wear
and damage.
If the fitting faces are excessively worn or
damaged, they must be replaced.
2. Listen for excessive bearing operating noise.
Excessive bearing operating noise indicates severe
bearing wear.
The bearings must be replaced.
Ball Bearing Replacement

Ball Bearing Removal
1. Set the bearing remover 1 to the ball bearing.
2. Place the crankshaft 2 with the bearings installed
between the base plates 3 of the bench press.
3. Use the bench press to gradually apply pressure to
the crankshaft to remove the ball bearings from
the crankshaft.
Take care not to damage the crankshaft.
130502-011
Ball Bearing Installation

1. Place the ball bearings 1 between the base plates
2.
2. Apply engine oil to the crankshaft.
3. Set the crankshaft to the ball bearings.
4. Use the bench press to gradually press the
crankshaft down until the two ball bearings are
correctly positioned.
Be absolutely sure that the bearing inner race is
130502-012
supported by the base plates.
REASSEMBLY
(6HH1 EURO-2 MODEL or 6SD1 MODEL)
9
13 8
6HH1
12 6SD1
11
15
10
14
6SD1 TC
2 1
15
14
039MY00005
Reassembly Steps
1. Crankcase 9. Snap ring
2. Oil seal 10. Cylinder and O-ring
3. Crankshaft and bearing 11. Gasket
4. Bearing cover 12. Cylinder head
5. Connecting rod assembly 13. Unloader
6. Piston ring 14. Injection pump timing gear
7. Piston 15. Nut
8. Piston pin
Reassembly Steps
1. Crankcase
2. Oil Seal
1. Install the oil seal to the crankcase.
The oil seal lip must be facing the bearing.
2. Apply engine oil to the oil seal lip.
3. Set the crankshaft and bearing to the crankcase.
4. Use the bench press to gradually insert the
crankshaft until the crankshaft bearing makes
contact with the crankcase.
130602-002
4. Bearing Cover
6 (0.6 / 4.3)
5. Connecting Rod Assembly

1. Apply engine oil to the connecting rod bearings.
2. Install the connecting rod to the crankshaft.
3. Tighten the connecting rod nuts to the specified
torque.
Connecting Rod Bolt Torque N·m (kg·m / lb·ft)
25 (2.5 / 18)
4. Bend back the connecting rod lock plate tangs.
130602-003
6. Piston Ring
Use a piston ring replacer to install the piston rings to
the piston ring grooves.
The piston ring punched mark must be facing the
cylinder head.
7. Piston
8. Piston Pin
130602-004
9. Snap Ring
1. Set the piston to the connecting rod small end.
2. Insert the piston pin to the piston and the
connecting rod.
3. Use snap ring pliers to install the snap rings to the
piston.
130601-005
10. Cylinder and O-Ring

1. Apply engine oil to the O-ring circumference.
2. Apply engine oil to the cylinder bore and the
piston.
130601-006
3. Position the piston ring gaps as shown in the

illustration.
130601-007
4. Install the cylinder to the piston and the crankcase.

5. Tighten the cylinder bolts to the specified torque.
Cylinder Bolt Torque N·m (kg·m / lb·ft)
29 (3.0 / 22)
130601-008
11.Gasket
12.Cylinder Head
1. Install the cylinder head to the cylinder.
The air inlet port must be facing the injection
pump.
2. Tighten the cylinder head bolts to the specified
torque.
Cylinder Head Bolt Torque N·m (kg·m / lb·ft)
49 (5.0 / 36)
130601-009
13. Unloader
Tighten the unloader to the specified torque.
Unloader Torque N·m (kg·m / lb·ft)
49 (5.0 / 36)
130601-010
14. Injection Pump Timing Gear

15. Nut
1. Install the injection pump timing gear to the
crankshaft.
2. Clamp the injection pump timing gear assembly in
a vise to prevent the crankshaft from turning.
Take care not to damage the crankshaft.
3. Tighten the injection pump timing gear nut to the
specified torque.
Injection Pump Timing Gear Nut
6HH1 or 6SD1 engine 255 (26.0 / 188)
1st step 2nd step

6SD1-TC engine 29 (3.0 / 22) 70°
REASSEMBLY
(6HH1 EXCEPT EURO-2 MODEL or 6HE1-TC MODEL)
11
7
8
10 6
4
3
9
4HE1-TC 3
4HH1
039MY00004
Reassembly Steps
1. Crankshaft and bearing 7. Piston pin
2. Connecting rod 8. Snap ring
3. Bearing 9. Cylinder body and O-ring
4. Bearing cover, O-ring and Oil seal 10. Cylinder head assembly gasket
5. Piston ring assembly 11. Unloader
6. Piston
Reassembly Steps
2. Connecting Rod
3. Bearing
Use the bench press and suitable bar to reassemble
each parts.
4. Bearing Cover, O-ring and Oil Seal

Bearing Cover Bolt Torque
6HE1-TC 8 (0.8 / 69) N·m (kg·m / lb·in)
6HH1 23 (2.3 / 17) N·m (kg·m / lb·ft)
5. Piston Ring Assembly

• The 1st and 2nd rings should be installed with the
“R” mark turned up.
• Install the piston ring using a piston ring pliers.
• Set the piston rings to position as recommended.

6. Piston
7. Piston Pin
8. Snap Ring
9. Cylinder Body and O-ring
Cylinder Body Bolt Torque N·m (kg·m / lb·ft)
29 (3.0 / 22)
10. Cylinder Head Assembly Gasket

Cylinder Head Bolt and
Unloader Valve Torque N·m (kg·m / lb·ft)
49 (5.0 / 36)
11. Unloader
Tighten the unloader to the specified torque.
Unloader Torque N·m (kg·m / lb·ft)
49 (5.0 / 36)
130601-010
After reassembling the air compressor, install the

drive gear to the specified torque.
Drive Gear Nut Torque N·m (kg·m / lb·ft)
147 (15.0 / 108)
AIR GOVERNOR
during inspection.
This part cannot be overhauled. If it is found faulty, replace its assembly with a new one.
1. Operating Test
Start the engine and check for an increase in the
pressure of air within the air tank using a pressure
gauge. Check to make certain compressor action
stops as the reading of the pressure gauge reaches
760 – 800 kPa (7.8 – 8.2 kg / cm2).
For South Africa: 790 – 830 kPa (8.1 – 8.5 kg / cm2).
NOTE:
Charging action of the compressor can be checked
easily by hand-feeling the pulse at the air pipe
between the compressor and air tank. When a pulse
is felt, it indicates that the air tank is being charged.
830 – 40 (8.5 – 0.4 / 121 +– 60 )
+0 +0
2. Low Pressure Valve Leak Test

With the engine running at idle, depress and release
the brake pedal repeatedly to discharge air and check
to make certain the compressor starts charging when
pressure of air within the air tank is lowered to 670 –
710 kPa (6.8 – 7.2 kg / cm2).
For South Africa: 700 – 740 kPa (7.1 – 7.5 kg / cm2).
740 – 40 (7.5 – 0.4 / 107 +– 60 )
+0 +0
EXHAUST BRAKE 5E-1
SECTION 5E
EXHAUST BRAKE
CONTENTS
PAGE
General Description.......................................................................................................... 5E- 2
Exhaust Brake ................................................................................................................... 5E- 3
Removal......................................................................................................................... 5E- 3
Installation .................................................................................................................... 5E- 4
Exhaust Brake Valve......................................................................................................... 5E- 6
Disassembly .................................................................................................................. 5E- 6
Inspection and Repair .................................................................................................. 5E- 7
Reassembly ................................................................................................................... 5E- 8
Control Cylinder................................................................................................................ 5E- 10
Disassembly ...................................................................................................................... 5E- 10
Inspection and Repair .................................................................................................. 5E- 11
Reassembly ................................................................................................................... 5E- 12
5E-2 EXHAUST BRAKE
GENERAL DESCRIPTION
The exhaust brake system, when turned on, increases with compressed air, the control cylinder pushes the
the amount of power absorbed by the engine while exhaust brake valve shut. With the exhaust brake
coasting with the clutch engaged. valve shut, exhaust pressure allows the engine to
When both accelerator and clutch pedals are in the become a more effective brake.
released position, current flows to the exhaust brake If the accelerator or clutch pedal is pushed in, the
switch. Both the accelerator switch and clutch switch accelerator switch or clutch switch opens. The power
are normally closed. When the exhaust brake switch supply to the magnetic valve is interrupted. The
is turned on, current flows to the magnetic valve and magnetic valve closes, removing air pressure from
to the indicator light. When energized, the magnetic the control cylinder. The control cylinder then pulls
valve opens, allowing compressed air to flow from the exhaust brake valve back open. Normal engine
the air tank to the control cylinder. When supplied operation resumes.
EXHAUST BRAKE 5E-3
EXHAUST BRAKE
REMOVAL
Removal steps
1. Flexible hose 3. Control cylinder
2. Valve assembly 4. Bracket
Removal Steps
1. Flexible Hose
2. Valve Assembly
3. Control Cylinder
Plug the open holes of the removed parts to prevent
the entry of foreign material.
4. Bracket
5E-4 EXHAUST BRAKE
INSTALLATION
Installation Steps
1. Bracket 3. Valve assembly
2. Control cylinder 4. Flexible hose
EXHAUST BRAKE 5E-5
Installation Steps
1. Bracket
2. Control Cylinder
Tighten the control cylinder and bracket bolts to the
specified torque.
Control Cylinder and
Bracket Bolt Torque N·m (kg·m / lb·ft)
24 (2.4 / 17)
3. Valve Assembly
1. Tighten the valve assembly and bracket bolts to
the specified torque.
Valve Assembly and
Bracket Bolt Torque N·m (kg·m / lb·in)
13 (1.3 / 113)
2. Connect the links.
3. Adjust the valve lever stop bolt so that control
cylinder shaft will be 0.5 mm (0.020 in) taken out.
4. Flexible hose
5E-6 EXHAUST BRAKE
EXHAUST BRAKE VALVE

DISASSEMBLY
Disassembly Steps
1. Brake valve lever 3. Seal ring
2. Body plate 4. Body cover
Disassembly Steps
1. Brake Valve Lever
2. Body Plate
3. Seal Ring
4. Body Cover
EXHAUST BRAKE 5E-7

during inspection.
Visual Inspection
Visually inspect the following parts for excessive wear
and damage.
1. Body
2. Exhaust brake shaft
3. Butterfly valve
4. Bushings
5. Control rod
5E-8 EXHAUST BRAKE
REASSEMBLY
Reassembly Steps
1. Body cover 3. Body plate
2. Seal ring 4. Brake valve lever
EXHAUST BRAKE 5E-9
Reassembly Steps
1. Body Cover
Tighten the body cover bolts to the specified torque.
Body Cover Bolt Torque N·m (kg·m / lb·ft)
D
ø70 and ø75 13 (1.3 / 9.4)
ø80 27 (2.8 / 20)
2. Seal Ring
3. Body Plate
Tighten the body plate bolts to the specified torque.
Body Cover Bolt Torque N·m (kg·m / lb·ft)
D
ø70 and ø75 13 (1.3 / 9.4)
ø80 27 (2.8 / 20)
4. Brake Valve Lever

Tighten the brake valve lever nuts to the specified
torque.
Brake Lever Nut Torque N·m (kg·m / lb·ft)
D
ø70 and ø75 13 (1.3 / 9.4)
ø80 19 (1.9 / 14)
5E-10 EXHAUST BRAKE
CONTROL CYLINDER
DISASSEMBLY
Disassemble Steps
1. Cover 8. Gasket
2. O-ring 9. Wear ring
3. Piston assembly 10. Piston plate
4. Return spring 11. Shaft assembly
5. Nut 12. Dust seal
6. Washer 13. Retainer and Filter
7. Retainer 14. Cylinder Body
EXHAUST BRAKE 5E-11
Disassembly Steps
1. Cover
2. O-ring
3. Piston Assembly
4. Return Spring
5. Nut
6. Washer
7. Retainer
8. Gasket
9. Wear Ring
10. Piston Plate
11. Shaft Assembly
12. Dust Seal
13. Retainer and Filter
14. Cylinder Body

during inspection.
Visual Inspection
Visually inspect the following parts for excessive wear
and damage.
If excessive wear or damage is discovered during
inspection, the part(s) must be replaced.
1. Cover
2. Retainer
3. Wear ring
4. Piston plate
5. Shaft assembly
6. Return spring
7. Cylinder body
8. Gasket
9. O-ring
5E-12 EXHAUST BRAKE
REASSEMBLY
Reassembly Steps
1. Cylinder body 8. Retainer
2. Filter and retainer 9. Washer
3. Dust seal 10. Nut
4. Shaft assembly 11. Return spring
5. Piston plate 12. Piston assembly
6. Wear ring 13. O-ring
7. Gasket 14. Cover
EXHAUST BRAKE 5E-13
Reassembly Steps
1. Cylinder Body
1. Apply a coat of molybdenum disulfide grease to
the entire inside surface of the cylinder body.
2. Apply a coat of liquid gasket to the dust seal
installation position of the cylinder body.
2. Filter and Retainer
3. Dust Seal
1. Apply grease to the dust seal lip.
2. Apply a coat of liquid gasket to the dust seal outer
circumference.
4. Shaft Assembly
Apply a coat of molybdenum disulfide grease to the
entire surface of the shaft assembly.
5. Piston Plate
6. Wear Ring
7. Gasket
Apply a coat of molybdenum disulfide grease to the
gasket.
8. Retainer
9. Washer
10. Nut
Tighten the retainer nut to the specified torque.
Retainer Nut Torque N·m (kg·m / lb·in)
13 (1.3 / 113)
11. Return Spring
12. Piston Assembly
13. O-ring
14. Cover Assembly
Tighten the cover assembly bolts to the specified
torque.
Cover Assembly Bolt Torque N·m (kg·m / lb·in)
13 (1.3 / 113)
MEMO
MGBRF-WE-0021
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all countries

except the USA and Canada.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Dec., 2002

No.MGBRF-WE-0021 PRINTED IN JAPAN

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WORKSHOP MANUAL

International Service & Parts

Before using this Workshop Manual to assist you in performing

All material contained in this Manual is based on the latest

For the disassembly, reassembly and inspection of MERITOR-

This manual is applicable to 2000 year model and later vehicles.

SECTION NO. CONTENTS

Quick Loss of 1. Leaking lines or connections. 1. Repair or replace.

BRAKE SYSTEM (CONT.)

Safety Valve 1. Safety valve malfunction. 1. Replace.

Material at Center of Oversize drum. Repair or replace as required.

Linings Glazed 1. Grease on lining. 1–2. Repair or replace as required.

Linings Scored 1. Scored drum. 1–2. Repair or replace as required.

Elongation of Rivet Loose rivets or bolts. Repair or replace as required.

BRAKE LINING (CONT.)

Groove on Edge of 1. Linings too wide. 1–2. Repair or replace as required.

Excessive Scoring of 1. Improper friction materials. 1–5. Repair or replace as required.

Excessive Drum 1. Driver abuse. 1–5. Repair or replace as required.

2. AIR DRYER DOES NOT PURGE OR EXHAUST AIR

Test to determine air flows

Test electrical circuit

NG Repair or replace purge

3. CONSTANT EXHAUST OF AIR AT PURGE VALVE

NG Repair or replace Purge

4. UNABLE TO BUILD SYSTEM PRESSURE

NG Repair or replace faulty

AIR COMPRESSOR AND GOVERNOR

Excessive Oil Flowing 1. Excessive wear. 1. Repair or replace.

High or Low Pressure 1. Governor out of adjustment. 1. Replace the governor.

Exhaust Brake “ON” 1. Improperly adjusted clutch or 1. Adjust.

EXHAUST BRAKE (CONT.)

MAIN DATA AND SPECIFICATIONS

Air Compressor and Governor

Brake Pedal (RHD)

Lining Clearance Adjustment and Wear

Remove the check hole rubber cap on the brake

Cleaning of Exhaust Port

Greasing Up for Camshaft and Slack

Rearward Rear Axle

Load Sensing Proportioning Valve (L.S.P.V.)

Model Rear axle set load

2. Align the mark (•) on the valve body and the

FVZ Model (for South Africa only) :

GVR Model (for Australia only) :

When valve is completely closed, with lever

Clutch Switch (Mechanical Type)

Exhaust Brake Switch

Rear Wheel Brake N·m (kg·m / lb·ft)

Brake Valve (RHD) N·m (kg·m / lb·in)

2 (0.2 / 17) 7 (0.7 / 61)

Spring Chamber N·m (kg·m / lb·ft)

Air Compressor N·m (kg·m / lb·ft)

PART NO. SERVICE

Brake shoe spring

Brake shoe spring

Anchor pin puller

NO PART NAME NO PART NAME

23 EXH BRK CYL