8-1

BRAKE
Page
GENERAL ........................................................................ 8-2
SPECIFICATIONS .......................................................... 8-7
COMPONENTS .............................................................. 8-8
FRONT BRAKE .............................................................. 8-12
DISASSEMBLY•INSPECTION •REASSEMBLY
(1• J3.5 TON SERIES) ................................................... 8-12
DISASSEMBLY•INSPECTION •REASSEMBLY
(2 • 3 TON SERIES) ........................................................ 8-17
BRAKE AIR BLEEDING ................................................ 8-23
BRAKING FORCE INSPECTION • ADJUSTMENT .. 8-23
BRAKE MASTER CYLINDER ...................................... 8-24
REMOVAL•INSTALLATION ............................................... 8-24
DISASSEMBLY•INSPECTION •REASSEMBLY .................. 8-25 8
PARKING BRAKE INSPECTION • ADJUSTMENT .. 8-27
BRAKE PEDAL INSPECTION• ADJUSTMENT ....... 8-28
INCHING PEDAL INSPECTION• ADJUSTMENT .... 8-29
8-2

GENERAL
Hydraulic Circuit Diagram

(1) (2)

(3)
(9)
(14)
(10) (11)

(8) (7)
(13) (12)
(4)

(6)

(5)

(1) Inching pedal (8) Flow divider

(2) Brake pedal (9) Oil control valve
(3) Reservoir tank (10) Lift cylinder
(4) Brake master cylinder (11) Tilt cylinder
(5) Brake wheel cylinder (12) Steering valve
(6) Oil tank (13) Power steering cylinder
(7) Oil pump (14) Solenoid valve
 8-3

Front Brake

1 ton Series

Wheel Cylinder
8-4

2 • 3 ton Series

Wheel Cylinder
 8-5

J3.5 ton Series

Wheel Cylinder
8-6

Parking Brake
 8-7

Master Cylinder

SPECIFICATIONS
Vehicle model 1 ton series 2 ton series 3 ton series J3.5 ton series
Item
Hydraulic internal 8
Foot brake type expanding duo ← ← ←
servo brake
Internal
expanding
Parking brake ← ← ←
mechanical
brake
Brake drum inside diameter mm (in) 254 (10.0) 310 (12.2) ← 317.5 (12.5)
Resin mold
Material ← ← ←
(asbestos-free)
Brake lining Dimensions 279 x 48.5 x 5 323 x 60 x 7 343 x 60 x 7 352 x 60 x 5.6
Length x width x (11.0 x 1.91 x (12.7 x 2.36 x (13.5 x 2.36 x (13.9 x 2.36 x
length mm (in) 0.20) 0.28) 0.28) 0.22)
Wheel cylinder bore mm (in) 22.2 (0.87) 28.5 (1.12) ← ←
Brake master Bore mm (in) 19.05 (0.75) ← ← ←
cylinder Stroke mm (in) 30 (1.18) ← ← ←

Applicable oil SAE J-1703-

DOT-3 ← ← ←
8-8

COMPONENTS
Front Brake

1 ton Series

4715

2 • 3 ton Series

4715
 8-9

J3.5 ton Series

4715

8
8-10

Brake Pipe

4714

Brake Master Cylinder

4702
 8-11

Parking Brake

4601

Brake Pedal
8
4701
8-12

FRONT BRAKE
DISASSEMBLY• INSPECTION • REASSEMBLY (1• J3.5 TON SERIES)

11 4

12

8 3
6

Disassembly Procedure
1 Drain brake fluid.

2 Remove the front axle hub W/brake drum. (See page 5-7.)

3 Remove the shoe hold down spring and cup. [Point 1]

4 Remove the anchor to shoe spring and shoe guide plate. [Point 2]

5 Remove the cable and cable guide.

6 Remove the lever strut. [Point3]

7 Remove the adjuster spring and adjusting screw. [Point 4]

8 Disconnect the parking brake cable. [Point 5]

9 Remove the brake shoe. [Point 6]

10 Disconnect the brake pipe.

11 Remove the wheel cylinder ASSY. [Point 7]

12 Remove the backing plate. [Point 8]

13 Separate the brake drum from the front axle hub. [Point 9]
 8-13

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• See that the brake lining and brake drum interior surface are free from grease or oil before
installation.
• Before reassembly, decrease the brake drum outside diameter for installation to approx. 1 mm
(0.04 in) less than the drum inside diameter by tightening the adjusting screw.
• After reassembly, perform brake air bleeding (see page 8-23) and braking force inspection (see
page 8-23).

Point Operations
SST
[Point 1]
Disassembly •Reassembly:
SST 09510-31960-71

Inspection:
Measure the free length of the hold down spring.

Standard:
1 ton series: 25.5 mm (1.004 in)
J3.5 ton series: 44.0 mm (1.732 in)

Reassembly:
Apply liquid packing (08826-00080) on the shoe hold down
pin and the contact surface on the back side of the backing
plate to eliminate any clearance.
8-14

[Point 2]
SST Disassembly:
SST 09717-20010

Inspection:
Measure the free length of the anchor to shoe spring.

Standard:
1 ton series: 102.2 mm (4.024 in)
J3.5 ton series: On the side of lining W/pin
138.2 mm (5.441 in)
On the side of lining L/pin
121.2 mm (4.772 in)
Limit: No clearance between coil turns

Reassembly:
SST 09718-20010

SST

[Point 3]
Inspection:
Measure the free length of the strut to shoe spring.

Standard:
1 ton series: 19.7 mm (0.776 in)
J3.5 ton series: 31.4 mm (1.236 in)

[Point 4]
Inspection:
Measure the free length of the adjuster spring.

Standard:
1 ton series: 99.4 mm (3.913 in)
J3.5 ton series: 125.4 mm (4.937 in)
Limit: No clearance between coil turns
 8-15

Reassembly:
Apply grease on the adjusting screw threaded portion and
fill grease in the cap.

Reassembly:
Tie a wire to the free end of the adjuster spring and set by
pulling with a screwdriver.

[Point 5]
Reassembly:
Apply liquid packing (08826-00080) on the parking brake
cable outlet in the backing plate to eliminate any clearance.

[Point 6]
Inspection:
Measure the brake lining thickness.

Standard:
1 ton series: 4.9 mm (0.193 in)
J3.5 ton series: 5.6 mm (0.220 in)
Limit:
1 ton series: 1.0 mm (0.039 in)
J3.5 ton series: 1.0 mm (0.039 in)

Reassembly:
Before brake shoe installation, apply grease on illustrated
portions of the backing plate (6 places in contact with the
shoe rim and the anchor pin).

[Point 7]
Inspection:
Measure the clearance between the wheel cylinder and pis-
ton.

Limit:
1 ton series: 0.125 mm (0.00492 in)
J3.5 ton series: 0.15 mm (0.0059 in)
8-16

Reassembly:
Apply liquid packing (08826-00080) to backing plate fitting
portion of the wheel cylinder and on whole periphery of the
set bolts to eliminate any clearance.

[Point 8]
Reassembly:
Carefully install the backing plate set bolts because they
are different in length.
Apply thread tightener (08833-00070) on the set bolts be-
fore reassembly.

Bolt length
B: = 40 mm (1.57 in)
1 ton series J3.5 ton series
C: = 45 mm (1.77 in)

Reassembly:
Apply liquid packing (08826-00080) on the backing plate
surface in contact with the front axle bracket to eliminate
any clearance.


←

[Point 9]
Inspection:
Measure the brake drum inside diameter.

Standard:
1 ton series: 254 mm (10.0 in)
J3.5 ton series: 317.5 mm (12.50 in)

Limit:
1 ton series: 256 mm (10.1 in)
J3.5 ton series: 319.5 mm (12.579 in)

Reassembly:
Apply thread tightener (08833-00070) on the brake drum
set nut before reassembly.
 8-17

DISASSEMBLY• INSPECTION •REASSEMBLY (2 • 3 TON SERIES)

14 13

7
11

10

4
6

9
4

Disassembly Procedure
1 Drain brake fluid.
2 Remove rear wheels.
3 Remove the front axle hub W/brake drum. (See page 5-7.)
4 Remove the hold down spring. [Point 1]
5 Remove the pawl lever stopper. [Point 2]
6 Remove the pawl lever.
7 Remove the anchor to shoe spring. [Point 3]
8 Remove the strut lever. [Point 4]
9 Remove the adjuster spring and adjusting screw. [Point 5]
10 Disconnect the parking brake cable. [Point 6]
11 Remove the brake shoe. [Point 7]
12 Disconnect the brake piping.
13 Remove the wheel cylinder ASSY. [Point 8]
14 Remove the backing plate. [Point 9]
15 Separate the brake drum from the front axle hub. [Point 10]
8-18

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
(With regard to steps 4 and 5, however, install the pawl lever stopper after installing the hold down spring.)

Note:
• See that the brake lining and brake drum interior surface are free from grease or oil before
reassembly.
• Before reassembly, decrease the brake shoe outside diameter for installation to approx. 1 mm
(0.04 in) less than the brake drum inside diameter by tightening the adjusting screw.
• After reassembly, perform brake air bleeding (page 8-23) and braking force inspection and ad-
justment (page 8-23).

Point Operations
[Point 1]
SST Disassembly-Reassembly:
SST 09510-31960-71

Inspection:
Measure the free length of hold down spring.

Standard: 32.3 mm (1.272 in)

Limit: 29.1 mm (1.146 in)

Reassembly:
Apply liquid packing (08826-00080) on the back side of the
backing plate in contact with the shoe hold down spring to
eliminate any clearance.
 8-19

[Point 2]
Inspection:
Measure the free length of the actuator spring.

Standard: 124.5 mm (4.902 in)

Limit: No clearance between coil turns

Reassembly:
Use snap ring pliers and install the pawl lever stopper and
actuator spring.

[Point 3]
Disassembly:
SST SST 09717-20010

Inspection:
Measure the free length of the anchor to shoe spring.

Standard: 106 mm (4.17 in)

Limit: No clearance between coil turns

Reassembly:
SST 09718-20010
SST
8-20

[Point 4]
Inspection:
Measure the free length of the strut to shoe spring.

Standard: 23 mm (0.91 in)

Limit: 20 mm (0.79 in)

[Point 5]
Inspection:
Measure the free length of the adjuster spring.

Standard: 86 mm (3.39 in)

Limit: No clearance between coil turns

Reassembly:
Apply grease on the adjusting screw threaded portion and
fill grease in the cap.

[Point 6]
Reassembly:
Apply liquid packing (08826-00080) on the parking brake
outlet on the backing plate to eliminate any clearance.

[Point 7]
Inspection:
Measure the brake lining thickness.

Standard: 7.0 mm (0.276 in)

Limit: 2.0 mm (0.079 in)
 8-21

Reassembly:
Apply grease on the illustrated portions of the backing plate
(6 places in contact with the shoe rim and the anchor pin)
before brake shoe installation.

[Point 8]
Inspection:
Measure the clearance between the wheel cylinder and pis-
ton.

Limit: 0.145 mm (0.00571 in)

Reassembly:
Apply liquid packing (08826-00080) on the wheel cylinder
backing plate fitting portion and whole periphery of set bolts
to eliminate any clearance.

[Point 9]
Reassembly:
Carefully install the backing plate set bolts in correct posi-
tions since they are different in length.
Apply thread tightener (08833-00070) on the set bolts be-
fore reassembly.

Bolt length
A: = 36 mm (1.42 in)
2 ton series 3 ton series B: = 40 mm (1.57 in)
C: = 45 mm (1.77 in)

Reassembly:
Apply liquid packing (08826-00080) on the backing plate
surface in contact with the front axle bracket to eliminate
any clearance.


←
8-22

[Point 10]
Inspection:
Measure the brake drum inside diameter.

Standard: 310 mm (12.20 in)

Limit: 312 mm (12.28 in)

Reassembly:
Apply thread tightener (08833-00070) on the brake drum
set nut before reassembly.
 8-23

BRAKE AIR BLEEDING

Note:
Add brake fluid to the reservoir tank during air bleeding
to prevent it from becoming insufficient.

1. Bleed air from the brake master cylinder.

(1) Depress the brake pedal several times to compress
the air in the piping, and hold that state.
(2) Loosen the breather plug to discharge air in the piping
with the brake fluid, and tighten the plug immediately
before the fluid stops to run out.
(3) Repeat steps (1) and (2) above until no air bubbles
are seen in the discharged brake fluid.
2. Bleed air from wheel cylinders RH and LH.
(1) Operate as described in step 1 above for each of the
RH and LH side at a time.
3. Add brake fluid to the specified level.
(1) Add brake fluid through the filter provided at the reser-
voir tank.
(2) Add brake fluid up to the staged portion in the reser-
voir tank.

BRAKING FORCE INSPECTION • ADJUSTMENT

1. Inspect the braking force by means of a brake tester or traveling test.
Braking distance (without load)

Initial speed of braking km/h (mph) Max. speed

Braking distance m (ft) 5.0 or less (16.4)

2. Adjust the braking force.

(1) Repeat traveling in the forward and reverse directions to adjust the brake shoe clearance.
The adjusting screw adjusts the clearance automatically when the brake pedal is depressed in
reverse traveling.
(2) If the braking force is insufficient, adjuster malfunction, lining contact defect, foreign matter adhe-
sion on the lining or brake fluid leakage is assumed. Remove and inspect the brake drum.
(3) When the brake shoe is replaced with a new one, repeat traveling in the forward and reverse direc-
tions for running in.
8-24

BRAKE MASTER CYLINDER

REMOVAL•INSTALLATION T = N•m (kgf-cm) [ft-lbf]

T = 6.8 ~ 15.8
8 T = (69 ~ 161)
T = [5.0 ~ 11.6]

Removal Procedure
1 Remove the toe board.

2 Remove the lower panel.

3 Remove the instrument panel.

4 Remove the combination meter cover.

5 Disconnect the brake side hose from the reservoir tank and drain brake fluid.

6 Disconnect the piping.

7 Remove the push rod clevis pin.

8 Remove the brake master cylinder.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, perform brake pedal adjustment (page 8-28) and air bleeding (page 8-23).
 8-25

DISASSEMBLY • INSPECTION • REASSEMBLY T = N•m (kgf-cm) [ft-lbf]

1
2

3 5

T = 52.0 ~ 82.4
T = (530 ~ 840)
T = [38.3 ~ 60.8]

Disassembly Procedure
1 Turn the boot up and remove the snap ring.

2 Remove the push rod. [Point 1]

3 Remove the piston. [Point 2]

4 Remove the pin and the fluid inlet elbow.

5 Remove the outlet plug and valve.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
8-26

Point Operations
[Point 1]
Installation:
Temporarily set the push rod length to the illustrated dimen-
sion, and make readjustment after installation.

130 mm (5.12 in)

[Point 2]
Installation:
Apply rubber grease on the piston cup and whole periphery
of the cup before reassembly.
 8-27

PARKING BRAKE INSPECTION• ADJUST-

MENT
1. Check the parking brake cable set position.

Standard: A = 0 ~ 2 mm (0 ~ 0.08 in)

2. Apply chassis grease on the portions indicated by ar-

rows.
A

3. Inspect and adjust the parking brake lever operating

force.
(1) Set a spring scale at the center of the lever knob, and
measure the operating force by pulling it backward.

Standard:
1~3 ton series
147 ~ 196 N (15 ~ 20 kgf) [33 ~ 44 lbf]
J3.5 ton series
196 ~ 245 N (20 ~ 25 kgf) [44 ~ 55 lbf]

(2) If the operating force is out of the standard range, re-

lease the parking brake and make adjustment at the
adjusting portion.

Clockwise turn: Increases the operating force.

Counterclockwise turn: Decreases the operating
force.
8-28

BRAKE PEDAL INSPECTION• ADJUSTMENT

Stop lamp switch

Stopper bolt protrusion

Brake master cylinder

Push rod

(145 ~ 150 mm (5.71 ~ 5.91 in)

C

Reference value

A
D
Floor mat

Toe board

1. Inspect brake pedal height A. (From toe board to top of pedal)

Standard: A = 150 ~ 155 mm (5.91 ~ 6.10 in) (with pedal pad)

If the standard is not satisfied, make adjustment by changing the stop lamp switch position or the
stopper bolt protrusion.

2. Inspect brake pedal play B.

Standard: B = 3 ~ 7 mm (0.12 ~ 0.28 in)

If the standard is not satisfied, make adjustment by changing the master cylinder push rod length.

3. Check master cylinder push rod play C with the brake pedal in the above state.

Standard: C = 1 mm (0.04 in)

4. After the adjustment, fully depress the brake pedal D and inspect the pedal height in that state.

Standard: D = 90 mm (3.54 in) or more

 8-29

INCHING PEDAL INSPECTION• ADJUSTMENT

Stop lamp switch (5.2° ~ 6.5°)

Inching Brake link

pedal plate

←
←
Stopper bolt protrusion

Adjusting nut

A
C

(145 mm (5.71 in))

(150 mm (5.91 in))

Floor mat

Inching lever
Toe board

Adjusting nuts

1. Inspect and adjust the brake pedal height and play (See page 8-28).

2. Inspect stroke A of the inching pedal until interlocking with the brake (pedal stroke until the inching
pedal plate comes into contact with the brake link).

Standard: 1 ton series A = 30 ~ 35 mm (1.18 ~ 1.38 in)

Others A = 20 ~ 30 mm (0.79 ~ 1.18 in)

If the standard is not satisfied, adjust the stop lamp switch or stopper bolt protrusion.
Make adjustment to make the deviation from the brake pedal height within ± 10 mm (0.39 in).
3. Inspect and adjust the inching cable.

(1) Inspect the inching cable length B on the pedal side.

Standard: B = 17.5 mm (0.689 in)

If the standard is not satisfied, make adjustment by turning the adjusting nuts on the pedal height.

(2) Inspect inching pedal play C until the torque converter inching lever starts to move.

Standard: C = 3 ~ 5 mm (0.12 ~ 0.20 in)

If the standard is not satisfied, make adjustment by turning the adjusting nuts on the torque con-
verter side.