BR (Brake System)

BRAKE
GENERAL ........................................................................... BRa - 2 SPECIFICATIONS ............................................................... BRa - 14 SERVICE STANDARDS ...................................................... BRa - 15 TIGHTENING TORQUE ....................................................... BRa - 18 SERVICE PROCEDURES Air Compressor ............................................................ BRa - 20 Dual Brake Valve ........................................................... BRa - 28 Relay Valve .................................................................... BRa - 37 Front Wheel Brake ........................................................ BRa - 43 Rear Wheel Brake ......................................................... BRa - 47 Disk Brake ..................................................................... BRa - 52 Brake Chamber ............................................................. BRa - 59 Exhaust Brake System ................................................. BRa - 66 Intarder System............................................................. BRa - 76 Air Drier ......................................................................... BRa-107 Auto Slack Adjuster ...................................................... BRa-126 TROUBLESHOOTING ........................................................ BRa-140
BRa-2
BRAKE
GENERAL
Full Air Brake
[WITHOUT ABS SYSTEM]
HOSE
8 1 2 6 7 3
Air suspension
12 5
Supply PARKG
(15)
5
Door
10
19
7
RR
(35)
17
(25)
FR
14
15
20 11 9
1. 2. 3. 4. 5. 6.
Air compressor Air dryer Purge tank PR-4 protection valve Air reservoir Safety valve
7. 8. 9. 10. 11. 12.
Drain valve Air gauge Dual brake valve Parking brake valve R-12 relay valve Check valve
13. 14. 15. 16. 17. 18.
Double check valve Brake chamber Spring brake chamber Magnetic valve Low air pressure switch Exhaust brake valve
19. QR1C vlave 20. Quick release valve
KMABR003
GENERAL
BRa-5
Service Brake
Service brake is full air type brake of complete two systems where one side system is secured even if a case occur that air leaks by plate damage of other side, etc. Leading trailing type is used for both front and rear of wheel brake. In air system, air pressure is generated in air compressor, which air is sent to air dryer from which the dried air is then supplied to air tank and air pressure is maintained in a certain range by air pressure governor. And air is exhausted by operation of safety valve attached to air tank if air pressure in air tank rises above specified pressure.
Air Compressor
The air compressor is driven with revolutions of half the number of engine revolutions by injection pump gear that is in mesh with the timing gear on engine. The cylinder head of the air compressor is provided with the suction valve, delivery valve, and unloader valve allowing the system to accomplish the suction discharge and exhaust operation.
From the air pressure governor to air tank Unloader valve Delivery valve From the air cleaner Suction valve Piston Injection pump gear
Cylinder head Cyliner liner
Crank shaft
Crank case
JMS58A-005
1. Suction stroke Air intake is by negative pressure in cylinder when piston goes down. Air is introduced into cylinder because suction valve that has been intercepting the inlet opens the inlet by compressing the valve spring if negative pressure is large in cylinder. But suction valve is again pushed down by valve spring so as to intercept air inlet of valve seat if piston goes up to the rising reciprocation step.
Air inlet
Valve spring Suction valve
Piston
JMS58A-006
BRa-6
2. Delivery stroke As piston moves upward on its compression stroke, discharge side valve spring causes suction valve to close. Pressure of air being compressed in cylinder overcomes delivery valve spring tension pushing the delivery valve open to send air to air tank under high pressure. If piston goes down the reciprocation step, delivery valve being pushed again by valve spring closes air exhaust exit of valve seat. 3. When unloader valve is actuated When air pressure inside the air tank exceeds predetermined level, air pressure governor is actuated. Then air pressure governor sends compressed air to unloader valve, which causes unloader valve to be pushed down. At the same time, governor maintains suction valve in open position; as a result, no air is compressed and air compressor runs under no load. As air pressure in air tank drops below predetermined level, air pressure governor is again actuated to discharge compressed air above unloader valve. This results in unloader valve being returned to its original position by unloader valve spring, thus actuating the suction valve.
Air tank
BRAKE
Delivery valve spring Delivery valve
JMS58A-007
Unloader valve compressed air (from air pressure governor)
Unloader valve spring Suction valve
JMS58A-008
Dual break valve

Dual brake valve is control unit that (dis)connects and regulates compressed air from air tank so as to operate, release and control the brakes. 1. When pedal is depressed Piston is pushed down by plunger to force inner valve to open. Compressed air from air tank passes inner valve to actuate relay valve or quick relay valve. 2. When pedal is released Piston and inner valve are returned to their original positions by return spring to cut off compressed air supply. At the same time, compressed air supplied in air line escapes from exhaust valve to atmosphere.
Compressed air Front brake chamber Rear brake chamber
Compressed air
JMS58A-009
Compressed air
Compressed air
Exhaust gas
JMS58A-010
GENERAL
BRa-7
Pressure protection valve

1. Function This acts to interrupt air flow until the set pressure is made up. This is brake system safety function unit to prevent air pressure drop so that brake power is influenced mainly by excessive use of auxiliary equipment or any other cause. This is used after installed between the two tanks so that primary tank for use in brake be filled before air is filled in auxiliary secondary tank. This valve would also be installed at emergency line of tractor to protect tractor system. 2. How to operate (1) Pressure is made up at piston B until force of control spring A is overcome if air enters supply inlet G. Whence valve stem C is raised according to piston rise so as to open the suction valve D. Accordingly air passes the exhaust outlet E. (2) If air pressure drops down (supply inlet side or exhaust outlet side), piston goes down by force of control spring A so that suction valve is shut. Accordingly air flow is interrupted.
A B C G D E
MS58A-017
Quick release valve

1. Function It is to quickly exhaust air pressure through this valve when brake is released, which air has been accumulated in chamber.
JMS58A-019
2. How to operate (1) Air pushes diaphragm down to shut the exhaust outlet when brake is operated. At the same time the air pressure is supplied to chamber as diaphragm brim is pushed down.
Air
JMS58A-020
(2) If air pressure at upper and lower parts of diaphragm equals each other, diaphragm brim closes body seat and exhaust outlet is yet closed at diaphragm center part.
JMS58A-019
BRa-8
(3) If brake is released, air at upper part of diaphragm is exhausted through dual brake valve and diaphragm is raised to open the exhaust outlet so that air of chamber side quickly goes out.
BRAKE
JMS58A-021
Quick release check valve

1. Function This valve has functions of traditional double check valve and quick release valve together. Firstly it acts as quick release valve that supplies air to emergency side of spring brake and secondly it plays anti-compound function. Double check valve prevents simultaneous operation of service and emergency side. 2. How to operate (1) When spring brake is released Air that has passed quick release check valve from gradual valve makes the double check and quick release diaphragm to be flexed so as to close the balance and the exhaust outlet. Accordingly parking is accomplished as air enters emergency inlet of spring brake through exhaust outlet. (2) When spring brake operates Air supplied to valve is depleted through gradual valve. Air pressure makes the the double check and quick release diaphragm to be flexed in opposite direction so as to open the exhaust outlet of balance. Parking is accomplished as chamber air pressure is depleted through exhaust while air between two diaphragms is expelled through relay valve and brake valve. (3) Anti-compounding When service brake is operated while spring brake is being operated, air enters the balance opening and then the air passing through valve closes the supply inlet and the exhaust outlet by making the double check diaphragm and the quick release diaphragm to be flexed. So air passes delivery opening so that air in spring brake is depleted to accomplish parking. This prevents service and spring brakes to be simultaneously held.
JMS58A-022
GENERAL
BRa-9
Spring Valve
Check valve
Check valves at entrance of each layer of air tank are preventing reverse flow of air pressure being sent from air compressor to air tank.
Body
Air supply inlet
Air exhaust outlet
JMS58A-028
Air switch (Stop lamp switch)

Air switch installed at air piping between dual brake valve and air tank senses the air pressure generated by treading dual brake valve and turns on the brake lamp.
Air switch
Seal is coated in case of reuse material JMS58A-032
Low air pressure switch

This switch turns on the warning lamp in meter cluster so as to notify air pressure drop when air pressure in air tank is decreased below designated value.
JMS58A-033
Double check valve

When air enters from either side, this valve interrupts the other side. Namely in case when air supply is from air inlet A, check valve moves to B side so that A side and C side are passable. On other hand in case when air supply is from air inlet B, check valve moves to A side so that B side and C side are passable.
Connector Check valve
Air supply inlet B
Air supply inlet A
Air exhaust outlet C
JMS58A-037
BRa-10
BRAKE
Indicated pressure (from hand control valve)
Relay valve (Parking)

1. When operating If indicated pressure is introduced from hand control valve, piston moves down and sit on inlet valve so that gas exhaust channel (room F) is shut. Then inlet valve pressing the spring is pushed down and gap between inlet valve and air supply valve P of body is opened. Accordingly the air pressure of room B is introduced in room A and the pressure released of parking brake from discharge exit is supplied.
Piston Air supply valve P Room A Discharge exit (to brake chamber) Supply inlet (from air tank) Room B Spring
JMS58A-034
Inlet valve Room F
2. Brake pressure stabilized If indicated pressure from hand control valve is maintained in definite pressure, air pressure from discharge exit is also stabilized by the indicated pressure. Air pressure of room A passes channel C to be applied to piston bottom surface so that piston and inlet valve are pushed up while these are closely attached together. If inlet valve touches air supply valve P of body then air supply from air tank is stopped and the rising air pressure for release of parking brake is interrupted to be stable.
Indicated pressure (from hand control valve) Piston Air supply valve P Channel C Room A
Inlet valve
Supply inlet (from air tank) Room B

JMS58A-035
3. Releasing the brake pressure If indicated pressure from hand control valve becomes naught, piston is pushed up by spring and air pressure of discharge exit side (pressure of room A) so that air supply valve S at piston bottom is separated from inlet valve. Accordingly air pressure of discharge side is exhausted to atmosphere from room F of central exhaust gas channel.
Piston Room A Spring Air supply valve S Discharge exit Supply inlet (from air tank) Room F Exhaust gas
JMS58A-036
GENERAL
BRa-11
Wheel brake
1. Drum brake If brake pedal is trodden, force transmitted through chamber makes S cam to rotate so that brake shoe assembly is expanded to brake drum to decelerate or stop the car. Brake shoe assembly is supported by pin at anchor bracket and plays role in contraction of piston of wheel cylinder and brake shoe assembly when releasing the brake by return spring installed at shoe.
Brake chamber
Slack adjuster
Front brake assembly
JMS58A-161
Parking brake (Gradual parking)

This is used in controlling pressure of emergency brake and hand control parking brake. Precise and gradual air pressure is supplied to this valve so as to operate emergency brake and parking brake through spring brake chamber. Spring brake chamber is directly controlled according to volume by relay valve or hand control valve.
JMS419A
BRa-12
BRAKE
Exhaust brake system
To battery relay Exhaust brake switch
Air tank Magnet valve
Fuse
Control cylinder
Control cylinder
Intake silencer valve
Exhaust brake valve
To tachometer
Microswitch
Exhaust brake
Meter cluster
Clutch switch
Power relay
JMS58A-040
This system is auxiliary brake of foot brake and is composed of an exhaust brake unit of butterfly valve type and an intake silencer to reduce air suction noise generated at exhaust brake operation. If exhaust brake switch is turned on, 3-way magnet valve is driven to send the air pressure of air tank to control cylinder in exhaust brake unit and to close the exhaust brake valve so that exhaust brake is operated. At the same time air pressure is also sent to control cylinder of intake silencer so that intake silencer valve is also closed. And if clutch pedal or accelerator pedal is trodden, the electric circuit is temporarily turned off and the exhaust brake system is released. The pressure in exhaust pipe is raised by closing exhaust pipe; and so as for exhaust brake the pressure at exhaust reciprocation stroke acts as force to push back the piston, which becomes brake force.
Exhaust stroke
Exhaust brake valve
Exhaust pipe
JMS58A-041
GENERAL Intarder System
BRa-13
The driver can drive at high speed as increasing the vehicle weight, high efficient engine, and improved road condition. Due to the above conditions, the heat created by brake power has increased in service brake system. Because of brake fade phenomenon caused by the increased heat, it is difficult to cope with the emergency situation. To improve these conditions, intarder has been studied as the third brake with retarder. Intarder, differently to retarder system, has the rotor and stator installed inside of transmission to derease the rotating power of thrust shaft by hydraulic pressure. As the result, intarder controls the vehicles speed with high-performanced brake effect. Intarder has been applied to the transmission of express bus. (Model : ZF ECOMID 6S 1600 TM)
Helical gear
PTO connection Flange output
Stator
Rotor Oil reservoir Heat exchanger
Z000001A
BRa-14
BRAKE
SPECIFICATIONS
Items Brake type Brake line system Air dryer model Heater capacity (for car where heater is installed) Switch operation range for ON-OFF (for car where heater is installed) Valve operation pressure Purge chamber capacity Regeneration time of desicants Dual brake valve type Safety valve working pressure Wheel brake I.D. of Brake drum (Limit) Brake lining (Width x thickness (Limit)) Clearance between brake shoe and brake chamber in push rod stroke (Limit value) Dimensions related to drum Diameter Roundness Angularity Concentricity Clearance between drum and lining Brake type Front Rear Maximum push rod stroke Exhaust brake system Air compressor Front Rear Control method Valve type Type Cylinder I.DStrokesNo. of cylinder Cylinder displacement Max. Revolution Max. Allowable output Air tank capacity 410 + 0.3 mm 0.05 mm 0.05 mm 0.05 mm 0.3~0.5 mm #24 #30 Spring brakes 57 mm 63.5 mm Combination method of air pressure and electro magnetic valve Butterfly valve Water-cooling, 2 cylinder 85502 mm 502cc 1150rpm 8.5kg/cm2 30+24+23 liters Rear 25~30 (50) mm Front Rear Front Rear Front 156 x 19 (6.3) mm 220 x 19 (6.3) mm 25~30 (45) mm 5~9.8 kg.cm2 2.7 liters 40~50 sec. Treadle type (dual) 8.5~11.50.4 kg/cm2 410 (414) mm Specified value description Compressed air actuated, internal expansion-leadingtrailing shoe brakes acting on all wheels (With spring brake) Dual system (Dual brake) DR-5 24V-100W 44C~20C or less
SERVICE STANDARDS
BRa-15
SERVICE STANDARDS
Check items Dual brake valve Brake pedal play Pressure stroke Depressing angle Full stroke Pressure pro- Setting tection valve pressure (PR-4 valve) Quick release check valve (QR-1C vlave) Operation test When pressure of supply inlet side is zero When pressurized 12.8 kg/cm2 Exhaust outlet side pressure 0.035kg/cm2 or more Pressure difference between supply inlet and exhaust outlet 0.07 kg/cm2 Safety valve Air drier Working pressure when air outlet is completely closed and an air pressure of 0.5~9kg/cm2 is applied to air inlet Air leaks at valve under the same Less then 20cc/min condition as above Air leaks any position when an air pressure of 9kg/cm2 is applied to control port Relay valve Piston spring Load/ Inlet and outlet pressure difference 0.280.149 kgf/cm2 or less 1.65 kg/10.3 1.35kg/10.3 2.4kg/15.7 Replace Inlet valve spring installed length 3.0 kg/15.7 Correct or replace Replace valve spring and valve complete Replace 8.5-11.54 Replace Periodically disassemble and check per year Depressing angle General For air suspension 16.5 181.5 5.96 kgf/cm2 3.16 kgf/cm2 Standard value 0.35kg/cm2 Depressing angle 12 Depressing angle Norminal value (Basic diameter[ ]) 41.5 Limit value Remedy and Remarks Adjust air susction pressure by adjusting screw Air pressure 2.30.4 kg/cm2 Air pressure 40.5 kg/cm2 Air pressure 7kg/cm2 Periodically check per 40,000km Air suction pressure 7kg/cm2
Air leaks at any position of the drier -
BRa-16
BRAKE
Unit : mm Nominal value Check items Operating pressure (Basic diameter[ ]) 2.89kg/cm2 0.079kg/cm2 or less 0.3 kg/cm2 Limit value Remedy and Remarks Replace Replace Replace
Quick Check valve Supply valve Cab control valve Brake drum
release valve Pressure difference Inlet and outlet pressure difference for service brake Valve opening pressure Valve closing pressure Working pressure (Return pressure of depressed knob) Inner diameter Cylindricity Brake shoe return spring Brake shoe Load/ installed length Front Rear
3.2~3.8 kg/cm2 3.0~3.4 kg/cm2 1.8~2.5 kg/cm2 [410] 0.05 43 kg/255 55 kg/255
Correct or replace Correct or replace 414 0.2 coil loops or between coils and cover Replace with I.D. when over size is used. Correct Any gap between Replace
Brake lining thickness Clearance between bushing and anchor pin Clearance between bushing and cam shaft
19 for all car models Abrasion limit : 6.3 Replace lining [35] 0.05~0.14 0.3 for all car models Replace bushing [40] 0.16~0.21 0.5 for all car models
SERVICE STANDARDS
BRa-17
Unit : mm
Check items
Nominal value (Basci diameter[ ])
Limit value
Remedy and Remarks Replace
Exhaust Exhaust Spindle to bushing clearance [12]0.25~0.35 brake brake Clearance between A, B 0.1 or less system butterfly valve and A+B and body at 0.1~0.4 /2 operating position Control cylinder Load/ Return spring installed 8.3kg/106 load length Intake Valve shaft to bushing clearance [16]0.03~0.11 silencer Clearance between 1 or less butterfly valve and coupler or air duct at DL 2~3 B+B DC 4~5 operating position Control cylinder Load/ Return spring installed 7.3kg/109 load length Magnet Air When outlet port is valve leak plugged and air at presTo be free of air sure of 3~10kg/cm2 leaks is applied to inlet port and valve operated. When air at a presMinimum sure of 10kg/cm2 20V or less operating is applied to inlet voltage port. Suction valve Air com- Suction valve spring Load/ Load/ 0.45kg/5 pressor bending length spring bending installed installed Delivery valve spring Delivery valve length 0.46kg/9.5 bending spring bending Compression Piston ring to fitting clearance (measured in ring cylinder liner) Oil ring Piston ring to piston Compression groove clearance ring Fit clearance between piston pin and piston [16] Piston pin to connecting rod small end part [16] clearance Fit clearance between Top side [80] piston cylinder and liner Skirt side [80] Crank shaft to connecting rod bearing [34] clearance End play of crank shaft End play of connecting rod -
Adjust
7.1kg/106
Replace Replace
Adjust
6.2kg/109
Replace
Replace
0.36kg/5 Replace 0.37kg/9.5 1.0 1.0 0.1 0.08 0.07 0.28 0.18 0.1 1.0 1.0 Replace piston ring set Replace Replace connecting rod Replace Replace bearing Replace crankshaft Replace crankshaft or connecting rod
Replace piston ring set
BRa-18
BRAKE
TIGHTENING TORQUE
Check items 6.35 Brake pipe flare nut 10 12 15 Air compressor Cylinder head mounting nut Piston plate mounting nut Tightening retainer Injection pump gear mounting nut Tightening switch assembly Tightening plug Bearing holder mounting bolt Connecting rod cap mounting nut Tightening unloader valve guide or unloader connector Tightening delivery valve holder Cylinder shell and cylinder body mounting bolt Tightening suction valve holder Air drier Case cover mounting nut Case cover screw Oil filter mounting nut Valve complete mounting bolt Tightening heater Thermostat complete mounting screw Bracket tightening nut Delivery brake valve Tightening Board mounting bolt Piston part bolt Tightening sleeve Tightening screw Plate assembly bolt Cover mounting bolt Tightening lock nut of adjusting screw side M10x1.25 8DC 8DC 8DC 8DC Screw size (O.D.pitch)
M12x1.0 M12x1.5
Tightening torque Nm(kgfm) 21~26 (2.1~2.6) 51~60 (5.1~6.0) 77~90 (7.7~9.0) 85~100 (8.5~10) 23~28 (2.3~2.8) 20~30 (2.0~3.0) 8.0~20 (0.8~2.0) 220 (22) 25~35 (2.5~3.5) 7.0~13 (0.7~1.3) 19~26 (1.9~2.6) 23~26 (2.3~2.6) 100~120 (10~12) 100~120 (10~12) 20~30 (2.0~3.0) 100~120 (10~12) 4.0~7.0 (0.4~0.7) 4.0~7.0 (0.4~0.7) 4.0~7.0 (0.4~0.7) 4.0~7.0 (0.4~0.7) 20~30 (2.0~3.0) 1.5~2.5 (0.15~0.25) 50~60 (0.5~0.6) 30~40 (3.0~4.0) 30~120 (3.0~12) 15~25 (1.5~2.5) 12~19 (1.2~1.9) 1.0~3.0 (0.1~0.3) 5.0~8.0 (0.5~0.8) 12~19 (1.2~1.9) 5.0~8.0 (0.5~0.8) 5.0~8.0 (0.5~0.8)
M16x1.5 M20x1.5 M22x1.5 M10x1.25 M24x1.5 M14x1.5 M8x1.25 M8x1.25 M28x1.5 M36x1.5 M10x1.25 M45x1.5 PT 3/8
SERVICE STANDARDS
Screw size (O.D. x pitch) Lock nut tightening Brake hose Tightening back plate mounting bolt Tightening anchor bracket mounting nut Anchor pin lock plate mounting bolt Rear wheel brake Tightening brake hose Tightening oil pipe plate Tightening back plate mounting bolt Tightening anchor bracket mounting nut Anchor pin lock plate mounting bolt Exhaust brake system Exhaust brake valve Control cylinder mounting bolt Lever mounting nut Stopper plate adjusting bolt lock nut Control cylinder Intake silencer Plate mounting bolt Lever mounting bolt Lock plate mounting bolt Control cylinder Plate mounting nut Cover mounting bolt Plate mounting nut Cover mounting nut M8x1.25 M12x1.25 M10x1.25 M10x1.25 M16x1.5 M10x1.25 M10x1.25 M10x1.0 M10x1.25 M14x1.25 M10x1.25 M8x1.25 M6x1.25 -
BRa-19
Tightening torque Nm (kgfm) 4.0~7.0 (0.4~0.7) 45~50 (4.5~5.5) 21~32 (2.1~3.2) 16~24 (1.6~2.4) 190~260 (18.7~25.3) 16~24 (1.6~2.4) 21~32 (2.1~3.2) 12~16 (1.2~1.6) 16~24 (1.6~2.4) 110~180 (10.3~17.3) 16~24 (1.6~2.4) 21~26 (2.1~2.6) 10~16 (1.0~1.6) 5.0~7.0 (0.5~0.7) 10~16 (1.0~1.6) 9.0~12 (0.9~1.2) 38~46 (3.8~4.6) 20~24 (2.0~2.4) 10~16 (1.0~1.6)
Check items Air pressure governor Check valve cap Front wheel brake
BRa-20
BRAKE
SERVICE PROCEDURES
1. Tightening torque of brake pipe Connector shape Pipe diameter (mm) Screw diameter (mm) 6.35 10 12 15 12 16 20 22 Pitch (mm) 1.0 1.5 1.5 1.5 1.5 39~50 (4.0~5.1) 59~78 (6~8) 69~93 (7.0~9.5) Tightening torque Nm (kgfm) 19~25 (1.9~2.6)
2. Sealant coating When reusing air line air hose or connector, fasten it after coating sealant except part of one or two threads at slanting end side of screw surface after removing water, grease, oil, sealant etc. remained after disassembling.
Slanting screw surface
Sealant is applied on slanting end side of screw surface except one or two threads.
Sealant is not applied on plain screw surface.
JMS58A-049
Air compressor
Removal and installation
1. Remove the injection pump assembly. 2. Disconnect all connections
Suction air pipe
Water outlet pipe Unloader pipe Water inlet pipe
Water inlet pipe
Air outlet pipe Unloader pipe
JMS58A-050
3. 8DC engine 1) Set No.1 cylinder piston of crank the engine at the top dead center on the compression stroke. When the pointer on the flywheel housing is aligned with the line 1, 4 on the flywheel pulley, the pistons in No. 1 and No. 4 cylinders are at TDC. At this time, the piston in the cylinder whose push rod is no pushing up the rocker, is at TDC on its compression stroke. NOTE : Whenever the engine is to be cranked, crank it by hand 180 in the direction of normal rotation.
JMS58A-050
SERVICE PROCEDURES
2) Insert the air compressor in the hole provided in flywheel housing until its gear end makes contact with the end surfaces of both injection pump gear and cam shaft gear. Align the inscribed lines on the rear plate and injection pump gear and push the air compressor inward.
BRa-21
Align inscribed lines Flywheel housing Rear plate
JMS58A-053
3) Remove tachometer sensor from flywheel housing. Make sure that the sensor plate projection is positioned at the center of the sensor mounting tapped hole, then secure air compressor. 4) If the projection is out of position, pull out the air compressor and perform step (b) again. NOTE : If the injection pump gear is in mesh with cam shaft gear one tooth off the specified tooth, about a half portion of the sensor plate projection disappears from the tapped hole.
Tachometer sensor
Sensor plate projection
JMS58A-054
5) Mounting the tachometer sensor Apply sealant to the threads of the sensor and screw and tighten the screw until its hexagonal part bottoms.
Apply sealant to threads (THREEBOND 1211 or 1212 or equivalent) Hexagonal part
JMS58A-055
BRa-22
BRAKE
< D6A ENGINE >

9 5 6 7 10 11 Settling 12 Settling 13 Wear, damage 17 16 15 14
4 Cracks, scratch 22 18 19 20 Cracks, wear of bushing, clogged 26 oil hole Damage of 28 circle, wear 23 21
Wear, damage Settling
21
1 Cracks, wear
32 30 28 Damage of circle, wear 27
24 25 Wear, damage Disassembly sequence 1. Sensor plate 2. Injection pump gear 3. Collar 4. Cylinder head 5. Snap ring 6. Unloader valve 7. Valve spring 8. Valve guide 9. Valve holder 10. Spring holder 11. Delivery valve spring
31
29
Crankshaft end play L 1.0 mm
12. Delivery valve 13. Delivery valve seat 14 Suction valve holder 15. Suction valve spring 16. Suction valve 17. Suction valve seat 18. Cylinder liner 19 Compression ring 20 Oil ring 21. Snap ring 22. Piston pin
23. Piston 24. Bearing holder 25. Oil seal 26. Connecting rod 27. Connecting rod cap 28. Connecting rod bearing 29. Crankshaft 30. Crankcase 31. Bearing 32. Bearing
For parts with an encircled number, refer to disassembly procedure that follows.
MA580190
SERVICE PROCEDURES Disassembly procedure

1. Removal of suction valve NOTE : Since the suction valve holder is staked by punching, do not attempt disassembly unless trouble is evident.
BRa-23
Suction valve tool
MA580210
2. Removal of piston ring NOTE : When a piston ring is removed, do not widen the open ends of the piston ring more than 26mm.
Suction valve tool
MA580220
BRa-24
BRAKE
Inspection and correction

< D6A ENGINE >
Deterioration load/installed length NV 4.5N (0.46 kgf)/9.5 mm L 3.6N (0.37 kgf)/9.5 mm Clearance BD 80 mm L Top 0.3 mm Skirt 0.2 mm Deterioration load/installed length NV 4.4N (0.45 kgf)/5 mm L 3.5N (0.36 kgf)/5 mm
Clearance BD 16 mm L 0.08 mm
Connecting rod end play L 0.5 mm
Clearance between piston ring to piston ring groove L 0.1 mm Piston ring end gap L 1.0 mm Crankshaft end play L 1.0 mm
BD ... Basic Diameter NV ... Nominal Value L ... Limit
MA580230
SERVICE PROCEDURES
BRa-25
< D6A ENGINE >
Apply 0.2 to 0.3 cc of THREBOND Thread Lock Cement 1323B or equivalent to three threads
98 to 115 Nm (10 to 12 kgfm) 9 10 11 12 13 25 to 29 Nm (2.5 to 3.0 kgfm)
98 to 115 Nm 8 (10 to 12 kgfm) 5 6 7 14 15 98 to 115 Nm 16
39 to 49 Nm (4 to 5 kgfm) 18 23 22 21 19 20
15 to 20 Nm (1.5 to 2.0 kgfm) 31

Apply engine oil to lips
17
(10 to 12 kgfm)
215 Nm (22 kgfm)

Dowel pin
25 24 14 to 18 Nm (1.4 to 1.8 kgfm) Bend lock washer 26 27 28 29 30 32 3 2 1
23 to 25 Nm (2.3 to 2.6 kgfm)
Reassembly sequence 30 32 31 29 24
25
28
27 13
26 12
23 11
22 10 9
21 17
20 16
19 15 7
18 14 5
For parts with an encircled number, refer to reassembly procedure that follows.
MA580250
BRa-26 Reassembly Procedure

1. Assembly of connecting rod Assemble the connecting rod with the matchmarks on the connecting rod and connecting rod cap at the same side.
Connecting rod
BEAKE
Nut 23 to 25 Nm (2.3 to 2.6 kgfm) Bend lock washer Match marks
Connecting rod cap
Face the cut side of bolt gead inside

MA580270
2. Installation of piston rings Make sure that the correct piston rings are installed at the correct positions and their sides with letters stamped faced up. Keep the compression ring ends 120 apart from one another; place the oil ring ends at the center between the ends of compression rings; place the side ring ends 45 further away to the right and left from the oil ring ends.
Piston ring tool
MA580280
Face side with letters stamped up 1st compression ring 2nd, 3rd compression ring Side ring < D8A > Oil ring Side ring 2nd compression ring ends Approx. 120 Approx. Approx. 45 45
Approx. 120
3rd compression ring ends
1st compression ring ends
Side ring ends Side ring ends < D8A > Oil ring < D8A >
MA580290
3. Installation of suction valve holder.
Suction valve tool
MA580300
SERVICE PROCEDURES
Stake the cylinder head at three places shown over the suction valve holder.
Punch at three places, except the head gasket surface
BRa-27
Cylinder head Suction valve holder
MA580310
4. Installation of injection pump gear Install the injection pump gear, sensor plate, and nut as shown above.
Align "O" mark with "U" mark
Face this side to gear
Nut
Injection pump gear Align notch in sensor plate with "O" mark in gear Align catch with notch in sensor plate MA580320
BRa-28
BEAKE
Dual brake valve

Brake pedal assembly
40~51 Nm (4.0~5.1kgfm)
40~51 Nm (4.0~5.1kgfm)
60~80Nm (6~8kgfm) 30~40 Nm (3~4kgfm)
60~80Nm (6~8kgfm) 30~40 Nm (3~4kgfm)
Dual brake valve
JMS58A-158
NOTE : 1. Plug the ends of the removed air pipes and the open parts of the dual brake valve. 2. Check for air leakage after installation.
SERVICE PROCEDURES Disassembly and inspection

Spindle hole I.D. BD9.5 L 9.68 Straight pin O.D. Roller mounting BD 9.5 L 9.44 Pedal mounting BD 9.5 L 9.45 Spring deterioration Load kg/Installed length L 22/12.6 Spring deterioration Load kg/Installed length L 21.8/26.5 Spring deterioration Load kg/Installed length L 6.1/19.1 Spring deterioration Load kg/Installed length L 9.9/17 4 2 3 2 8 7 6
BRa-29
Unit :mm
Roller I.D. BD19.9 Roller I.D. BD18.3 L 18.5 Plunger O.D. BD19.9 L 19.8 Roller contact surface wear Slide surface damage or jaw wear
6 1
10 11 23 24 25 Straight pin hole O.D. BD9.5 L 9.68 Bushing I.D. BD20 L 20.08
26 21 22 27 28 29
14 12 13 15 16 Corrosion, damage
38 Spring deterioration Load kg/Installed length L 4.8/12.8 Spring deterioration Load kg/Installed length L 3.8/14.3 20 37 36 35 34 33 32 31 30
17 Deterioration 18 19 39 49 Internal surface damage, wear, corrosion 48 47
Spring deterioration Load kg/Installed length L 4.8/12.9 BD ... Basic diameter NV ... Nominal value L ... Limit value
46 45 44 43 42 41 40
FJR58A-042
BRa-30
Disassembly sequence 1. Spring pin 2. Straight pin 3. L-pin 4. Roller 5). Pedal cover 6. Pedal assembly 7. Boot 8. Plunger 9. Plate assembly 10 . Retaining ring 11. Spring 12 . Relay piston 13 . O-ring 14 . O-ring 15. Sleeve 16. Washer 17. Sleeve outer spring
BEAKE
18. 19. 20. 21. 22 . 23. 24. 25. 26. 27. 28 . 29. 30 . 31. 32. 33 .
Sleeve inner spring Screw Relay piston spring Bushing O-ring Self-locking bolt Spring seat Primary piston outer spring Primary piston inner spring Primary piston O-ring Primary piston spring Retaining ring Primary inlet valve retainer O-ring O-ring
34. 35. 36. 37. 38. 39 . 40 . 41. 42. 43 . 44 . 45. 46. 47. 48. 49.
Washer Primary inlet valve spring Washer Primary inlet valve Body O-ring Retaining ring Exhaust cover assembly Washer O-ring O-ring Secondary inlet valve retainer Secondary inlet valve spring Valve retainer Secondary inlet valve Cover
NOTE : 1. Before disassembly, remove dust, dirt, and other foreign matter from the surface. During the procedure, use utmost care to prevent entry of any foreign object. 2. Display arranged mark at each connection part before disassembling. 3. Wipe or wash the disassembled parts using the following procedure. (1) Rubber parts : For rubber parts seeming intact, wipe surfaces clean of deposits with a soft cloth dampened with alcohol or light oil. (2) Metallic parts : Clean metal parts in light oil except plate then blow air to dry. Dry it by blowing compressed air in order to completely remove the cleaning solution.
Part A
Plate assembly
Body
Disassembly procedure
1. Alignment marks Put alignment marks on each joint before disassembly. Part A : Plate assembly and body Part B : Body and cover 2. Removal of relay piston Clamp socket wrench (width across flats 14mm) in a vise. Secure the body so that the piston bolt is aligned with socket wrench. Then, gradually loosen the screw. NOTE : When the screw is loosened, the tension of the spring in the body may cause the piston and spring to jump out. Be sure to hold down the body, together with the relay piston, when loosening the screw.
Part B Cover
JJR58-032
Philips screwdriver Relay piston
Screw Socket wrench
JJR58-033
SERVICE PROCEDURES
3. Removal of O-ring 1) Using the Needle, remove the O-rings from the relay piston.
In relay piston Needle O-ring Relay piston O-ring
BRa-31
JJR58-034
2) Remove the O-ring from the piston.
At piston
O-ring
Needle
Piston
JJR58-036
3) Remove the O-ring from the bushing.
At bushing O-ring Bushing
Needle
JJR58-035
4) Remove the O-ring from the cover.
In cover
Needle
Cover O-ring
JJR58-037
a. Using a pliers, remove the retaining rings from the inlet valve.
At inlet valve Retaining ring Pliers
JJR58-038
BRa-32
b. Using a pliers, remove the retaining ring from the exhaust cover assembly.
At exhaust cover assembly Pliers
BEAKE
Retaining ring
JJR58-039
SERVICE PROCEDURES
BRa-33
Reassembly
3 2
Apply multipurpose type grease (NLGI No. 2) Li soap.
Section A-A
4 12 to 19 Nm (1.2 to 1.9 kgfm)
Adjusting screw A 4.9 to 7.8 Nm (0.5 to 0.8 kgfm) 4.9 to 7.8 Nm (0.5 to 0.8 kgfm) 23 24 21 * 27 25 26 29 * 37 35 20 A
8 7 10 11 1 to 2.9 Nm (0.1 to 0.3 kgfm)
13 34 39 12 33 32 45 42 48 * 41 44 43 40 46 47 49 0.6 to 1.2 Nm (6 to 12 kgfm) Apply multipurpose type grease (NLGI No. 2) Li soap to sliding surfaces of parts marked with *
9 22 28 38 15 16 17 36 18 19 31 30 4.9 to 7.8 Nm 14 4.9 to 7.8 Nm (0.5 to 0.8 kgfm) (0.5 to 0.8 kgfm) Apply multipurpose type grease (NLGI No. 2) Li soap to O-ring at installation
Reassembly sequence 49 48 45 38 37 47 44 36 31 46 43 27 35 32 19 28 34 33 18 17 16 15 12 14 13 21 30 22 29 26 25 24 23 20 11 10 9 8 5 7 1 6 3 4 2 42 41 40 39
For parts with an encircled number, refer to reassembly procedure that follows.
MA580430
BRa-34
1. Installation of retaining ring 1) Exhaust cover assembly Using a pliers, install the retaining ring to the exhaust cover assembly.
BEAKE
Pliers Retaining ring
MA580440
2) Inlet valve Using a pliers, install the retaining ring to the inlet valve assembly.
Retaining ring Pliers
MA580450
2. Installation of relay piston O-ring

Insert tool O-ring Relay piston
MA580460
3. Locking of piston After inserting the piston into the body, install the retainer to prevent the piston from jumping out.
Retainer
MA580470
Inspection and adjustment after installation

1. Installation pressure gauge [capable of measuring 980 kPa (10 kgf/cm) or more] to the primary outlet port of the dual brake valve. Fit foot pressure gauge to the brake pedal. Increase the air tank pressure to 685 kPa (7 kgf/cm) and check parts for possible air leaks.
Foot pressure gauge
Pressure gauge
MA580480
SERVICE PROCEDURES
2. Tighten the push rod in the dual brake valve and set the screw on the pedal to adjust the brake pedal angle so that the following characteristic diagram can be met.
BRa-35
3 to 5, 12 to 20 mm (play)
Adjusted with adjusting screw Air pressure setup
12 12 1.5
224.0 kpa (2.20.4 kgfcm2) 70 kpa (7kgfcm2)
G7BR0800
3. Use the adjusting screw to adjust the play at the tip of the pedal.
y Pla Increase Decrease Turn clockwise to decrease play and turn counter clockwise to increase paly
Adjusting screw
G7BR0810
BRa-36 Air brake valve characteristic diagram
BEAKE
Full stroke : 30 3 19.5 1.5 (at output pressure 7 kgf/cm) 8 7 6 Primary output pressure (kgf/cm) Output pressure 5 2.2 0.4 kgfcm DEPRESSING FORCE (kgf) 22 0 4
3 2 1 10.0 2.0 kgf (at 2.2 kgf/cm) 0 2 4 3.5 1.5 6 8 10 12 14 16 18 20 Foot pressure : 26 2 kgf
PEDAL DEPRESSING ANGLE
MA580510
SERVICE PROCEDURES
BRa-37
Relay valve
Disassembly, inspection and correction
Disassembly sequence 1. 2. 3. 4. 5. 6. 7. 8. 9. Retaining ring Exhaust cover assembly Retaining ring Valve guide O-ring O-ring Spring Valve retainer Inlet valve assembly
Spring deterioration Load/installed length NV 29 N (3.0 kgf)/15.7 mm L 24 N (2.4 kgf)/15.7 mm Spring deterioration Load/installed length NV 16 N (1.65 kgf)/10.3 mm L 13 N (1.35 kgf)/10.3 mm
10 12 14 13 15 11 16
10. Cover 11. O-ring 12. Piston 13. O-ring 14. O-ring 15. Spring 16. Body
NV ... Nominal Value L ... Limit
9 7 8
6 NOTE : 1. Wash the disassembled metallic parts in a cleaning solution and work carefully to prevent ingress of metal chips, dust, etc. 2. Never wash rubber parts in a cleaning solution. 5 3 4 2 1
MA580520
12 to 19 Nm (1.2 to 1.9 kgfm) 13 11 15
10 12 13 16 14 5 9 8 7 4 6 3
Reassembly sequence 16 9 8 7 6 5 4 3 12 2 1 14 15 13 10 2 1
MA580530
BRa-38 Inspection after pressure gauge reassembly

Apply air pressure to the inlet and control port after installing air pressure gauge in a piping circuit as in right figure. Difference between pressures at control port and outlet port shall not exceed 0.28kg/cm. If it is above this specific value then replace spring or assembly.
Air supply Air pressure
BEAKE
Pressure gauge (control port pressure) Pressure gauge (delivery port pressure)
Output pressure (kg/cm2)
Gauge pressure(kg/cm2)
JMS58A-084
SERVICE PROCEDURES
BRa-39
Pressure protection valve
JMS58A-086
How to test
1. Operation test 1) Install drain valve and air gauge at supply and delivery sides. 2) Stop the engine after filling air to maximum. 3) Deplete air from delivery side until cut-out pressure is reached. 4) Confirm whether pressure after valve closure is in range of standard value 0.35kg/cm2(5PSI). 5) Supply side gauge stops at set pressure level while delivery side shows continuous decrease. 2. Leak test 1) Stop the engine after filling air to maximum. 2) Check for air leakage after applying soap suds around cap. 3) Deplete air from delivery port but do not connect air line. 4) Check for air leakage after applying soap suds at delivery port. 3. Durability There shall be no abnormality after 50,000 operations with air pressure 8.4kg/cm2(12PSI).
Setting pressure (kg/cm2)

Pressure 5.96 (85PSI) 3.16 (45PSI) For use in air suspension Remark
Caution items at (dis)mounting

1. It shall be installed in vertical direction and a sufficient space shall be secured for upper part to enable pressure adjustment. 2. Usable temperature range : -49C~93C
Maintenance items
1. Set pressure value shall be checked per 40,000 km period. If pressure value is beyond 0.35kg/cm2 check the pressure or confirm whether there is any parts abnormality. 2. Disassemble per cycle of each year and perform checking and cleaning where metallic parts shall be cleansed using mineral oil. 3. Rubber parts shall be replaced per cycle of each year.
BRa-40
BEAKE
Quick release check valve (QR-1C VALVE)
JMS58A-022
How to test
Car must be parked by means of other than brake. 1. Leak test 1) Release from parking by locating gradual valve at release position. 2) Check for air leakage after applying soap suds at exhaust balance ports after removing air line connected to QR1C balance port. 3) Operate the parking brake after connecting the balance line. 4) When suds are applied around supply port, body and cover pause under condition where service brake is operated after removing air line connected to supply port, soap bubble within 1'' in 5sec is allowable at supply port while interface between body and cover allows no leakage. 2. Operation test 1) Delivery side pressure shall not exceed 0.035kg/cm2 when supply side pressure drops to zero. 2) Pressure difference between supply and delivery shall be within 0.07kg/cm2 when pressure is applied 2.8kg/cm2. 3. Durability There shall be no abnormality in each part after 1,000,000 cycle operations with supplied air pressure 0~8.45kg/cm2.
Caution items at (dis)mounting

1. Usable temperature : -40C~93.3C 2. Maximum appliable pressure : 10.5kg/cm2 3. Two spring brake actuators are used while tube connection method is as follows: 1) Delivery port is connected to spring brake emergency port. 2) Balance port is connected to delivery port of relay valve or brake valve. (It is not service or signal side in case where relay valve is mounted.) 3) Supply port is connected to gradual valve delivery port.
Maintenance method
1. 2. 3. 4. Disassemble per cycle of 3,600hr with 160,000km per year and perform checking and cleaning. Metallic parts shall be cleansed using mineral oil. Rubber parts shall be replaced per cycle of each year. Check wear and damage of all parts.
SERVICE PROCEDURES
BRa-41
(Check valve removal)
Check valve
1. Removal, inspection, correction, assembling and installation 1) Cap 2) O-ring 3) Valve 4) Valve spring 5) Valve body NOTE : 1. O-ring shall be replaced at time of removal or per each year. 2. When assembling, take heed to arrow mark direction on valve body that indicates air flow direction so as not to err in assembling direction. 3. When installing valve horizontally, position can be rightly taken by what is indicated by top and bottom marks. Description Standard value
45~55 Nm (4.5~5.5kgfm)
Deterioration Damage, deformation

JJR58-051
Valve (Assembling) Valve spring Valve body
Cap
To air tank
Air inflow from air compressor

JJR58-050
Pressure difference between 3.0 Nm (0.3kgf/cm2) or less intake and exhaust port
Double check valve

Disassembly
Body
Suttle guide Suttle valve O-ring Cap Bolt 58~92 (5.8~9.2kgfm)
Disassembly sequence 1. Bolt 2. Cap 3. Suttle guide 4. O-ring 5. Suttle valve 6. O-ring
JMS58A-087
BRa-42
BEAKE
Reassembly
Body
Suttle guide
Cap
3-PT 3/8-19
[NOTE]
Suttle valve
O-ring
Installation shall be done so that shuttle valve may be moved horizontally.

JMS58A-088
Safety valve
Category CUT CUT OUT Standard value 10.50.4kg/cm2 8.5kg/cm2 or more
Adjuster nut Lock nut
Spring Valve Body
Rivet Spring case Release pin

JJR58-053
Gradual valve
Brake operation position Steering position
Release sleeve
Locker arm Piston rod

Compression spring
Inlet Valve body
Outlet
Gradual position
JMS58A-089
* Gradual valve does not need special check.
SERVICE PROCEDURES
BRa-43
Front wheel brake

1. Brake hose Remove the brake hose of the frame side first. At reassembly, install it to the wheel brake end first. NOTE : Make sure that the brake hose is not twisted during installation. 2. Wheel brake.
Brake hose 40~45 Nm (4.0~4.5kgfm)
JMS58A-160
Brake chamber
Slack adjuster
Front brake assembly
JMS58A-161
BRa-44 Disassembly, inspection and correction

BD......Basic diameter NV......Nominal value L ...... Limit value 10 11 12 13 17 18 Lining thickness NV 19 mm L 6.3 mm 6 Load/installation length
BEAKE
NV 43kg/25.5 mm L Deficiency in between coil and cover or in coil distance Anchor pin to bushing clearance
15 19 17 1 16 14 5 Bushing to cam shaft clearance BD 41 mm NV 0.16~0.21 mm L 0.5 mm 8 9 6 7 4
BD 35 mm NV 0.05~0.04 mm L 0.3 mm
Brake drum I.D. BD 410 mm L 414 mm Roundness NV 0.05 mm L 0.2 mm Dust cover Oil seal Dust seal Bushing Anchor bracket
Inner wall side scratch Uneven wear Disassembly sequence 1 . Return spring 2. Anchor pin lock washer 3. Anchor pin lock plate 4 . Anchor pin 5. Bushing 6 . Brake shoe assembly 7. Roller pin 8. 9. 10. 11. 12. 13. 14. Roller Return spring pin Snap ring Washer Slack adjuster Spacer Cam shaft 15. 16. 17. 18. 19.
* Refer to the next disassembling method for disassembling of circle marked parts.
JMS58A-162
1. Removal of return spring
Return spring setter
JMS58A-163
2. Removal of anchor pin
Anchor pin puller
JMS58A-164
SERVICE PROCEDURES
3. Replacement of brake lining 1) Removal of the rivet When drilling out the brake lining rivets, use care not to enlarge or damage the brake shoe hole by the drill. 2) Installation of the rivet Riveting of lining from the center portion and working toward the ends. Make sure that no gap is produced between the shoe and lining. Stake the rivets to 1700 to1900kgf Select the lining according to the operating conditions of the vehicles. Use linings of the same size and paint color on right and left wheels of the same axle. After relining, check contact with the drum inside and correct poor contact if any. Correct the lining as incorporated into the wheel and brake assembly. 4. Correction of drum If the drum has a cylindricity of 0.2mm or less scratching, correct to the repair limit value. After machining, use an oversize lining. Brake drum I.D. 410 mm Repair limit value 412 mm Limit value 414 mm
BRa-45
JJR58-058
NOTE : Correct the brake drum with the wheel hub installed. 5. Assembly is worked in reverse order of disassembly.
BRa-46 Reassembly
Install oil seal to be flush with surface. Make sure of the bushing inserting direction printed on its outside surface and press-fit it to be flush with this surfaces.
BEAKE
Make sure of the bushing inserting direction printed on its outside surface and press-fit to be flush with this surfaces. Install dust seal to be flush with this surface.
16 18
17
(Apply wheel grease to bushing inside ( surface after press-fitting it.)
7 6 9
Direction of drum rotation for forward direction 14 11
12
13
10 1.6~2.4kgfm
1.6~2.4kgfm 2 15 (Apply wheel grease to bushing inside surface after press-fitting it.)
(Bend securely after tightening bolt)
Reassembly sequence 191817161514131211104321 65879 NOTE : 1. Use 2mm thick washer in the slack adjuster only when 1.2mm thick washer cannot be used. 2. Keep the drum inside and lining surface free of grease and oil.
JMS58A-165
Reassembly procedure
Installation of return spring.
JMS58A-166
SERVICE PROCEDURES
BRa-47
Rear wheel brake

1. Brake hose Remove brake hose from the connector. Connect brake chamber side at first when installing. NOTE : Take heed brake hose is not twisted when installing.
JMS58A-167
2. Wheel brake.
Wear or damaged of lip 14 13 12 10 Wear or damaged of lip 11 9 Rust, damage 8 Wear, rust 7 Condition of rotation 6 5 4 3 2 Stepwise wear of spline 1
Disassembly sequence 1. Rear axle shaft 2. 3.

4
9.
Rear brake drum
Bolt washer assembly Lock plate
. Lock nut 5. Lock washer 6. 7.

8
10. Oil seal 11. Inner bearing 12. Oil seal ring . 13. Rear brake assembly 14. Oil seal * For parts with an encircled number, refer to the disassembling method.
JMS52-023
Outer bearing Wheel bolt
. Rear wheel hub
BRa-48 Disassembly, inspection and correction

Bushing to cam shaft clearance BD 40 mm NV 0.16~0.21 mm L 0.5 mm
BEAKE
10 11 12 13
6 1417 18 16
Spring deterioration Load/Installed length NV 55kg/25.5 mm L Defect in coil hanger
Inner wall scratch Uneven wear BD 410 mm L 414 mm Roundness NV 0.05 mm L 0.2 mm
1 20 19 15 3 2 22 BD ... Basic diameter NV ... Nominal value L ... Limit value

Bushing to anchor pin clearance BD 35 mm NV 0.05~0.14 mm L 0.3 mm
21
8 7
Brake drum
4 9 5 6
Lining thickness NV 19 mm L 6.3 mm
Disassembly sequence 1 . Return spring 2. Anchor pin lock washer 3. Anchor pin lock plate 4 . Anchor pin 5. Bushing 6 . Brake shoe assembly 7. Roller pin 8. Roller
9. 10. 11. 12. 13. 14. 15.
Return spring pin Brake chamber Snap ring Washer Slack adjuster Spacer Cam shaft
16. 17. 18. 19. 20. 21. 22.
Chamber bracket Oil seal Bushing Dust seal Bushing Dust cover Anchor bracket
JMS58A-169
1. Removal of return spring
Return spring
JMS58A-170
2. Removal of anchor pin
Anchor pin puller
JMS58A-171
SERVICE PROCEDURES Reassembly

Install bushing aligning with this surface, noting correct direction of installation (print mark on bushing outside) Install oil seal aligning with this surface 17 20 18 10 Apply multipurpose type grease 7 8 1 6 9
This side up when installed on vehicle
BRa-49
Install dust seal aligning with this surface 19
15
16
14 12
11
16 Direction of drum rotation when vehicle moves forward (Bend securely after tightening bolt) 22 3 2 4 5 21 Apply multi-purpose type grease to the inside surface. 13
Reassembly sequence 2221162017181915141312114321 65879 NOTE : 1. Use 1.2mm thick washer at the slack adjuster only when 2mm thick washer cannot be installed. 2. Install bushing on the anchor bracket side of the cam shaft after installation of the chamber bracket. 3. Keep the drum inside and lining surface free from oil and grease.
JMS58A-172
Reassembly procedure
1. Installation of return spring.
Return spring
JMS58A-173
BRa-50
2. Replacement of brake lining 1) When drilling out the brake lining rivets, use care not to enlarge or damage the brake shoe hole by the drill. 2) In case of rivet Rivet starting from the center and working toward the ends. Make sure that no gap is produced between the shoe and lining. Stake the rivets : 1700 to1900kgf Select the lining according to the operating conditions of the vehicle. Use linings of the same size and paint color on right and left wheels of the same axle. After installing of lining, check contact with the drum inside and correct poor contact if any. Correct the lining as incorporated into the wheel and brake assembly.
BEAKE
JJR58-058
3. Correction of drum If the drum has a damage of 0.2mm or less correct to the repair limit. After correcting, use an oversize lining. Brake drum I.D 410 mm Repair limit value 412 mm Limit value 414 mm
NOTE : Correct the brake drum with the wheel hub installed.
SERVICE PROCEDURES
BRa-51
Adjustment of brake shoe clearance

Inspection before adjustment
1. Perform the following checks after removing the clevis pin of brake chamber push rod. Turn the worm shaft in the direction of arrow as shown in illustration to make sure that the turning torque is 0.5kgm or more.
To increase shoe clearance
Worm shaft
JMS58A-092
2. If the torque is smaller than the specified, replace the spring and set screw of slack adjuster with new ones. Adjust the set screw to obtain a turning torque of 0.6 to 1.5kgfm, then lock the screw by staking it at two points.
Stake (Punch)
Set screw Spring
JMS58A-093
3. Turn the slack adjuster to right and left to check for looseness. If the slack adjuster moves beyond the limits value shown in illustration, replace it.
Looseness : Less than 4 mm
JMS58A-094
Adjustment
1. Connect the push rod and check the air line for leaks and the push rod for smooth movement.
<Front, #24, Brake chamber>
Push rod stroke

JMS58A-095
2. Increase the air pressure to 8kg/cm and check that the fall of the air pressure gauge reading in 30 minutes does not exceed 0.8kg/cm. Also check that compressed air is working to the spring brake side of the spring brake chamber and high air pressure is working to the main brake.
JMS58A-096
BRa-52
3. To adjust the brake shoe clearance, press the brake shoes against the brake drum by turning the worm shaft of the slack adjuster until it does not move any further. With the brake pedal fully depressed, release the worm shaft to adjust the brake chamber push rod stroke to the standard value (25mm front tire, 30mm rear tire) and now the correct clearance is obtained.
BEAKE
JMS58A-097
4. When the brake chamber push rod stroke has reached the limit (40mm front tire, 50mm rear tire), readjust by the slack adjuster. NOTE : The brake chamber push rod length should be set at the standard value at reassembly. When the brake shoe clearance is adjusted, make sure that there is a air pressure of 7.0 to 8.0g/cm in the air tank.
Disk brake
Assembled status of single part materials and each part nomenclature
Component Carrier Pad Bus Housing Lever Bridge Rotor
Pad
Tapper Adjuster Plate Needle race Washer Operating shaft Thrust race Adjuster wheel
Fixed pamp
Guide pin
AA58006A
SERVICE PROCEDURES Disassembly and Reassembly
BRa-53
1 2 4
15
7 10 14 8 12
11 13
<Disassembly sequence> 1. Clevis pin 2. Chamber assembly 3. Operating lever 4. Pad retainer plate 5. Pad spring 6. Pad 7. Bridge 8. Housing
9. 10. 11. 12. 13. 14. 15.
Carrier Long guide pin Short guide pin Guide pin dust cover Terminal cap Terminal cover Dust cover
<Reassembly sequence> Reassembly is reverse procedure of disassembly.

AA58049A
BRa-54 Pad replacement procedure
BEAKE
When pad is remained 5mm from the back plate after abrasion or pad wear alarm unit is operated so that ( L ) sign is displayed on steering instrument panel, it tells that pad is in complete weared condition so that immediate replacement should be done. Pad wear condition shall be inspected per 5,000km or per week. Minimum air pressure 6kg/cm2 should be maintained at pad replacement work which shall be performed under state where parking brake has been released.
1. Pad disassembly sequence 1) Disassemble bolt pad retainer by tool.
AA58008A
2) Remove by lifting the pad retainer plate.
AA58009A
3) How to return pad Manually dismantle step cover 3. Unfasten lock nut 5 unto 4 adjuster step end stage. Push 4 adjuster stem to connect in 6 adjuster wheel groove. Return pad by turning 4 adjuster stem (about 12 turns). Disassemble by hand.
2 3 4 5 6
AA58200A
NOTE : Clean by vacuum cleaner if necessary and do not use compressed air because if foreign substance of disk brake would be removed by compressed air then it will clog oil passage.
AA58015A
SERVICE PROCEDURES
4) Separate the pad from the disk brake.
BRa-55
Pad Disk brake
AA58010A
NOTE : Perform procedure 3) and 4) under state of pushing the spreader plate as in right figure for spreader plate not to be separated at time of pad return. If tappet pin and spreader plate are separated from each other, pad return work is not normally performed. The work must be by hand and air tool shall not be used. Tappet head part shall not be turned because of worry about adjuster stem damage. When working the pad return, spreader plate should be in close contact with tappet as in right figure. Confirm whether or not of each part after pad separation.
AA58011A
AA58012A
2. Pad assembly sequence 1) When the disk brake is pushed and pulled by hand and the force at time of sliding is measured, then if the force is found to be over 20kg, the sliding pin part should be checked. Pull brake by hand as in right figure.
AA58013A
2) Assemble a new pad and push the brake in opposite direction as in right figure.
AA58014A
BRa-56
3) Assemble inner pad. If pad cannot be correctly assembled, it is because spreader plate has not been completely pushed back. so reassemble pad after returning referring to pad return method of the preceding section. * How to adjust pad clearance Turn adjuster stem for pad to be in close contact with rotor. Turn adjuster stem 3/4 in opposite direction. 4) Take off adjuster stem using a driver and then fix by turning the lock nut. (Tightening torque : 1~1.5kgm) NOTE : The above work is a must because if the above work has not been performed, pad clearance adjustment function cannot be done. After the above work, mount the stem cover. 5) Mount spring on top of spreader plater, both pads. - Disk rotor thickness shall be 45mm if it is a new stuff. It can be used until abrasion limit of 35mm. - If disk rotor is a new stuff, pad shall be used with pad back plate thickness of 8mm. - If disk rotor thickness has been weared out over 3mm on one side, pad shall be used having pad back plate thickness of 10mm. 6) Mount pad retainer, then fix with bolt.
BEAKE
AA58015A
AA58016A
AA58017A
AA58008A
3. Pad and disk brake abrasion limits 1) Disk thickness : 45mm (A) 2) Disk use limit : 37mm (B) 3) Pad and back plate thickness : 30mm (C) 4) Back plate : 9mm (D) 5) Pad wear limit : 5mm (E) 6) Pad and back plate wear limit : 13mm (F)
A B
F
AA58018A
SERVICE PROCEDURES Disassembly of brass bushing in brake housing

1. Disassembly Before disassembling mark the alignment marks on housing and brass bushing using a punch etc.
BRa-57
AA58918A
2. Reassembly Press-fit the brass bushing in housing using a special tool.

50mm
40mm
40mm
31.7mm
AA58919A
50mm
40mm 10mm 50mm
31.7mm 35.7mm
AA58921A
BRa-58 (Dis)assembly of long and short guide pins

1. Removal Remove guide pin out of carrier using a plastic hammer.
BEAKE
Guide pin assembly

AA58923A
2. Reassembly Mount dust cover and terminal cap to guide pin and then mount it on carrier.
Terminal cap
3.5mm Guide pin
Guide pin Dust cover
Dust cover
Guide pin sleeve Terminal cap
AA58916A
SERVICE PROCEDURES
BRa-59
Brake chamber
Outline
Brake chamber is a unit that converts air pressure to mechanical force when braking. There are many kinds of brake chamber because each brake requires different force than others. Brake chamber is classified by number according to size which number indicates effective area of diaphragm. For example chamber of type 24 signifies that effective area of diaphragm of brake chamber is 24in2 while force acting on push rod by brake chamber is value obtained by multiplying this area with air pressure.
Operation
If brake pedal is depressed, compressed air enters brake chamber through supply port at pressure plate so that air pushes diaphragm. Diaphragm is supported by push plate to push forward the push rod. Push rod is connected to slack adjuster which moves forward to rotate cam shaft so as to brake. When air pressure is discharged from brake chamber, push rod return spring acts simultaneously with brake shoe return spring so as to return the push rod assembly, the slack adjuster and the cam shaft to their respective original positions of state when brake was not applied.
Tightening torque 15~20 Nm (1.5~2kgfm) Clamp ring Diaphragm Pressure plate Push rod Return spring
From brake valve
Nut tightening nut 24 45~67 Nm (4.5~6.7kgfm )

JMS58A-101
Removal
NOTE : Replace diaphragm and return spring as respective sets for each axle. Mark the coincidence marks on cylinder assembly (in case of car furnished with spring brake), pressure plate and clamp ring before disassembling.
BRa-60
1. Brake chamber (#24, #30) 1) Removal, inspection and correction NOTE : Before disassembly, pull out the push rod and fix completely. Work it cautiously preventing the return spring from bouncing out.
3 4 2
BEAKE
5 1. 2. 3. 4. 5. 6. 7. Clamp ring Pressure plate Diaphragm Push rod complete Return spring Dust cover Non-pressure plate complete 1 7 6
JMS58A-102
Disassembly
Unfasten support part of brake chamber, separate air hose, and separate push rod from slack adjuster. Remove brake chamber by unfastening installation nut. 1. Clearly cleanse outside of brake chamber using methanol. At this cleansing you must not polish with gasoline, diesel, or water solution etc. And before disassembly firstly mark upon brake chamber the original assembly locations of clamping ring and plate for time of reassembly. When replacing diaphragm or spring in car without removing non-pressure plate of brake chamber, return spring pressure should be removed by unfastening slack adjuster.
Maintenance
1. Each month after driving 12,000km or 300hr, check the stroke of push rod and adjust slack adjuster stroke. Type of chamber 24 Adjustment limit 45 mm Remark 5.6 kgf/cm2 or less
Remember that push rod stroke must be as short as possible when braking. Excessive push rod stroke drops down brake efficiency, shortens diaphragm life, retards brake reaction and increases air consumption. 2. Check the push rod in slack adjuster operation stroke arrangement and whether the push rod is operated without interference. And check angle formed by slack adjuster arm and push rod. The angle must be larger than 90 under state of brake release and the readjusted maximum stroke should be near 90. 3. Check if mounting nut is fastened tightly and confirm that cotter pin is installed at proper location. 4. Each year after driving 150,000km or 3,600hr, maintain as follows. (1) Disassemble brake chamber and cleanly polish every part. (2) Replace spring and push rod if they are corroded, worn or distorted and replace diaphragm. (3) When replacing diaphragm or spring, it should be replaced by same thing as in other chamber in same axle part.
SERVICE PROCEDURES
BRa-61
Spring brake chamber

Outline
Spring brake chamber is designed so that brake function might be exerted in emergency and parking. And when pressure in air system is reduced, braking is automatically applied by pressure reduction amount. Spring brake is not only emergency brake but also substitutes general hand brake by manually operating gradual valve installed at driver's position.
10 11
18 17 16 15 14
13
12
1. 2. 3. 4. 5. 6. 7. 8. 9.
Clevis assembly Service brake housing Service brake diaphragm return spring Push rod Connecting clamp of adapter and service brake chamber Service brake diaphragm Push rod plate Adapter Connecting clamp of parking brake chamber and adapter
10. 11. 12. 13. 14. 15. 16. 17. 18.
Pressure plate Compressor spring Release stud excess plug Parking brake diaphragm Adapter push rod Parking brake diaphragm Release stud assembly O-ring Nylon screw
JMS58A-103
BRa-62 Normal driving
BEAKE
Parking brake chamber
Parking brake chamber
JMS58A-104
It holds spring compressed to allow driving (so that parking or emergency operation may be feasible). * Spring of parking brake consistently maintains state as above during driving.
Main brake (Service brake)
JMS58A-107
Spring brake is not operated under condition of normal main brake operation. It is held in by air pressure. If brake is depressed, air is supplied to main brake chamber as in the above figure so that braking is accomplished.
SERVICE PROCEDURES Release of main brake
BRa-63
Exhaust gas
JMS58A-106
If brake pedal is released, air in line is exhausted through brake valve bottom and air in main brake chamber is quickly discharged through quick release valve.
Parking brake (spring brake)
JMS58A-107
Parking valve (gradual valve) operation discharges air from spring brake so that force that has been holding the spring is removed, and so oppositely main brake is operated through push rod by spring force so as to brake. Emergency brake : if air pressure drops below spring pressure, main brake is automatically operated by spring force so as to brake.
BRa-64 Mechanical release or maintenance

1. Fix wheel and remove cap from spring chamber. Unfasten release bolt from side pocket. 2. Put release bolt in location where cap has been removed and then insert pressure plate.
BEAKE
Cap
JMS58A-108
3. Turn the release bolt clockwise by 1/4 round so that cross pin is fixed at pressure plate.
JMS58A-109
4. Assemble nut and washer at the release bolt.
Turn clockwise.
JMS58A-110
5. Tighten the release bolt tightening nut by wrench until compression spring is completely compressed. Check by adjustment that push rod goes back while tightening. Tightening torque : 6.8kgfm Because strong spring has been compressed in spring chamber, it may cause fatal injury if clamping is unfastened without controlling the spring.
JMS58A-111
Chamber diaphragm replacement

If to replace diaphragm of parking brake or main brake without removing car brake it shall be performed as follows. Diaphragm shall be replaced per six months or about 80,000km run.
JMS58A-112
SERVICE PROCEDURES
1. Parking brake [Disassembly] 1) Compress the parking brake spring as in right figure. Remove the spring brake clamp so as to replace spring brake diaphragm. 2) Take off the diaphragm by pushing off the parking brake chamber from adaptor.
BRa-65
JMS58A-113
3) Replace the diaphragm removed from the chamber to new diaphragm. Cleanly polish inside of adaptor with clear solvent and again with suds.
JMS58A-114
[Reassembly] 1) Lay the new diaphragm plainly in adaptor housing. Place the parking brake housing, the spring and the pressure plate on the adaptor housing and install clamp. Fasten by 2.6 to 3.4kgfm with clamp bolt. 2) Applying the air into chamber to check for air leakage. 3) Unfasten the parking brake release bolt to install at side pocket and then install plug at parking brake chamber. [Main brake] 1) Unfasten main brake bottom clamp after manually holding the parking brake spring. 2) Replace main brake diaphragm after pulling off chamber. 3) Polish inside of adaptor housing with clear solvent. 4) Check push rod, spring, housing, and push rod and plate adaptor. 5) Replace worn or damaged parts. 6) Install the diaphragm, place the clamp so as to be suitably mounted, and fasten the clamp bolt by 25~33Nm. Apply pressure to the spring and the main chamber and check the clamp with suds to confirm if leak occurs. Leak out only the air of main brake. Remeasure clamp torque.
JMS58A-115
BRa-66
BEAKE

1. Disassembly and inspection
10
5 1
2 Disassembly sequence 1. Snap pin 2. Pin 3. Clevis 4. Lever 5. Control cylinder
6. 7. 8. 9. 10.
Stopper plate Seal ring (small) Seal ring (large) Bushing Valve and body assembly
NOTE : If valve lever side bushing and spindle are defective, do not disassemble but replace by assembly.
JMS58A-116
How to disassemble
1. Removal of the spindle Remove control cylinder plate cover lamp. Put bar at spindle and strike with hammer so that spindle comes out. Make body only clean after removing the spindle. NOTE : At this removing, valve and spindle shall be replaced by new ones.
Valve
Hammer
Bushing Spindle (Lever side)
Bushing (cover side) Spindle
Sealing
FJR58A-151
SERVICE PROCEDURES
2. Reassembly and adjustment <D6A Engine>
BRa-67
6 9 4
2 Turn adjusting screw so that the butterfly valve runs parallel with the 8 valve body when it is opened and clearances A and B are up to specification when it is closed. 7 5
21 to 25 Nm (2.1 to 2.6 kgfm)
Fully opened
30 30
3
Fully closed
9.8 to 16 Nm 4.9 to 6.9 Nm (1.0 to 1.6 kgfm) (0.5 to 0.7 kgfm)
A Valve Valve body B 10

Clearance between valve and body when valve is closed NV A, B 0.1 mm or more (A+B)/2 0.1 to 0.4 mm
NV ... Nominal Value
Reassembly sequence 10 9 8 6 7 5 4 3 2 1
NOTE : To install the control cylinder, place the valve at full open position, pull out the control cylinder shaft 2 mm or more from the free state and connect it with the clevis.
MA580850
BRa-68
BEAKE
6 2.1~2.6kgfm 5
2 1 Fully opened 3 4 44.5
Turn adjusting screw so that the butterfly valve runs parallel with the valve body when it is opened and clearances A and B are up to specification when it is closed. Clearance between valve and body when valve is closed NV A,B 0.1 mm or more A+B/2 0.1~0.4 mm 1.0~1.6kgfm 10 8 9
30.5 Fully closed 0.5~0.7kgfm 1.0~1.6kgfm Adjusting bolt 7 NV : Nomianl value
JMS58A-119
Reassembly Procedure
Installation of the spindle 1. Support with spindle after taking close contact with inner wall of body centerline while taking A and B of valve by hand.
Body Valve
FJR58-154
2. Firstly insert spindle lever side into inside of body using a pressfitting tool. Strike press-fitting tool end by hammer so that install spindle at valve. Install cover side spindle in same manner.
Spindle (Lever side)
Valve
Spindle (Cover side)
Pressfitting tool Machining surface to install lever
Press-fitting tool Body

FJR58-154
SERVICE PROCEDURES
3. Insert until jawed surface of press-fitting tool comes contact with body.
Spacer
BRa-69
Pressfitting tool
Pressfitting tool
Machining surface to install lever

JMS58A-156
4. Install short bushing at lever side spindle and long bushing at cover side spindle. Install the sealing on the spindle as in right figure.
Short bushing (Lever side)
Long bushing (Cover side)
JMS58A-157
Control cylinder
Damage, rust, wear in inner surface Deterioration, uneven wear 8 9
Spring deterioration load/installed length NV 8.3kg/106 mm L 7.1kg/106 mm
NV ... Nominal value L .......Limit value
Disassembly sequence 1. Cover 2. Retainer 3. Packing 4. Plate 5. Wear ring 6. Shaft assembly 7. Spring 8. Dust seal 9. Cylinder
1 6 5 4 3 2
JMS58A-120
BRa-70
2. Reassembly
10~16 Nm (1.0~1.6kgfm) 1 10~16 Nm (1.0~1.6kgfm) 9 6
BEAKE
3 Reassembly sequence 9763218 45
NOTE : 1. Apply grease 2cc to inner surfaces of the cylinder. Apply the grease also to f12 section of shaft assembly. 2. Apply sealant to the area in the shaft assembly to which the plate is fitted.
FJR58A-071
Air intake silencer

8 9
11 4 7 1 Seizure Clearance (Replace bushing) BD 16 mm NV 0.03~0.11 mm 12 Crack 11 Disassembly sequence 1. Snap pin 2. Pin 3. Clevis pin 4. Control cylinder 5. Valve 6. Lever 7. 8. 9. 10. 11. 12. Bracket Plate Valve shaft Oil seal Bushing Silencer coupler 10 Wear, damage Wear 6 3
BD...Basic diameter NV...Nominal value
JMS58A-120
SERVICE PROCEDURES
2. Reassembly and adjustment
BRa-71
Opened 80
Closed
Apply sealant to threads (LOCTITE No. 271 or equivalent) A B Butterfly valve to coupler clearance NV A,B 1 mm or more (A+B) 2 to 3 mm NV ... Nominal Value 7 Bend lock washer 4 3 12 1 2 6 37 to 45 Nm (3.8 to 4.6 kgfm) Apply sealant to threads (LOCTITE No. 271 or equivalent) Pack grease (JT-6 grease or equivalent 8 8.8 to 12 Nm (0.9 to 1.2 kgfm) Replace gasket Replace O-ring 11 10 9 5 Identification mark O 20 to 24 Nm (2.0 to 2.4 kgfm) Apply sealant to threads (LOCTITE No. 271 or equivalent) Reassembly sequence 12 11 9 10 5 8 7 6 4 3 2 1 NOTE : To install the control cylinder, place the valve at full open position, pull out the control cylinder shaft 2 mm or more from the free state and connect it with the clevis.
MA580910
Replace lock washer
BRa-72
3. Control cylinder 1) Disassembly and inspection
BEAKE
Lost tension load/installed length NV 72 N (7.3 kgf)/109 mm L 61 N (6.2 kgf)/1.9 mm
NV ... Nominal Value L ... Limit
8 12
1 11 10 3 4 5 6 7 2
Disassembly sequence 1. Cover 2. O-ring 3. Retainer 4. Packing 5. Plate 6. Wear ring
7. 8. 9. 10. 11. 12.
Shaft assembly Spring Dust seal Retaining ring Filter Cylinder

MA580930
SERVICE PROCEDURES
2) Reassembly
BRa-73
9.8 to 16 Nm 12 (1.0 to 1.6 kgfm) 1 9.8 to 16 Nm (1.0 to 1.6 kgfm)
10
11
3 2
Reassembly sequence 12 7 5 6 11 10 4 3 8 2 1 9
NOTE : 1. Apply grease (NICHIMOLY L2 by Nichinoly Century System Eye Co. or equivalent) 2 cc to inner surfaces of the cylinder. Apply the grease also to 12 section of shaft assembly. 2. Apply sealant (HERMETIC GA by Sanno Kogyo or equivalent) to the area in the shaft assembly to which the plate is fitted.
MA580940
Exhaust brake control

1. Removal and installation 1) Remove the 3-way magnet valve NOTE : 1. At installation air pipe and hose, making sure that they do not the interfere with other parts. 2. Do not twist or bend the hose excessively; keep them in natural position. 2) Remove the Clutch switch. 3) Remove the Combination switch.
3-way magnet valve Air pipe ( 6.35) 19 to 25 Nm (1.9 to 2.6 kgfm)
MA580950
BRa-74
2. Inspection 1) 3-way magnet valve (1) Airtightness check With output "2" completely plugged and with a 295 to 980 kPa (3 to 10 kgf/cm) air pressure applied from input "1", apply and shut down alternately a 24V voltage to check for possible leaks. Port Voltage ON OFF Input "1" Output "2" Output "4"
BEAKE
0.75R
Output "2" Input "1"
0.75B Output "4" (plugged) 295 to 980 kPa (3 to 10 kgf/cm)

MA580960
(2) Operation check With a 980 kPa (10 kg/cm) air pressure applied to input "1", apply voltage, gradually increasing from 0V. Then, make sure that the voltage at which the valve is actuated is up to specification. Nominal value 20 V or less
0.75R
Output "2" Input "1"
0.75B Output "4" (plugged) 295 to 980 kPa (3 to 10 kgf/cm)
MA580960
2) Clutch switch continuity check Check to see if there is no continuity when the push rod in the advanced position and there is continuity when the push rod is retracted. 3) Combination switch continuity check.
Push rod
ON OFF
MA580980
SERVICE PROCEDURES
BRa-75
Adjustment and inspection after installation

1. Adjusting of microswitch With the engine running at about 1000 rpm under no load, turn ON the exhaust brake switch. Slowly release the accelerator pedal and adjust with the adjusting screw so that the exhaust brake operated when the engine speed reaches 600 to 700 rpm. 2. Exhaust brake system operation check Start the engine and turn ON the exhaust brake switch. Then, make sure that the exhaust brake valve and intake silencer valve are operated. Make also sure that the exhaust brake and intake silencer deactivate when the clutch pedal and accelerator pedal are depressed.
Microswitch Adjusting screw

MA580990
Adjusting screw Micro switch
Injection pump
Micro switch
Adjusting screw
MA581000
BRa-76
BEAKE
Intarder System
Structure
4 PTO connection 21 Flange output
Helical gear
22 Stator 23 Rotor
30 Heat exchanger
50 Oil reservoir
Z000001A
SERVICE PROCEDURES Intarder Chracteristercs

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. High braking power. Shared oil circuit with the transmission. Integrated transmission cooling system. Unchanged transmission installation length up to the output flange. Compact construction due to the integration in the transmission. Low weight. Compatible with ABS braking system. Integrated emergency steering pump (on request). Bremsomat mode. Bremsomatic mode.
BRa-77
How the intarder works
32 95 30 57 34 20 2 1 31 90 40 98 99 33 91
Schematic diagram of the ZF intarder system in the vehicle.
Comp. air Water line Electrical cable

Z000002A
The oil in the Intarder is used to create a brakin effect. You can operate the ZF Intarder using the electronic braking level selector (91). Depending on the position of the braking level selector, the intarder fills with the required quantity of oil in order to produce the desired braking troque. The desired braking torque is readhed in 0.75s after switch-on. Reduction of the torque, e.g. with ABS, takes about 0.3s from switch-off of the intarder. A step-up gear set on the transmission output shaft accelerates a rotor (23). As the rotor turns, its blades push oil into the stationary blades of the turbine wheel (Stator [22]) where the oil is slowed. This converts the braking energy into heat energy. The braking torque achieved is applied to the vehicle driveline through a helical gear set (21). The heat created is dissipated through the direct-mounted oil/water heat exchanger to the vehicles engine cooling water circuit (30).
BRa-78 Intarder master switch
BEAKE
The master switch controls the power supply to the intarders electronic system. A master switch is recommended to switch the Intarder on and off. It is to be fitted to the dashboard and easily accessible. If your vehicle does not have ABS, we recommend use of the master switch since this prevents the interder engaging if the driver accidentally moves the braking level selector (e.g. on a slippery road surface).
Intarder pilot lamp

The Intarder pilot lamp gives the driver a continuous survey of the current Intarder condition. The pilot lamp comes on when the Intarder master switch is switched on and the Intarder is activated by moving the braking level selector. NOTE : When the Intarder is switched on, the Intarder pilot lamp flashes continuously if there is any fault in the electrical system.
Electronic Control Unit EST

The Intarder is controlled by the electronic control unit. This unit receives and processes various signals; 1. The signal from the braking level selector activates the accumulator solenoid vlave and the proportional solenoid valve. This activates the oil resevoir and the Intarder hydraulic control system. The oil contained in the resevoir is immediately fed into the Intarder circuits. 2. The ABS signal siwtches the Intarder off automatically. As soon as the ABS system allows the Intarder to operate again, the Intarder is automatically switched back on. In this case braking torque rises smoothly to the level currently set according to a specified characteristic curve. 3. The signal from the electronic pulse sensor for Intarder speed limits the Intarder braking power and is used to enable Bremsomat operation. 4. The signal for the cooling water temperature allows the electronic control unit to control the Intarder power reduction function. this prevents the cooling water temperature exceeding a specified maximum value (standard value 105C). 5. The Bremsomat or Bremsomatic signal allows the driver to select and maintain his speed when descending hills. The Intarder electronics automatically set the braking torque needed. NOTE : If the vehicle has an engine brake, this can be controlled by the Intarder as well.
SERVICE PROCEDURES Fail-Safe Functions
BRa-79
The electronic control unit comprised additional safty functions which ensure limited Intarder operation if any electrical component should fail (short circuit, interruption). 1. Fault in braking level selector or interruption of braking level signals. The highest braking level selectable is the level corresponding to the number of intact braking level signals. If the signal for braking level 1 fails, the Intarder is switched off. 2. Fault in the speed and/or temperature sensor The electronic control unit reduces maximum braking power to braking lever 2 (even if a higher braking level is engaged). This ensures the Intarder still functions, although with reduced braking torque. 3. Fault the speed and/or temperature sensor The electronic control unit reduces maximum braking power to braking level 2 (even if a higher braking level is engaged). This ensures the Intarder still functions, although with reduced braking torque. 4. Fault in the proportional solenoid valve The Intarder is automatically switched off. 5. Fault in the accumulator solenoid vlave No reduction in braking power. The Intarder takes longer to respond.
Fault recognition
The Intarder pilot lamp indicates Intarder function and also assists fault recognition. The Intarder pilot lamp lights for 3 sec, when the ignition is switched on (lamp check). In the unlikely event of a failure of an electrical component of the Intarder, this is indicated by the lamp flashing continuously. This informs you that only a limited braking effect or no braking effect at all is available from the Intarder.
Error diagnosis
The Intarder electronic control system is capable of diagnostic functions. Errors recognized by the Intarder electronic control unit are stored in an error memory. During vehicle inspection, the information stored can help you to indentify any faults quickly and clearly. You can call up this information as follows :
BRa-80 Hydraulic diagram

EST Brake light acc. to local regulations Main switch Braking level selector
0 B 1 2 5 4 3
BEAKE
in cabin Intarder Control lamp Pressure relief valve 12 bar
Main oil flow Control circuit Electr. line
Regulating Pressure valve elevation valve
Control valve
Safety valve
Proport. solenoid valve
Pump
Impulse sensor Preload valve Intarder Reversing valve
Compr. Oil tank/reservoir air Temperature sensor
Sump Filter
Z010143A
SERVICE PROCEDURES Spring table

Order No. 0732 042 402 0732 042 470 0732 042 471 0732 041 247 0732 042 348 0732 042 403 0732 042 406 Location Intarder control unit (cooler changeover valve) Intarder control unit (pressure relief valve) Intarder control unit (pressure relief valve) Intarder control unit (safety valve) Intarder control unit (pressure increase valve) Intarder (preload valve) Intarder (drain valve) 16.5 1.7 15.6 14.5 1.6 17.6 8.5 1.5 18.3 7.5 1.4 9.4 11.5 1.6 10.8 7.5 1.9 15.8 No. of coils 52.5 Wire dia. in mm 3.0 Spring dia. in mm 16.5
BRa-81
Untensioned length in mm 238.0 31.2 32.6 19.6 52.4 85.0 72.0
Adjustment data
Description Oil pump Impeller Axial play Stator-Rotor Axial play of taper roller bearing 0.05-0.1 mm Fixture and dial gauge Dimension spec. 0.03-0.05 mm Measuring device Dial gauge Preload (pressure) Remarks
BRa-82 Special tool

Tool (Number and Name) 1x89 122 292 Hydraulic spindle Illustration Use Pressing out rotor and stator (use with 1x56 138 047)
BEAKE
ZF00001A
1x56 138 045 Centring dis
Guide when installing stator and rotor
ZF00002A
1x56 138 046 Adjustment fixture
Installation of taper roller bearing on stato and rotor
ZF00003A
1x56 138 047 Extraction fixture
Pressing out stator and rotor
ZF00004A
1x56 138 050 Ring
Installation of spur gear when assembling inner race of taper roller bearing
ZF00005A
1x56 137 124 Tool
Installation of shaft seal (use with 1x56 138 038)
ZF00006A
1x56 137 974 Tool
Driving in inner race of taper roller bearing
ZF00007A
SERVICE PROCEDURES
Tool (Number and Name) 1x56 137 975 Tool Illustration Use Installing needle sleeve in control housing and pump housing
BRa-83
ZF00008A
1x56 138 038 Tool
Installation of shaft seal (Use with 1x56 137 124)
ZF00009A
1X56 138 049 Ring
Pressing out stator and rotor (Use with spindle press or hydraulic press)
ZF00010A
1x56 136 471 Tool
Driving retaining plate into output flange
ZF00011A
1x56 138 048 Tool
Installation of shaft seal on output flange.
ZF00014A
1x56 138 054 Calibration mandrel
Bore-pressure relief valve/ control valve
ZF00015A
1x56 138 055 Calibration mandrel
Bore-pressure increase valve
ZF00016A
BRa-84
Tool (Number and Name) 1X56 138 056 Calibration mandrel Illustration Use
BEAKE
Bore-cooler changeover valve
ZF00017A
1X56 138 057
Bore-pilot valve
ZF00018A
1x56 138 068 Measuring plugs
Intarder housing/control housing for intarder outlet pressure or intard or temperature
ZF00019A
1P01 138 069 Test unit
Test on test bench
ZF00020A
1P01 138 070 Test unit
Testing electric speedometor
ZF00021A
SERVICE PROCEDURES Disassembly

1. Remove oil filter (1).
BRa-85
ZF000534A
1) Remove M8x20 retaining screw (1) and washer from oil filter.
1
ZF000529A
2) Pull filter from filter neck using a pliers. Remove oil filter from Intarder housing CAUTION : Beware of escaping oil. Catch escaping oil in suitable container.
ZF000552A
3) Remove filter cover from oil filter. 2 = Remove filter cover from oil filter. 3 = O-ring filter 4 = Magnetic disc CAUTION : Always renew filter. Cleaning oil filter is not sufficient.
2 3 4
ZF004467A
BRa-86
2. Remove heat exchanger, solenoid valve, reservoir, and temperature sensor.
BEAKE
35 Nm (3.8kgfm) 5
7 23 Nm (2.5kgfm) 13
23 Nm (2.5kgfm) 12 8 9 10
62 Nm (6.8kgfm) 3 1 23 Nm (2.5kgfm) 4
18
14
15 23 Nm (2.5kgfm) 2 16 35 Nm (3.8kgfm) 18 Nm (2.5kgfm) 3 62 Nm (6.8kgfm) 1 17 40 Nm (4.4kgfm)
1. 2. 3. 4. 5. 6. 7. 8. 9.
Nut (M12) O-ring Stud bolt Hex screw (M8x1.15) Screw plug O-ring Hex screw (M8) Line connection - solenoid valve Screw plug
10. 11. 12. 13. 14. 15. 16. 17. 18.
O-ring Solenoid valve Hex screw (M8) Reservoir Retaining screw Retaining screw Screw plug Temperature sensor (M18x1.5) Angle plate
ZF001229A
1) Unfasten nuts (1) (wat 18) on stud bolts and unscrew. Unscrew and remove on M8x115 (4) hex nut from oil connection flange on heat exchanger. 2) Remove heat exchanger and reservoir. 3) Remove heat exchanger and reservoir. 4) Remove two O-rings (2) from heat exchanger oil ducts in control unit housing. 5) Unscrew and remove retaining screws (12) from solenoid valve, remove valve from reservoir. 6) Unscrew and remove retaining screws (14 or 15) from angle plate and on reservoir connection flange (7), remove reservoir. 7) Remove O-ring (6) from annular groove in reservoir. 8) Unscrew and remove temperature sensor (17) from heat exchanger.
SERVICE PROCEDURES
3. Removal of intarder from main transmission.
46 Nm (5kgfm) 8 50 Nm (5.5kgfm) 9 50 Nm (5.5kgfm) 12 50 Nm (5.5kgfm) 10 50 Nm (5.5kgfm) 11 4 5 6 7 A B 19 14 13 50 Nm (5.5kgfm)
BRa-87
18 20 A C 17 50 Nm (5.5kgfm) 15 50 Nm (5.5kgfm) 16 50 Nm (5.5kgfm)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Retaining plate Hex screw (TT=60 Nm depen. on version, 120 Nm) Washer O-ring (68x4) Output flange Ring Shaft seal Hex screw (M10x35 / 8.8) Hex screw Hex scrw Hex screw Hex screw
13. Hex screw (M10x215) 14. Hex screw for cardan shaft 15. *Hex scrw (head with bore for wire retainer) 16. Hex screw 17. Hex screw 18. Shim (thickness 1.6 to 0.9 mm, 0.1 mm steps) 19. Shim (thickness 0.6, 0.5, 0.4, 0.3, 0.2 mm) 20. Gasket A = Sealing face of Intarder housing B = Contact face for output shaft ball bearing C = Contact face for stator
ZF001202A
1) Release output flange (5), remove shim (3) and O-ring (4), extract flange with two-leg puller. 2) Remove ring (6) or, instead of ring (6), remove ring gear (not shown in drawing) from output flange. CAUTION : In the following procedure, the Intarder becomes free and may fall. Secure Intarder to prevent it from falling. 3) Remove hex screws (8, 9, 10, 11, 12, 13, 15, 16 and 17) from Intarder, remove Intarder. 4) Remove gasket (20) and shims (18 and 19).
BRa-88
4. Oil pump removal
BEAKE
8 23 Nm (2.5kgfm)
7 9 23 Nm (2.5kgfm) 6
5 4 3 2 1 10
11
11
1. 2. 3. 4. 5. 6.
O-ring Ring gear Shaft V-ring Needle sleeve O-ring
7. 8. 9. 10. 11.
Pump housing Hex screw, (x4) (M8x80) TT = 23Nm Hex screw, (x1) (M8x30) TT = 23Nm Dowel pins (x2) Mark on ring gear (ease of assembly)
ZF001202A
1) Unscrew and remove screws (8 and 9). 2) Remove pump, pressing off with pry lever if necessary until dowel pin (10) comes free. 3) Remove O-rings (1 and 6) from control unit housing. 4) Remove shaft (3) and ring gear (2) from pump housing. Check the following : Axial play on ring gear : 0.03 - 0.05 mm No scoring permitted on ring gear, shaft and ring gear bore in housing. Check that pump pinion (3) is firmly located on shaft.
SERVICE PROCEDURES
5. Control unit housing and vlave removal
BRa-89
1.1
2.1 2.2 1 2.3 2.4 1.2 2.5 1.3
9 2 5 3.1 2.5 3.3 4 3 6 17 7.1 7 7.2
7.3
8.3 8.2
8 8.1 10 10.2 10.1
16 14 16.1 16.2 16.3 15.3 15.1 15.2 16 15 13 12 11.5 11.4
10.3
11.3 11 11.2
11.1
16.3 16.2 16.1

ZF004275A
8 10
3 2
11
1
ZF004127A
BRa-90
1. Cooler changeover valve 1.1 Screw plug (M48) with seal 1.2 Compression spring, e.g. 0732 042 402 1.3 Piston 2. Pressure relief valve (12 bar) 2.1 Screw plug (M26) with seal 2.2 Piston 2.3 Compression spring, e.g. 0732 042 470 Compression spring, e.g. 0732 042 471 2.5 Piston 3 = Safety valve (14, 5 bar) 3.1 = Screw plug M12x1.5 with seal 3.2 = Compression spring. e.g. 0732 041 247 3.3 = Ball 4 = Screw plug M26 with seal 5 = Screw plug M12 (pump pressure) with seal 6 = Screw plug M12 (control pressure) with seal 7 = Cover 7.1 = Gasket 7.2 = Hex screw 7.3 = Hex screw 8 = Proportional solenoid with control valve 8.1 = Cylindrical screw 8.2 = O-ring 8.3 = Piston (control valve)
BEAKE
9 = Hex screw (M10) 10 = Pressure valve 10.1 = Screw plug (M30x1.5) 10.2 = Compression spring. 10.3 = Piston 11 = Control valve 11.1 = Sealing cover 11.2 = Adjusting screw 11.3 = Piston 11.4 = Compression spring 11.5 = Piston 12 = Hex screws 13 = Screw plug (M24x1.5) with seal 14 = Screw plug (M24x1.5) with seal 15 = Preload vlave (1.5 bar) 15.1 = Screw plug (1.5 bar) M26x1.5 with seal and recess for compression spring. 15.2 = Compression spring. 15.3 = Piston 16 = Drain valve 16.1 = Screw plug (M22x1.5) with seal 16.2 = Compression spring. 16.3 = Piston 17 = Needle sleeve and V-ring (for pump shaft).
1) Remove Intarder control unit. 2) Remove gasket (14). NOTE : When removing the vlaves, ensure that the removed pistons and piston guides are not damaged. 3) Remove the valves shown in this diagram. Clean Loctite residue from thread on screw plugs and threads for screw plugs. CAUTION : Proportional solenoid (8) must not be subjected to 24V power source. Check solenoid using terminal tester only. Technical data - proportional solenoid (8) Stroke Limit current Resistance at 20C Activation time 2 + 2 mm 0.5 A 25.0 6% 100 %
SERVICE PROCEDURES
6. Stator and rotor removal
BRa-91
1 2
3 4 5
6 7
1= 2= 3= 4= 5=
Retaining ring Circlips Spindle (or press) 1X56 122 292 Pressing-out fixture 1X56 138 047 Pressure piece (in-house manufacrure, refer to tools, item 15)
6 = Rotor 7 = Stator 8 = Baseplate or ring (ring 1X56 138 049 when using press) 9 = Shaft seal
ZF004276A
1) 2) 3) 4)
Release retaining ring (1) and remove (strike with chisel). Remove circlips (2). Fit pressing-out fixture (4) with pressure piece (5). Heat housing at points around circumference marked with arrows to between 90 and 100C using hot air blower. NOTE : When using fixture (4) with spindle (3), an appropriate height of baseplate can be inserted instead of item 8 (ring). When using a press, item 8 (ring) 1X56 138 049 must be used. If no baseplate is used, housing may become distorted or damaged. 5) Press out shaft with stator and rotor from housing. 6) Press out shaft seal (9) from housing.
BRa-92
7. Input spur gear removal
BEAKE
12 11
3 4 5 6 7 8 9 10
1. 2. 3. 4. 5. 6.
Special hex screw Shim Spur gear Inner race of taper roller bearing Outer race of taper roller bearing Stator
7. 8. 9. 10. 11. 12.
Ring (not fitted to all versions) Rotor Rectangular ring (piston ring) Baseplate or ring Three-leg puller Pressure piece
ZF004277A
1) Clamp shaft in vice using soft chucks. 2) Remove hex screw (1) and shim (2). 3) Remove spur gear (3) using three-leg puller and pressure piece.
SERVICE PROCEDURES Stator removal
BRa-93
2 3 4 5 6 7 8 9 10
1. 2. 3. 4.
Three-leg puller Pressure piece Inner race of taper roller bearing Stator housing pocker
5. 6. 7. 8.
O-ring Stator Ring (not fitted to all versions) Rotor
9. Rectangular ring 10. Ring (or baseplate) 11. Inpulse sensor
ZF004278A
1) Place rotor (8) on baseplate, remove stator using three-leg puller. 2) Remove inner race of taper roller bearing. 3) Remove ring (7) 4) Remove O-ring (5) from stator. 5) Remove outer race of taper roller bearing from stator (6) 7) Remove rectangular rings (9) from rotor (8). 8) Remove impulse sensor (11). Technical data - impulse sensor (11) Operating voltage Ub Current intake Tightening torque Air cap sensor/impulse wheel ZF operating voltage max 6 -15V max. 18 mA 40 Nm 1.4 mm 8V
11
ZF004278A
BRa-94 Reassembly
BEAKE
2 3
5 6 7 8
9 10 1. 2. 3. 4. 5. Hex screw M12x80 Powerlock (95 Nm) Shim Spur gear Inner race of taper roller bearing Outer race of taper roller bearing
6. 7. 8. 9. 10.
Stator O-ring Ring (not fitted to all versions) Rectangular ring (piston ring) Rotor
ZF004280A
Stator and rotor assembly

NOTE : Clean all parts. Lightly coat all moving parts with oil. 1. Coat rectangular rings (9) with oil, insert in annular grooves of rotor. 2. Heat stator bore for outer race of taper roller bearing (5) to approx. 80C, install outer race of bearing in stator, facing in correct direction. 3. Slide ring (8) onto stator (6). 4. Place rotor on bench (end of shaft) as shown in diagram. 5. Fit stator with ring onto rotor. 6. Heat inner race of taper roller bearing (4) to approx. 100C, slide correctly onto rotor shaft (contact face for inner race of taper roller bearing protrudes, i.e. inner race of bearing faces rotor). Apply light coat of oil to inner, race of taper roller bearing. 7. Heat spur gear (3) to approx. 85C place correctly on rotor. 8. Fit shm (2). 9. Screw in special hex screw (1), tighten provisionally. When cooled down, tighten to 95 Nm (10.4 kgfm) 10. Place O-ring (7) in stator and coat lightly using grease.
SERVICE PROCEDURES Stator and rotor installation
BRa-95
1 2
5 6 7
4 8
1. 2. 3. 4.
Stator O-ring Rectangular ring (piston ring) Intarder housing
5. 6. 7. 8.
Rotor Shaft seal Plate (in-house manufacture, refer to tools, item 16) Centring disc (1X56 138 045)
ZF004281A
1. Apply light coat of oil to rectangular ring (piston ring) and align centrally. 2. Fit centring disc (8) to Intarder housing. 3. Heat Intarder housing (4) to approx. 90 to 100C (in heating chamber at 100C for approx. 15 mins., if possible) NOTE : Ensure no scoring occurs inside housing when fitting. 4. Firmly install stator (1) and rotor (5) in Intarder housing until tips of arrows on cam surface of Intarder housing and stator are precisely aligned with one another. Maximum tolerance 1mm. Using manual press lever, apply pressure to stator and rotor for approx. 5 minutes until stator locates firmly in housing recess. NOTE : When correctly installed, stator must be located lower than the groove on the Sealing face (corresponds to plate (7) supporting face. 5. Press shaft seal (depending on version) to correct depth using suitable tool (refer to list of tools). 6. Screw 1.5 bar preload valve (refer to control unit), spring, seal pulg (with recess for spring) and seal into Intarder housing.
BRa-96 Fitting of taper roller bearing to rotor and taper roller bearing adjustment
BEAKE
1 2
7 3 8 A
9 10 5
1. 2. 3. 4. 5. 6. 7.
Retaining ring Circlip Adjusting fixture (1X56 138 046) Inner race of taper roller bearing Ring (for assembly of item 4) (1X56 138 050) Baseplate Tightening torque to spin point [20.5 Nm (225 kgfcm)]
8. Feeler gauge 9. Spur gear 10. Rotor shaft A = Gap [measure at spin torque 2 0.5 Nm. (225 kgfcm) Taper roller bearing must have preload of 0.05 to 0.1 mm]
ZF004281A
1. 2. 3. 4.
Fit Intarder and spur gear to ring 1X56 138 050 as shown in diagram. Heat inner race of taper roller bearing (4) to approx. 85C, fit correctly on rotor shaft. Apply light coat of oil to inner race (4) of taper roller bearing. Allow bearing to cool. Remove ring (5). Place Intarder housing on baseplates (6). This enables spur gear (9) to rotate freely. 5. Fit adjusting fixture (3), preload inner race of taper roller bearing until spin torque reaches 20.5 (22 5 kgfcm) 6. Using feeler gauge (8), measure gap A and note dimension. Circlip is supplied in 0.05 mm grades from 2.9 to 3.7 mm Taper roller bearing must have pressure of 0.05 to 0.1 mm. This is assured if a circlip with thickness equivalent to gap A is fitted. At a spin torque of 2Nm, circlip with next possible dimension can be installed. 7. Fit retaining ring (1) and peen onto baseplate at 3 points (120 apart).
SERVICE PROCEDURES Valve assembly and fitting of control unit housing
BRa-97
1.1
2.1 2.2 1 2.3 2.4 1.2 2.5 1.3
9 2 5 3.1 2.5 3.3 4 3 6 17 7.1 7 7.2
7.3
8.3 8.2
8 8.1 10 10.2 10.1
16 14 16.1 16.2 16.3 15.3 15.1 15.2 16 15 13 12 11.5 11.4
10.3
11.3 11 11.2
11.1
16.3 16.2 16.1

ZF004275A
23 Nm (2.5kgfm) 47 23 Nm (2.5kgfm) 46
36 25 Nm (2.7kgfm)
25 Nm (2.7 kgfm) 35
37 25 Nm (2.7kgfm) 100 Nm (11kgfm) 45 70 Nm (7.8kgfm) 44 38 70 Nm (7.8kgfm) 39 70 Nm (7.8kgfm)

8 10 3 2
11
40 150 Nm (16.5kgfm)
42 60Nm (6.6 kgfm)

ZF004127
BRa-98
1. = Cooler changeover valve 1.1= Screw plug (M48) with seal 1.2 = Compression spring, e.g. 0732 042 402 1.3 = Piston 2. = Pressure relief valve (12 bar) 2.1= Screw plug (M26) with seal 2.2 = Piston 2.3 = Compression spring, e.g. 0732 042 470 2.4 = Compression spring, e.g. 0732 042 471 2.5 = Piston 3. = Safety valve (14.5 bar) 3.1 = Screw plug M12x1.5 with seal 3.2 = Compression spring. e.g. 0732 041 247 3.3 = Ball 4. 5. 6. 7. 7.1 7.2 7.3 8. 8.1 8.2 8.3 Screw pulg M26 Screw plug M12 (pump pressure) with seal Screw plug M12 (control pressure) with seal Cover Gasket Hex screw Hex screw Proportional solenoid with control valve Cylindrical screw O-ring Piston (control valve) 9 = Hex screw M10x215 10 = Pressure valve 10.1 = Screw plug (M30x1.5) with seal 10.2 = Compression spring. e.g. 0732 042 348 10.3 = Piston 11 = Control valve 11.1 = Sealing cover 11.2 = Adjusting screw 11.3 = Piston 11.4 = Compression spring 11.5 = Piston 12 = Hex screws
BEAKE
13 = Screw plug (M24x1.5) with seal (entry to heat exchanger, oil temperature) 14 = Gsket (on sheet metal version, do not bend) 15 = Preload vlave (1.5 bar) 15.1 = Screw plug (1.5 bar) M26x1.5 with seal and re cess for compression spring. 15.2 = Compression spring. e.g. 0732 042 403 15.3 = Piston 16 = Drain valve (not on all versions) 16.1 = Screw plug (M22x1.5) with seal 16.2 = Compression spring. e.g. 0732 042 406 16.3 = Piston 17 = Needle sleeve and V-ring (for pump shaft). (Install needle sleeve so that thick collar faces pressing-in side)
Technical data proportional solenoid (8) Stroke Limit current Resistance at 20C Activation time NOTE : Check compression springs against spring table. Apply light coat of oil to moving parts. Calibrate bores for valve pistons using calibration mandrel In all cases, check piston for ease of movement in piston bore. 1. Install appropriate piston and compression springs in control housing. Apply light coat of Loctite 574 to seal plug threads and screw in with new sealing ring. Tighten to required torque. 2. Fit proportional solenoid (8) with O-ring (8.2) and piston (8.3). 3. Fit control unit with gasket (14). Tighten retaining screws to required torque. 2 + 2 mm 0.5 A 25.0 6% 100 %
SERVICE PROCEDURES Mounting bolts on control housing

Control housing Items 1 to 33
BRa-99
1 29 28 33 27 30 32 26 25 31 8 9 24 23
O1
2 11 12 13 7 14
6 10 5 15
22 21
O2 O2
O1
20
19
18
17
16
ZF004098A
Item no. 2 1, 3, 4 5 6, 7, 8, 9, 10 11 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24 25, 26, 27, 28, 29, 30, 31 32, 33
Screw size O.D x pitch (mm) M12 x 115 M2 x 120 M8 x 115 M8 x 30 M10 x 215 M8 x 80 M8 x 105 M8 x 30
Tightening torque Nm (kgfm) 62 (6.8) 62 (6.8) 23 (2.5) 23 (2.5) 50 (5.5) 23 (2.5) 23 (2.5) 23 (2.5)
BRa-100 Oil pum Reassembly and mounting

8 23 Nm (2.3kgfm)
BEAKE
7 9 23 Nm (2.3kgfm) 6
5 4 3 2 1 10
11
11
1. 2. 3. 4. 5. 6.
O-ring Ring gear Shaft with internal rotor V-ring Needle sleeve O-ring
7. 8. 9. 10. 11.
Pump housing Hex screws. (x4) Hex screw. (x1) Dowel pins (x2) Mark on ring gear (for ease of assembly)
ZF001227A
NOTE : Apply light coat of oil to moving parts. Once needle sleeve and V-ring have been removed from pump housing or control unit housing, heat housing to approx. 40C and install needle sleeve correctly using tool 1X56 137 975 (thick collar facing pressing-on side). Note that mark (dot) on ring gear (11) points upwards. This ensures that the lug on the ring gear external diameter points towards pump housing. 1. Install shaft (3) with internal rotor and ring gear (2) in pump housing. 2. Install O-ring (6 and 1) in control unit housing. 3. Fit pump housing, avoiding damage to drive spigot on shaft (3). Drive in dowel pins (10). Tighten screws to required torque.
SERVICE PROCEDURES Axial paly measurement (stator and grooved ball bearing on main transmission)
8 5kgfm 9 5.5kgfm 12 5.5kgfm 10 5.5kgfm 11 5.5kgfm 5 6 7 A B 19 14 13 3 4 2 1
BRa-101
18 20 A C 17 5.5kgfm 15 5.5kgfm 16 5.5kgfm

ZF001202A
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Retaining plate Hex screw (depending on version) Shim O-ring (68x4) Output flange Ring (ring or ring gear) Shaft seal (possibly already fitted) Hex screw (M10x35/8.8) Hex screw Hex screw Hex screw Hex screw * Hex screw (M10x215) TA = 50Nm Hex screw for universal shaft * Hex screw (head with bore for wire retainer to secure with impulse sensor) 16. Hex screw 17. Hex screw
18. Shim (thickness 1.6 to 0.9 mm. available in 0.1 mm steps) 19. Shim (thickness 0.6, 0.5, 0.4, 0.3, 0.2 mm) 20. Gasket A = Sealing face of Intarder housing B = Contact face for ball bearing on output shaft C = Gap between bearing and D = Gap between bearing and sealing face of basic housing GAP A - C e.g. 1.1 mm GAP A - B e.g. 10.5 mm Gap D e.g. 10.0 mm Axial play : Axial play of stator must be 0 0.05 mm Axial play of output flange bearing must be 0 to 0.1 mm.
BRa-102
BEAKE
A C
A B
= Gap between sealing face of basic transmission and face end of grooved ball bearing. A-B = Gap between sealing face of Intarder housing and face end of grooved ball bearing - must be 0 to 0.1 mm larger than dimension D
A-C = Gap between sealing face of Intarder housing and face end of stator must be 0 0.05 mm E = Impulsgeber
ZF004284A
NOTE : Various versions of the gasket between Intarder and main transmission are in circulation. 1. Paper gasket. 2. Paper gasket and gasket bead. 3. Steel plate gasket (with corrugated strip). When measuring this part, do not include gasket bead or corrugated strip. When being measured, the paper gaskets are placed on the Intarder housing. The steel plate gasket is measured separately.
SERVICE PROCEDURES
BRa-103
1. Meausre shim (19) Shim must have play of 0 to 0.1 mm Measure dimension A-B from sealing face (A) with paper gasket fitted to contact face (B), note dimension e.g. 10. 5 mm (On version with steel plate gasket, dimension A-B is thinner by the thickness of the gasket. In this case, thickness of steel plate gasket without corrugated strip must be added to dimension A-B). A-B. Measure dimension D from outer race of ball bearing to sealing face of main transmission, note dimension, e.g. 10. 0 mm E.G. 10.5 mm Dimension A-B 10.0 mm - Gap D 0.5 mm Gap = 0.1 mm - Axial play 0.4 mm Thickness of shim (19)
Fitting of Intarder
1. Measure shim (18). Shim must be adjusted to 0.05 mm pressure and 0.05 mm paly. Measure dimension A-C from sealing face (A) with fitted paper gasket to contact face (C), note dimension, e.g. 1. 1 mm. (On version with steel plate gasket, dimension A-C is thinner by the thickness of the gasket. In this case, the thickness of the steel plate gasket without corrugated strip must be added to dimension A-C). E.g. Dimension A-C 1.10 mm + Pressure 0.05 mm Thickness of shim (18) 1.15 mm 2. Attach corrected shms (18 and 19) to contact faces C and B with grease. 3. Fit gasket (20) to basic transmission. On version with gasket bead or corrugated strip, raised portion of bead (corrugated strip) points towards Intarder housing. Secure the gasket by inserting as many hex screws as possible to the basic transmission and by screwing in long enough stud bolts. Fit stud bolts at the points where through bores exist on the Intarder housing. The stud bolts also serve as dowels when fitting the Intarder. 4. Carefully fit Intarder to basic transmission and screw down. Note tightening torques. 5. Slide ring (6) onto output flange. 6. Correctly install retaining screws for cardan shaft in output flange. (screws cannot be inserted when flange is fitted). 7. Fit output flange (5) without heating. 8. Fit O-ring (4) and shim (3). 9. Screw in hex screws (2), tighten to correct torque and secure with retaining plate (1) using tool (refer to transmission). 10. Screw in impulse sensor, tightening torque 40Nm. (4.4kgfm) Technical data - impulse sensor (11) Operating voltage Ub Current intake Tightening torque ZF operating voltage max 6 - 15V max. 18 mA 40 Nm (4.4 kgfm) 8V
11
ZF004279A
Air gap between sensor/impulse gear 1.4 mm
BRa-104 Fitting of reservoir and temperature sensor to heat exchanger

1. Install O-ring (3) in annular groove of reservoir. Fit reservoir to heat exchanger.
3 1 2
BEAKE
ZF001226A
2. Screw temperature sensor (1) into heat exchanger, tighten. Max. tightening torque 40 Nm (4.4 kgfm) Technical data - Temperature sensor at 20C at 91C at 100C at 110C at 140C approx. 50000 approx. 2380 approx. 1830 approx. 1340 approx. 573
1 2
ZF001225A
SERVICE PROCEDURES
BRa-105
62 Nm (6.8 kgfm) 1 62 Nm (6.8 kgfm) 1 23 Nm (2.5 kgfm) 1 3 3 62 Nm (6.8 kgfm) 1 *
1. 2. 3.
Retaining nut (waf 18) (* coat with Loctite 574) Hex screw (M8) O-ring
Fitting of heat exchanger

1. Install new O-rings (3) in annular grooves of control unit housing. 2. Screw stud bolts (1) into heat exchanger with Loctite 574. 3. Apply thin coat of Loctite 574 to designated surfaces (*) of heat exchanger. Fit heat exchanger to control unit housing, insert and tighten hex nuts using Loctite 574. Tightening torque 62Nm (6.8 kgfm) 4. Screw in one M8 hex screw (2) and tighten.
BRa-106 Fitting of oil filter to Intarder

1. Install new O-rings in filter cover and filter cartridge. 2. Fit filter cartridge to filter cover. 3. Fit magnet from old filter cartridge to face of new cartridge. If magnet disc is missing, obtain a new one and fit. 4. Install filter cover with cartridge in housing, secure with hex screw and washer. 2 = O-ring in filter cover 3 = O-ring in filter cartridge 4 = Magnet disc
BEAKE
4
ZF004467A
Fitting of solenoid valve to reservoir

1. Slide retaining screw (2) into solenoid valve. Install O-ring (4) in groove. Fit solenoid vlave. Tightening torque for screws (2) is 23Nm (2.5 kgfm)
ZF000534A
Technical data - solenoid valve Operating voltage Coil resistance 24V Approx. 55.6 (23C)
SERVICE PROCEDURES
BRa-107
Air Drier
General
Compressed air is used in vehicles for various purposes, and is condensed and drained in the reservoir or is used in the piping line to affect the devices. For example, the compressed air may flush off the lubricant(grease) from moving parts to interrupt smooth operation or stimulate corrosion by impurities contained in the drain and lower the service life. In addition the drain may freeze in wintertime or cold areas to disable operation of various devices including the brake system. Therefore the air drier is installed to remove moisture and impurities contained in the compressed air in the compressor and protect various devices in the air line
Specifications
No. 1 2 3 4 Item Flowing material Max. used pressure Max. air pressure Relative humidity Specification Air 9.8kg/cm2 5~9kg/cm2 30% or less Discharge 160/min., Operation ratio 20%, Inlet air temperature approx. 40C, Pressure 6.0-7.5kg/cm2, Tank capacity 69, Air consumption approx. 27/min(standard) 5 6 Time lag Applicable compressor 40~50 seconds Actual discharge 1200/min or less 7 8 Air consumption Operating temperature range 36/min or less -4C~+70C -30C~+70C 9 10 Heater capacity Thermostat operation temperature 11 12 Weight Drying agent weight 24V 100W On at 4C4C, Off at 20C or less Approx. 8.6kg Approx. 1.5kg or more Without heater Within heater 50W2 Pressure drop 8.20kg/cm2 Remarks
BRa-108 Components
BEAKE
28
34
27
26 25 29 31 30 24 22 23 14
19 20 22 18 17 15 33 16 21 8 32 36 37 30 31 6 5 4 2 3 12 1 7 10 11 13 9 35
JJMS58C-002
SERVICE PROCEDURES
BRa-109
40
38
49
51
50 44 46 43 48 47 45 42 57 56 55 54 53 41 39
52
58
1. Body 2~10 Valve body assembly 3. Valve body 3. O-ring 4. O-ring 5. Piston 6. O-ring 7. Valve compressor 8. Valve spring 9. Spring washer 10. Bolt 11. Exhaust body 12. O-ring 13. Retaining ring 14~31 Cartridge 14. Case 15. Oil filter assembly 16. Gasket ring 17. Gasket ring 18. Filter plate 19. Bolt
20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
O-ring Spacer Filter Desiccant Filter plate(2) O-ring Set spring Case cover Check valve Bolt Spring washer Nut O-ring Screw and washer Purge pump Plug O-ring Stopper ring Bolt and washer Stopper plate(1) Stopper plate(2)
41~46. Thermostat (A) 41. Thermostat (B) 42. Cord cover 43. Heater boot 44. Terminal 45. Terminal cover 46. Terminal 47. Heater 48. Gasket 49. FT screw 50. Cord clamp 51. Rolling screw 52. Bracket 53. Bolt 54. Spring washer 55. Nut 56. Terminal and cord 57. Rolling screw 58. Bolt
JMS58C-002
BRa-110 Outline
BEAKE
Purge chamber
Check valve
Check valve Governor Drier
Main tank
Compressor Body
Air drier
JMS58C-003
Drying mechanism
At the compressor duty cycle, air in the drier goes into the air drier inlet and cooled at the body wall surface, and then moisture and oil vapor precipitate down in the body. The air will again go through the assembled (with the oil coated separator) oil filter, where oil particulates and dust will be removed. Thereafter the air will flow up from bottom in the drier cylinder contacting the drier, to reduce moisture and become dry at the top of the drier cylinder. The dried air will go through the check valve and the purge chamber to the main tank.
Check valve
Purge chamber Drier
Oil filter
Case
Body
JMS58C-004
SERVICE PROCEDURES Removal and installation
BRa-111
Purge chamber
Check valve
Orifice
Check valve
Governer Desiccant
Main pump
Control line Drain valve Outlet Air drier
Compressor
JMS58C-005
Recovery mechanism
When the air pressure in the system reaches the maximum value, the governor makes the compressor idle without load, and the compressed air in the air tank flows back to the air drier. At the same time the air pressure governor opens the valve located below the air drier to rapidly drain the compressed air. Then the rapid opening of the valve generates pressure in the drier cylinder, that cleans the oil filter and drain moisture and oil precipitates to ambient air. After the drastic pressure reduction, dry air in the purge chamber will pass through the orifice expending and reducing pressure to make ultimately dry air, that will pass in reverse through the drier cylinder, absorb and discharge moisture from the drier, and recover the drier. During running, air in the air tank is consumed and pressure in the air tank reaches the minimum pressure adjusted by the governor, and then the drain valve in the air drier is closed to remove moisture.
Orifice, Purge chamber Drier Case
Oil filter
High pressure from the air tank check valve
Valve
Exhaust
JMS58C-006
BRa-112 Inspection Inspection items after every three months or 15,000km
BEAKE
1. In order to check normal operation of the air drier, open the drain cock and check air drain. (However, if the temperature drop around the tank is above 17C , only a little drain may occur.) 2. Watch the drain out of the air drier outlet. If oil is drained excessively, check the compressor and remedy the excessive oil drain. 3. If the drain is too low at normal operating condition, check correct adjustment of the governor pressure. If the governor is normal disassemble the air drier and check the drier for precipitated oil and impurities. If the precipitation is above one fifth of the drier, replace the drier. NOTE : When replacing the drier, replace the oil filter and filter together.
Inspection items after every one year or 100,000km

1. 2. 3. 4. Disassemble the air drier and replace the drier, the oil filter, filter, and all rubber parts. As for metal parts, replace only rusted parts. If aluminum bodies or purge chamber is damaged, replace the air drier with a new one. Check piping and wiring for defects.
SERVICE PROCEDURES
BRa-113
Removal And Disassembly
1 12 13 14 1 36 2 5 4 8 7 9 10 6 21 15 16 17 18 19 20
11 35 3 28 27 29 32 30 31 26 24 23 33
22
25 34
34
Disassembly procedure 1. Bracket 2. Cord 3. Stopper plate 4. Stopper ring 5. Purge chamber 6. Case 7. Case cover 8. Check valve 9. O-ring 10. Spring 11. Filter plate 12. Filter
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Desiccant Filter Filter plate Gasket ring Oil filter Gasket ring O-ring Spacer O-ring O-ring Retaining ring Nipple
25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.
O-ring Valve Piston O-ring Valve spring Valve body O-ring O-ring Thermostat complet Heater Body Elbow
NOTE : In order to remove stained materials, cleanse the disassembled parts using detergent oil and dry them (Except rubber parts, drier, oil filter).
JMS58C-007
Removal
1. 2. 3. 4. 5. Secure the vehicle without using the air brake. Throughly drain air from the brake line. Remove the thermostat wiring. Remove the whole piping from the air drier. Remove the air drier mounting bolt.
Air drier
70~95 Nm (7.0~9.5kgfm) 70~95 Nm (7.0~9.5kgfm) 19~26 Nm (1.9~2.6kgfm)

JMS58C-008
BRa-114 Disassembly of the cartridge

1. Disconnect the ground wire from the bracket and the bolt, and remove the stopper plate releasing the hexagonal bolt of 10mm.
BEAKE
JMS58C-009
JMS58C-010
2. Disconnect the stopper ring from the purge chamber using a (-) screwdriver. On removing insert the screwdriver into the purge chamber groove and lift up the stopper ring, and then it will be easily removed.
JMS58C-011
3. Putting out the body to outside of the purge chamber, and release the four screws and washers that hold the cartridge using a (+) screwdriver.
JMS58C-012
4. Remove the cartridge from the body release the six nuts holding the cover using a 10mm spanner. On removal, press the case cover using a vice, etc, and release all nuts.
JMS58C-013
SERVICE PROCEDURES
5. Disassemble from above in the order of the set screw, the filter plate, the wheel, the desiccant, filter.
BRa-115
JMS58C-014
JMS58C-015
JMS58C-016
JMS58C-017
6. Reverse the case and hold the center hexagonal bolt in a vice using a 12mm socket. Release nut of the case from the top using a 10mm double ended wrench or a socket wrench. and then disassemble filter plate, gasket ring, oil filter compressor, spacer, O-ring.
JMS58C-018
BRa-116
BEAKE
JMS58C-019
1) From the upper left case, desiccant, filter 2) From the mid left case cover, set spring and O-ring, filter plate 3) From the lower left filter plate, gasket ring, check valve, oil filter compressor [Cartridge components] a : Case b : Desiccant c : Filter d : Case cover e : Set spring and O-ring f : Filter plate g : Gasket ring h : Check valve and oil filter compressor
b a
f d
f g h
JMS58C-020
Disassembly of body
1. Put the heater connection assembled on the exhaust body face upward, and prise out the retaining ring using a C type retaining ring pliers, and disassemble the exhaust body and the Oring. 2. Hold the hexagonal bolt head using a pliers, and disassemble the valve body complete.
JMS58C-021
JMS58C-022
SERVICE PROCEDURES
3. Secure the piston in the valve body using a 10mm hexagonal wrench, and release the valve complete connecting bolt, and disassemble the piston, valve spring, valve complete.
BRa-117
JMS58C-023
(Body components) a : Retaining ring b : Exhaust body c : O-ring d : Valve body complete e : Body, Heater, Thermostat complete A
b a
d
JMS58C-024
(Valve body complete components) a : Piston b : Valve spring c : Valve body d : Valve compressor e : Spring washer and bolt f : O-ring
JMS58C-025
BRa-118 Reassembly
Clean all disassembled parts using clean detergent oil excert rubber parts and desiccant, and blow off all stained materials to dry. Replace damaged or worn parts with new ones, if any. For reusing a rubber part, clean the part using soft rag. Replace desiccant with new one.
BEAKE
8 Outlet 1
7 10 9
4~7 Nm (0.4~0.7kgm) 11 12 Control hole 3 2 B 1.5~2.5 Nm (0.15~0.25kgfm) Inlet 5~6 Nm (0.5~0.6kgfm) 19 14 15 16 4~7 Nm (0.4~0.7kgm) 33 21 22 4 4~7 Nm (0.4~0.7kgm) 28 32 31 25 26 20 18 17 29 13 6 36
27 30
34
A 24 23
35
4~7 Nm (0.4~0.7kgm)
NOTE : 1. Apply grease on the slip surface between the O-ring and the piston. 2. Install the filter facing the soft area toward desiccant.
JMS58C-026
SERVICE PROCEDURES Reassembly of the cartridge

1. Insert the O-ring at the spacer groove and install the gasket ring.
BRa-119
JMS58C-027
JMS58C-028
2. Press the spacer, O-ring, and gasket ring toward the oil filter complete rugged area to contact. Put the filter plate and the gasket ring together on the opposite side, and insert the bolt from the filter plate side. Put the filter plate center protrusion face toward the oil filter.
JMS58C-029
JMS58C-030
3. Insert the bolt into the case center hole, and tighten the spacer, O-ring, gasket ring, oil filter complete, gasket ring, filter plate from above using the spring washer and the nut.
JMS58C-031
BRa-120
BEAKE
JMS58C-032
4. Put the filter pressed to the case bottom with the soft layer facing upward, and put desiccant in the case. Charge approx. 1.15kg of desiccant, or the whole desiccant in the case if provided as a repair kit.
JMS58C-033
JMS58C-034
5. For charging the desiccant well, turning the case lightly tap the cylindrical part using a plastic hammer, and then fill the second filter. (call it tapping) For the second charge put the soft area of the filter layer face downward.
JMS58C-035
JMS58C-036
SERVICE PROCEDURES
6. Insert the O-ring and the check valve on the case cover. Apply grease on the check valve center protrusion, then it will be inserted easily.
BRa-121
JMS58C-037
JMS58C-038
7. Put the filter plate and the set spring at the center of the case in which desiccant is contained, and the case cover on them, and pressing the cover with a special tool tighten them using the bolt, the spring washer, and the nut. Be careful to the spring tension that reaches 74kg on setting in the assembly procedure. Tightening torque : 4~7 Nm (40~70kgcm)
JMS58C-039
JMS58C-040
Reassembly of body
1. Apply grease on the O-ring and install the O-ring on the piston. Use specified silicone type grease only. 2. Apply grease on the valve bodys O-ring moving part and piston guide part, and insert the valve spring into the valve body. Then at the opposite direction that the valve spring is installed, holding the piston assembled with the O-ring as it is, tighten the valve complete using the spring washer and the bolt. Tightening torque: 4~7 Nm (40~70kgcm)
JMS58C-041
BRa-122
3. Insert the valve body complete and the O-ring in order, and install on the retaining body groove. On inserting the valve body complete in the valve body, be careful not to make the O-ring caught at the bodys cut area.
BEAKE
JMS58C-042
Reassembly of the main body

1. Apply grease on the O-ring and install the O-ring in the body groove. 2. Install the cartridge in the body guide area, and tighten the cartridge using the screw and the washer. (tightening torque 40~70kgfcm)
JMS58C-043
3. Install the body and the cartridge on the purge chamber, and the stopper ring on the purge chamber groove, then pressing one part of the body press-fit them into the purge chamber groove using two hands.
JMS58C-044
JMS58C-045
4. Connect the stopper plate using bolts and washers. Connect the stopper plate that is vertically bent with the purge chamber rugged area using a bolts
JMS58C-046
SERVICE PROCEDURES
5. Connect the heater on the gasket. Tightening torque : 20~25 Nm (200~250kgfcm)
BRa-123
JMS58C-047
6. Fix the thermostat complete using screws, connect the terminals to the heater, and install the terminal cover.
JMS58C-048
JMS58C-049
7. Fix one end of the terminal & cord(smaller connecting hole side of the pressed terminal) using screws. Tightening torque : 2~4 Nm (20~40kgfcm)
JMS58C-050
8. Install and fix the bracket on the purge chamber, insert the bolts in the bracket bolt hole, install the spring washer and nut, tighten the bolts head using a 12mm spanner, and tighten the nuts using a impact wrench. Tightening torque : 8.5~9.5 Nm (85~95kgfcm)
JMS58C-051
BRa-124
9. Insert the other end of the terminal & cordon the thread part of the bolts that connects the bracket and tighten it. Tightening torque : 5~9 Nm (50~90kgfcm)
BEAKE
JMS58C-052
Inspection after mounting on the vehicle

1. Operate the engine. When the pressure reaches the maximum pressure, it turns from loaded condition to unloaded condition. Then check leak at the air drier outlet. (The draining air is high at first, and no sound will be generated after approx. three seconds. Recovery time is approx. 40~50 seconds.) 2. When the air pressure decreases up to the minimum pressure and turned from unloaded to loaded condition, check leak at the drier outlet. If leaks, the leak shall be 20cc/min. (the air bubble size shall be f15 in six seconds) 3. Check each piping connection for leak.
SERVICE PROCEDURES Troubleshooting

Symptom Drain from the main tank Probable causes Time is required to dry from saturated condition when additionally install the drier after modification Excessive air consumption to override the air drier recovery. The governor (pressure regulator) cut-in pressure is decreased(to 5kg/cm2 or less) and the drain valve does not open. The air drier and the compressor is too close to make the inlet temperature high, and dehumidifying ability is low. Desiccant and the oil filter is overused beyond the replacement frequency. The heater does not operatee and the drier does not freeze. The governor cut-in pressure is low (to 5kg/cm2 or less) and the drain valve does not open. Foreign material is in the drain valve, and the valve does not operate. The air drier installation condition is abnormal, and the temperature decreases to 30C or less during driving. The heater has circuit-break, no heat reservation. The thermostat does not operate and the heater does not operate either. Remedy
BRa-125
Drain until the completely dry condition
Adjust the use of air to enable the recovery, and check the drier installation condition. Adjust the governor cut-in pressure to 5kg/ cm2 or more. Adjust the inlet temperature to 60C of less. (Make the distance between the air drier and the compressor as far as possible.) Replace the desiccant kit every one year or 100,000km. If the heater is failed replace the heater. If the thermostat is failed replace the thermostat. Adjust the governor cut-in pressure to the specified pressure, 5kg/cm2. Overhaul the valve and replace the valve kit. Change the air drier installation position or install a windshield. Check the heater for circuit-break using a tester, and replace the heater in case of a circuit-break. Check the thermostat operation: 1) Check the continuity using a tester at 0C or less, and; 2) Press the thermostat with palm and check if it switches off. * If the thermostat does not operate replace the thermostat. Check the heater and the thermostat wiring. Remove theice caring not to damdge the heater wiring, and change the drier installation position. Overhaul the valve part, and replace the valve or the valve body if the valve body sealed surface is damaged. Overhaul the check valve between the main tank and the air drier and replace the check valve if required.
No drain from the drain valve
Drain from the main tank
Air leak from the drain valve Abnormally low main tank pressure
The heater thermostat wiring is disconnected and the heater does not operate. Ice is frozen at the air drier drain outlet, and the recovery procedure is not effective. Foreign material is in the valve, and the valve does not seat completely. The check valve does not operate effectively between the main tank and the drier when the compressor is load-free, and the air in the air tank flows in reverse and drains from the drier.
BRa-126
BEAKE
Auto Slack Adjuster

General
As for brake lining, because gap between drum and lining gows larger according to use, control is necessary to maintain adequate lining gap through its adjustment when lining gap is adjusted by slack adjuster in case of full air S-cam brake. But if it is not adjusted in due period cycle, brake performance is deteriorated because brake chamber stroke is lengthened owing to excessive lining gap when braking so that brake shove phenomenon arises. The reaseon is that it has characteristics to decrease the brake power in region where brake chamber stroke is larger than about 80% of maximum stroke. Therefore because lining gap adjustment is a very important maintenance service item in S-cam brake, auto slack adjuster herein 1. Pursue stability by securing always stable brake performance by automatically adjusting and maintaining the lining with adequate gap and maintaining the adequate chamber stroke. 2. Reduces maintenance service time because there comes no need of lining gap adjustment by hand after installation until complete wear-out.
Gap
In case when adjusted manually
In case when adjusted automatically Time
The effect of Auto-Slack-Adjuster(compared to By-Hand-Adjust)
JMS58B-001
SERVICE PROCEDURES Component
BRa-127
24
2 7 18 19
25 1
4 11 23
15
14
16
24
3 23 22 17 12 20 13 24 21
10
1 . Housing 2 . Bushing 3.4.Worm gear 5 . O-ring 6 . Bearing 7 . Oneway clutch 8 . Needle bearing 9 . Cover 10. Cotrol unit
11. 12. 13. 14. 15. 16. 17. 18. 19.
Rack Return spring Plug Coil spring Thrust washer Cover Control disc Clutch spring Gear wheel
20. 21. 22. 23. 24. 25.
Screw Nipple Gasket O-ring Rivet Plug
CYBR007A
BRa-128
1. Housing is cast in nodular iron and tenifer treated to give a low coefficient of friction and high wear resistance.
BEAKE
Bushing
Housing
JMS58B-003
2. Worm gear transmits force from housing to the S-cam shaft. The tooth profile of the gear is asymmetrical, and both parts are made of specially treated high-grade steel.
Worm gear
O-ring Worm O-ring gear
JMS58B-004
3. Rack converts the rotation of control disc to a reciprocating liner action. Return spring keep the rack in contact with the lower flank of the recess in the control disc when one way clutch and is disengaged.
Rack
Return spring
Plug
JMS58B-005
4. Control unit supplies the motion required for the compensatory action of the adjuster. The unit consists of control disc, control arm and cover. The control arm and disc are rigidly joined to each other and can rotate freely as a unit in the cover.
Cover Control unit
Gasket
Control disc Control arm Screw
JMS58B-006
SERVICE PROCEDURES
5. Needle bearing, thrust washer and screw cover control the thrust from coil spring. Coil spring is held by four springs to be in touch with clutch ring; rivet lets cover to be fixed at proper position and also allows it to be easily dismounted.
Cover Needle bearing Thrust washer Coil spring
BRa-129
Cover
JMS58B-007
6. One-way clutch converts the linear motion of the rack to rotary motion. The clutch consists of gear wheel, clutch spring and clutch ring.
Clutch ring Clutch spring Gear wheel Bearing
one
-way
clutc
h
JMS58B-008
Operation Principle
Maintaining gap is secured by gap A between the rack rotating together with slack adjuster and the control disc in control unit fixed at anchor bracket etc. as shown in right figure. Namely it is not adjusted until rack end comes in touch with control disc when slack adjuster rotates in direction at time of braking whence gap is adjusted in the afterward region.
Control disc Slack adjuster
Control disc
JMS58B-009
1. When brake is operated with excessive gap between drum and brake lining, slack adjuster slope may be divided into the following factors: 1) Clearance angle C: normal gap. 2) Excessive clearance angle() : for excessive gap that is made by wear of brake lining etc. 3) Elasticity angle E: determined by elasticity of component parts transmitting between wheel brake, brake cylinder, brake drum and lining.
JMS58B-010
BRa-130
2. The working cycle of the brake adjuster can be divided into the following stages: 1) Starting position Slack adjuster control arm is located so that the rack is at the bottom of its travel and its tooth is in contact with the upper flank of the recess in the control disc. Angle A (clearance angle) between the lower flank of the recess in the control disc and the tooth of the rack determines the normal angle that will be obtained between brake lining and brake drum.
BEAKE
Rack 13 Control 21 disc A
JMS58B-011
2) Application of brake with excessive clearance Movement through clearance angle (C) The slack adjuster moves through angle A until the toe of the rack pushes against the lower flank of the recess in the control disc. The brake shoes expand, but not enough to touch the brake drum. Thus normal clearance (C) corresponds to the clearance angle (A).
Rack 13
Control disc 21
JMS58B-012
Movement through excess clearance angle (Ce) The control disc pushes the rack upwards so that it turns the gear wheel(7) of the one-way clutch(7, 8, 9). The one-way clutch is disengaged in this sense of rotation. At the same time the S-cam shaft expands the brake shoes until the linings are in contact with the brake drum.
Gear wheel 7 Clutch spring 8 Clutch ring 9
Rack 13 Control disc 21

JMS58B-013
SERVICE PROCEDURES
Movement into elasticity zone (E) The worm screw is displaced axilally and compresses the coil spring so that the cone clutch between screw and (9) is disengaged. This happens when the torque on the S-cam shaft rises rapidly as a result of the brake linings being pressed with increasing force against the brake drum.
BRa-131
Clutch ring 9 Worm 4 screw
17 Coil spring
JMS58B-014
Movement through elasticity angle (E) The control disc continues to push the rack upward. Now, however, the rack turns the whole one-way clutch assembly (7-8-9) because the cone clutch and 9 is disengaged.
7 8 9 4
13
21
JMS58B-015
3) Release of brake with excess clearance Movement through elasticity angle (E) The return springs 14 and 15 hold the tooth of the rack 13 against the lower flank of the recess in the control disc 21. The rack 13 turns the one-way clutch because the cone clutch 4 and 9 is disengaged.
7 8 9 4 13 21
JMS58B-016
BRa-132
Movement into clearance zone (C) The cone clutch 4 and 9 engages when the torque on the S-cam shaft falls to a level at which the coil spring 17 can push the worm screw 4 into contact with the clutch ring 9.
BEAKE
9 4
17
21
JMS58B-017
Movement through clearance angle (C) The force exerted by the return spring 14 and 15 on the rack 13 is not enough to turn the one-way clutch 78-9 when the cone clutch is in engagement. As a result contact between the tooth of the rack and the recess in the control disc shifts from the lower to the upper flank (angle A).
13
The control disc 21 pushes the rack down to its bottom position in the housing 1. As both clutchs are now in engagement the worm screw 4 is turned by the rack and the wheel 3 and the S-cam shaft turn with it. The net result is an automatic adjustment which keeps the clearance between the brake shoes and the drum at a constant value. If the clearance is abnormally large, e.g. after the slack adjuster has been removed in connection with repairs, the brake will have to be applied many times to adjust the slack adjuster to its normal stroke. Alternatively the excess clearance can be taken up manually by turning hut clockwise. The takeup of the slack adjuster per stroke is determined by the gear ratio.
21
JMS58B-018
1 9 8 7 4 14,15 3 13 21
JMS58B-019
SERVICE PROCEDURES
4) Braking at normal clearance Working cycle in this case is generally same as described above but there is difference as follows. In case when brake was applied with normal clearance, lining is installed in drum just after slack adjuster rotated through angle A. Result is as B and B when brake was applied forcibly. When brake is released, slack adjuster is operated as explained in C and the following action takes place. Slack adjuster moves through clearance angle A. Rack tooth is in contact with top part in recess of control disc 21 and at the same time rack is in touch with housing bottom so that slack move upward no more.
BRa-133
Service Standards
Maintenance items Chamber stroke Worm screw slip torque (anticlockwise) Worm screw in axle direction play Conical clutch (serration portion) Coil spring tension 380~20kg Front Rear Nominal value 45 mm max. 50 mm max. 1.8 kgf.m or more 0.15~0.6mm 0.6mm 0.08mm 0.6mm 0.08mm Limit value Remark
Special Tools
Tool name Spanner Part number 76025 Shape Application
JMS58B-020
Distant tube
76026
JMS58B-021
Extension piece D.T1
76034
JMS58B-022
BRa-134
Tool name Spanner Part number 76035 Shape
BEAKE
Application
JMS58B-023
Lubricating tool
76843
JMS58B-024
Holder
76591
JMS58B-025
Mandrel
76493
JMS58B-026
Spline key 1 -10C
76494
JMS58B-027
SERVICE PROCEDURES
BRa-135
Service Procedures
Disassembly
1. Release the screw and remove the control unit and the gasket. After that disassemble the rack, plug and the return spring. 2. Remove rear screw cover with a hexagon wrench, and remove the spring and the thrust washer.
JMS58B-028
3. Check the worm screw play. If the axial play is beyond 0,6mm, the housing is worn and replace auto slack adjuster assembly without removal check. Worm screw travel in axle direction 0.6mm or less
4. Remove the front screw cover using the spanner(76025) and take out the needle bearing, O-ring and the one way clutch. 5. Remove the worm screw and bearing using the mandrel(76493) and distance tube(76126). NOTE: If remove, remove the same direction of the arrow in the housing 6. Remove the worm wheel with its O-rings. 7. Replace the following parts without fail in case auto slack adjuster assembly has been disassembled: 1) O-ring 2) One-way clutch 3) Clutch 4) Rivet 5) Plug
JMS58B-029
JMS58B-030
Reassembly
1. Place the worm wheel with the two O-rings in the housing with flange uppermost. Fit the worm screw against the recess in the housing. At that time, hexagonal head part should be located toward the arrow position of the housing. NOTE: Before reassembly all part materials are to be begun adjustment after coating grease of lithium series. 2. Fit the bearing over the worm screw and press it into the housing by means of mandrel(76493). NOTE: Ensure that the bearing is correctly seated against its recess in the housing, and that fit the bearing to the hexagonal head side of worm screw and check the worm wheel turn aroud the worm screw one time.
JMS58B-032
JMS58B-031
BRa-136
3. Mount clutch ring, clutch spring and gear wheel of one-way clutch and confirm the contact state of gear wheel surface with clutch ring. 4. Fit the O-ring on the worm screw. 5. Assemble the front screw cover with the needle bearing. 6. Tighten the front screw cover against recess in housing with a torque of (5.1kgfm). Recheck that the worm screw train revolves easily. 7. Recheck worm screw play in axle direction using the spline key (76494) and the holder (76591) that are special tools of dial gauge. Worm screw travel in axle direction 0.6mm or less
BEAKE
NOTE: If worm screw travel in axle direction that is axial play of worm screw worm movement is outside tolerance then substitute a new one and at this time also if adjuster limit value is exceeded then change auto slack adjuster assembly. 8. Compress the two return springs with the spring inserter fit rack. Check that the rack sits correctly in its slot, and that the springs are correctly placed on the abutment of the rack. 9. Place a new welch plug in the recess of the hole for the two return springs with the convex surface outwards. Lock by punching it in the centre.
JMS58B-033
JMS58B-034
10. Measure serration part height of conical clutch using special tools of holder (76591), spline key (76594) and 18mm spanner. Worm screw travel in axle direction 0.6mm or less
If below limit value, a new worm screw is required. NOTE: During measuring, the rack must be kept in position by using the thumb. Please see picture. 11. Lock the front cover using rivet. 12. Place the thrust washer into the housing with its bearing sphere foword the worm screw. Insert the coil spring against the thrust washer. 13. Screw the rear cover by means of a hexagon wrench about 4 turns against the coil spring.
JMS58B-035
SERVICE PROCEDURES
14. Fit the lubricating tool(76593). Fill the adjuster with prescribed grease and dismantle the lubrication tool.
BRa-137
JMS58B-036
15. Place a new gasket on the control unit place the control unit in the housing ensuring that the toe of the rack enters the cut out in the control disc. Tighten six screws. 16. Adjust the spring force by means of an end load tester(76035) to (380-20kg). NOTE: Spring force adjustment shall be precise because it plays important role in auto slack adjuster function. 1) To ensure proper function of the auto slack adjuster, the force of the coil spring has to be adjusted to 380~20kg. This force is reached when the gauge pointer is inside the red area. NOTE: The minimum gap of the vice must be 215mm.
JMS58B-037
2) Place the auto slack adjuster in the tool so that the hexagon wrench in the hexagon of the rear screw cover and that the hexagon on the worm screw is fitted into the locking plate.
JMS58B-038
3) Load the adjuster until the pressure gauge is about halfway to the red area. Rotate the control arm clockwise so that the rack of the adjuster is moved fully up in its slot. Then rotate the control arm backwards over the control angle A.
JMS58B-039
BRa-138
4) Load the adjuster until the gauge pointer is whin the red area. The control arm should then return to its starting point due to the release of the conical clutch. If the control unit should only move slowly it may be necessary to press it lightly by hand to return it to the normal position. NOTE: The gauge must be read at the same time as the control arm begins to return to its starting position. 5) (Un)fasten rear screw cover by spanner to control tensile force if control arm starts to return when gauge pointer is before or beyond red area. 6) Sufficiently return the vice so that adjuster will receive no load. 7) The above ~ must be repeated until accurate spring force is got. 17. Lock rear screw cover using a rivet.
BEAKE
JMS58B-040
SERVICE PROCEDURES
BRa-139
Periodical Check
Operation Status Check
1. Check per drive distance 20,000 km whether chamber push rod stroke is within nominal value. Chamber push rod Stroke(mm) 45mm 50mm 45mm 50mm
2. If the stroke is beyond nominal value then confirm whether it is auto slack adjuster abnormality or other parts abnormality by means of reverse adjustment torque checking.
Reverse Adjustment Torque Check

1. Reverse adjustment torque shall be checked per six months. 2. Check if slip occurs below nominal torque of one-way clutch by measuring the torque by turning the worm screw hexagon head anticlockwise. Nominal torque 1.8kgfm
3. The above reverse adjustment torque shall be measured more than three times and then if one-way clutch slips below nominal torque then auto slack adjuster function is abnormal. NOTE: Take heed that phenomenon is frequent that mainly oneway clutch spring is broken.
Wear Limit
Min 61.87mm
Max 62.2mm
Max 16.15mm
Min 15.90mm
Max 9.4(Nom 9.0)mm
A A
CYBR007B
BRa-140
BEAKE
TROUBLESHOOTING
1. Wheel brakes Symptom Poor braking action Air leaks when brake pedal is depressed Probable cause Loose connectors Leaky primary and secondary valves of dual brake valve Damaged dual brake valve O-ring Air leaks when brake pedal is released Low air pressure Loose connectors Leaky primary and secondary valves of dual brake valve Air leak Air pressure governor improperly adjusted Air compressor malfunctioning No air leaks Oil or grease on brake lining Hardened lining surface Excessive brake shoe clearance Remedy Tighten connectors Disassemble dual brake valve to remove foreign matter or replace inlet valve Disassemble dual brake valve and replace O-ring Tighten connectors Disassemble dual brake valve to remove foreign matter or replace inlet valve Check air line and correct air leaks Adjust air pressure governor Overhaul air compressor Wash deposits off the surface or replace brake lining Machine brake lining surface or replace lining Adjust shoe clearance replace brake lining if it has worn to limit Brake drum overheats The brake shoes are not moving away from the brake drum when the brake pedal is released (brake dragging) Improper return motion of the primary or secondary valve of the dual brake valve, or exhaust port being plugged with foreign matter Small brake shoe clearance Weak or broken brake shoe return spring Rusty anchor pin makes brake shoes unable to return Air pressure brake chamber not released Rusty camshaft Spring brake is activated Adjust shoe clearance Replace return spring Remove anchor pin and remove rust Check dual brake valve and quick release valve Correct Find the cause and release spring brake Disassemble, check, and clean dual brake valve and correct problem or replace Ref. group
TROUBLESHOOTING
Symptom Brakes are noisy when pedal is depressed Probable cause Brake lining worn to allow rivet head to be exposed Hardened brake lining Unevenly worn brake drum inner surface Brake shoe not in tight contact with brake lining Brake drum left loose Anchor pin left loose Improper brake shoe clearance or brake lining in poor contact Oil or grease on brake lining and brake drum inner surface Brake drum runout, or left loose Uneven right and left inflation pressures Different brake lining materials used Weak or broken brake shoe return spring Chassis spring U-bolt left loose Air pressure to each brake chamber uneven Small brake shoe clearance Retighten Tighten anchor pin lock nut to specification Vehicle pulls to one side when brake pedal is depressed Adjust shoe clearance correct poor contact or reline brake lining Completely remove deposits or reline brake lining Correct runout retighten Adjust to specified inflation pressure Reline brake lining or pad of the same material Replace return spring Retighten Check piping to brake chambers for leaks or check operation of each components Abrupt braking action of wheel brakes Adjust shoe clearance Replace brake lining Machine or replace drum Replace brake lining Remedy Replace brake lining
BRa-141
Ref. group
BRa-142
2. Air drier Symptom Air drier Air tank drain cock drains Exhaust port does not drain frozen Probable cause Desiccant becoming ineffective and filter Heater fails to operate and air drive is Replace heater if defective replace thermostat if defective Valve inoperative due to foreign matter Disassemble and check trapped Air drier interior is frozen Heater circuit is open valve and replace valve complete as necessary Check heater for continuity with a tester and replace heater if there is an open circuit Heater inoperative due to defective ther- Use following procedure to mostat check thermostat and replace if found defective o Leave thermostat under environment 0C or below and check for continuity using a multimeter using a multimeter o Heat thermostat to make sure that it turns OFF at temperature between 0C and 20C Snow or ice on air drier, abnormally lower- Remove snow or ice with ing its temperature care not to damage air driver and heater wires Heater inoperative due to heater and ther- Connect heater and thermostat wires properly mostat wires left disconnected Air leaks from exhaust port Valve fails to seat properly due to foreign Disassemble and check valve and replace valve matter complete or replace valve body, if its sliding surface is damaged Excessively low air tank pressure When check valve on air tank side is not Replace check valve befunctioning properly in unloading cycle of tween air tank and air driver air compressor, backward flow of dry air from air tank occurs. Engine oil is discharged Oil working up in air compressor from exhaust port Replace piston rings and cylinder liner Remedy Replace desiccant, oil filter,
BEAKE
Ref. group
TROUBLESHOOTING
3. Exhaust brake Symptom Exhaust brake Exhaust brake ineffective Faulty electrical circuit Probable cause Abnormal air pressure Remedy Check for air compressor performance and piping and correct as required Check and repair clutch switch, microswitch, and exhaust brake harness Air piping crushed 3-way magnet valve inoperative Exhaust brake valve inoperative Exhaust brake valve shaft sticking Control cylinder inoperative Replace Replace Clean Replace Disassemble control cylinder and replace defective parts Exhaust brake cannot be released 3-way magnet valve inoperative Exhaust brake valve inoperative Exhaust brake valve shaft sticking Faulty electrical circuit Replace Clean Replace Check and repair clutch switch, microswitch, and exhaust brake harness
BRa-143
Ref. group

BR (Brake System)

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BR (Brake System)

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BRAKE

7. 8. 9. 10. 11. 12.

13. 14. 15. 16. 17. 18.

19. QR1C vlave 20. Quick release valve

Cylinder head Cyliner liner

Valve spring Suction valve

Delivery valve spring Delivery valve

Unloader valve compressed air (from air pressure governor)

Unloader valve spring Suction valve

Dual break valve

Pressure protection valve

Quick release valve

Quick release check valve

Air supply inlet

Air exhaust outlet

Air switch (Stop lamp switch)

Seal is coated in case of reuse material JMS58A-032

Low air pressure switch

Double check valve

Connector Check valve

Air supply inlet B

Air supply inlet A

Air exhaust outlet C

Relay valve (Parking)

Inlet valve Room F

Supply inlet (from air tank) Room B

Front brake assembly

Parking brake (Gradual parking)

Exhaust brake system

To battery relay Exhaust brake switch

Air tank Magnet valve

Intake silencer valve

Exhaust brake valve

Exhaust brake valve

GENERAL Intarder System

PTO connection Flange output

Rotor Oil reservoir Heat exchanger

Air leaks at any position of the drier -

Nominal value (Basci diameter[ ])

Remedy and Remarks Replace

Replace piston ring set

Slanting screw surface

Sealant is not applied on plain screw surface.

Water outlet pipe Unloader pipe Water inlet pipe

Water inlet pipe

Air outlet pipe Unloader pipe

Sensor plate projection

Apply sealant to threads (THREEBOND 1211 or 1212 or equivalent) Hexagonal part

< D6A ENGINE >

Wear, damage Settling

32 30 28 Damage of circle, wear 27

Crankshaft end play L 1.0 mm

SERVICE PROCEDURES Disassembly procedure

Suction valve tool

Suction valve tool

Inspection and correction

Connecting rod end play L 0.5 mm

BD ... Basic Diameter NV ... Nominal Value L ... Limit

< D6A ENGINE >

98 to 115 Nm (10 to 12 kgfm) 9 10 11 12 13 25 to 29 Nm (2.5 to 3.0 kgfm)

98 to 115 Nm 8 (10 to 12 kgfm) 5 6 7 14 15 98 to 115 Nm 16

15 to 20 Nm (1.5 to 2.0 kgfm) 31