How it Works
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hd78
Service Manual
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Hyundai HD78 User Manual

Brake System
(WABCO ABS)
General
Description.................................................... BR -3
Components ................................................. BR -14
Dignosis ........................................................ BR -16
On-Vehicle Inspection And Adjustment ....... BR -20
Specifications ............................................... BR -22
Vacuum Assisted Hydraulic Brake
Brake Pedal
Removal .................................................. BR -28
Installation ............................................... BR -28
Adjustment .............................................. BR -28
Brake Booster
Component ............................................. BR -30
Removal .................................................. BR -31
Installation ............................................... BR -32
Brake Master Cylinder
Removal .................................................. BR -37
Installation ............................................... BR -38
Load Sensing Proportioning Valve(LSPV)
Removal .................................................. BR -40
Front Brake Assembly
Disc Brake
Removal .................................................. BR -42
Installation ............................................... BR -43
Drum Brake
Removal .................................................. BR -49
Replacement ........................................... BR -50
Installation ............................................... BR -51
Parking Brake System
Components ................................................. BR -52
Removal ....................................................... BR -53
Installation .................................................... BR -54
Adjustment .................................................... BR -56
Rear Brake Assembly
Drum Brake
Removal .................................................. BR -58
Replacement........................................... BR -59
Installation ............................................... BR -61
Exhaust Brake
Component Location .............................. BR -62
Replacement........................................... BR -67
ABS(Anti-Lock Brake System)
Specifications ............................................... BR -72
Description.................................................... BR -72
Using Blink Code Diagnostics ..................... BR -76
DTC Troubleshooting ................................... BR -83
Repair Instruction ......................................... BR -88
Connector Configurations ............................ BR -90
Full Circuit Diagram ..................................... BR -91
Inspection ..................................................... BR -91
Adjustment .................................................... BR -92
ABS Modulator
Removal .................................................. BR -94
Installation ............................................... BR -94
Wheel Speed Sensor
Description .............................................. BR -95
Replacement........................................... BR -95
ABS Control Module
Removal .................................................. BR -97
Installation ............................................... BR -98
Schematic Diagrams .............................. BR -99
DTC Chart ............................................... BR -104
0000 ........................................................ BR -107
0001 ........................................................ BR -110
0002 ........................................................ BR -113
0003 ........................................................ BR -116
0004 ........................................................ BR -119
0009 ........................................................ BR -122
000A ........................................................ BR -125
000B ........................................................ BR -128
000C ........................................................ BR -131
000D ........................................................ BR -134
000E ........................................................ BR -137
000F ........................................................ BR -140
0010 ........................................................ BR -143
0011 ........................................................ BR -146
0017 ........................................................ BR -149
0018 ........................................................ BR -152
0019 ........................................................ BR -155
001A ........................................................ BR -158
001B ........................................................ BR -161
001C ........................................................ BR -164
001D ........................................................ BR -167
001E ........................................................ BR -170
001F ........................................................ BR -173
0020 ........................................................ BR -176
0021 ........................................................ BR -179
0022 ........................................................ BR -182
0023 ........................................................ BR -185
0024 ........................................................ BR -188
0029 ........................................................ BR -191
002A ........................................................ BR -194
002B ........................................................ BR -197
002C ........................................................ BR -200
002D ........................................................ BR -203
002E ........................................................ BR -206
002F ........................................................ BR -209
0030 ........................................................ BR -212
0032 ........................................................ BR -215
0033 ........................................................ BR -218
0037 ........................................................ BR -221
0038 ........................................................ BR -223
0039 ........................................................ BR -225
003B ........................................................ BR -227
003C ........................................................ BR -230
003D ........................................................ BR -233
003F ........................................................ BR -235
0040 ........................................................ BR -237
0041 ........................................................ BR -240
0042 ........................................................ BR -243
0043 ........................................................ BR -246
0044 ........................................................ BR -249
0045 ........................................................ BR -252
0046 ........................................................ BR -255
0047 ........................................................ BR -257
0049 ........................................................ BR -260
004A ........................................................ BR -263
004B ........................................................ BR -266
004C ........................................................ BR -269
004D ........................................................ BR -272
004E ........................................................ BR -275
004F ........................................................ BR -278
0050 ........................................................ BR -281
0051 ........................................................ BR -284
0052 ........................................................ BR -287
0053 ........................................................ BR -290
0054 ........................................................ BR -293
0055 ........................................................ BR -296
0056 ........................................................ BR -299
0057 ........................................................ BR -302
0058 ........................................................ BR -305
0059 ........................................................ BR -308
005A ........................................................ BR -311
005B ........................................................ BR -314
005C ........................................................ BR -317
005D ........................................................ BR -320
General
DESCRIPTION
BRAKE SYSTEM
The service brakes are internally expanding type hydraulic brakes acting on all w h e els. The brakes for the front wheels are 2-leading type and those for the rear wheels are duo-servo or dual 2-leading type.
The brake booster gives faster hydraulic pressure buildup. Tandem type brake master cylinder also contributes to safety. The brake pedal, which is easy-to-operate pendant type, transmits depression force via operating rod, etc. to the BRAKE BOOSTER, which boosts it and drives the master cylinder.
The BRAKE BOOSTER vacuum line is equipped with a vacuum tank which minimizes negative pressure change even in the case of repeated and frequent braking operation.
Brake Booster
1. When not in Operation
When not in operation, no force acts on the operating rod and hence the valve plunger is seated on the poppet to open the negative pressure valve and to close the atmospheric valve.
Negative pressure generated by the engine draws out air from the chamber on the left side of the diaphragm plate. And as the chamber on the right side of the diaphragm plate is also evacuated via the vacuum channel and the negative pressure valve that is opened. As a result, the diaphragm plate is pressed tightly onto the rear shell surface by the diaphragm plate return spring. Atmosphere goes through the air filter into space around the operating rod but does not flow further as the atmospheric valve of the valve plunger is closed.
2. When in Operation
When the brake pedal depression force overcomes the valve return spring force, the operating rod, valve plunger and poppet now move to the left and the poppet is pressed tightly onto the valve plunger seat by the poppet spring, closing the negative pressure valve. When the brake pedal is further depressed following closure of this valve, the valve plunger clears the poppet to open the atmospheric valve and atmosphere now flows through the channel into the chamber on the right side of the diaphragm.
This flow of atmosphere produces the pressure difference across the diaphragm and the force resulting from such pressure difference overcomes the piston return spring force. As a result, the
diaphragm pushes the push rod as it moves from right to left. The push rod thus pushes the master cylinder piston, generating high fluid pressure from low pedal depression force.
SUDBR9016L
Brake Master Cylinder
1. Normal Operation
The tandem type brake master cylinder has independent hydraulic systems for front and rear brakes.
Should one of the two hydraulic systems fail, braking by survived system (front or rear wheels) ensures safety. When the brake pedal is depressed, the primary piston is pushed to left, developing hydraulic pressure in the pressure chamber on the primary side. This pressure directly acts on the secondary piston to push the secondary piston to left, developing hydraulic pressure also in the pressure chamber on the secondary side. As a result, each piston pressurizes brake fluid to generate hydraulic pressure in both front and rear brake systems.
SUDBR9017L
2. When fluid leaks are caused in front brake system
In this case, depression of the brake pedal to push the push rod does not develop hydraulic pressure as the brake fluid leaks from the front brake system. Therefore, the primary piston compresses the primary return spring and the retainer pushes the secondary piston, which then pressurizes brake fluid in space between the secondary piston and cylinder body, thus generating hydraulic pressure in the rear brake system only.
Front And Rear Wheel Brakes Front wheel Brakes
The wheel cylinder is so constructed that the piston extends in one direction only to push the shoes which are held down to the backing plate by the shoe hold down pin. The return springs mounted on the shoe fixed and moving sides cause contraction of the shoe and wheel cylinder piston when the brake is released.
When the vehicle is running forward, both shoes work as leading shoes.
SUDBR9018L
3. When fluid leaks are caused in rear brake system
In this case, when the brake pedal is depressed to push out the push rod, the secondary piston end comes into contact with the cylinder body since brake fluid in the rear brake system leaks. When the push rod is further pushed, the primary piston pressurizes brakefluidinthespacebetweentheprimaryand secondary pistons, generating hydraulic pressure in the front brake system only.
EMTBR5004A
When the pedal is depressed, brake fluid supplied under pressure from the master cylinder enters the wheel cylinder, of which piston moves the shoe moving side so thattheliningispressedagainstthedruminside. Resultant friction between the lining and drum causes the shoe to try to turn with the drum, thus boosting the braking force.
EMTBR5005A
Rear Wheel Brake Dual 2-leading Brake
The wheel cylinders are installed at front and rear and the pistons extend in both upward and downward directions to push the shoes from both directions. The shoes are held down to the backing plate by shoe hold down pins and the return springs mounted on the shoes causing contraction of the shoe and wheel cylinder piston when the brake is released. During both forward and reverse operation of the vehicle, the shoes work as leading shoes.
EMTBR5004A
When the pedal is depressed, brake fluid supplied under pressure from the master cylinder enters the wheel cylinder, of which piston causes the shoe to expand in both directions to press the lining against the drum inside. Resultant friction between the lining and drum causes the shoe to try to turn with the drum, thus boosting the braking force.
Wheel Cylinder
The wheel cylinder driven by hydraulic pressure generated by the brake master cylinder presses the shoe (lining) against the brake drum.
There are following two types of wheel cylinder according to the method of pushing the shoe.
EMTBR5007A
1. 2-leading type : Front brake
In pedaling brake, oil pressure rising is master cylinder goes into wheel cylinder and pushes piston. Shoe contacting with the end of piston sticks to brake drum and generates frictional force.
EMTBR5006A
EMTBR5008A
2. Dual 2-leading type : rear brake
EMTBR5009A
Brake Fluid Level Sensor
The brake fluid level sensor installed in the brake fluid tank senses the brake fluid level in the tank. When the fluid level drops to a preset level, the sensor operates to turn on the warning lamp in the cluster to warn low brake fluid level.
EMTBR5010A
Exhaust Brake
The exhaust brake system, as an assistant function of the service brake, comprises of the exhaust brake device installed at the middle portion of the exhaust pipe and the intake shutter installed at the intake manipulate to reduce the intake air noise.
When the exhaust brake device close the butterfly valve, the pressure inside of the pipe increases. This increased pressure influences to the piston to get the braking force. At that time, the intake shutter is also closed. When the clutch pedal, the accelerator pedal or the exhaust brake switch is released, the electric circuit is OFF and the exhaust brake is released.
The exhaust brake is the vacuum type assistant device which uses the negative pressure.
SUDBRA015L
Intake Shutter
When the exhaust brake is operating, the intake shutter(A) reduces the amount of the intake air through the intake manipulate so as that the exhaust pressure is operated to the piston effectively. As a result, the noise will be reduced and the brake will be more effective.
KMTBR5513A
Exhaust Brake Unit
1. At Working
If the exhaust brake switch is ON, the three-way magnetic valve is opened. The vacuum pressure of the vacuum tank is applied to the exhaust brake unit so as to pull the piston.
Asaresult,thebutterflyvalvelinkedtothepushrod is closed so that the exhaust brake is working.
2. At releasing
If the exhaust brake switch, the clutch switch and the accelerator switch are OFF, the 3-way magnetic valve closes the circuit to the vacuum tank and opens the atmosphere circuit.
Therefore, the atmospheric pressure is applied to the exhaust brake unit. Due to the spring tension, the butterfly valve is opened. The exhaust brake is released.
EMTBR5013A
The 3-way Magnetic Valve
1. At working
If the exhaust brake switch is ON, an electric current will flow through the coil and then a magnetic field is formed. The magnetic force pulls the plunge to upward. At that time, the valve seat at the plunger closes the way to the atmosphere pressure while it opens the way linking the vacuum tank and the brake chamber.
EMTBR5012A
EMTBR5014A
2. At releasing
If the exhaust brake switch is OFF, the electric current flowing through the coil is shut down. Due to the spring tension, the plunger will be pushed so as to close the way to vacuum tank while the way to the atmosphere pressure and the brake chamber.
EMTBR5060A
LOAD SENSING PROPORTIONING VALVE
1. LSPV assembly
2. Bleeder screw
3. Bracket
4. Lever assembly
5. Sensor spring
6. Spring guide
SUDBRA021L
7. Adjusting nut
8. Operating lever
9. Connecting link assembly
Construction
LSPV is consist of sensor part and pressure controller part.
1. Sensor part
It consists of spring, operating lever, link. It senses the height of vehicle with varying according to the amount loads
2. Pressure controller part
It consists of valve stem mechanism for proportioning control of sensor force.
SUDBR9036L
Service and Inspection of the LSPV
Check the LSPV as below when replace the sensor spring, valve body assembly or reinstall the rear axle, rear spring.
EMTBR5016A
Operating Principle
LSPV body is mounted in the frame and the end of the link is mounted in the rear axle. With varying of amount of vehicle load changes the relative position of frame and rear axle, so sensor spring force varies to the valve stem. It controls the rear axle brake fluid pressure.
1. Unloaded status
The sensor spring presses the valve stem slightly, so the brake fluid pressure is set weakly.
2. Loaded status
The sensor spring presses the valve stem strongly, sothebrakefluidpressureissethighly.
NOTICE
Don't loose or don't retighten the adjusting nut crimping.
Symptom
Braking force is i ­nsufficient.
Rear brake is loc­ktoofast.
Probable Cause Remedy
Insufficient air bl-
Air bleeding
eeding
Maladjusted sen-
Readjust
sor spring
Sensor spring br­oken
Oil leakage in the brake fluid line or LSPV assembly
Maladjusted sen-
Replace valve a­ssembly
Tighten brake flu­id line or replace LSPV assembly
Readjust
sor spring
Inner fault the L­SPV
Replace LSPV a­ssembly
PARKING BRAKE GENERAL
1. Parking brake lever assembly
2. Cam lever
3. Parking brake drum
4. Adjusting nut
5. Parking brake cable
The parking brake installed behind the transmission is an internal expansion type acting on the propeller shaft.
It controls propeller shaft rotation to work as a parking brake.
The control is wire mechanical type; brake shoes are pressedviaawiretocontrolthepropellershaft.
SUDBRA022L
Parking Brake Proper
When the lever at the driver's seat is pulled, the cam lever is actuated via a wire cable and resultant cam rotation causes the brake shoes to expand and be forced against the brake drum. The braking force is thus obtained by friction between the shoes and drum. When the lever is released, the cam lever returns to the initial position and the braking force is released by the brake shoe return springs.
EMTBR5019A
COMPONENTS(LHD)
1. Vacuum tank
2. Vacuum hose
3. Brake booster
4. Master cylinder
5. Reservoir tank
6. A.B.S modulator
SUDBRA001L
COMPONENTS(RHD)
1. Brake booster
2. Master cylinder
3. Brake pedal
4. Parking brake lever
5. Vacuum tank
6. Exhaust brake
7. ABS HECU(Hydraulic Electrical Control Unit)
SUDBRA002L
Diagnosis
Symptom Causes Remedy Remark
Irregular Braking Force
After releasing t­he brake pedal, the braking force is release too la­te.
Unbalance at th­erightandleft braking force
The air pressures of tire are different. Adjust the air pressure of tire.
The sizes of the right and left tires are different .
The adjustment of the wheel bearing is defecti­ve.
The sizes of the right and left wheel bases are different.
The wheel alignment is defective. Adjust
The vertical surface of the back plate is rough.
The operation of the wheel cylinder is defective.Check the contacting, the piston cup and
The return spring is damaged. Replace the spring.
The surface of the lining is contaminated by th­e oil, grease or water.
The lining is defective or The material of lining is improper.
Replace the tire.
Adjust (Check the wheel bearing)
Check and adjust the loosening the U-b­olt or damages on center bolt.
Replace the back plate or check the lini­ng.
wearing status. If needed, replace it. Ch­eck the lining.
If it is contaminated by oil or grease, the­nreplaceit.Ifitiscontaminatedbywater ,dryit.
Replace or adjust.
Unstable brakin­gforce
Improper Lock Point
The wear is irregular. The surface is rough. Replace the lining. Check the inside of t-
he drum, if needed, replace it.
The lining contact is defective. Adjust the lining with being installed.
The brake drum is worn irregularly. Adjust or replace it.
The brake drum is deformed. Replace
The back plate is deformed or loosened. The vertical surface of it is rough.
The drum is worn. Adjust or Replace Drum limit
The lining is worn irregularly. Adjust
The lining contact is defective. Adjust with being installed.
If it is loosened, tighten with specified to­rque. Otherwise, replace it.
STD :Dia+2m­m
(Temperature of lining should be less th­an 100°C)
Symptom Causes Remedy Remark
Low Braking Fo­rce
The clearance b­etween the ped­al and the floor i­s too narrow.
The clearance between the brake pedal and fl­oor is 45mm or more. (at Pressure-600mmHg, Pressure 50kg)
Refer to the item for decreasing the clea­rance between the brake pedal and floor.
The lining contact is defective. Adjust with being installed not being dis-
assembled. (Temperature should be 100
°
Corless)
The surface of the lining is contaminated by th­e oil, grease or water. The lining is deteriorated.
If it is contaminated by oil or grease, the­nreplaceit.Ifitiscontaminatedbywater ,dryit.
The vacuum force is too low. Replace the lining.
The drum surface is rough. Check the pipe or the vacuum pump. If
needed, replace.
The brake booster is defective. Adjust or Replace
The brake oil level is too low. Adjust or Replace
The air intrudes. Refill
Vapor lock Air Exhausting
The adjustment on pedal is defective. The clearance is too large.
Referring to the brake drawn item, adjust or replace. And then exhaust the air.
During braking, the noise and s­hock are made abnormally.
The shoe clearance is too large.
Adjust the pedal clearance. Check the t­otal stroke.
The cup of the master cylinder is defective. Adjust the shoe clearance.
If the wear exceeds the limit, replace.
The brake shoe is deformed or damaged. If the tightening does not satisfy the spe-
cifications, replace the kit.
The brake booster is defective. Replace
When the wheel is rotating with being lifted by jack, there are some noises.
During braking (at low speed), noise is made continually.
Foreign materials in d­rum
Return spring is dama­ged.
Hold down cup is dam­aged.
The grease is deficien­cy in sliding parts.
Improper adjustment on wheel bearing
Replace
Check that the brake is damaged. Remo­ve the foreign materials.
Check that the parts are damaged by br­oken parts. If needed, replace.
Check that the parts are damaged by br­oken parts. If needed, replace.
Check the rotating surface. Adjust
The lining is worn. Replace
The drum inside surface is rough. Apply the grease.
Modify the inner surface with sand paper
The drum is cracked.
. Replace
Symptom Causes Remedy Remark
The drum is ove­rheated.
The outlet of the brake master cylinder is clog­ged.
If the booster operating rod is not proper­ly adjusted, adjust the pedal clearance of the rod clevis to 10~15mm.
The brake does not return. Check the burst of the return spring, the
bearing lubricant, the stop lamp switch a­djustment. If needed, adjust.
The booster is defective. Replace
The vertical surface of the back plate is scratc­hed.
If the surface is too rough, replace. If it is too dry, apply the grease.
The wheel cylinder piston cup is defective. Replace
The oil return has problems due to the over tig­ht of the brake pipe nut.
When the wheel is rot­ating with being lifted by jack, the wheel is h­ardtorotate.
The wheel bearing cle­arance is too large.
Shoe clearance is imp­roper.
Return spring is defec­tive.
Check the connector hole diameter. If it
is reduced, replace.
Replace bearing or adjust.
Adjust
Check the part damages due to the spri­ng over working. If needed replace.
Brake shoe is worn. Replace
Specific wheel is o­verheated.
The pedal retur­ning is defective.
The pedal linkage is rusted or deformed.
It is bursting due to the defectives on the pedal return spring.
The booster operating rod is pushed.
Disassemble. Adjust or replace. Oil the grease.
Replace
Adjust the pedal clearance with 10~15 mm.
Brake is vibratin-g.The drum is eccentrically centered. Replace
The drum is deformed. Replace
The king pin bushing is worn. Replace the bushing
The hub bearing is worn.
Adjust (Check the rolling surface) or repl ­ace.
Brake is drawn. The pedal clearance is too narrow. Adjust the booster working rod.
The shoe clearance is improper. Adjust
The back plate vertical surface is rough. Replace the back plate.
Theshoespringisburst. Replace
The master cylinder or wheel cylinder piston c­up is deteriorated and swelled.
Replace
Symptom Causes Remedy Remark
Brake makes n­oises.
Exhaust brake does not work.
Brake shoe contacting is defective. Adjust the lining with being installed not
being disassembled (Temperature shoul­d be 100°Corless)
Lining is deformed. Replace the lining. Replace the drum if it
has hardened surface.
Drum has hardened surface. Replace.
Shoe is deformed. Replace.
Back plate is deformed or installed improperly. Replace or adjust
Front bearing is loosened. Adjust (Check the rolling surface)
Powder from the wear of the lining is adhered. Clear
Lining is worn. Replace.
Vacuum pressure is improper.
Check the vacuum pump or piping. If ne­eded repair.
Electric circuit is defective. Check the clutch switch, the micro switch
and the exhaust brake circuit. If needed, repair.
Vacuum pipe is damaged. Replace.
3-way magnetic valve does not work. Replace.
Exhaust brake c­an not be relea­sed.
Exhaust brake valve does not work. Replace.
Exhaust brake valve shaft is adhered. Replace.
Power chamber is defective. Disassemble and check.
3-way magnetic valve does not work. Replace.
Exhaust brake valve does not work. Replace.
Exhaust brake valve shaft is adhered. Replace.
Electric circuit is defective. Check the clutch switch, the micro switch
and the exhaust brake circuit. If needed, repair.
Diagnosis (Parking brake)
Symptom Causes Remedy Remark
Parking brake d­oes not work.
Parking brake c­an not be relea­sed.
Operating mechanis­mhasap­roblem.
Parking b­rake is de­fective.
Operating mechanis­mhasap­roblem.
When pulling the parking brake wi­th 30kg, there is no lever stroke cl­earance and shoe clearance.
The locking status between the le­ver lock latch and Ratchet pull is i­mproper.
Wire is broken or elongated. Replace the cable.
Tolerance between the shoe clear­ance and the brake lever pulling is too large.
Drum inner surface is deformed or twisted.
Lining is irregularly worn. Drum in­ner surface is contacted irregularly .
The oil of drum and lining is conta­minated.
Return spring is damaged. The te­nsion of the return spring is inferior .
The inner cable does not move s­moothly.
Adjust the shoe clearance and cable.
Adjust the Ratchet pull lock status. Repl­ace it
Adjust the shoe clearance.
Repair the drum inner surface. Replace the lining.
Replace the lining.
Clear the inner surface of the drum. Rep­lace the lining.
Replace the return spring.
Replace the cable.
After the parking brake is released , the brake is operating.
Parking b­rake is de­fective.
Return spring is damaged. The te­nsion of the return spring is inferior .
The shoe clearance is too narrow.
On-Vehicle Inspection and Adjustment
Air bleeding of the Brake
1. Fill up the brake oil tank with the brake oil at the maximum level. During the air bleeding, if the level is lowered, refill the brake oil.
CAUTION Be careful that the brake oil does not drop on the painted surface. If the brake oil contacts the painted surface, immediately wash it by water.
2. Connecting an end of transparent vinyl tubes at the air breather of the front wheel cylinder and the rear wheel cylinder, put the other end of the tubes into the transparent container having the brake oil.
Adjust the pulling tolerance limit.
Replace the return spring.
Adjust the shoe clearance.
KMTBR5518A
3. Step on the brake pedal several times. Pressing the brake pedal at half, loosen the air bleeder screw to evacuate the air with the brake oil.
And then, pressing the pedal until it reaches to the floor, tighten the air bleeder screw. Release the pedal. There procedures should be repeated until any air bubble is not shown in the brake oil.
Adjustment of Brake Shoe Gap
1. Using the screw driver(A), turn the wheel cylinder adjuster(B) to the shoe expansion direction until the drum is not rotate anymore. Turn the adjuster reversely with the following notch number. (At that time, the drag torque between the lining and the drum should be less than 50kgf.m).
KMTBR5519A
4. Tighten the bleeder screw
Tightening Torque for the bleeder Screw Front: 6.9~8.8Nm(0.7~0.9kgf.m, 5.1~6.5lb-ft) Rear : 6.9~8.8Nm(0.7~0.9kgf.m, 5.1~6.5lb-ft)
5. Step on the brake pedal several times. Pressing the brake pedal at half, loosen the air breather screw to evacuate the air with the brake oil.
And then, pressing the pedal until it reaches to the floor, tighten the air breather screw. Release the pedal. There procedures should be repeated until any air bubble is not shown in the brake oil.
KMTBR5521A
The Notch Number for reverse rotation of the Adjuster.
Front Wheel Cylinder
Auto adjuster type 9~11
Manual adjuster type 4~6
Rear Wheel Cylinder Auto adjuster type 9~11
Manual adjuster type 4~6
KMTBR5520A
Specifications
Front Wheel Brake (Drum Type)
Item Specifications
Brake type 2-leading Brake
Wheel cylinder Inner diameter 31.75mm
Brake drum Inner diameter 320mm
Brake lining Width x Thickness (mm) 85 x 10(Standard), 110 x 11(Option in case of HD72,78)
Front wheel Brake (Disk Type)
Item Specifications
Cylinder diameter Ø76mm
Effective radius 118 mm
Disk outer diameter Ø304mm
Disk inner diameter Ø164mm
Pad thickness 12.5 mm
Padeffectivethickness 10.5 mm
Rear Wheel Brake
Item Specifications
Brake type 2-leading Brake
Wheel cylinder Inner diameter 28.57mm
Brake drum Inner diameter 320mm
Brake lining Width x Thickness (mm) 85 x 10(Standard), 110 x 11(Option in case of HD72,78)
Brake system
Item Specification
Brake Pedal Total Stroke 140 mm
Booster Total Stroke 31 mm
Master Cylinder Inner Diameter Ø 31.75 mm, Ø 30.15 mm
Stroke Piston 31±1mm
Primary 17±0.5 mm
Secondary 14±0.5 mm
Exhaust Brake
Item Specification
Control System Combination of Electric and Vacuum Type
Exhaust Brake Valve Type Butterfly Valve
Exhaust Brake Cham­ber
Diaphragm Effective Diameter 76.2mm
With Installing N(kg)
Spring Tension 90~110 (9.18~11.22)
Rod Tensile Force 142.1(14.5): Vacuum Pressure-400mmHg
Spring Tension 125~153 (12.78~15.62)
Rod Tensile Force 103(10.5) Vacuum Pressure-400mmHg
Parking brake
Item Specification
Type Internalexpansiontypeactingonpropellershaft
Control Mechanical cable
Parking lever Normal stroke 8~9clicks(20kgf)
Parking brake size Drum i.d. x Lining width x Li-
ning thickness
180 x 35 x 5 (T/M : M2S5, M3S5) 190 x 45 x 4 (T/M : M035S5) 230 x 55 x 4 (T/M : T60S5, T60S6)
SERVICE STANDARDS
Brake pedal
Brake master cylinder
Front drum b­rake
Rear w­heel br­ake
Description
Bushing to collar clearance [16]0.02 to 0.26 0.5 Replace bushing
Brake pedal play 3-8 Adjust
Stop lamp switch installation clearance 0to1 Replace
Primary and secondary piston to cylinder body clearance 0.038~0.145 0.2 Replace
Primary retainer assembly Free length 38.1 Replace
Secondary spring deterioratio-nFree length 37.7 Replace
Brake drum I.D. 320 322 Replace
Brake lining Thickness 10 4 Replace
Return spring 30±3/227 19/227 Replace
Wheel cylinder body to piston clearance [31.75]0.03 to 0.13 0.2 Replace
Brake shoe clearance(No. of notches returned of wheel c­ylinder adjuster)
Brake drum I.D. 320 322 Replace
Brake lining Thickness 10 4 Replace
Return spring Load N(kgf)/installed length 30±3/227 19/227 Replace
Nominal value, mm
(Basic diameter in [ ])
Auto 9~11 Adjust
Manual 4~6
Limit
(mm)
Correction and
remarks
Wheel cylinder Body to piston clearance 0.02-0.11 0.2 Replace
Brake drum Out of roundness 0.05 - Replace
Brake shoe clearance (number of return notches of wheel cylinder adjuster)
Auto 9~11 Adjust
Manual 4~6
Description
Nominal value, mm
(Basic diameter in [ ])
Limit
(mm)
Correction and
remarks
Exhau­st brak­e
Power chamber air tightness [15 seconds after applicatio­n of -67 kPa (-500 mmHg) negative pressure]
Valve to body clearance when butterfly valve is fully clos­ed [at power chamber vacuum -87 to -93 kPa(-650 to -70 0 mmHg)
3-way magnet valve
Air tightness When -100 kPa (-750 m-
mHg) negative pressure is applied from vacuum tan­k side to operate valve wi­th exhaust brake unit side plugged tightly
When 98 kPa (1 kgf/cm² air pressure is applied fro­matmospheresidetoop­erate valve with exhaust brake unit side plugged ti­ghtly
Minimum op­erating volta­ge
When -100 kPa(-75 0 mmHg) negative pressure is applied
24V type unit
to vacuum tank side
-63 kPa (-475 mmHg) or
Replace
more
0.1 to 0.4mm Replace
Noairtobesuckedinf-
Replace
rom atmosphere side
No air to leak from vacu-
Replace
um tank side
22V or less Replace
When 98 kPa (1 kgf /cm² air pressure is applied from atmos­phere side with exh­aust brake unit side plugged tightly
24V
22V or less Replace type unit
SERVICE STANDARDS (Parking brake)
Description Nominalvalue,mm
(Basic diameter in [ ])
Brake drum I.D. 180 181 Correct to limit,
190 192
230 232
Squareness 0.05 or less Correct or repla-
Concentricity 0.1 or less
Cylindricity 0.1 or less
Static rotation imbalance 0.49 N.cm(50 gf.cm) or l-
ess
Brake lining thickness Model with M2S5 T/M 10~11 4.0 Replace
Brake shoe clearance Model with M2S5 T/M 0.25 to 0.35 Adjust
Brake shoe r­eturn spring
Shoe hold d­own spring
Free length Model with M2S5 T/M 98 -
Load N (kgf)/instal­led length
Spring A(longer o­ne of free length)
Model with M2S5 T/M 67 to 86 (6.8 to 8.8)/104 104.364
Free length 34.1 Replace
Load N (kgf)/installed l­ength
59 to 69 (6.0 to 7.0)/13.7 59 (6.0)/13.7
Limit (mm)
(6.5)/104
Correction and remarks
replace when li­mit is reached.
ce
Replace
Spring B(shorter o­ne of free length)
Free length 23.6
Load N (kgf)/installed l­ength
59 to 69 (6.0 to 7.0)/10.5 59 (6.0)/10.5
Tightening torque table
Description Tightening torque
Nm Kgf.m Lb-ft
Mounting nut between the master cylinder and booster 17.7~24.5 1.8~2.5 13~18.1
Master cylinder set bolt 12~16 1.2~1.6 8.7~11.6
Brake booster mounting nut 12.7~15.7 1.3~1.6 9.4~11.8
Brake booster clevis lock nut 15.7~21.6 1.6~2.2 11.6~15.9
Master cylinder outlet port nut 12.7~16.8 1.3~1.7 9.4~12.3
LSPV connecting link mounting bolt 22~33 2.2~3.3 15.9~23.9
LSPV flange bolt mounting bolt 22~33 2.2~3.3 15.9~23.9
Front drum brake air bleeding port 6.9~12.7 0.7~1.3 5.1~9.4
Front spindle mounting bolt 98~137 10~14 72~101
Brake hose to union mounting bolt(Front drum brake) 24.5~29.4 2.5~3 18.1~21.7
Exhaust brake to exhaust pipe mounting bolt 44.1~58.8 4.5~6 32.5~43.4
Vacuum Assisted Hydraulic Brake
Brake Pedal
Component
1. Clevis pin
2. Hose connector
3. Grommet
4. Master cylinder
SUDBRA003L
5. Booster
6. Pedal assembly
7. Return spring
Removal
1. Loosen the steering column assembly mounting bolt. Pull down the steering column.
2. Loosen the bolt(A), Remove the instrument panel(B).
KMTBR5527A
2. Install the brake light switch.
3. Install the booster and the master cylinder.
KMTBR5003A
3. Remove the master cylinder (Refer to the BR-"Master cylinder")
4. Remove the brake booster (Refer to the BR-"Booster")
5. Remove the brake light switch.
6. Remove the shaft bolt(A) connected to the bracket.
CAUTION Apply the grease on the clevis pin and the washer
Adjustment
Adjust the height of the brake pedal
1. Turn the booster operating rod so that the distance from the center of the brake pedal pad to the A point of the instrument panel lower portion is the 'B'. After adjusting, fix the clevis with the nut. Check that the maximum stroke of the pedal is more than 'C' (before filling the brake oil)
KMTBR5040A
Installation
1. Install the brake pedal assembly(A) to the bracket(B).
CAUTION Before the assembling, apply the grease inside of the brake pedal assembly pipe.
SUDBRA004L
Engine B(mm) C(mm)
Non A-BSD4DD, D4GA 280±2 140±4
The others 273±3 140±4
ABS D4DD, D4GA 280±2 140±4
The others 273±2 140±4
Free play clearance of the Brake pedal
1. Setting the brake pedal to the original position, check if the free play(B) clearance is 5mm at least by pressing the pedal(A).
If the clearance excesses the reference, re-adjust the position of the brake pedal.
CAUTION When checking the free play clearance of the brake pedal, the master back negative pressure should be 0.
Gap between the brake pedal and the floor.
1. After cranking the engine, check if the gap between the floor and the pedal is more than 45mm by pressing the pedal with 50kg.
EMTBR5023A
Stop Lamp Switch
1. Adjusting the gap between the end of the brake. Stop lamp switch screw and the pedal stopper to 0~1mm, tighten the locknut.
KMTBR5005A
SUDBR9014L
Brake Booster
Components
1. Clevis pin
2. Hose connector
3. Grommet
4. Master cylinder
SUDBRA005L
5. Booster
6. Pedal assembly
7. Return spring
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