BRAKE SYSTEM

Structure and Functions ....................................................................... 8 – 1

General ..................................................................................................... 8 – 1
Wheel Brake Assembly ............................................................................. 8 – 2
Brake Pedal Assembly .............................................................................. 8 – 6
Brake Booster ........................................................................................... 8 – 7
Master Cylinder ........................................................................................ 8 – 8
Reservoir Tank .......................................................................................... 8 – 9
Master Cylinder ..................................................................................... 8 – 11
Disassembly ............................................................................................. 8 – 11
Inspection and Repair ............................................................................... 8 – 12
Reassembly .............................................................................................. 8 – 13
Wheel Cylinders ...................................................................................... 8 – 14
Disassembly ............................................................................................. 8 – 14
Inspection and Repair ............................................................................... 8 – 15
Reassembly .............................................................................................. 8 – 15 8
Wheel Brakes .......................................................................................... 8 – 16
Disassembly ............................................................................................. 8 – 16
Inspection and Repair ............................................................................... 8 – 18
Reassembly (GP40K, GP40KL, DP40K, DP40KL) .................................... 8 – 20
Reassembly (GP45K, GP50K, DP45K, DP50K) ........................................ 8 – 21
Parking Brake Lever .................................................................................. 8 – 24
Inspection and Adjustment ................................................................. 8 – 25
Automatic Adjustment ............................................................................... 8 – 25
Manual Adjustment ................................................................................... 8 – 25
Brake Line Bleeding .................................................................................. 8 – 26
Brake Pedal .............................................................................................. 8 – 27
Brake Booster Test ................................................................................... 8 – 28
Troubleshooting ...................................................................................... 8 – 30
Service Data ............................................................................................ 8 – 31
 BRAKE SYSTEM

Structure and Functions

General

3 7
5
8
6

9
11
10

4
2
The system for the diesel-engine models is shown. 208518
1 Parking brake lever 7 Master cylinder
2 Wheel brake assembly 8 Alternator and vacuum pump
3 Brake pedal (diesel-engine models)
4 Wheel cylinder 9 Vacuum tank
5 Brake booster 10 Check valve
6 Brake fluid reservoir 11 Parking brake cable

When the operator depresses the brake pedal 3, the engine models and the vacuum created by the vacuum
movement of the pedal is transmitted through the pump (directly coupled to the alternator) in the diesel-
mechanical linkage to the brake booster 5 and master engine models.
cylinder 7. The master cylinder forces brake fluid The parking brake is mechanically controlled. When
under pressure to the wheel cylinders 4 of the right and the parking brake lever 1 is pulled rearward, the right
left brake assemblies. The fluid pushes the piston of and left parking brake cables 11 move, pulling the
each wheel cylinder 4 causing the brake shoes to parking brake lever in each wheel brake assembly. This
expand. The shoes are then pressed against the brake causes the brakes to be applied by mechanical means.
drum and thus the brake is applied.
The wheel brake assemblies 2 and master cylinder 7
The brake booster magnifies the pressure applied on the are different between the GP/DP40K, 40KL models and
pedal by the operator’s foot. When the operator GP/DP45K, 50K models. The GP/DP45K, 50K models
depresses the brake pedal, the rod attached to the have a brake system of larger capacity.
booster’s diaphragm is moved toward the master
For structure and functions of each main brake system
cylinder by difference in pressure between the
component, refer to the relevant subsection.
chambers on both sides of the diaphragm (atmospheric
pressure in the chamber on the brake pedal side and
vacuum in the chamber on the master cylinder side).
Assisted by the push force of the rod, the operator can
move the piston of the master cylinder 7 with a force
smaller than the force that would otherwise be
necessary. As the source of the vacuum, the brake
booster uses intake manifold vacuum in the gasoline-

8-1
BRAKE SYSTEM

Wheel Brake Assembly

GP40K, GP40KL,
DP40K, DP40KL
1 2 3 4 5 6 7 8 9
A

14

15

A Section A – A
10 11 12 13
203586

1 Parking brake lever 9 Shoe and lining (secondary)

2 Shoe and lining (primary) 10 Return spring
3 Strap 11 Parking brake cable
4 Return spring 12 Adjusting screw
5 Shoe guide plate 13 Adjusting lever
6 Wheel cylinder 14 Fitting cable
7 Backing plate 15 Hold-down spring
8 Sheave

The wheel brakes are duo-servo drum brakes. Brakes • a mechanism that allows the brake to function as a
of this type are suitable for lift trucks, which move parking brake;
backward as frequently as they move forward, because • a mechanism that automatically adjusts the shoe-to-
they can generate the same level of braking force in drum clearance.
both directions.
The operation of these mechanisms is described on the
Each wheel brake incorporates: following pages.
• a mechanism that allows the brake to function as a
service brake;

8-2
 BRAKE SYSTEM

GP45K, GP50K 5
DP45K, DP50K 4
6
3
2

11

A A

10
7
9
8 202804

12

Section A – A
202811

1 Parking brake lever 7 Return spring

2 Shoe and lining (primary) 8 Adjusting screw
3 Strap 9 Adjusting lever
4 Return spring 10 Fitting link assembly
5 Wheel cylinder 11 Shoe and lining (secondary)
6 Backing plate 12 Parking brake cable

8-3
BRAKE SYSTEM

1. Service Brake Mechanism

When the brake pedal is depressed during forward Drum rotation
movement of the truck, wheel cylinder 1 pushes primary (during forward movement)
shoe 2 and secondary shoe 3 outward symmetrically.
When the lining of the primary shoe touches the drum, the Anchor pin
6
shoe is dragged by the drum in the direction of drum 5
rotation. The primary shoe thus moves adjusting screw 4 in 2 3
the direction of the arrow such that the adjuster end of the
adjusting screw pushes the secondary shoe with significant
1
force. Now pressed firmly against the anchor pin at the top,
secondary shoe 3 cannot move further in the direction of
rotation. As a result, it is pushed against the drum more
strongly than the primary shoe.
The directions of component movements are opposite when Brake drum Adjuster end
the brake pedal is depressed during reverse movement of
4
the machine. 208681
When the brake pedal is released, shoes 2 and 3 are moved
toward the center of the wheel by the forces of return
springs 5 and 6.

2. Parking Brake Mechanism

Secondary shoe
Pivot A 1
Strut
Pull
Anti-rattle spring
Pivot B

Parking brake
cable assembly

Primary shoe
Parking lever

L.H. wheel brake

208676

When the parking brake lever is pulled, the parking The parking brake lever has an over-center design, i.e.,
brake cable is pulled accordingly. The other end of the it is locked when moved beyond the upright position.
cable is connected to the parking lever in the wheel This design prevents the braking force generated by the
brake. When pulled by the cable, the parking lever wheel brake from decreasing while the parking brake is
turns about pivot A, pushing the strut rightward. The being applied.
strut pushes the secondary shoe against the drum. The It is possible to adjust the effort required to operate the
parking lever next turns about pivot B, pushing the lever by turning the lever grip either way. With the
primary shoe against the drum. The wheel brake thus lever properly adjusted, the effort required to operate
acts as a parking brake. the lever is in the range of 245 to 294 N (25 to 30 kgf)
[55 to 66 lbf].
8-4
 BRAKE SYSTEM

3. Automatic Adjusting Mechanism

Shoe end moves

away from Primary shoe
anchor pin. Secondary
Anchor pin shoe
Drum rotation
(during reverse movement)

Brake released Brake applied Brake released

Fitting cable

ll
Pu Pivot

Adjusting nut Adjusting screw Sprocket (24 teeth) Adjusting lever

spring

Adjusting lever
sion
ten
Ex Adjusting sprocket

Sprocket rotation in direction of arrow causes

extension by this dimension

208682

The illustration above shows the brake for the single- lever thus turns the sprocket. The resulting increase in
speed transmission models. The brake for the models the adjuster’s dimension causes the shoe-to-drum
with a two-speed transmission is slightly different from clearance to decrease.
it in the construction but the same in the basic principle The adjusting mechanism does not operate while the
of operation. shoe-to-drum clearance is within the proper range.
The automatic adjusting mechanism maintains the The adjusting screw in the brake on an RH wheel has a
correct shoe-to-drum clearance of approximately 0.4 right-handed thread, and the adjusting screw in the
mm (0.016 in.). It can operate only when the brakes are brake on an LH wheel has a left-handed thread.
applied during reverse movement of the truck. After
each incremental 0.01 mm (0.0004 in.) of wear on the
shoe linings, its screw automatically makes one
complete turn to correct the clearance.
When the operator depresses the brake pedal with the
shoe-to-drum clearance excessively large, the top end of
the secondary shoe moves away from the anchor pin.
At this time, the fitting cable that runs from the anchor
pin to the adjusting lever via the sheave on the
secondary shoe is pulled upward, causing the adjusting
lever to swing about its pivot. The edge of the adjusting

8-5
BRAKE SYSTEM

Brake Pedal Assembly

11 12
10
9
2

5 8
13
Vacuum

4
7

3
6

1 208809

1 Pedal bracket 8 Pushrod

2 Brake pedal 9 Brake booster operating rod
3 Inching pedal 10 Brake booster
4 Tongue of inching pedal 11 Brake booster diaphragm
5 Return spring for brake pedal 12 Diaphragm rod
6 Return spring for inching pedal 13 Master cylinder
7 Shaft

Brake pedal 2 and inching pedal 3 are assembled in 13 makes its way to the right and left wheel cylinders,
bracket 1. They turn about the shaft 7 when depressed. causing the service brakes to be applied.
When the service brakes are applied in an ordinary way, Inching pedal 3 enables the operator to use the service
the operator uses brake pedal 2. When the brake pedal brakes for precise movement control of the truck.
is depressed in the direction of the arrow, the pedal When this pedal is depressed, tongue 4 at its bottom
turns about shaft 7, moving pushrod 8 linked to the pushes down brake pedal 2. The right and left service
bottom of the pedal in the direction of the arrow. Then, brakes are then applied through the same process as the
brake booster operating rod 9 is moved in the direction process described above for the case when brake pedal
of the arrow. As a result, the valve in brake booster 10 2 is depressed.
operates such that an atmospheric pressure acts on the Even if brake booster 10 fails to function, the service
back surface of diaphragm 11 and a vacuum on its front brakes can operate normally although assistance by the
surface. This creates a pedal operation assist force and brake booster cannot be obtained.
diaphragm rod 12 pushes the piston of master cylinder
13 with a force 1.5 to 2 times as large as the original
force in the pressure. The brake fluid with a pressure
increased by movement of the piston in master cylinder
8-6
 BRAKE SYSTEM

Brake Booster

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22

208526

1 Silencer 9 Diaphragm plate (front) 17 Valve plunger

2 Filter 10 Pushrod seal 18 Reaction disc
3 Poppet washer 11 Projection stud 19 Spring
4 Cylinder shell (rear) 12 Operating rod 20 Cylinder shell (front)
5 Diaphragm (rear) 13 Retainer 21 Cylinder plate
6 Diaphragm plate (rear) 14 Valve body guard 22 Pipe
7 Pushrod 15 Spring
8 Diaphragm (front) 16 Poppet assembly

8-7
BRAKE SYSTEM

Master Cylinder

GP40K, GP40KL 7
DP40K, DP40KL

1 2 4 3 5 6 208521

1 Cylinder body 5 Cup spacer, Primary cup

2 Stopper ring 6 Spring
3 Piston 7 Filler union, Clamp
4 Secondary cup

GP45K, GP50K 9
DP45K, DP50K

2 5 4 6 7 8 1

3
208522

1 Cylinder body 6 Spacer, Primary cup, Spring seat

2 Stopper ring 7 Snap ring
3 Piston assembly 8 Spring
4 Piston 9 Filler union, Clamp
5 Secondary cup

8-8
 BRAKE SYSTEM

Reservoir Tank

(contacts close when fluid

3

level falls in this range)

5

Indicator ON range
2
(0.12 ± 0.08 in.) 1

6
3 ± 2 mm

206672

1 Reservoir assembly 4 Cap seal

2 Reservoir tank 5 Reservoir cap
3 Cap assembly 6 Indicator assembly

8-9
BRAKE SYSTEM

Master Cylinder Operation

1. Brake pedal not depressed 3. Moment when brake pedal is released

Inlet port Return port

Return port is open.
Small holes

Piston moves quickly.

208381 Primary cup 208383

Fluid from reservoir enters to fill cavity formed in front

of primary cup.

2. Brake pedal depressed 4. Short time after release of brake pedal

Return port is closed.

208382 Pressurized brake fluid 208384

8-10
 BRAKE SYSTEM

Master Cylinder

Disassembly

202806

Sequence
1 Stopper ring 5 Spring seat
2 Piston 6 Primary cup, Cup spacer
3 Spring 7 Secondary cup
4 Snap ring 8 Cylinder body

NOTE
Use the repair kit for periodic replacement of the parts
1 thru 7.

8-11
BRAKE SYSTEM

Inspection and Repair

1. Brake fluid level sensor

(1) The sensor is satisfactory if the warning lamp of OK
monitor glows when the fluid level in the reservoir is
lower than “MIN” line.
(2) If the lamp fails to glow even when the fluid level is
lower than “MIN” line, check its bulb for burning out.
(3) If the lamp is satisfactory but it does not glow when the
fluid level is lower than “MIN” line, test the level
sensor for electrical conductivity.

2. Cylinder body
(1) Check the bore of the body for rusting, erosion or 206673
scoring.
(2) Check the inlet port and relief port for cleanliness.
Also check the threads of screw connections for
damage.

3. Piston
Replace the piston if it is damaged. Check the clearance
between the piston and cylinder, and replace the piston and
cylinder if the clearance exceeds the service limit.
A: Standard value B: Repair or service limit
Unit: mm (in.)
0.020 to 0.105
A
Clearance between (0.00079 to 0.00413)
piston and cylinder
body 0.2 (0.008)
B
[Replace every 1 year]

4. Return spring
Measure the free length, and replace the spring if the
measurement exceeds the service limit.

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP40K, GP40KL GP45K, GP50K
Item DP40K, DP40KL DP45K, DP50K

A 73 (2.87) 89 (3.50)
Free length of
return spring
B Replace every 1 year

8-12
 BRAKE SYSTEM

Reassembly
9
GP40K, GP40KL
DP40K, DP40KL

208521
7 8 2 1 3 6

GP45K, GP50K 9
DP45K, DP50K

8 2 1 3 3 4 5 6 7 208522

Sequence
Assemble parts 1 to 6 prior to final assembly. 4 Spring seat (GP45K, GP50K, DP45K, DP50K)
1 Piston 5 Snap ring (GP45K, GP50K, DP45K, DP50K)
2 Secondary cup 6 Spring
3 Primary cup, Cup stopper (GP40K, GP40KL, 7 Cylinder body
DP40K, DP40KL); Primary cup, Cup spacer 8 Stopper ring
(GP45K, GP50K, DP45K, DP50K) 9 Filler union, Clamp

NOTE
(1) Be sure to replace the piston and cups whenever
they are removed.
(2) Wash metal parts in volatile solvent and
completely dry the solvent on parts with
compressed air.
(3) Smear the following surfaces of parts with a thin
coat of the specified rubber grease (Metal Rubber
#20): inner surface of the cylinder; back surface
and periphery of the secondary cup.
(4) Apply sealant to the relevant portion of the
cylinder body before installing filler union 9. 6.9 to 8.8 N·m
Tightening torque for
(5) Tighten the clamp bolt to a torque within the (0.7 to 0.9 kgf·m)
clamp bolt
indicated range. [5.1 to 6.5 lbf·ft]

8-13
BRAKE SYSTEM

Wheel Cylinders

Disassembly

GP40K, GP40KL
DP40K, DP40KL

200278

200279

GP45K, GP50K
DP45K, DP50K

2 202812

202813

Sequence
1 Connector ring
2 Boot
NOTE
3 Piston Use the repair kit for periodic replacement of the parts
4 Piston cup
(❋) 2 thru 5.
5 Return spring
6 Bleeder screw, Cap
7 Cylinder body

8-14
 BRAKE SYSTEM

Inspection and Repair

1. Cylinder body
(1) Check the bore of the cylinder body for rusting, erosion
or scoring.
(2) Check the threads of bleeder screw and oil pipe screw
connections for damage.

2. Piston
(1) Check the sliding surfaces of the piston for rusting or
scoring.
(2) Insert the piston into the cylinder body, and measure the
clearance between the two. Replace the piston and
cylinder body if the clearance exceeds the service limit.
A: Standard value B: Repair or service limit
Unit: mm (in.)

A 0.020 to 0.105 200280

Clearance between piston (0.00079 to 0.00413)
and cylinder body
B 0.15 (0.0059)

3. Piston cups
Check each cup for swelling or other defects, and replace it
even if its defect is minor.

A: Standard value B: Repair or service limit

Unit: mm (in.)

Fit of piston cups in A 1.85 (0.0728)

cylinder body B 0.65 (0.0256)

4. Boot
Replace the boot if it is hardened, damaged or otherwise
deteriorated. Replace it every 1 year.

Reassembly
To reassemble, follow the reverse of disassembly sequence,
and do the following steps:
(1) Apply a uniform coat of brake fluid to the cylinder bore
and piston cups.
(2) Be careful not to damage the lips of piston cups.
(3) Position the cups correctly in the cylinder body.

8-15
BRAKE SYSTEM

Wheel Brakes

Disassembly

GP40K, GP40KL
DP40K, DP40KL

13

1
2

8 7 6 1 5

202808

Sequence
1 Return springs 8 Hold-down spring, Cup, Pin
2 Fitting cable, Sheave 9 Shoe and lining (secondary)
3 Shoe guide plate 10 Shoe and lining (primary)
4 Strap, Anti-rattle spring 11 Parking brake lever, Retainer, Washer
5 Adjusting lever, Adjusting spring 12 Wheel cylinder
6 Return spring 13 Parking brake cable
7 Adjusting screw 14 Backing plate

8-16
 BRAKE SYSTEM

GP45K, GP50K
DP45K, DP50K
13 12 11

6 9

203796

Sequence
1 Return springs 7 Strut, Retainer, Web washer
2 Fitting link assembly, Cotter pin, Plain washer, 8 Shoe and lining (secondary)
Spring and link assembly, Lever, Link 9 Shoe and lining (primary)
3 Adjusting lever, Adjusting spring 10 Parking brake lever, Retainer, Web washer
4 Return spring 11 Wheel cylinder
5 Adjusting screw 12 Parking brake cable
6 Hold-down spring, Cup, Pin 13 Backing plate

Start by:
(1) Remove the front wheel.
(2) Remove the wheel hub and drum.
(3) Disconnect the parking brake lever and cable at the
lower side of the brake.
(4) Disconnect the brake pipe from the brake assembly.

8-17
BRAKE SYSTEM

Suggestions for Disassembly

1. Removing return springs

Using the special tool A, remove the return springs from the
shoe guide plate.
Special tool needed

Spring remover A 64309 - 15411

200271

2. Removing hold-down springs

Using the special tool B, remove the hold-down springs
from the backing plate. B
Special tool needed

Spring retainer B 91868 - 00600

200272

Inspection and Repair

1. Backing plate
(1) Check for cracks.
(2) Check the bolts for tightening torque.
Unit: N·m (kgf·m) [lbf·ft]
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
Tightening torque 160 to 196 238 to 284
for backing plate (16.3 to 20.0) (24.3 to 29.0)
bolts [118 to 145] [176 to 210]

2. Shoe and lining assemblies

(1) Check the shoe and lining for cracks.
(2) Replace the lining if it is badly soaked with oil,
hardened or otherwise deteriorated.

8-18
 BRAKE SYSTEM

(3) Check the thickness of the lining, and replace the shoe
if it is worn beyond the service limit.
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model GP40K, GP40KL GP45K, GP50K
Item DP40K, DP40KL DP45K, DP50K

A 5.62 (0.22) 10 (0.39)

Thickness of
lining B 3 (0.12), 4.2 (0.17),
maximum maximum
203005

3. Brake drums
Check the inside surface for grooving or abnormal wear.
Repair a grooved or otherwise defective drum by grinding,
provided the service limit on the inside diameter is not
exceeded.

A: Standard value B: Repair or service limit

Unit: mm (in.)
+ 0.2
317.5 0
A + 0.008
(12.500 0 )
Inside diameter
of brake drum 318.5
B (12.539)

4. Adjusting screw
Turn the screw by hand to see if its rotating parts turn
smoothly.

5. Parking brake link

(1) Check the lever support pin and pin hole for wear, and 200274
replace the link if necessary.
(2) Replace the parking brake cable if it is stretched, rusted
or damaged.

6. Other parts
(1) Check the shoe return spring for cracks or fatigue.
(2) Check the adjusting spring for cracks or fatigue.
(3) Check the fitting cable for stretch or broken strands.

8-19
BRAKE SYSTEM

Reassembly (GP40K, GP40KL, DP40K, DP40KL)

4 5 11 5 14 8 3 1 14 12 6
A

12

B B

10 9 A 13
Section A – A

Section B – B 2 208529

Sequence
1 Backing plate 8 Shoe guide plate
2 Parking brake cable , Snap ring 9 Adjusting screw
3 Wheel cylinder 10 Return spring
Preassemble parts 4 and 5 before installation. 11 Strut, Anti-rattle spring
4 Parking brake lever, Retainer, Washer 12 Fitting cable, Sheave
5 Shoe and lining (primary) 13 Adjusting lever, Adjusting spring
6 Shoe and lining (secondary) 14 Return spring
7 Hold-down spring, Cup, Pin

8-20
 BRAKE SYSTEM

Reassembly (GP45K, GP50K, DP45K, DP50K)

3
1

13

8
Identification color mark
L.H.: red; R.H.: black

11
4

7
5

A A

10
12
9

Section A – A 2
208530

Sequence
1 Backing plate 8 Strut, Retainer, Webbed washer
2 Parking brake cable 9 Adjusting screw
3 Wheel cylinder 10 Return spring
Preassemble parts 4 and 5 before installation. 11 Fitting link assembly, Cotter pin, Plain washer,
4 Parking brake lever, Retainer, Webbed washer Spring and link assembly, Lever, Link
5 Shoe and lining (primary) 12 Adjusting lever, Adjusting spring
6 Shoe and lining (secondary) 13 Return spring
7 Hold-down spring, Cup, Pin

8-21
BRAKE SYSTEM

Suggestions for Reassembly

1. Installing parking brake cable

Retain the cable with the snap ring for the wheel brakes of
the models GP40K, GP40KL, DP40K and DP40KL.
Retain the cable with the nut by tightening it to a torque
within the range shown below for the wheel brakes of the
models GP45K, GP50K, DP45K and DP50K.

41.2 to 54.9 N·m

Tightening torque for nut (4.1 to 5.5 kgf·m)
[30 to 40 lbf·ft]

2. Installing wheel cylinder

Apply liquid packing to the cylinder mounting surface
before installation. Tighten the bolts to a torque within the
range shown below.

17.7 to 26.5 N·m

Tightening torque for bolts (1.8 to 2.7 kgf·m)
[13 to 19.5 lbf·ft]

200275
3. Greasing
Apply a thin coat of the specified brake grease to the
following parts:
(1) Shoe ledges (6 places) (the portions of backing plate in
contact with the shoes)
(2) Anchor pin surface in contact with the shoe web
(3) The portions of cable guide in contact with the cable
and the pin to be fitted in the cable guide hole (GP40K,
GP40KL, DP40K, DP40KL)
(4) Adjusting lever pin (GP45K, GP50K, DP45K, DP50K)

4. Installing shoes and linings

Make sure that the pushrod of wheel cylinder is correctly
fitted to the shoe web.

5. Installing return springs

Using the special tool A, install the return springs to the
backing plate pins.
Special tool needed

Spring installer A 64309 - 15413

200276

8-22
 BRAKE SYSTEM

6. Installing automatic adjuster

(1) Clean the automatic adjuster and its related parts, and
Apply grease to the threads and screw socket. Make
sure that the screw turns smoothly when rotated by
hand. If the screw is hard to turn, replace it with a new
one.
(2) Adjusting screws in LH wheel brakes are different from
those in RH wheel brakes. Each type can be identified
200277
by its thread direction (left-handed or right-handed) or
by the shape of its sprocket teeth. Thread directions are
shown below.

Adjusting screw in LH
Left-hand thread
wheel brake

Adjusting screw in RH
Right-hand thread
wheel brake

(3) Install the automatic adjusting device, then perform

inspection and adjustment in accordance with the
“Automatic Adjustment” subsection in the “Inspection
and Adjustment” section (page 8-25).

NOTE
After reassembly, bleed air out of the brake fluid lines.
(Refer to “Inspection and Adjustment” on pages 8-25
through 8-29.)

7. Installing backing plate

When installing the backing plate on the front axle housing
support, apply Loctite No.271 to the bolts and tighten the
bolts to a torque within either of the applicable ranges
shown below.
Unit: N·m (kgf·m) [lbf·ft]
Truck Models GP40K, GP40KL GP45K, GP50K
Item DP40K, DP40KL DP45K, DP50K

160 to 169 238 to 284

Tightening torque (16 to 17) (24 to 28)
[118 to 125] [175 to 209]

8. Connecting brake piping

When connecting the brake piping to the cylinder, tighten
the bolts to a torque within the range shown below.
12.7 to 17.6 N·m
Tightening torque (1.3 to 1.8 kgf·m)
[9.4 to 13 lbf·ft]
8-23
BRAKE SYSTEM

Parking Brake Lever

Released Applied

2
3
4
7

205504

1 Grip 5 Bracket
2 Stud 6 Parking brake cable
3 Lever assembly 7 Pin
4 Rod assembly

Inspection and Repair

(1) If the lever support pin and/or the pin hole in the lever
are badly worn, replace the worn part(s).
(2) Replace the parking brake cable if it is elongated,
damaged, or rusted.

Reassembly
After connecting the parking brake cable to the parking
brake lever, make sure that the force required for operating
the lever is within the range shown below.

245 to 294 N
Parking brake lever
(25 to 30 kgf)
operating effort
[55 to 66 lbf]

8-24
 BRAKE SYSTEM

Inspection and Adjustment

Automatic Adjustment
1. With all wheel brake components installed correctly, the
drum-to-shoe clearance should be within the correct
range of 0.25 to 0.4 mm (0.010 to 0.015 in.) for the
GP/DP40K, 40KL models and 0.4 to 0.6 mm (0.015 to
0.023 in.) for the GP/DP45K, 50K models as seen at
right angles to the side of the brake. Push the cable by
thumb to pull the adjusting lever. Observe the lever 202816
turns the adjusting screw by one tooth, and remove the
push to observe the adjusting screw returns to the
original position.
2. If the lever fails or is sluggish to turn the adjusting
screw in the above test, the likely cause is that the lever
is not properly positioned relative to the sprocket wheel.
Be sure that the lever is so positioned that its actuating
tip touches the sprocket wheel at a level about 9 mm
(0.35 in.) under the center line of the screw, as shown. 9 mm
(0.35 in.)
3. Where the automatic adjusting device is suspected of
malfunctioning during normal use of the machine, the 200282
following possible causes must be considered:
Adjusting sprocket wheel and lever positions
(1) Check that springs A and B are correctly installed.
(2) Any of these parts is in bad condition and requires
replacement:
a) fitting cable, b) adjusting lever, and c) adjusting
screw.
4. Use the following methods to determine whether the
drum-to-shoe clearance is correct.
(1) Fit the wheel hub in position, then turn it by hand. If the
drum-to-shoe clearance is correct, you will feel only
slight resistance. If you feel significant resistance, the
clearance is too small.
(2) Air-bleed the brake fluid lines, then depress the brake
pedal. If the pedal stroke is unusually long, the drum-
to-shoe clearance is too large.
If the drum-to-shoe clearance is incorrect, make the
necessary adjustment in accordance with the “Manual
Adjustment” subsection.

Manual Adjustment
The drum-to-shoe clearance can be adjusted by rotating the
adjusting screw with a screwdriver put to the sprocket
wheel. The hole thorough which the screwdriver tip can be
inserted is provided in the backing plate.

200283

8-25
BRAKE SYSTEM

Brake Line Bleeding

Whenever any part of the brake fluid line was disconnected
for servicing, or when the brake pedal feels spongy, bleed
the brake lines. For bleeding operation, use two men – one
at the brake pedal and the other at the bleeder screw of the
wheel cylinder, and keep the engine idling.
(1) Fill the reservoir with fluid. Always keep the reservoir
more than half full of the fluid during bleeding
operation.
(2) Remove the bleeder cap. Connect a transparent vinyl
tube to the bleeder screw with the free end of the tube
put in a glass jar filled with the fluid. (Make sure the
end of the tube is below the fluid level in the jar.)
(3) Have someone get into the truck and pump the brake
pedal full stroke several times, allowing it to return
slowly, then keep the pedal depressed. Loosen the
bleeder screw to allow the fluid to flow into the jar.
(4) Tighten the bleeder screw and release the pedal slowly.
200285
(5) Repeat Steps (3) and (4) above until the fluid flows
from the vinyl tube into the jar in a solid stream that is
free of air bubbles.
(6) Recap the bleeder cap and fill the reservoir with the
fluid up to the specified level.
Precautions for Bleeding Operation
(1) Maintain proper fluid level in the reservoir.
(2) Be careful not to spill the fluid on the painted surface.
(3) Avoid mixing different types of fluids.
(4) Connect the vinyl tube to the bleeder screw in such a
manner as to prevent fluid leaks.
(5) Be sure to allow the pedal to return slowly when
pumping it to prevent air from being sucked into the
system in the pedal return strokes.
(6) Do not release the pedal before tightening the bleeder
screw.
(7) When the bleeding operation is completed, make sure
the fluid level in the reservoir is correct. Add fluid if
necessary.
(8) Do not attempt to reuse the fluid in the glass jar. It is
likely to be contaminated or dirty.

8-26
 BRAKE SYSTEM

Brake Pedal

2
Operating rod
(booster side)

6
5
4
1

Lock nut
Stopper (booster side)

9 Left-hand thread
7
2 8
3
P

3 4 6
208811

1 Brake pedal 4 Jam nut 7 Stopper bolt

2 Brake booster 5 Lock nut 8 Clevis pin
3 Clevis 6 Pushrod 9 Lock nut

Assemble the brake linkage as follows: Unit: mm (in.)

(1) Put together the pushrod assembly components (clevis Pedal height 207.5 ± 3
3, joint nut 4, and lock nut 5 and pushrod 6) as shown A
(brake and inching) (8.17 ± 0.1)
in the illustration. The lock nut and jam nut must be
turned in fully and the pushrod must be screwed fully Pedal height above floor
B 185 (7.28)
into the clevis. (for reference)

(2) Connect the pushrod assembly to the operating rod of C Stroke of brake pedal 82 (3.2)
the brake booster 2 by screwing it until the dimension
indicated in the illustration is reached. Then tighten the D Stroke of inching pedal 122 (4.8)
lock nut on the brake booster side against the pushrod.
(3) Connect the clevis 3 of the pushrod assembly to the arm
P of the brake pedal with the clevis pin 8.
(4) Turn the pushrod 6 until the dimension A or B is up to
specification, then tighten the jam nut 4 and lock nut 5
to prevent the pushrod from turning.
(5) Screw in the stopper bolt 7 until it comes in contact
with the brake pedal stopper, then tighten the lock nut 9
to prevent the stopper bolt from turning.
202815

8-27
BRAKE SYSTEM

Adjusting pedal free play and stroke

B
(1) Free play B of the pedal will be 5 to 15 mm (0.2 to 0.6
C
in.) if the pedal is properly adjusted as in preceding
items (1) to (4).
(2) The entire stroke of the pedal should be 82 mm (3.2
in.). The stroke to the point where the brakes start
applying should be as follows:
Unit: mm (in.)
Stroke to the point where
42 (1.65)
brakes start applying C

208810

Brake Booster Test

1. Test method using no gauge

The brake booster may be considered to be satisfactory if it
meets the following three tests and requirements:
(1) Run the engine for 1 to 2 minutes, then stop it, and
depress the brake pedal with normal operating effort
several times to see how the pedal changes its stroke as
you repeat depressing the pedal. If the pedal stroke
decreases each time you depress the pedal, the booster
is in satisfactory condition. No change in pedal stroke
means that the booster is faulty.
(2) Depress the brake pedal several times with the engine
stopped, then keep the pedal depressed, and start the
engine. If the pedal goes down slightly when the
engine is started, the booster is in good condition. The
booster is faulty if the pedal fails to go down.
(3) Depress the brake pedal with the engine running.
Under this condition, stop the engine, and keep the
pedal depressed for about 30 seconds. If the pedal
height will not change, the booster is in good condition.

8-28
 BRAKE SYSTEM

2. Test method using a gauge 3 1

Use a vacuum gauge, a pressure gauge and a force gauge.

4
Bleed the pressure gauge, and proceed as follows:
(1) No-load air-tightness test
Start the engine, and run it until the vacuum gauge
reads about 500 mm Hg (20 in. Hg). The booster is in
good condition if the vacuum drop is less than 25 mm 2
Hg (1 in. Hg) for about 15 seconds after the engine has
been stopped. 5
207603
(2) Under-load air-tightness test 1 Pressure gauge 4 Vacuum tank
Start the engine, depress the brake pedal with an operating 2 Vacuum gauge 5 Check valve
effort of 196 N (20 kgf) [44 lbf], and stop the engine when 3 Force gauge
the vacuum gauge reads about 500 mm Hg (20 in. Hg). The
booster is in good condition if the vacuum drop is less than
25 mm Hg (1 in. Hg) for about 15 seconds after the engine
has been stopped.
(3) Characteristic test
Carry out this test after the tests (1) and (2).
(a) Non-booster action test Truck
Make sure that the vacuum gauge reads 0 mm Hg Model GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
with the engine stopped, and depress the brake Item
pedal with an operating effort of 98 N (10 kgf) 981 kPa 490 kPa
[22 lbf] and 196 N (20 kgf) [44 lbf] to see if the *1 (10 kgf/cm2) (5 kgf/cm2)
[142 psi] [71 psi]
pressure meet the specifications. Pressure
2648 kPa 1471 kPa
*2 (27 kgf/cm2) (15 kgf/cm2)
[384 psi] [213 psi]
*1: With 98 N (10 kgf) [22 lbf] operating effort
*2: With 196 N (20 kgf) [44 lbf] operating effort

(b) Booster action test

Start the engine and, when the vacuum gauge Truck
reads 500 mm Hg (20 in. Hg), depress the brake Model GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
pedal with an operating effort of 98 N (10 kgf) Item
[22 lbf] and 196 N (20 kgf) [44 lbf] to see if the 4217 kPa 2648 kPa
pressure meets the specifications. *1 (43 kgf/cm2) (27 kgf/cm2)
[611 psi] [384 psi]
Pressure
NOTE 5884 kPa 3923 kPa
*2 (60 kgf/cm2) (40 kgf/cm2)
The operation test outlined above is a simplified field [853 psi] [569 psi]
test. Be sure to test the booster on the test bench as *1: With 98 N (10 kgf) [22 lbf] operating effort
specified by the manufacturer for verification or *2: With 196 N (20 kgf) [44 lbf] operating effort
careful analysis of the problem if the booster is faulty.

8-29
BRAKE SYSTEM

Troubleshooting

Oil leaking past primary cup in master Replace piston cup if cylinder
cylinder, or oil leaking past cups in is worn. Replace the cup and
Lack of braking wheel cylinders fluid if the cup is distorted.
force Oil leaking from oil pipe connection Replace pipe and connector
and retighten.
Shoe linings excessively worn Replace.
Linings dirty with oil or grease Clean or replace.
Air trapped in brake oil line Bleed air at brake booster
and wheel cylinder.
Piston cup defective in master Replace.
cylinder
Pedal stroke is Not enough fluid in reservoir Add fluid.
too large Push rod to piston clearance too large Readjust.
in master cylinder
Brake fluid leakage Replace piston cup if cylinder
is worn. Replace the cup and
fluid if the cup is distorted.
Automatic adjuster out of order Check cable guide and adjust-
ing spring installation. If they
are defective, replace fitting
cable, lever and adjusting
screw.
Uneven braking Lining or drum dirty with oil or Clean or replace.
(wheel brake is grease in less effective brake
more effective on Wobbly or loose-mounted drum in Replace drum. Readjust and
Wheel one side than on less effective brake retighten.
brakes the other) Wheel tires inflated unequally Re-inflate.
Linings glazed Sand.
Linings badly worn Replace shoe and lining
assembly.
Brake squeals Backing plate securing bolts loose Retighten.
Wheel bearings loose Readjust preload and
retighten.
Brake drum dirty Clean.
Anchored ends of shoes rattling on Repair or replace.
Brake chatters or anchor
clatters Shoe ledges badly worn Replace backing plate.
Piston badly worn in wheel cylinder Replace.
Vacuum hose joint loose Retighten.
Vacuum hose flat or ruptured Replace.
Vacuum pump malfunctioning Repair or replace.
Pedal will give Alternator drive belt loose Readjust.
resistance Vacuum valve or atmospheric pressure Repair or replace.
valve dirty or damaged in brake booster
Brake booster element clogged Clean or replace.
Brake booster diaphragm defective Replace.
Brake cylinder internally dirty Clean and lubricate.
Lack of brake cylinder fluid Add fluid.
Spongy pedal Brake cylinder fluid leaks Repair or replace.
Air in system Bleed.

8-30
 BRAKE SYSTEM

Service Data
A: Standard value
Unit: mm (in.)
Truck Model
GP40K, GP40KL, GP45K, GP50K
DP40K, DP40KL, DP45K, DP50K
Item
Height of pedal 1 (from floor plate to top of
A 185 (7.28)
pedal pad)

Free play of pedal 2 A 5 to 15 (0.2 to 0.6)

Stroke to the point where brakes start

A 42 (1.65)
applying 3

Stroke of brake pedal A 82 (3.2)

Tightening torque of master cylinder

A 12 (1.2) [8.7]
mounting bolts N·m (kgf·m) [lbf·ft]

Tightening torque of brake booster mounting

A 12 (1.2) [8.7]
bolts N·m (kgf·m) [lbf·ft]

Tightening torque of vacuum pipe union nuts

A 39 to 49 (4 to 5) [29 to 36]
N·m (kgf·m) [lbf·ft]
Brake
Tightening torque of brake pipe union nuts
pedal A 13 to 18 (1.3 to 1.8) [9.4 to 13]
N·m (kgf·m) [lbf·ft]

2
4 3

Floor plate

208812

8-31
BRAKE SYSTEM

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model
GP40K, GP40KL GP45K, GP50K
DP40K, DP40KL DP45K, DP50K
Item
+ 0.052
22.22 0
Inside diameter of cylinder body 1 A − 0.00205 28.57 (1.125)
(0.8748 0 )
− 0.020
22.22 − 0.053
Outside diameter of piston 2 A − 0.00079 28.57 (1.125)
(0.8748 − 0.00209 )

A 0.020 to 0.105 (0.00079 to 0.00413)

Clearance between piston and cylinder body
0.2 (0.008)
B
(Replace every 1 year)

23.2 ± 0.25
A 28.57 (1.125)
(0.913 ± 0.0098)
Diameter of primary cup (lip side) 3
B (Replace every 1 year)

23.5 ± 0.25
A 28.57 (1.125)
(0.925 ± 0.0098)
Diameter of secondary cup (lip side) 4
Master B (Replace every 1 year)
cylinder
A 73 (2.87) 104 (4.09)
Free length of return spring 5
B (Replace every 1 year)

208813

8-32
 BRAKE SYSTEM

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model
GP40K, GP40KL, GP45K GP50K
DP40K, DP40KL, DP45K DP50K
Item
+ 0.052 + 0.062
28.58 0 31.75 0
Inside diameter of cylinder body 1 A + 0.00205 + 0.00244
(1.125 2 0 ) (1.2500 0 )
− 0.020 − 0.025
28.58 − 0.058 31.75 − 0.064
Outside diameter of piston 2 A − 0.00079 − 0.00098
(1.1252 − 0.00228 ) (1.2500 − 0.00252 )

0.020 to 0.105 0.025 to 0.126

A
(0.00079 to 0.00413) (0.00098 to 0.00496)
Clearance between piston and cylinder body
B 0.15 (0.0059)

30.5 ± 0.25 33.6 ± 0.25

A
(1.201 ± 0.0098) (1.323 ± 0.0098)
Diameter of piston cup (lip side) 3
32.4 (1.276)
(To be replaced
B (To be replaced
every 1 year)
every 1 year)

Free length A 58 (2.28) 33.4 (1.31)

Wheel Length under test force A 23 (0.91) 14 (0.55)

cylinder
Return spring 4 13 ± 1 16 ± 1
A (1.3 ± 0.1) (1.6 ± 0.1)
Test force
[2.9 ± 0.2] [3.5 ± 0.2]
N (kgf) [lbf]
B (Replace every 1 year)

Tightening torque of cylinder bolt 5

A 18 to 26 (1.8 to 2.7) [13 to 20]
N·m (kgf·m) [lbf·ft]

Tightening torque of bleeder screw 6

A 6 to 9 (0.6 to 0.9) [4 to 7]
N·m (kgf·m) [lbf·ft]

200426

8-33
BRAKE SYSTEM

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model
GP40K, GP40KL, GP45K GP50K
DP40K, DP40KL, DP45K DP50K
Item
+ 0.2 + 0.008
A 317.5 0 (12.500 0 )
Inside diameter of brake drum 1 GP40K, GP40KL, DP40K, DP40KL: 318.5 (12.539)
B
GP45K, GP50K, DP45K, DP50K: 318.5 (12.539)
A 5.62 (0.22) 10 (0.39)
Thickness of lining 2
B 3 (0.12), maximum 4.2 (0.17), maximum
Clearance between drum and lining 3 0.25 to 0.40 0.4 to 0.6
A
(one side) (0.010 to 0.016) (0.016 to 0.024)
Free length A 124 (4.88) 93 (3.66)
Length under test force A 138 (5.43) 101.2 (3.98)
Return spring 4
226 ± 23
Test force N (kgf) [lbf] A (23 ± 2.3) 245 (25) [55]
[51 ± 5.1]
Free length A 126 (4.96) 123.2 (4.85)
Adjusting Length under test force A 145.7 (5.74) 152 (5.98)
spring 5
Test force N (kgf) [lbf] A 78 (8) [18]
160 to 196 238 to 284
Tightening torque for backing plate 6
A (16.3 to 20.0) (24.3 to 29.0)
N·m (kgf·m) [lbf·ft]
[118 to 145] [176 to 210]
Wheel
brakes Upper: 97 (3.82)
Length of fitting cable 7 A 335 (13.20)
Lower: 97.8 (3.85)

203588

Note: Fitting cable 7 is for GP40K, GP40KL, GP45K, DP40K, DP40KL and DP45K. In GP50K,
DP50K column, “Upper” and “Lower” mean upper link and lower link respectively.

8-34
 BRAKE SYSTEM

A: Standard value
Truck Model
GP40K, GP40KL, GP45K GP50K
DP40K, DP40KL, DP45K DP50K
Item
Lever swing angle A A 71° to 76°

Lever operating effort F

A 245 to 294 (25 to 30) [55 to 66]
N (kgf) [lbf]

F
A
Parking
brake

200428

8-35