Function of main parts
Master cylinder : Generates hydraulic pressure to apply on the disc and / or drum brakes.
Disc [ Rotor] : Transmit the stopping force from the disc brake caliper to the road wheel.
Disc brake caliper : Provides stopping force at the wheel by clamping the disc pads against the
disc / rotor.
Booster : Provides power assistance to reduce the amount of brake pedal effort
required by the driver.
Drum brake : Provides stopping force at the road wheel, by pushing the brake shoes
against the inner diameter of the brake drum.
LSPV : To prevent rear wheel locking
By pass valve : In the event of the front brake circuit failure,rear circuit will get bypass & full
pressure will go to rear wheel.
Brake System with 9” booster
Tandem Servo Master Assembly : 9” Booster with TMC Ø 23.81 mm
Front Disc Brake : Single Pot Caliper (Ø 57 mm ) with Pad ( R804 )
Rotor: : Ø 272 mm x Thickness 21 mm
LSPV : 0.45 Slope
By-Pass : Mounted on a separate Bracket On Vacuum Booster
Below the TMC
Rear Brake : 11” One Shot type auto adjuster with W/C Ø 22.22 mm
with Liner AF3691
Brake circuit with 9”booster
Bleed screw
T. M. C.
By pass valve L. S. P. Valve
Load sensing proportioning valve ( L.S.P.V. )
When the brakes are applied then there is a load
transfer to the front wheel & the load coming on to the rear
wheels is reduced. If full Pressure of brake fluid is going to
the rear wheels then the rear wheels lock up & tyres start
skidding on the road.
The LSPV function is to ensure that the amount of
brake fluid going into the rear wheels is in proportion to the
weight (load) and thus to ensure that the rear wheels do not
lock up. The effect is that the braking efficiency is the same
irrespective of the load.
In the event of any unlikely failure of the front brake
circuit, the LSPV presence will result in braking being
insufficient as the LSPV reduces the amount of brake fluid
going into the rear brake. To avoid such a condition a bypass
valve is provided.
LSPV setting
1. Remove the spring holding Special bolt & nut take off the bolt from the hook.
2. Remove the rubber washer from the bolt and put it in the pin projection of the special tool.
3. Position the lower portion of the tool [MST 568] behind the plate
4. Locate the tool on the hook of the spring.
5. The slot position in the tool is the desired position for spring eye.
6. Mount the bolt in the correct position as indicated by the tool.
7. Remove the tool and then tighten the bolt to the specified torque.
8. Pull down the spring and locate the eye in the washer.
9. Ensure that the spring is sitting properly in its position.
Bypass valve
The bypass valve is near the master cylinder in the firewall. The hydraulic pressure
of both the front and the rear circuits go onto the bypass valve. In the event of the front brake
circuit failure the brake fluid goes through the bypass valve and instead of entering the LSPV ,
goes directly to the rear through the T-junction – bypassing the LSPV.
By pass valve By pass circuit
Brake bleeding with 9” booster
A] Loosen the bleed screw on the by pass valve, Attach a transparent tube and put it in the
reservoir.
B] Bleed the rear LH wheel cylinder & then RH wheel cylinder.
C] Bleed the by pass valve & tighten the bleed screw..
D] Bleed the front LH caliper & then front RH caliper.
2
4 5
3
1
Brake System with 10” booster
Tandem Servo Master Assembly : 10” Booster with TMC Ø 23.81 mm
Front Disc Brake : Single Pot Caliper (Ø 57 mm ) with Pad ( R808 )
Rotor: : Ø 272 mm x Thickness 21 mm
LSPV : 0.3 Slope with integral bypass.
Rear Brake : 11” One Shot auto adjuster type with W/C Ø 22.22 mm
with Liner AF3691
Brake circuit with 10”
Bleed screw
T. M. C.
2 Way connector
L. S. P. Valve
with integral bypass
Load sensing proportioning valve ( L.S.P.V. )
When the brakes are applied then there is a
load transfer to the front wheel & the load coming on
to the rear wheels is reduced. If full pressure of brake
fluid is going to the rear wheel then the rear wheels
lock up & tyres start skidding on the road.
The LSPV function is to ensure that the
amount of brake fluid going into the rear wheel is in
proportion to the weight (load) and thus to ensure that
the rear wheels do not lock up. The effect is that the
braking efficiency is the same irrespective of the load.
In the event of any unlikely failure of the
front brake circuit, the LSPV presence will result in
braking being insufficient as the LSPV reduces the
amount of brake fluid going into the rear brake. To
avoid such a condition a bypass valve is provided.
The bypass valve is integral with LSPV.
The hydraulic pressure of secondary circuit [Which is
going to front wheel] go onto the LSPV bypass valve.
In the event of the front brake circuit failure,rear circuit
will get bypass & full pressure will go to rear wheel.
LSPV setting
1. Remove the spring holding Special bolt & nut take off the bolt from the hook.
2. Remove the rubber washer from the bolt and put it in the pin projection of the special tool.
3. Position the lower portion of the tool behind the plate
4. Locate the tool on the hook of the spring.
5. The slot position in the tool is the desired position for spring eye.
6. Mount the bolt in the correct position as indicated by the tool.
7. Remove the tool and then tighten the bolt to the specified torque.
8. Pull down the spring and locate the eye in the washer.
9. Ensure that the spring is sitting properly in its position.
Brake bleeding with 10” booster
A] Bleed the rear wheel LH wheel cylinder & then RH wheel cylinder.
B] Bleed the LSP valve.
C] Bleed the front LH caliper & then front RH caliper.
2
5
1
4
Brake System with tandem booster and single pot caliper
Tandem Servo Master Assembly : Tandem Booster 8” + 9” with TMC Ø 23.81 mm
Front Disc Brake : Single Pot Caliper (Ø 57 mm ) with Pad ( R808 )
Rotor: : Ø 272 mm x Thickness 21 mm
LSPV : 0.3 Slope with integral bypass.
Rear Brake : 11” One Shot auto adjuster type with W/C Ø 22.22 mm
with Liner AF3691
Brake circuit with tandem booster with single pot caliper
Bleed screw
T. M. C.
L. S. P. Valve
with integral bypass
Load sensing proportioning valve ( L.S.P.V. )
When the brakes are applied then there is a
load transfer to the front wheel & the load coming on
to the rear wheels is reduced. If full pressure of brake
fluid is going to the rear wheel then the rear wheels
lock up & tyres start skidding on the road.
The LSPV function is to ensure that the
amount of brake fluid going into the rear wheel is in
proportion to the weight (load) and thus to ensure that
the rear wheels do not lock up. The effect is that the
braking efficiency is the same irrespective of the load.
In the event of any unlikely failure of the
front brake circuit, the LSPV presence will result in
braking being insufficient as the LSPV reduces the
amount of brake fluid going into the rear brake. To
avoid such a condition a bypass valve is provided.
The bypass valve is integral with LSPV.
The hydraulic pressure of secondary circuit [Which is
going to front wheel] go onto the LSPV bypass valve.
In the event of the front brake circuit failure,rear circuit
will get bypass & full pressure will go to rear wheel.
LSPV setting
1. Remove the spring holding Special bolt & nut take off the bolt from the hook.
2. Remove the rubber washer from the bolt and put it in the pin projection of the special tool.
3. Position the lower portion of the tool behind the plate
4. Locate the tool on the hook of the spring.
5. The slot position in the tool is the desired position for spring eye.
6. Mount the bolt in the correct position as indicated by the tool.
7. Remove the tool and then tighten the bolt to the specified torque.
8. Pull down the spring and locate the eye in the washer.
9. Ensure that the spring is sitting properly in its position.
Brake bleeding with tandem booster with single pot caliper
A] Bleed the rear wheel LH wheel cylinders & then RH wheel cylinder.
B] Bleed the by LSP valve.
C] Bleed the front LH caliper & then front RH caliper.
2
5
1
4
Brake System with tandem booster & twin pot caliper
Tandem Servo Master Assembly : Tandem Booster 8” + 9” with TMC Ø 26.99 mm
Front Disc Brake : Twin Pot Caliper (2 x Ø 45 mm ) with Pad ( R808 )
Rotor: : Ø 298 mm x Thickness 24 mm
LSPV : 0.3 Slope with integral By-Pass
Rear Brake : 11” RAUS Type with w/c Ø 25.4 mm with
Liner AF4179
Brake System Layout
Bleed screw
T. M. C.
L. S. P. Valve
with integral bypass
Load sensing proportioning valve ( L.S.P.V. )
When the brakes are applied then there is a
load transfer to the front wheel & the load coming on
to the rear wheels is reduced. If full quantity of brake
fluid is going to the rear wheel then the rear wheels
lock up & tyres start skidding on the road.
The LSPV function is to ensure that the
amount of brake fluid going into the rear wheel is in
proportion to the weight (load) and thus to ensure that
the rear wheels do not lock up. The effect is that the
braking efficiency is the same irrespective of the load.
In the event of any unlikely failure of the
front brake circuit, the LSPV presence will result in
braking being insufficient as the LSPV reduces the
amount of brake fluid going into the rear brake. To
avoid such a condition a bypass valve is provided.
The bypass valve is integral with LSPV.
The hydraulic pressure of secondary circuit [Which is
going to front wheel] go onto the LSPV bypass valve.
In the event of the front brake circuit failure,rear circuit
will get bypass & full pressure will go to rear wheel.
LSPV setting
1. Remove the spring holding Special bolt & nut take off the bolt from the hook.
2. Remove the rubber washer from the bolt and put it in the pin projection of the special tool.
3. Position the lower portion of the tool behind the plate
4. Locate the tool on the hook of the spring.
5. The slot position in the tool is the desired position for spring eye.
6. Mount the bolt in the correct position as indicated by the tool.
7. Remove the tool and then tighten the bolt to the specified torque.
8. Pull down the spring and locate the eye in the washer.
9. Ensure that the spring is sitting properly in its position.
Brake bleeding with tandem booster with twin pot caliper
A] Bleed the rear wheel LH wheel cylinders & then RH wheel cylinder.
B] Bleed the by LSP valve.
C] Bleed the front LH caliper & then front RH caliper.
2
5
1
4
Brake System Layout
Bleed screw
T. M. C.
L. S. P. Valve
with integral bypass
Working of Master Cylinder
Reservoir Port
Compensating Port
Compensating
Normal condition
Pressure Chamber Chamber
After Brake Application.
Exploded View :TMC
Sr. No. Description
Tandem Master Cylinder Assembly
1
with reservoir
2 Reservoir Assembly with cap
Tandem Master Cylinder Assembly
without Reservoir
3 Cap , Reservoir
4 Filter
5 Reservoir Body
6 Fluid Level Indicator Switch
7 Reservoir Grommet
8 Secondary Piston Assembly
9 Primary Seal , Secondary Piston
10 Secondary Seal , Secondary Piston
11 Primary Piston Assembly
12 Circlip
Working of Tandem Booster
Normal condition
After Brake Application.
Exploded View :Tandem Booster
1 Vacuum Booster Assembly
2 Non - Return Valve Grommet
3 Non - Return Valve ( Check Valve )
4 Gasket -- Booster mounting
Working of Disc Brake
1. 2.
3. 4.
Piston Return Mechanism : Disc Brake
Condition -- Brakes Release
Caliper Body
Seal
Piston
Condition -- Brakes Applied
Exploded View : Twin Pot Caliper
Sr. No. Description
1 Caliper Assembly
2 Guide Pin
3 Locking Pin
4 Bolt , Pin
5 Bleed Screw
6 Cap , Bleed Screw
7 Bush , Locking Pin
8 Boot , Pin
9 Spring , Pad
10 Spring , Pad
11 Seal , Pistom
12 Piston
13 Boot , Piston
14 Anti squeal shim
15 Perforated shim
16 Friction Pad
Changing of caliper pad
Loosen and remove the bolt - Pin of the guide pin .
Swing up the caliper.
Remove the old pads one by one
Connect a transparent plastic pipe to the bleed
screw on the caliper & dip the other end of the
pipe into a container filled with brake fluid.
Ensure the tip of the plastic pipe always
remains dipped in the brake fluid.
Loosen the bleed screw & push both the pistons
one by one into the caliper bore as shown in the fig.
Ensure the pistons are pushed back fully into the
caliper bore.
The Pads in the Pad kit are marked < RH > &
< LH > on the pad plate. Assemble < RH >
marked pads on RH Caliper & < LH > marked
pads on LH Caliper. Apply the anti squeal
grease provided in the caliper kit on pad back
plate. Fit the perforated shim & apply the anti
squeal grease on the perforated shim. Care
must be taken to fill up all perforations on the
shim with grease.
Fit the steel shim on the perforated shim.
Now remove the old pad springs (anti-rattle clips )
from the carrier & replace with the new ones
supplied in kit.
The pad springs should be snap fitted properly on
the machined lugs provided on carrier.
The pad springs have a projection on one side
as shown in the photograph. The pad springs
which fits on the carrier has a projection on
one side. Care must be taken while
assembling the pad spring such that this
projection will never point towards the brake
disc but always towards the opposite side of
the brake disc.
Projection on Pad
Spring
Fit the pads with anti squeal shim one by one.
Swing down the caliper. Care must be taken
not to damage the anti squeal shims.
Retighten the Bolt - Pin (4) with a tightening
torque of 2.2 to 3.2 Kgm.
A new bolt – pin is provided with the pad kit. The
removed bolt – pin should be scrapped.
After tightening, rotate the disc and ensure that
the disc is free to rotate.
Caution :
While pushing the pistons back into the
caliper bore , since the bleed screw is in
loose condition there is a possibility of air
entrapment ; hence it is necessary to bleed
the brake system .
Care should be taken while fitting the guide pin
to match the straight portion on pin with the ear
of the caliper body.
Servicing Of Caliper
Disconnect the hose from the caliper by removing
the banjo bolt .
Loosen and remove the bottom retaining bolt of
the guide pin .
Now remove the top retaining bolt of the locking
pin and remove the caliper sub assembly. No
need to remove the Carrier Assembly with pads
from the rotor or stub axle.
Clean the caliper sub assembly externally with
alcohol or fresh brake fluid.
Remove the caliper pistons from the bore by
blowing dry compressed air through the inlet
port of the caliper . Care must be taken to
remove both the pistons at a time. Also to
avoid the damage to the pistons , place a
wooden block in front of the pistons. ( Approx..
30 mm thick)
Remove the boot, pistons with the help of a
screw driver. Care must be taken not to
damage the seat of the boot in caliper body.
By using a blunt edged connector or filler
gauge , remove the seal- Pistons from the
groove . While removing the seal care to be
taken not to damage the bore.
Never use any mineral oil base fluids like kerosene , diesel , petrol etc,. For cleaning
of removed parts
The piston boots (8) are to be lubricated
internally with the special grease supplied in
Caliper Repair Kits before it is assembled on
the pistons. Please ensure that this grease will
not come in contact with the piston while fitting
the boot on the piston.
Locate the boots on to the caliper pistons.
Insert the caliper pistons into the bore & push
it gently into the bore. Once the piston is home,
ensure the fitment of the boot on to the boot
groove on the piston. The piston should be
inserted into the bore in a straight position only.
If it gets tilted while pushing , there is a chance
that the piston will get jam half way & also can
damage the seal.
Correct orientation of the boot to be ensured
Correct Orientation of Boot.
Wrong Orientation of Boot.
Once the piston is inserted inside the bore, put
a wooden block on the piston & with the help of
a ‘C’ Clamp push it inside the bore. Face to
face fitment of the boot to be insured .
Repeat the procedure for the other piston.
The wooden block should have the corners
rounded to ensure the proper fitment of boot
into the grooves. Otherwise the wooden block
can foul against the radius on caliper body.
Replacement of Sliding pin Kit
Remove the locking pin with bush from the carrier along
with the boot Then separate the boots from the pin.
Remove the guide pin along with boot from the carrier &
separate the boot from the pin.
Smear the pins and the pin bores with the special grease supplied in Sliding Pin Kit. Apply light
grease on locking pin with Bush . Ensure locking pin with bush on top ( Near the bleed screw )
& Guide pin ( with no bush ) on bottom end of the caliper. Fit the pin boots on to the pins and
assemble it on to the carrier bore. Ensure proper location of the boot lip on to the carrier. Move
the pins in and out 3 to 5 times in order to allow for the trapped air inside the bore to escape.
During the assembly of caliper the following points are to be ensured
The braking surface on brake disc should be free from any type of grease , score marks.
Thickness , runout and faceout of the disc to be within the prescribed limits.
Bleed screw to be torque tightened to 1.0 to 1.2 Kgm
Banjo bolt to be torque tightened as per vehicle manufacturers specification. Use of new
copper washers is highly recommended.
In case the carrier is removed from stub axle, then the mounting bolts to be checked for its
tightening torque as per vehicle manufacturer’s instructions .
Rear drum Brake
Hand brake setting
1] Hand brake to be set after removal of initial cable slackness & brake bleeding.
2] Apply brake pedal min. 6 to 8 times to set auto adjuster in brake assembly.
3] Pull parking lever upto 5th notch & keep on tightening adjustments nut until rear wheels
get locked firmly.
4] Release parking brake lever & check the wheels for freeness.
5] Lock both adjustments nuts positively against pulley hold bracket.
Bleeding
• Bleeding is removal of air from the system.
• Ensure to bleed the system perfectly.
• Always use the recommended brake fluid for bleeding the system.
• Pedal sponginess is the indication of improper bleeding.
• Bleeding has to be done whenever hydraulic brake circuit is opened.
Do’s & Don’ts
• Use only fresh Brake fluid to clean the • Never use any mineral oils like Petrol /
Brake Aggregates. Diesel to wash the brake system parts .
Also never allow lubricants which are
mineral based like Engine oils or Gear oils
or other types of greases in contact with the
rubber parts of any Brake System.
Only rinse the bore with fresh brake Do not use a piece of cloth to wipe/ clean
fluid & blow air. the bore of Master Cylinder or Caliper.
Only blow compressed air in the bore Do not polish the bore of Master Cylinder
& assemble the internals. To remove with emery paper as this will increase the
clearance between the bore & seal. Also do
Caliper rubber seals use filler gauge
not use sharp tools like screw drivers inside
like tools which are without sharp
the bore as this can damage Master
edge.
Cylinder or Caliper bore.
• Use wooden block for tapping the While disassembling master cylinder. Assy.
master cylinder Assy. do not tap the flange on any hard surface.
Do not top up brake fluid without
While topping up the brake fluid care
taking due care.
should be taken to use the brake fluid only
from a sealed container as the brake fluid
in an open container absorbs the moisture
from atmosphere which can result in
inferior performance of brake fluid. Also
while selecting the brake fluid only Dot 3 or
4 standard brake fluid should be
purchased. Also only use the brands
suggested by the manufacturer
• Disconnect the LSPV control spring Do not allow the LSPV control spring to
from rear axle before lifting the vehicle overstretch while lifting the vehicle on two
on two post lift. post lift.
Brake care
• Always exercise cleanliness when handling any part of the hydraulic system.
• Use separate containers for brake fluid while dispensing out brake bleeding.
• Use transparent bleed pipe and bottle while bleeding.
• Replace the shoe return springs whenever lined shoes are replaced.
• Use same grade of brake lining on both sides of the brake.
• Check the brake pedal feel before taking the vehicles for testing.
• Don’t handle rubber seals or internal parts with greasy hands.
• Don’t use cotton waste for cleaning, since the threads of cotton waste likely to block the
ports and holes of the component.
• Don’t use drained brake fluid for topping up. Bleed brake fluid will have air bubbles.
• Don’t allow the lining to wear upto rivets.
• Don’t use emery paper for removing stains and rusty patches from cylinder bore surface.
Use brasso polish, clean with cloth for removing stains and rusty patches with brake fluid
and wipe out with clean cloth.
• Don’t use sharp tools for pushing the piston out of cylinder, use wooden stick or hylem rod
for removing the piston out of the cylinder. Sharp tools like screw driver will spoil the bore
finish.
• Don’t skim the brake drum beyond the recommended oversize.
Normal conditions
Following conditions are considered normal and not indicate that the brake master
cylinder is in need of service.
• Pedal effort on the modern braking system is not very hard as in the past. Light pedal
effort complaint should be compared with the pedal effort of another vehicle of the same
model and year of manufacture.
• During brake application fluid level goes down in the reservoir and reverts back to normal
level when the pedal is released.
• The fluid level in the reservoir will fall depending upon the wear of friction material in
calipers. Reservoir need topping up with fresh brake fluid when the fluid level warning
indicator glows continuously on the dash board.
• If the fluid level fall off is very high with a change in the brake pedal feel, there could be a
leak in the system which should be identified and rectified immediately.
Abnormal conditions
Following conditions are considered abnormal and indicate that the brake master
cylinder is in need of service.
• The brake pedal goes down fast. This could be caused by an external or internal leak.
• Brake pedal low or spongy -
Fluid level very low in master cylinder and there could be air in the system.
• Slight brake binding -
If the reservoir cap vent hole is clogged the brake could start binding slightly apart from
other general causes of brake binding.
• Brake pedal effort is excessive -
This could be due to insufficient vacuum coming to booster, obstruction in pedal cross shaft
and linkages. If the brakes are binding that could also result in hard pedal.
• Brake pedal effort is erratic -
Mal functioning of booster, improper installation of brake shoes, high piston knock in
calipers on high speed turnings.
BRAKE PROBLEM DIAGNOSIS
Sl.No Problems Test Brief Description Ref. Value
1 Pull, Vibration, To determine if concern is First use foot brake and then parking
Pulsation in front or rear braking brake. If the condition (i.e. pull,
system vibration, pulsation) occurs only on
operation of the parking brake, the
concern is in the rear brake system. If
the condition occurs when the foot
brake is depressed, the concern in front
brake
2 Brake pull or drift Check pressure control Install pressure gauge in the left hand
valve ( Proportionating front and right hand rear bleed nipples
valve)
3 Brake light Brake warning lamp Remove the brake master cylinder
always on check reservoir filler cap. Allow the float to rest
at its lowest point. If the brake warning
indicator illuminates, the wiring/ switch
is O.K. If the fluid level is below the
minimum level brake light will
continuously glow.
4 1. Brake judder. Disc thickness check Check the front disc thickness varience If any of the reading vary by
using a micrometer. Measure at eight 0.015 mm or more or if
positions 45 degree aprt and 15 mm thickness is less than 19/22
away from the outer edge of the disc. mm change the disc.
Check mounting bolts of rotor for proper
2. Erratic brake
torque.
pedal travel.
BRAKE PROBLEM DIAGNOSIS
Sl.No Problems Test Brief Description Ref. Value
5 Hard brake Booster vacuum test Install pressure gauge on the brake Should read more than 600 mm
booster hose end. Check the reading. of Hg
6 Brake judder Disc run out check 1. Position the dial gauge so that it Maximum brake disc run out
contacts the disc face 10mm. (0.4inch) allowed is 0.12 mm
from the outer edge.
2. Rotate the disc and absorve reading.
7 Brake judder Hub face run out check Position the dial gauge so that it
contacts the hub. Rotate the hub.
8 Poor hand brake Parking brake cable Lower the parking brake control lever.
operation adjustment Loosen the adjusting nut. Depress the
foot brake six times. Raise the parking
brake control lever by five clicks of the
retchet. Tighten the adjusting nut
Precautions with brake fluids
• Brake fluid should be not be exposed to the atmosphere.
• Lowering of boiling point could lead to vaporization of the fluid under heavy braking which
result in brake failure.
• Brake fluid being hydroscopic in nature, will absorb moisture from the atmosphere and lead
to lowering of boiling point and corrode internal parts of hydraulic cylinders.
• Brake fluid is subjected to repeated heating & cooling cycles which can lead to gradual
deterioration of its properties hence it is absolutely essential that the brake fluid be drained
and replaced once in a year.
• Always exercise cleanliness when handling any part of the hydraulic system
• Never handle rubber seals or internal parts with greasy hands
• Always buy brake fluid in sealed tins.
• For cleaning master cylinder and wheel cylinder, use only fresh brake fluid. Never use
mineral oils like petrol, kerosene, diesel, thinner etc.,
• Seal swelling is due to the usage of mineral oils for cleaning or using spurious brake fluid for
filling / topping up.
• If old seal is swollen, contamination is established. Drain the brake fluid and refill it with fresh
brake fluid and change all rubber parts in the system.
Maintenance
Every Service
• Brake fluid level should be checked during every service & it should be between min.and
max. markings in the reservoir.
• Clean the reservoir cap before topping up the brake fluid.
• Check the brake lining & brake pads for wear during every service.
• Replace shoe return springs whenever liner shoes are replaced.
• Replace antirattle clip whenever pads are changed.
Every 40,000 kms / Every year
• Change brake fluid.Overhaul the tandem master cylinder and wheel cylinders.
Service Limits
Lining
: Do not allow the lining to wear upto the rivets or pad back plate.
Wheel cylinder
: If the clearance between the plunger outer diameter and bore diameter exceeds
0.25mm, the cylinder to be replaced.
Master cylinder
: If the clearance between the plunger outer diameter and bore diameter exceeds
0.20mm, the cylinder to be replaced.
Hoses
: To be replaced once in two years or if any damage is noticed.
Seals
: As a brake system preventive maintenance every brake system seals should replace
after 40000 kms.
Tool for LSP Valve setting
91.50 mm for 9” brake booster system
92.50 mm for all other brake systems.
8.80 mm for 9” brake booster system
10.20mm for all other brake systems.
MST - 570 Tool for rear brake hold down spring
MST - 569 Brake shoe return spring puller
MST - 568 LSPV Setting gauge [ 9" Booster ]
