Challenge for Excellence
DP20~35N3
Brake System
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Service Brake
Components
PARKING BRAKE LEVER
RESERVE TANK
BRAKE PEDAL
STOP LIGHT SWITCH
PARKING BRAKE CABLE
WHEEL CYLINDER
MASTER CYLINDER
WHEEL BRAKE
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Service Brake
Assembly < Inspection points >
*Backing plate (12)
*Shoe & Lining (8 & 6)
*Brake drum (13)
*Adjuster (5)
*PKB cable (10)
1. RETURN SPRING *Brake fluid leaks (9)
2. CABLE WITH SPRING
3. HOLD-DOWN SPRING, CUP, PIN
4. ADJUSTING LEVER, ADJUSTING SPRING,
RETURN SPRING
5. CABLE GUIDE, SHEAVE, ADJUSTING
SCREW, PIN, WASHER
6. SHOE GUIDE PLATE, SHOE AND LINING
(SECONDARY)
7. STRAP, ANTI-RATTLE SPRING
8. SHOE AND LINING (PRIMARY), PARKING
BRAKE LEVER, RETAINER, SPRING
WASHER
9. WHEEL CYLINDER & INSTALL BOLTS
10. PARKING BRAKE CABLE
11. MOUNTING BOLT, SPRING WASHER
12. BACKING PLATE
13. BRAKE DRUM
NOTE: The parts marked by * are included
in the repair kit and must be changed
periodically.
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Parking Brake
Parking Brake Lever
Parking brake lever
Released
PKB Switch PKB Adjusting Screw
Applied
Brake systems LH &
RH wheel side
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Parking Brake Lever Adjustment
The Parking Brake Lever a requires a certain force (see table below) to be applied, if the amount of force
is out of spec the parking brake adjusting screw requires being screwed in or out, depending whether
the applying force is too small or too large, the screw requires tightening or untightening.
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Maintenance & Inspection
Automatic Adjuster
• With the clearance A between the lining and drum
being set to specification, pull the cable with attached
spring using a finger as shown. The lever should turn the
adjusting screw wheel by one notch and, when the
cable is released, return to the original position.
• If the lever fails, or turning the adjusting screw wheel is
slow, check that adjuster screw is turned 2.5 mm
outwards and the position of the lever relative to the
toothed wheel. The lever's actuating tip should touch the
toothed wheel at approximately 7 to 9 mm (0.28 to 0.35
in.) below the center line of the screw. If the lever contact
is out of range, the lever will not correctly engage with the
toothed wheel, and the lever will either fail or the wheel
will turn slowly.
6
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Maintenance & Inspection
Brake Adjustment
▪ Use a screwdriver through the hole on the back of the
backing plate to turn the adjusting screw wheel.
1 (one) tooth makes
0.026mm (diameter)
Hole for release only
Items 2 - 3 ton
Drum inside diameter 310mm (12.2 in.)
Drum-to-lining clearance A 0.1 to 0.35 mm (0.004 to 0.014 in.)
NOTE: Only use this sequence when brake shoes or other components have been
replaced, if the drum to lining clearance is incorrect the auto adjuster system
won’t work properly, and neither will the brakes.
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Brake system
Brake Lines bleeding
▪ To release air trapped in the brake fluid system
▪ Perform brake line bleeding if below symptoms occur:
– Brake pedal feels spongy when depressed
– Any portion of the brake fluid line has been disassembled
for repair of servicing
▪ Brake lines bleeding is 2 men operation (or use special
bleeding tools)
▪ Make sure that the level of brake fluid in the reservoir tank
remained sufficient during the procedure
▪ Use only specified brands and grade of fluids
▪ Do not mix different types of fluids into the system
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Maintenance & Inspection
Brake Lines bleeding
1. Install rubber tube on wheel brake cylinder
2. Ensure brake fluid at correct level.
bleeding screw.
Fill up if necessary
Put the other end of the tube in a
container
4.Keep brake pedal depressed during step 4.
Loosen bleeding screw to bleed the brake fluid.
Tighten bleeding screw while the brake fluid is still flowing.
3. Depress and release brake pedal a few
Repeat step 2 until there are no more air bubbles during the bleeding times and then hold at depressed.
After sequence is completed and bleeding screw has been tightened
release the brake pedal and check the pedal feeling and brake Use only DOT3 or DOT4 brake fluid
performance.
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