models fa and fb with allison at542 parking … service manual...models fa and fb with allison at542...

Models FA and FB with Allison AT542 PARKING BRAKE 14-1

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14

14-143E-05

CHAPTER 14PARKING BRAKEModels FA and FB with Allison AT542

TROUBLESHOOTING...............................................................14 - 2

SPECIAL TOOLS ......................................................................14 - 3

INSPECTION AND ADJUSTMENT ...........................................14 - 4

PARKING BRAKE .....................................................................14 - 7

PARKING BRAKE CONTROL ..................................................14 - 15

FINAL INSPECTION AND ADJUSTMENT................................14 - 18

1 INDEX

1Models FA and FB with LF05S

Models FA and FB with Allison AT54214-2 PARKING BRAKE

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Too much play noted on Excessively large drum-to-lining ..............Re-adjust the brake properlyparking brake lever clearance

Maladjusted control linkage......................Re-adjust

Not enough braking force Excessively large drum-to-lining ..............Re-adjustclearance

Maladjusted control linkage......................Re-adjust

Burnt lining ...............................................Repair or replace

Worn lining ...............................................Replace

Shoes are too dirty with water, dust, etc ..Disassemble and clean

Linings are soaked with oil .......................Replace

Linings get burnt easily Not enough drum-to-lining clearance .......Re-adjust

Shoe or drum is distorted .........................Repair or replace

Springs are broken ...................................Replace

Can not keep the lever in full Over stroke of lever ..................................Adjust cable lengthstroke position Wear or broken ratchet ............................Replace parts

Lever does not return to running Water inside the cable ..............................Replace the cableposition during cold weather(below zero)

TROUBLESHOOTING

Symptom Possible cause Remedy


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SPECIAL TOOLS

Prior to starting a parking brake overhaul it is necessary to have these special tools.

Illustration Tool No. Tool name

09606-1060 REMOVER

09653-1370 HOOK

09665-1170 ADJUSTING TOOL


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SM14-061Fig. 1

SMAT-040Fig. 2

SM17-289Fig. 3

SM14-060Fig. 4

INSPECTION AND ADJUSTMENT

WARNINGFailure to properly adjust the brake can result inpersonal injury and/or property damage.

1. LEVER STROKE1. Pull the parking lever with approx. 30 kg (66 lb) force

and count the number of clicks. If the lever strokeexceeds 8 clicks, adjust brake shoe clearance andcontrol cable.

2. ADJUSTING SHOE CLEARANCE1. Adjusting of Shoe clearance. Block the front wheels.

NOTE: Be sure to apply wheel stoppers in the fronttires.

2. Jack up the rear axle off the ground and release theparking lever, rotate the drum by hand, and stop ro-tating the drum when the adjusting hole comes tothe bottom side.

WARNING● When jacking up the rear axle, place a jack cor-

rectly to the axle, and then lift up the axle.● Do not get under the vehicle when it is supported

by a jack only. It is very dangerous as the jackmight slip.

● Use safety stands which have sufficient strengthand stability to support the vehicle.

3. Remove the rubber cap from the adjusting hole. Turnthe adjuster in the arrow direction with a special toolinserted through the hole. Keep on turning the ad-juster until the shoe linings bear against the drum toreduce the clearance to nought.

Special Tool: Adjusting Tool (09665-1170)NOTE: When adjusting shoe clearance, check the

thickness of lining according to the “THICK-NESS OF LINING” on page 14-6.

30 kg


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SM14-060Fig. 5

SM14-145Fig. 6

Fig. 7

ADJUSTER ROD

LOCK NUT

4. Turn the adjuster backward by 10 - 12 notches, thiswill introduce the prescribed drum-to-lining clearance,the value of which is:

Standard: 0.30 – 0.35 mm(0.0119 – 0.0137 in.)

Repair Limit: 0.50 mm (0.0197 in.)

5. Check the adjustments so far made by operating theparking brake lever several times. Turn the drum byhand to see that the shoes are not dragging. If thereis any dragging, repeat the operation from item 3.4.

NOTE: ● Whenever the drum-to-lining clearancehas to be readjusted be sure to follow thesteps outlined above.

● Upon completing the foregoing adjust-ments, be sure to close the adjusting holeby fitting the rubber cap.

3. ADJUSTING THE CONTROL PARTS1. Adjust the L1 part of the parking brake cable to 33

mm (1.30 in.).2. Perform the adjustment after item 1.1.3. Release the parking brake lever fully.4. Disconnect the control cable from the parking brake

lever and adjust the control cable length by turningthe adjuster rod.Connect the cable to the parking brake lever and lockthe adjuster rod with the lock nut.

NOTE: When putting in a new replacement cable, besure to pre-stress it so that it will not developappreciable sag later. This can be accom-plished by operating the parking brake leverwith approx. 50kg (110.23 lb) force severaltimes, with the new cable in place, beforeadjusting its tension as above.

L1


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SM14-061Fig. 8

SM14-046Fig. 9

SM14-146Fig. 10

LIMIT4 mm RUBBER

CAP

ADJUSTING HOLE

5. Check the parking brake lever stroke.Make sure that, when the lever is pulled all the way,with approx. 30 kg (66 lb) force, the dimension “A”will not take a value greater than what is indicated inthe following table. If the dimension “A” is found tobe greater, it means that the cable length is too longand needs readjustment.A = Parking lever stroke: 3 – 6 clicks

6. After adjusting, operate parking brake lever severaltimes to confirm there is no dragging.

7. Adjust the parking buzzer switch.Adjust the “A” part of the parking switch to 5mm(0.197 in.), when the parking brake lever is fullyreleased, and confirm the indicator lamp lights, whenthe lever is applied by one notch.

WARNINGFailure to properly adjust the brake can result inpersonal injury and/or property damage.

3. THICKNESS OF LINING1. Every 36,000 miles, every 12 months or at the time

of adjusting, check the thickness of lining. When thelining is worn, or when it is considered that it will beunserviceable for further use, replace the lining.

2. Bring adjusting hole of the drum to the groove at thecenter part of the lining which shows the life of liningas shown in the Fig. and measure the depth of grooveto check the wear.No groove shows limit of life.

Assembly Standard : 7.0 mm (0.276 in.)Service Limit : 4.0 mm (0.157 in.)

3. Connect the rubber cap which has been removed atchecking securely.

4. Use of lining which exceeds service limit may causethe damage of drum because of damage or maylower the braking force.

A

A

BUZZER SWITCH


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SM14-116Fig. 2

Fig. 3

PARKING BRAKE

1. Lever return spring2. Anchor plate3. Spacer4. Camshaft5. Shoe return spring6. Rubber cap

7. Parking brake drum8. Flange9. Adjuster spring

10. Adjuster11. Rivet12. Lining

13. Brake shoe14. Cable bracket15. Spacer16. Parking brake cam lever17. Lever sub assembly

1. REMOVAL1. Dismount the propeller shaft.

Disconnect the propeller shaft at flange of the park-ing brake.

NOTE: Draw match marks on the flange and yokebefore disconnecting.

2. Disconnect the parking brake cable from the brakelever.

SM14-232AFig. 1

1

23 4

5 6

78

9

10

111213

14

15

16

17


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SM14-060Fig. 4

SM14-117Fig. 5

SM14-118Fig. 6

SM14-119Fig. 7

SM14-120Fig. 8

3. Remove the drum.Remove the rubber cap from the adjusting hole. Bringthe adjusting hole to the bottom side by turning drum.Turn the adjuster using a special tool, to contract thebrake shoes.

Special Tool: Adjusting Tool (09665–1170)

4. Loosen the fitting nuts.

5. Remove the parking brake drum.Before removing the brake drum, mark the drum andflange coupling so that the parts can be installed inthe same relative position.

6. Remove the cotter pin, then loosen the lock nut.

7. Remove the flange coupling with spacer.


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SM14-121Fig. 9

Fig. 10

Fig. 11

Fig. 12

SM14-122Fig. 13

8. Loosen the four fitting bolts for parking brake anchorplate and then take out the brake assembly withanchor plate.

2. DISASSEMBLY1. Remove the brake lever return spring.

2. Draw match marks on camshaft lever and camshaftacross their serration fit.

3. Remove the lock bolt and lock nut of the lever andpull off the camshaft lever.

4. Remove the adjuster and adjuster spring.a. Expand the shoes by levering with screwdrivers, as

shown, and remove the adjuster.b. Spread the shoes apart and remove the adjuster

spring.


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SM14-086Fig. 14

SM14-064Fig. 15

Fig. 16

Fig. 17

Fig. 18

5. Remove two return springs by using a special tool.

Special Tool: Remover (09606–1060)

3. INSPECTION1. Linings

Check each lining for wear, and inspect it for cracks,tightness of rivets or signs of surface glazing. Re-pair linings as necessary. Linings deteriorated be-yond repair must be replaced. (For the replacementof lining, refer to SECTION OF CHAPTER 13 SERV-ICE BRAKE).

Standard: 7.0 mm (0.276 in.)Service limit: 4.0 mm (0.157 in.)2. Check each shoe for wear particularly at its camshaft

part and adjuster part, and also for alignment. Visu-ally inspect it for cracks.

3. Anchor plate and Drum coverInspect the plate for distortion and cracks. Visuallyexamine the seal part of the cover for distortion ordamage. The surface of the seal part must be per-fectly smooth, or water or dust may find its way intothe brake resulting in a slipping brake or in prema-ture failure of brake parts.

4. CamshaftInspect the camshaft for cracks or wear.

ADJUSTER PART

CAMSHAFT PART


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SM14-136Fig. 19

SM14-137Fig. 20

SM14-067Fig. 21

SM14-068Fig. 22

5. AdjusterSee if the threaded portion of the adjuster is rustedor otherwise damaged.

6. SpringsCheck each spring for elastic strength and inspect itfor mechanical damage. The assembly standard ofeach spring is as follows.

Adjusting springsetting length: 74.0 mm (2.913 in.)setting load: 10.8 – 13.2 kg (23.82 – 29.1 lb)

Shoe return springsetting length: 75.2 mm (2.961 in.)setting load: 16.6 – 20.4 kg (36.61 – 44.97 lb)

Lever return springsetting length: 139 mm (5.472 in.)setting load: 15.4 – 18.8 kg (33.96 – 41.44 lb)

7. Parking brake drumInspect and check for cracks, wear, out-of-round andburns on the parking brake drum. Observe the fol-lowing reference values. A drum in too bad a condi-tion to repair must be replaced.

a. Check the parking brake drum inside diameter.

Standard: 254 mm (10.00 in.)Service Limit: 256 mm (10.07 in.)

b. Check the parking brake drum for runout.

Standard: 0–0.1 mm (0–0.004 in.)Repair Limit: 0.2 mm (0.008 in.)


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Fig. 23

SM14-087Fig. 24

SM14-088Fig. 25

Fig. 26

Fig. 27

4. ASSEMBLY1. Apply the heat-resistance grease to the camshaft,

and then install the camshaft.

Heat-resistance grease:Refer to RECOMMENDED LUBRICANTS LIST.

2. Apply the heat-resistance grease to the rubbing ormating face of brake shoes, and install the brakeshoes.


3. Raise the middle portions of shoes and install thespacer and return springs with the special tool.

Special Tool: Hook (09653–1370)

4. Install the adjuster and adjuster spring.Apply the heat-resistance grease to the adjuster, andposition the adjuster in place.


5. Install the camshaft lever with spacer to the camshaft,aligning the match marks. Secure them fit by tight-ening the securing bolts.

Tightening Torque: 180–230 kg·cm (14–16 Ib·ft)

6. Install the cam lever and return spring.


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SM14-121Fig. 28

SM14-120Fig. 29

SM14-119Fig. 30

SM14-037Fig. 31

SM14-140Fig. 32

S

O-RINGA

5. INSTALLATION1. Install the anchor plate assembly on the transmis-

sion rear cover. Tighten the bolts.

Tightening Torque: 1,122–1,346 kg·cm (82–97 lb·ft)NOTE: Make sure the grease and oil do not contact

dust cover or transmission installation sur-face. If soiled with grease or oil be sure toclean the parts.

2. Install the flange coupling.

3. Install the spacer and O-ring to the main shaft, andsecure the spacer by tightening the nut. Use thesocket wrench and handle. Refer to CHAPTER 7,TRANSMISSION.

Tightening Torque: 1,150–1,380 kg·cm (84–99 lb·ft)

NOTE: Install the spacer “S”.Apply adhesive (THREE BOND No. 1215 or equiva-lent) to “A”.

4. Install the cotter pin.


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SM14-118Fig. 33

SM14-117Fig. 34

SM14-116AFig. 35

Fig. 36

5. Install the brake drum, aligning the marks.Match the alignment marks on the flange couplingand brake drum.

6. Secure the drum with nuts.

Tightening Torque: 650–870 kg·cm (47–62 lb·ft)

7. Install the propeller shaft, Tightening the propellershaft yoke with flange.


8. Connect the control cable with the camblock lever.



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SM14-234Fig. 2

SM14-233Fig. 1

PARKING BRAKE CONTROL

1. Release rod knob2. Compression spring3. Parking brake lever4. Pin5. Parking brake switch

6. Spring retainer7. Parking brake cable8. Spacer9. Pawl

10. Pawl release rod

1. Parking brake lever2. Control cable

12

3

4

5

6

789

10

6

8

1

2

4


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SM14-168Fig. 3

Fig. 4

Fig. 5

SM14-145Fig. 6

Fig. 7

1. REMOVAL1. Remove the parking brake lever.a. Disconnect the parking brake cable and parking

switch harness.b. Remove four bolts which tighten parking brake le-

ver, and remove the lever ass’y.

2. DISASSEMBLY AND INSPECTION1. Disassemble the parking brake lever.

2. Inspect the parking brake lever.a. Ratchet and Pawl

Inspect the ratchet teeth and pawl tip for wear ordamage.

b. Pins and BushingsCheck cable pin, pawl pin and their bushing for wear.Check pivot pin, brake lever and bracket for play.

c. WashersCheck washers for wear.

b

a

c

b

b

a

SM14-233A

SM14-171A

SM14-171B

A

3. Inspect the control cable for sliding condition, rust-ing and any other damage.The cable must be free from any evidence of cut ortendency to kink. Replace defective cables, if any.

3. ASSEMBLY1. Parking brake lever assembly.a. Apply sufficient wheel bearing grease to the ratchet

teeth and both sides of part A.

Wheel bearing grease:Refer to RECOMMENDED LUBRICANTS LIST.


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Fig. 8

SM14-170Fig. 10

SM14-169Fig. 9

SM14-233A

b. Assemble the parking brake lever.Apply sufficient wheel bearing grease to release rodand pin of pawl, then assemble the components.Adjust the parking buzzer switch. (See Page 14-6).

Wheel bearing grease:Refer to RECOMMENDED LUBRICANTS LIST.

4. INSTALLATION1. Install the parking brake lever.


2. Connect the parking brake lever with the control ca-ble, and coat pin with chassis grease.

Chassis grease:Refer to RECOMMENDED LUBRICANTS LIST.

NOTE: Installation of the cable (When replacing withnew one)● Band radius of cable should be more than

200 mm (7.87 in.).● The cable should not be touched with

flange edge of the frame.● Clip the cable with part of marked portion.


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FINAL INSPECTION AND ADJUSTMENT

1. ADJUSTMENT1. Adjustment of shoe clearance and cable.

After assembling, adjust them according toitem INSPECTION AND ADJUSTMENT.

2. Burnishing of lining.When replacing lining or drum of parkingbrake to new parts be sure to perform lap-ping by the following procedure. Brakingforce may be extremely lowered withoutlapping, so be sure to perform the lapping.

NOTE: Apply parking brake only burnish-ing after replacing the lining and inan emergency when the vehicle ismoving.

a. Confirm that shoe clearance and cablehave been correctly adjusted.

b. While running the vehicle at a speed of10 km/h (6.21 mph) in a safe place, de-press the clutch pedal and apply the park-ing brake with about 25 kg (55 lb) pull. Re-peat this 10 times.

c. After operation, adjust shoe clearance andcable clearance according to item IN-SPECTION AND ADJUSTMENT.

3. Confirmation of parking brake application.After completing all brake adjustment,stop the vehicle on a safe slope or usinga brake tester, confirm whether the park-ing brake is securely applied.

models fa and fb with allison at542 parking … service manual...models fa and fb with allison at542...

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