2007 ISUZU KB P190 brake

5C-28 BRAKES

27. After the bleeding operation is completed on each individual
wheel, check the level of the brake fluid in the reservoir and
replenish up to the “MAX" level as necessary.
28. Attach the reservoir cap.
29. Stop the engine.




05007-1

BRAKE LINE (HOSES AND PIPES)
• Inspect all hoses and pipes for wear, bending, chafing,
cracks, dents, or any other damage.
Make necessary correction or replace parts if these abnormal conditions are found through inspection.
• All hoses, pipes and joints can be damaged easily.
Do not allow the hose to become excessively twisted and bent when working with them, and pay special attention to
all the brake lines not to damage them when repairing o
r
replacing other parts (axle, suspension, etc).
• Inspection for leakage should be performed by depressing
the brake pedal fully.
If leakage is apparent at the circumference of joints, retighten or replace these parts.
This procedure must be performed whenever brake lines are installed.
• After disconnecting the hoses and pipes, cap or tape the
openings to prevent entry of foreign material.



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ISUZU KB P190 2007

BRAKES 5C-29
ADJUSTMENT PROCEDURE OF SERVICE AND PARKING BRAKE


Stick type
All brakes are self-adjusting.
Brakes are adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rear brake
auto-adjuster, produces a clicking sound.
The same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released position.

311R300007





























































2. Parking cable must be loosened sufficiently.
(Loosen the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly and releasing it until the clicking sound can no longer be heard.
If the difference between the brake drum inside diameter o
f
the brake shoes is adjusted to be 0.5 mm, the number of
times for depressing the brake pedal can be reduced.
4. Remove the drum.
Measure the brake drum inside diameter and diameter o
f
the brake shoes.
Shoe Clearance mm (in)
0.25 - 0.40 (0.0098 - 0.0157)
If incorrect, check the brake auto-adjusting system.
5. Turn the adjuster nut so that the parking brake lever travels 10 notches when pulled up with a force 30 kg (66 lbs.).
6. Make sure there is no brake drag.




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ISUZU KB P190 2007

5C-30 BRAKES

Floor mount type
All brakes are self-adjusting.
Brakes are adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rear auto-
adjuster, in the rear brake, produces a clicking sound.
The same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released position.
2. Parking cable must be loosened sufficiently.
(Loosen the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and releasing it until the clicking sound can no longer be heard.
If the difference between the brake drum inside diameter o
f
the brake shoes is adjusted to be 0.5 mm (0.020 in), the
number of times for depressing the brake pedal can be
reduced.
4. Remove the drum.
Measure the brake drum inside diameter and diameter o
f
the brake shoes.


Shoe Clearance mm (in)
0.25 - 0.40 (0.010 - 0.016)
If incorrect, check the brake auto-adjusting system.



RUW 55CSH000301
5. Turn the adjuster nut so that the parking brake lever travels
7 notches when pulled up with a force 294N (30 kg / 66 lb).
6. Make sure there is no brake dragging.





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ISUZU KB P190 2007

BRAKES 5C-31
ADJUSTMENT PROCEDURE OF BRAKE PEDAL



The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.

RTW 35CSH000601


Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal. mm (in)
Pedal free play (L1) 6 - 10 (0.24 - 0.39)
M/T 174 - 186 (6.85 - 7.32) Height (L2)
A/T 176 - 188 (6.93 - 7.40)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times
or more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c)
Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.



Lock Nut Torque
N⋅m (kgf ⋅m/lb ⋅
⋅⋅
⋅
ft)
15 - 25 (1.5 – 2.5 / 11 - 18)

d) Install the stop lamp switch.

Note:
Pedal height (L
2) must be 57 mm (2.24 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.

331R300005

How to connect the CLEVICE of the BOOSTER ROD with the
PEDAL ARM and how to adjust the PEDAL SW .
After connecting the CLEVIS of the BOOSTER ROD to the
PEDAL ARM, adjust the PEDAL SW mounted (PDA) to the
PEDAL BRACKET using the procedure explained below.
1. Set the hole of the CLEVIS of the BOOSTER & M/CYL
ROD with the hole in the PEDAL ARM.
2. Enter the PIN; PUSH ROD to the PEDAL to the holes from the left side of the PEDAL.
3. Enter and fix the PIN; SNAP PIN FIX to the DITCH o
f
the PIN; PUSH ROD to PEDAL from right side of the
PEDAL.
4. Release the LOCK by turning the SW ITCH counter- clock-wise.

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ISUZU KB P190 2007

5C-32 BRAKES

5. Pull the PEDAL ARM a little towards you so that the
PEDAL ARM is not pushed in.
6. Holding the PEDAL ARM still with one hand, push in the whole SW ITCH with the other hand until the PLUNGER
of the SW ITCH is pushed in and the SW ITCH itself hits
the RUBBER of the PEDAL ARM.
In this condition, turn the SW ITCH clock-wise until a “click” sound is heard and lock it.
By doing this the SW ITCH is adjusted at 0.7 ±0.5 mm
(0.028 ± 0.020 in) clearance.



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BRAKES 5C-33
FRONT DISC BRAKE ASSEMBLY
REMOVAL AND INSTALLATION



RTW 55CMF000501

Removal Steps
1. Brake flexible hose
2. Lock bolt
3. Caliper assembly
4. Pad assembly with shim
5. Clip; pad
6. Slide pin
7. Boot
8. Support bracket
9. Front hub and disc assembly

Installation Steps
9. Front hub and disc assembly
8. Support bracket
7. Boot
6. Slide pin
5. Clip; pad
4. Pad assembly with shim
3. Caliper assembly
2. Lock bolt
1. Brake flexible hose



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ISUZU KB P190 2007

5C-34 BRAKES


RUW 55CSH000101

Important Operations - Removal
1. Brake Flexible hose
Remove the bolt and gasket and disconnect the brake flexible
hose from the caliper.
After disconnecting the flexible hose, cap or tape the openings
to prevent entry of foreign material.




RUW 55CSH001501

2. Lock Bolt
Remove the lock bolt from the caliper.



4. Pad Assembly with Shim
Rotate the caliper upward.



RUW 55CSH001601

Mark the lining locations if they are to be reinstalled.




RUW 55CSH000101

8. Support Bracket
Take care not to damage the brake flexible hose when
removing the support bracket.


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ISUZU KB P190 2007

BRAKES 5C-35


9. Front Hub and Disc Assembly
For the removal procedure, refer to Section 4C “FRONT
W HEEL DRIVE”.



Important Operations - Installation
9. Front Hub and Disc Assembly
For the installation procedure, refer to the front hub and disc
reassembly procedure in Section 4C “FRONT W HEEL
DRIVE”.




RUW 55CSH000101







8. Support Bracket
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
206 - 245 (21.0 – 25.0 / 152 - 181)
Set up the clip and pad before installation of the support
bracket.
7. Boot
6. Slide Pin • Be sure to install the boots to the slide pin and the
support bracket securely.
•
Apply rubber grease to the sliding surface of the slide
pin before installation of the slide pin. (Don’t use mineral
type grease.)



















1) Assemble a slide pin boot to a slide pin.
2) Use 0.6g to apply grease to the slide pin entirely as shown bellow.
3) Insert the slide pin to the housing and make sure the boot is also inserted to the housing tightly.


5. Clip; Pad
Install new parts if necessary.




RUW 55CSH000201
2. Lock Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
32 - 40 (3.3 – 4.1 / 24 - 30)


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ISUZU KB P190 2007