LOAD SENSING PROPORTIONING VALVE ON-VEHICLE INSPECTION


  1. SET REAR AXLE LOAD

    A01KGX7
    Rear axle load (including vehicle weight):
    LY220R-TBMDSQ3 7845N(800kgf)
    LY225L-TBMDS(3) 7845N(800kgf)
    LY225R-TBMDS(3) 7845N(800kgf)
    LY230R-TBMGSN3 13729N(1400kgf)
    LY230R-TBMGSQ3 13729N(1400kgf)
    LY235L-TBMFS(3) 8335N(850kgf)
    LY235R-TBMFS(3) 8335N(850kgf)
    LY235R-TLMGS 8335N(850kgf)
    LY235R-TLMKS 8335N(850kgf)
    KDY220R-TBMDYW 11768N(1200kgf)
    KDY220L-TBMDYW(3) 11768N(1200kgf)
    KDY230R-TBMGYW3

    w/o ABS: 14709N(1500kgf)

    w/ ABS: 16671N(1700kgf)
    KDY230L-TBMGYW3

    w/o ABS: 14709N(1500kgf)

    w/ ABS: 16671N(1700kgf)
    KDY230L-PBMEYW3

    w/o ABS: 14709N(1500kgf)

    w/ ABS: 16671N(1700kgf)
    KDY230L-PSMBYW(3) 10787N(1100kgf)
    KDY250R-TBMGYW3

    w/o ABS: 14709N(1500kgf)

    w/ ABS: 16671N(1700kgf)
    KDY250L-TBMGYW3

    w/o ABS: 14709N(1500kgf)

    w/ ABS: 16671N(1700kgf)
    KDY250L-PBMEYW3

    w/o ABS: 14709N(1500kgf)

    w/ ABS: 16671N(1700kgf)
    KDY260L-TBMGYW3

    w/o ABS: 14709N(1500kgf)

    w/ ABS: 16671N(1700kgf)
    KDY260L-PBMEYW3

    w/o ABS: 14709N(1500kgf)

    w/ ABS: 16671N(1700kgf)

    Tech Tips

    If the vehicle unladen weight exceeds the specification, set it by following steps in the step 4.

  2. INSTALL LSPV GAUGE (SST) AND BLEED AIR

    A01KI1VE01
    SST
    09709-29018

  3. RAISE FRONT BRAKE PRESSURE 9,807 kPa (100 kgf/cm2, 1,422 psi) AND CHECK REAR BRAKE PRESSURE

    A01KI1VE01
    Rear brake fluid pressure:
    LY220R-TBMDSQ3

    4,460 kPa (45 kgf/cm2, 640 psi)
    LY225L-TBMDS(3)

    4,460 kPa (45 kgf/cm2, 640 psi)
    LY225R-TBMDS(3)

    4,460 kPa (45 kgf/cm2, 640 psi)
    LY230R-TBMGSN3

    6.850 kPa (70 kgf/cm2, 995 psi)
    LY230R-TBMGSQ3

    6.850 kPa (70 kgf/cm2, 995 psi)
    LY235L-TBMFS(3)

    4,460 kPa (45 kgf/cm2, 640 psi)
    LY235R-TBMFS(3)

    4,460 kPa (45 kgf/cm2, 640 psi)
    LY235R-TLMGS

    4,930 kPa (50 kgf/cm2, 711 psi)
    LY235R-TLMKS

    4,930 kPa (50 kgf/cm2, 711 psi)
    KDY220R-TBMDYW

    4,460 kPa (45 kgf/cm2, 640 psi)
    KDY220L-TBMDYW(3)

    4,460 kPa (45 kgf/cm2, 640 psi)
    KDY230R-TBMGYW3

    6.850 kPa (70 kgf/cm2, 995 psi)
    KDY230L-TBMGYW3

    6.850 kPa (70 kgf/cm2, 995 psi)
    KDY230L-PBMEYW3

    6.850 kPa (70 kgf/cm2, 995 psi)
    KDY230L-PSMBYW(3)

    4,460 kPa (45 kgf/cm2, 640 psi)
    KDY250R-TBMGYW3

    6.850 kPa (70 kgf/cm2, 995 psi)
    KDY250L-TBMGYW3

    6.850 kPa (70 kgf/cm2, 995 psi)
    KDY250L-PBMEYW3

    6.850 kPa (70 kgf/cm2, 995 psi)
    KDY260L-TBMGYW3

    6.850 kPa (70 kgf/cm2, 995 psi)
    KDY260L-PBMEYW3

    6.850 kPa (70 kgf/cm2, 995 psi)
    Service limit
    +/- 588 kPa (6 kgf/cm2, 85 psi)

    Tech Tips

    Gradually press on the brake pedal until it reach the specified pressure. Do not overshoot the specified pressure. Read the value of rear pressure 2 seconds after adjusting to the specified fluid pressure.

  4. IF VEHICLE UNLADEN WEIGHT EXCEEDS SPECIFICATION, SET IT BY FOLLOWING STEPS

    A01KGJN
    Example
    B
    (7.7 kN, 2.7 MPa {789 kgf, 27.1 kgf/cm2})
    C
    (15.9 kN, 6.1 MPa {1620 kgf, 62.3 kgf/cm2})

    1. Measure the rear axle load.

    2. Calculate the fluid pressure crossover point (P) at the measured rear axle load by applying the following formula.

      X = (Cp - Bp) / (Cw - Bw) x (W - Bw) + Bp
      X: Fluid pressure crossover point at "W"
      W: Measured axle load
      Cw: Rear axle load at "C"
      Bw: Rear axle load at "B"
      Cp: Fluid pressure crossover point at "C"
      Bp: Fluid pressure crossover point at "B"

      Tech Tips

      Example: The fluid pressure crossover point when the rear axle load is 9806N (1000kgf).


      • X = (62.3 - 27.1) / (1620 - 789) x (1000 - 789) + 27.1

      • = 0.0424 x 211 + 27.1 = 8.946 + 27.1 = 36.05

      Fluid pressure crossover point: 3.535 Mpa (36.05 kgf/cm2, 513psi)

      Fluid Pressure Crossover Point
      Model

      A

      [kN (kgf), MPa (kgf/cm2)]

      B

      [kN (kgf), MPa (kgf/cm2)]

      C

      [kN (kgf), MPa (kgf/cm2)]
      LY220R-TBMDSQ3 6.1 (678) , 0.5 (5) 7.7 (789) , 3.1 (31.4) 15.9 (1620) , 6.5 (66.5)

      LY225L-TBMDS(3)

      LY225R-TBMDS(3)

      		 6.1 (625) , 0.5 (5) 7.8 (797) , 3.1 (31.7) 15.8 (1610) , 6.5 (66.1)
      LY230R-TBMGSN3 10.5 (1067) , 0.5 (5) 12.0 (1224) , 3.9 (39.4) 19.6 (2000) , 9.4 (95.8)
      LY230R-TBMGSQ3 10.5 (1067) , 0.5 (5) 12.0 (1224) , 3.9 (39.4) 19.4 (1980) , 9.2 (94.3)

      LY235L-TBMFS(3)

      LY235R-TBMFS(3)

      		 5.7 (584) , 0.5 (5) 7.3 (745) , 2.7 (27.5) 19.5 (1990) , 7.7 (78.7)
      LY235R-TLMGS 6.0 (608) , 0.5 (5) 6.6 (675) , 2.3 (23.4) 19.4 (1980) , 10.5 (107.1)
      LY235R-TLMKS 6.0 (608) , 0.5 (5) 6.6 (675) , 2.3 (23.4) 19.9 (2030) , 10.7 (109.3)

      KDY220L-TBMDYW(3)

      KDY220R-TBMDYW

      		 7.2 (730) , 0.5 (5) 7.7 (789) , 1.4 (14.5) 15.3 (1565) , 4.6 (47.3)
      KDY230L-PSMBYW(3) 6.9 (704) , 0.5 (5) 7.7 (789) , 1.8 (18.7) 15.9 (1620) , 5.3 (53.8)
      KDY230L-PBMEYW3

      w/o ABS: 10.8 (1100) , 0.5 (5)

      w/ ABS: 11.4 (1167) , 0.5 (5)

      w/o ABS: 12.0 (1224) , 3.1 (32.1)

      w/ ABS: 12.0 (1224) , 1.7 (17.5)

      w/o ABS: 20.7 (2110) , 9.5 (96.5)

      w/ ABS: 20.7 (2110) , 8.0 (82.0)

      KDY230R-TBMGYW3

      KDY230L-TBMGYW3

      w/o ABS: 10.8 (1100) , 0.5 (5)

      w/ ABS: 11.4 (1167) , 0.5 (5)

      w/o ABS: 12.0 (1224) , 3.1 (32.1)

      w/ ABS: 12.0 (1224) , 1.7 (17.5)

      w/o ABS: 19.2 (1960) , 8.4 (85.6)

      w/ ABS: 19.2 (1960) , 7.0 (71.1)

      KDY250R-TBMGYW3

      KDY250L-TBMGYW3

      w/o ABS: 10.8 (1100) , 0.5 (5)

      w/ ABS: 11.4 (1167) , 0.5 (5)

      w/o ABS: 12.0 (1224) , 3.1 (32.1)

      w/ ABS: 12.0 (1224) , 1.7 (17.5)

      w/o ABS: 18.6 (1900) , 8.0 (81.2)

      w/ ABS: 18.6 (1900) , 6.5 (66.7)
      KDY250L-PBMEYW3

      w/o ABS: 10.8 (1100) , 0.5 (5)

      w/ ABS: 11.4 (1167) , 0.5 (5)

      w/o ABS: 12.0 (1224) , 3.1 (32.1)

      w/ ABS: 12.0 (1224) , 1.7 (17.5)

      w/o ABS: 18.1 (1845) , 7.6 (77.2)

      w/ ABS: 18.1 (1845) , 6.1 (62.7)
      KDY260L-TBMGYW3

      w/o ABS: 10.8 (1100) , 0.5 (5)

      w/ ABS: 11.4 (1167) , 0.5 (5)

      w/o ABS: 12.0 (1224) , 3.1 (32.1)

      w/ ABS: 12.0 (1224) , 1.7 (17.5)

      w/o ABS: 18.6 (1900) , 8.0 (81.2)

      w/ ABS: 18.6 (1900) , 6.5 (66.7)
      KDY260L-PBMEYW3

      w/o ABS: 10.8 (1100) , 0.5 (5)

      w/ ABS: 11.4 (1167) , 0.5 (5)

      w/o ABS: 12.0 (1224) , 3.1 (32.1)

      w/ ABS: 12.0 (1224) , 1.7 (17.5)

      w/o ABS: 18.1 (1845) , 7.6 (77.2)

      w/ ABS: 18.1 (1845) , 6.1 (62.7)

    3. Calculate the rear brake pressure when the front brake pressure is 9.807 MPa (100 kgf/cm2, 1,422 psi) in the following formula.

      X: Fluid Pressure Crossover Point

      LY220R-TBMDSQ3

      LY225L-TBMDS(3)

      LY225R-TBMDS(3)

      LY235L-TBMFS(3)

      LY235R-TBMFS(3)

      LY235R-TLMGS

      LY235R-TLMKS

      KDY220L-TBMDYW(3)

      KDY220R-TBMDYW

      KDY230L-PSMBYW(3)

      		 X + (100 - X) x 0.2

      LY230R-TBMGSN3

      LY230R-TBMGSQ3

      KDY230R-TBMGYW3

      KDY230L-TBMGYW3

      KDY230L-PBMEYW3

      KDY250R-TBMGYW3

      KDY250L-TBMGYW3

      KDY250L-PBMEYW3

      KDY260L-TBMGYW3

      KDY260L-PBMEYW3

      		 X + (100 - X) x 0.37

      Tech Tips

      Example: X= 3.535 MPa (36.05 kgf/cm2, 513 psi)

      36.05 + (100 - 36.05) x 0.2 = 48.75

      Rear brake pressure: 4.78 MPa (48.75 kgf/cm2, 693 psi)

      Service limit
      +/- 490 kPa (5 kgf/cm2, 71 psi)

  5. IF NECESSARY, ADJUST FLUID PRESSURE

    A01KEQZE01

    1. Adjust the length of the No. 2 shackle.

      Lower pressure - Lengthen "A"

      High pressure - Shorten "A"

      Initial set
      78 mm (3.07 in.)
      Adjusting
      72 - 84 mm (2.83 - 3.31 in.)

      Tech Tips

      One turn of the No. 2 shackle nuts changes the fluid pressure about the following specifications.

      Model Changes the fluid pressure

      LY220R-TBMDS3

      LY225L-TBMDS(3)

      LY225R-TBMDS(3)

      LY235L-TBMFS(3)

      LY235R-TBMFS(3)

      KDY220L-TBMDYW(3)

      KDY220R-TBMDYW

      KDY230L-PSMBYW(3)

      181.4 kPa (1.85 kgf/cm2, 26 psi)

      LY235R-TLMGS

      LY235R-TLMKS

      363.7 kPa (3.71 kgf/cm2, 53 psi)

      LY230R-TBMGSN3

      LY230R-TBMGSQ3

      KDY230R-TBMGYW3

      KDY230L-TBMGYW3

      KDY230L-PBMEYW3

      KDY250R-TBMGYW3

      KDY250L-TBMGYW3

      KDY250L-PBMEYW3

      KDY260L-TBMGYW3

      KDY260L-PBMEYW3

      481.3 kPa (4.91 kgf/cm2, 70 psi)
    2. A01KEZW

      If the pressure cannot be adjusted by the No.1 shackle, raise or lower the valve body.

      Lower pressure - Lower

      High pressure - Raise

    3. Torque the nuts.

      Torque:
      12.5 N*m  { 130 kgf*cm, 9 ft.*lbf }

    4. Adjust the length of the No.2 shackle again.

      Tech Tips

      If it cannot be adjusted, inspect the valve body.

  6. IF NECESSARY, CHECK VALVE BODY

    A01KI6H

    1. Assemble the valve body in the uppermost position.

      Tech Tips

      When the brakes are applied, the piston will move down about 1 mm (0.039 in.). Even at this time, the piston should not make contact with or move the load sensing spring.

    2. In this position, check the brake pressure.

      Tech Tips

      If the measured value is not within the standard, replace the valve body.

  7. REMOVE LSPV GAUGE (SST) AND BLEED BRAKE SYSTEM