INTRODUCTION

GENERAL
This section has a description and the repair procedures
for the parts of the brake system. These parts include the
brake booster, master cylinder and brake shoe assem-
blies.
DESCRIPTION (See FIGURE 1.)
The brake system on this series of lift trucks uses a hy-
draulic actuator (brake booster) (1) to actuate the master
cylinder (7). The operation of the brake booster (1) de-
creases the foot effort necessary to apply the brakes. The
oil flow from the outlet of the steering control unit is
used to operate the brake booster.
The brake system consists of service brakes and the
parking brake. The service brakes have the brake pedal,
booster and master cylinder and a brake assembly at
each drive wheel. The parking brake has the hand lever
assembly, cables to each service brake assembly and a
lever in the service brake assembly to mechanically
move the brake shoes.
OPERATION
The operator pushes the brake pedal to apply the brake.
This action pushes the push rod of the booster to move
the plunger. When the plunger moves, it moves the pis-
ton. When the piston moves, it allows the pressure from
the steering pump to enter the booster and help move the
piston. As the piston moves, it moves the piston rod to
move the piston of the master cylinder. Brake fluid is
forced through the brake lines to the wheel cylinders.
The fluid forces the pistons of the wheel cylinders to
move the brake shoes against the brake drums to stop the
lift truck.
When the operator releases the latch and pulls the park-
ing brake lever, the cables move the lever to move the
brake shoes against the brake drum to keep the lift truck
from moving.
BRAKE BOOSTER AND MASTER
CYLINDER (See FIGURE 2. and
FIGURE 3.)

11687

1. BRAKE BOOSTER 9. INLET FROM RESERVE RESERVOIR

2. PISTON ROD 10. RELIEF VALVE (MASTER CYLINDER
3. PISTON ASSEMBLY 11. TUBE, RELIEF VALVE
4. INLET FOR HYDRAULIC OIL 12. OUTLET TO BRAKE SYSTEM
5. OUTLET FOR HYDRAULIC OIL 13. PISTON, LOW PRESSURE
6. RELIEF VALVE (BRAKE BOOSTER) 14. CYLINDER, LOW PRESSURE
7. MASTER CYLINDER, TWO STAGE 15. PISTON, HIGH PRESSURE
8. RESERVOIR 16. CYLINDER, HIGH PRESSURE
FIGURE 1. BRAKE BOOSTER AND MASTER CYLINDER

1
 11689

BRAKES NOT APPLIED

Hydraulic oil flows from the steering control unit to the inlet (3) of the brake booster. The
hydraulic oil flows freely between the piston rod (1) and the piston assembly (2) and returns to
the hydraulic tank at (4).

11689

BRAKES APPLIED
The movement of the piston rod (1) causes a restriction of oil flow between the rod and the
piston assembly (2). As the oil pressure increases the piston assembly moves on the shaft
until the flow and pressure are in balance. The movement of the piston assembly actuates
the master cylinder. The relief valve (5) gives a 1205 to 1275 kPa (175 to 185 psi) limit to the
hydraulic pressure in the brake valve.

FIGURE 2. OPERATION OF THE BRAKE BOOSTER

2
 1

11690

A B 5 C
STAGE 1
When the brakes are not applied, the relief valve (1) is closed and the port (2) between the reservoir (3) and
the low pressure cylinder is open. when the brakes are applied, the movement of the low pressure piston (4)
causes the following:
a. The Cup A on the low pressure piston closes the port (2). The high pressure piston (5) closes the
opening at the seal C
b. Brake fluid moves from the low pressure cylinder through the high pressure piston (5) and the cylinder
to the brake system. The cup B on the high pressure piston permits a oneway flow of brake fluid.
c. The low pressure and larger volume of the brake fluid causes the brake shoes to expand against the
brake drum. 1
3
6

4 2

11690

7
A B 5 C
STAGE 2
When pressure increases it causes the following to happen:
a. The pressure in the brake system is sensed through the relief valve tube (6). The relief valve permits
the fluid in the low pressure cylinder to return to the reservoir at 620 kPa (90 psi).
b. The pressure difference between the high and low pressure cylinders causes cup B to close the ports
in the high pressures piston.
c. The high pressure piston applies a pressure to the brake system in a ratio of the force applied by the
brake pedal and actuator.
STAGE 3
When the force of the brake pedal is released, the brake springs retract the brake shoes and wheel
cylinders. The master cylinder returns to the beginning condition. A check valve (7) keeps a pressure of
approximately 110 kPa (16 psi) in the brake system when the brake are released. This small pressure
keeps the brake system filled with fluid and keeps dirt from entering the system.

FIGURE 3. OPERATION OF THE MASTER CYLINDER

3
 moves away from the adjuster plate. When there is
9 clearance between the shoe and drum, the adjuster plate
can move and engage the next tooth of the adjuster
wheel. The springs on the adjuster plate cause the ad-
juster plate to rotate when the brake pressure is released.

1. HAND LEVER
2. ADJUSTMENT KNOB
3. CABLES TO SERVICE BRAKES
4. SWITCH (UNITS WITH
MONOTROL PEDAL ONLY)
5. LINK, SWITCH
6. SWITCH LEVER
7. SLOT
8. TERMINALS FOR THE
NORMALLY CLOSED (NC)
CIRCUIT

11685

1. BACK PLATE 7. AUTOMATIC

2. SHOE GUIDE ADJUSTER
3. WHEEL CYLINDER MECHANISM
4. RETURN SPRING 8 BRAKE LEVER
5. GUIDE SPRING 9. BRAKE LINK
6. BRAKE SHOE

FIGURE 4. SERVICE BRAKE ASSEMBLY

SERVICE BRAKE ASSEMBLY
(See FIGURE 4.)
A service brake assembly is used at each end of the drive
axle housing. Each service brake assembly has a wheel
cylinder (3) at the top of each back plate (1). A shoe
guide (2) and guide springs (5) keep the shoes (6)
against the back plate. Return springs (4) hold the brake
11684
shoes tight against the wheel cylinder and the adjuster
mechanism (7).
FIGURE 5. PARKING BRAKE ASSEMBLY
When the piston of the wheel cylinder is moved by fluid
pressure from the master cylinder, the piston moves the PARKING BRAKE (See FIGURE 5.)
brake shoes to contact the drum. The primary shoe starts
The parking brake uses the service brake shoes. Addi-
to turn with the brake drum. This action pushes the sec-
tional linkage pushes the shoes apart when the hand
ondary shoe tight against the brake drum. This servo ac-
lever (1) pulls the cables (3). On units with a powershift
tion increases the force applied to the brake drums.
transmission and a Monotrol pedal, the hand lever also
The automatic adjuster mechanism turns the adjuster operates a switch (4) that allows the key switch to ener-
wheels to adjust the clearance between the brake shoes gize the starting circuit for the engine. When the parking
and the drum. The adjuster mechanism operates when brake is applied, the switch deenergizes the circuit for
the the lift truck is traveling in forward or reverse. When the Monotrol pedal and the Forward and Reverse sole-
the brakes are applied, the brake shoes move toward the noids. This action puts the transmission in Neutral. The
brake drum. When the bottom of a brake shoe moves starting circuit for the engine is energized when the
away from the adjuster mechanism, the adjuster wheel parking brake is applied.

4
 REPAIRS
BRAKE SHOE ASSEMBLIES
Removal And Disassembly
(See FIGURE 4. and FIGURE 6.)
WARNING
Brake linings can contain dangerous fibers. Breath-
ing the dust from these brake linings is a cancer or
lung disease hazard. Do not create dust! Do not clean
brake parts with compressed air or by brushing. Use
vacuum equipment approved for brake dust or fol-
low the cleaning procedure in this section. When the
brake drums are removed, do not create dust.
Do not sand, grind, chisel, hammer, or change linings
in any way that will create dust. Any changes to
brake linings must be done in a restricted area with
special ventilation. Protective clothing and a respira-
tor must be used.
1. Tilt the mast back and put blocks under the outer mast
weldments. Tilt the mast forward to raise the tires from
the floor.
2. See FIGURE 6. The wheels (12), hub (2) and brake
drum (3) can be removed as an assembly.
3. See FIGURE 6. Remove the capscrews that hold the
axle shaft (1) to the hub. Remove the axle shaft.
4. See FIGURE 6. Remove the seal (4) from the hub.
Remove the nuts (6 and 8) for the bearings (9 and 10)
from the axle housing (5). Slide the wheel, hub and
brake drum from the axle housing.
WARNING
When the brake shoes are removed do not create
dust in the air. See the cleaning procedures in this
section.
5. See FIGURE 4. Use spring pliers to remove the shoe
return springs (4). Remove the clips at the back plate (1)
for the guide springs (5). Remove the guide springs.
6. See FIGURE 4. Disconnect the parking brake cable
from the parking brake lever. Remove the brake shoes
(6).
7. See FIGURE 4. If necessary, the adjuster mechanism
(7) and wheel cylinder (3) can be removed from the back
plate. The back plate can be removed from the axle
housing.
Cleaning And Inspection
WARNING
DO NOT use mineral oil solvent to clean the master
cylinder, wheel cylinder, or the brake linings. Use a
solvent approved for cleaning brake parts. Do not
permit oil or grease in the brake fluid or on the lin-
ings.
Use alcohol to clean the master cylinder, wheel cylin-
ders and the brake linings. Use solvent to clean all of
the other parts of the brake system.
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the safety instructions of the sol-
vent manufacturer.
CLEANING PROCEDURES
1. Do not release brake lining dust from the brake linings
into the air when the brake drum is removed.
2. Use a solvent approved for cleaning brake part to wet
the brake lining dust. Follow the instructions and cau-
tions of the manufacturer for the use of the solvent. If a
solvent spray is used, do not create dust with the spray.
3. When the dust is wet, clean the parts. Put any cloth or
towels in a plastic bag or an airtight container while they
are still wet. Put a DANGEROUS FIBERS warning
label on the plastic bag or airtight container.
4. Any cleaning cloths that will be washed must be
cleaned so that the fibers are not released into the
air.
5
 SEQUENCE FOR BACK
PLATE NUTS

11688

1. AXLE SHAFT
2. HUB
3. BRAKE DRUM
4. SEAL
5. AXLE HOUSING
6. LOCKNUT
7. LOCK PLATE
8. ADJUSTMENT NUT
9. BEARING, OUTER
10. BEARING, INNER
11. BACK PLATE
12. WHEEL
13. CAPSCREW
14. WHEEL NUT
FIGURE 6. DRIVE AXLE AND BRAKE ASSEMBLY

INSPECTION
1. Check the bore of the wheel cylinder for corrosion,
pitting or scratches. Replace the wheel cylinder if there
is any damage.
2. Check the return springs for wear or damage. Inspect
the back plate for wear where the brake shoes touch the
back plate.
3. Inspect the brake shoes for cracks or damage. If the
linings or shoes are worn or damaged, replace the brake
shoes.
WARNING
The brake shoes on both wheels must be replaced if
any shoe is damaged so that both wheels have equal
brake performance.
4. Inspect the brake drum for deep grooves or other dam-
age on the surface for the brake shoes. Use sandpaper to
smooth the grooves on the brake drum surface.
NOTE: If the brake drums require turning on a lathe, do
not remove more than 1.5 mm (0.060 in) from the diam-
eter. The maximum inside diameter of the brake drum,
including wear, is 316.82 mm (12.473 in). If the diame-
ter is larger than this, replace the brake drum.
Assembly And Installation
1. See FIGURE 4. Install the wheel cylinder (3) and
shoe guide (2) on the back plate (1). Install the adjuster
mechanism (7) on the back plate. Torque the adjuster
mounting capscrew to 175 N.m (130 lbf ft). Use the fol-
lowing procedure to adjust the adjuster mechanism:

6
 a. See FIGURE 7. Check the clearance between the
adjuster plate (2) and the adjuster wheels (1). Use
shims (3) between the adjuster wheels and the
housing until the clearance is 1.04 to 1.34 mm
(0.041 to 0.053 in). This adjustment is important
for the correct operation of the automatic brake
adjuster.
NOTE: If the lift truck does not have frequent hard
braking applications and the position of the brake pedal
is low, the brakes are not adjusting enough. Change the
shims at the adjuster wheel so that there is a clearance of
1.50 mm (0.059 in) at the arrows (See FIGURE 7.)
NOTE: If the lift truck has frequent hard braking ap-
plications and the brakes are too tight, the brakes are not
adjusting correctly. Change the shims at the adjuster
wheel so that there is a clearance of 1.80 mm (0.079 in)
at the arrows (See FIGURE 7.)
NOTE: Use the inspection hole in the back plate and
check the clearance between the brake drum and brake
shoe. The correct clearance is 0.94 mm (0.013 in) maxi-
mum
2. Install the back plate on the axle housing. Install the
tapered sleeves and the nuts. Tighten the nuts in the
cross pattern to 55 to 80 N.m (41 to 59 lbf ft), then tight-
en the nuts in the same cross pattern to 110 to 125 N.m
(81 to 92 lbf ft).
11702
1. ADJUSTER WHEEL
2. ADJUSTER PLATE
3. SHIMS
FIGURE 7. AUTOMATIC ADJUSTER
MECHANISM
3. See FIGURE 4. Install the lever for the parking brake
(8) on the brake shoe (6). Install the brake shoe. Install
the parking brake link (9). Connect the parking brake
cable to the lever.
4. See FIGURE 4. Install the guide springs (5) and
install the clips on the back of the brake plate. Install the
shoe return springs (4).
5. See FIGURE 6. If removed, install the hub, brake
drum (3) and wheels (12) on the hub (2). Tighten the
nuts (14) for the brake drum and wheels to 610 to 680
N.m (450 to 500 lbf ft).
6. See FIGURE 6. Lubricate the inner wheel bearing
(10) with grease, then install the inner seal (4) in the hub.
7. See FIGURE 6. Slide the wheel and hub assembly on
the axle housing (5). Lubricate the outer wheel bearing
(9) with grease and install the bearing on the axle hous-
ing.
CAUTION
Do not damage the seal when installing the wheel and
hub assembly.
8. See FIGURE 6. Install the bearing adjusting nut (8).
Tighten the nut to 200 N.m (150 lbf ft) while turning the
hub. Loosen the nut to less than 27 N.m (20 lbf ft). Tight-
en the nut to 35 N.m (26 lbf ft). Lock the adjusting nut at
this position or tighten the nut to the first position where
the lock plate (7) fits. Install the locknut (6) and tighten it
to 135 N.m (100 lbf ft).
9. See FIGURE 6. Use a sealant on the flange of the oil
seal and install the outer seal in the hub. Use a sealant on
the flange of the axle shaft and install the axle shaft (1).
Tighten the capscrews (13) to 165 N.m (122 lbf ft).
Check the differential oil level and fill as described in
the section, PERIODIC MAINTENANCE, 8000
SRM 341.
10. Fill the brake reservoir and remove the air from the
brake system and adjust the brakes as specified in
CHECKS AND ADJUSTMENTS in this section.
7
 10076

1. LINE ADAPTER 9. RETAINER 17. SPRING RETAINER

2. GASKET 10. ORING 18. SPRING
3. FITTING 11. SEAL 19. SEAL
4. PLUG 12. RETAINER 20. PISTON, LOW PRESSURE
5. VALVE SEAT 13. SPRING 21. BODY
6. CHECK VALVE 14. RETAINER RING 22. FILL PLUG
7. CHECK VALVE SPRING 15. PISTON, HIGH PRESSURE 23. RELIEF VALVE
8. SEAL 16. CUP SEAL 24. TUBE

FIGURE 8. MASTER CYLINDER

MASTER CYLINDER (See FIGURE 8.)
NOTE: It is a recommendation that when the master
cylinder is repaired or replaced, replace the piston ring
(7) in the brake booster as shown in FIGURE 10.
Removal
1. Disconnect the brake line at the master cylinder. Cov-
er the end of the brake line. Disconnect the wires at the
brake switch. Disconnect the hose from the reservoir.
Put a plug in the end of the hose.
2. Remove the capscrews that hold the master cylinder
to the brake booster.
Disassembly (See FIGURE 8.)
CAUTION
Use a cleaning fluid made for brake parts when
cleaning the master cylinder.
1. Loosen the relief valve tube (24). Remove the adapter
(1) and gaskets (2). Remove the relief tube.
WARNING
The plug (4) has a compressed spring (13) behind it.
Remove the plug carefully. Make sure to hold the
spring in position so that it cannot cause damage or
injury to someone.
2. Remove the plug (4). Remove the check valve assem-
bly, retainer (9) and spring (13).
3. The retainer (9) will come out of the bore when the
plug is removed. Remove the seal (8) and Oring (10).

8
Remove the retainer (11) and the seal (12) from the re-
tainer (9).
NOTE: The tip of the relief valve extends into the cylin-
der bore when installed.
4. Remove and disassemble the relief valve assembly as
follows: (See FIGURE 9.)
WARNING
(See FIGURE 9.) The plug (1) has a compressed
spring (3) behind it. Remove the plug carefully.
Make sure to hold the spring in position so that it
cannot cause damage or injury to someone.
a. Remove the plug (1) and the Oring (2). Remove
the relief valve spring (3).
b. Lift the relief valve assembly from the chamber
in the reservoir.
c. Remove the piston assembly (5) from the valve
body (7). Pull and rotate the piston from the valve
body. Do not lose the metering pin (6).
d. Remove the cotter pin, seal washer and spring
from the valve body.
5. Remove the piston assembly from the valve body.
WARNING
The high pressure piston (15) has a compressed
spring (18) behind it. (See FIGURE 8.) Remove the
piston carefully. Make sure to hold the spring in posi-
tion so that it cannot cause damage or injury to some-
one.
6. See FIGURE 8. Push the high pressure piston (15)
into its bore and remove the retaining ring (14). Remove
the high pressure piston (15) and the spring (18) from
the bore. Remove the cup seal (16) from the piston.
Assembly (See FIGURE 8.)
NOTE: Lubricate the parts of the master cylinder with
clean brake fluid.
1. Install the retainer (17) on the small end of the spring
(18). Install the spring (18) in the low pressure piston
(20).
2. Install the cup seal (16) on the high pressure piston
(15).
3. Put the high pressure piston and the cup seal in posi-
tion against the retainer (17). Carefully push the high
pressure piston into the bore of the low pressure piston
(20). Install the retaining ring (14).
4. Install the seal (11) and retainer (12) in the retainer
(9).
5. Install the seals (8, 19) on the low pressure piston (20).
Install the piston assembly into the bore of the master
cylinder.
6. Install the spring (13) in the bore of the master cylin-
der. Install the check valve seat (5), check valve (6), and
valve spring (7) in the plug (4).
7. Install the Oring (10) and seal (8) on the retainer (9).
Install the retainer into the bore of the master cylinder.
Install the plug (4) and check valve assembly against the
retainer. Turn the plug into the master cylinder. Tighten
the plug.
8. Assemble and install the relief valve assembly (See
FIGURE 9.) as follows:
a. Make sure all of the parts are clean. Use new parts
from the repair kit.
b. Install the cotter pin (11), seal (8), washer (9) and
spring (10) in the bottom of the valve body (7).
c. Put the metering pin (6) in the orifice at the
bottom of the valve body.
d. Assemble the Orings and backup rings on the
piston (5). Lubricate the piston with J1703
brake fluid. Install the piston assembly in the
valve body (7).
e. Install the spring (3), Oring and plug for the
relief valve.
9. Install the two gaskets and the line adapter on the mas-
ter cylinder. Install the line adapter on the plug for the
relief valve. Tighten the fittings for the relief valve tube.
Install the fill plug and gasket.
9
 BRAKE BOOSTER
1. PLUG
2. ORING Removal (See FIGURE 1.)
3. SPRING
4. BACKUP RING 1. Remove the floor plates. Clean the area around the
5. PISTON
6. METERING PIN brake line and hydraulic line connections.
7. VALVE BODY
8. SEAL 2. Disconnect the brake pedal from the brake booster at
9. WASHER the push rod.
10. SPRING
11. COTTER PIN 3. Disconnect the hydraulic lines at the brake booster.
Put caps on the open lines.

4. Disconnect the brake lines and wires at the master cyl-

inder (7). Disconnect the hose from the reservoir at the
master cylinder. Put a plug in the end of the hose.

5. Remove the capscrews that hold the brake booster (1)

to the bracket. Remove the brake booster and master
cylinder as an assembly.

Disassembly (See FIGURE 10.)

1. Remove the master cylinder from the brake booster.

2. Remove the dust cover (2) and push rod (1).

WARNING
The threaded plug (3) has a compressed spring (13)
behind it. Make sure to hold the spring in position so
that it cannot cause damage or injury to someone.
10077
3. Carefully remove the threaded plug (3). Remove the
FIGURE 9. RELIEF VALVE ASSEMBLY retainer and piston assembly. Remove the piston and
spring retainer.

4. Push on the piston rod and remove the pin that holds
the piston rod in the piston plunger. Remove the piston
rod and spring.

5. Remove the relief valve assembly from the housing.

Installation Cleaning and Inspection

Clean the parts of the brake booster with solvent. Check

1. Put the master cylinder in position on the brake boost-
er and install the capscrews for the master cylinder.
2. Connect the brake lines and wires. Connect the hose
to the brake fluid reservoir. Fill the reservoir and remove
the air from the brake system as described in CHECKS
AND ADJUSTMENTS in this section.
the surface of the machined parts for wear and damage.
Assembly (See FIGURE 10.)
NOTE: Use new parts from the repair kit. Lubricate the
parts with hydraulic oil during assembly. Make sure the
parts are clean.

10
 1. PUSH ROD
2. DUST COVER
3. PLUG
4. ORING
5. SEAL
6. PISTON ROD
7. PISTON RING
8. PISTON
9. SPRING
10. PIN
11. PISTON PLUNGER
12. RETAINER
13. SPRING
14. HOUSING
15. VALVE STEM
16. SHIMS
17. SPRING
18. ORING
19. PLUG

10075

FIGURE 10. BRAKE BOOSTER

CAUTION
Do not let brake fluid touch any of the parts of the
brake booster. The brake fluid can damage the seals
in the brake booster.
1. Assemble the parts for the relief valve. Make sure all
of parts are in their original positions.
2. Install the seals in the retainer and the housing.
3. Install the spring (13) and piston rod in the piston
plunger. Install the pin that holds the piston rod in the
piston plunger.
4. Install the piston ring on the piston. Install the piston
on the piston rod. Install the spring retainer and the
spring on the piston assembly.
5. Install the piston assembly in the housing. Install the
dust cover and push rod on the retainer.
Installation
1. Install the master cylinder on the brake booster. Install
the brake booster on the bracket.
2. Connect the hydraulic lines to the brake booster. Con-
nect the brake lines and wires to the master cylinder.

11
Connect the hose from the reservoir to the master cylin-
der.
3. Connect the push rod to the crank and the brake pedal.
Install the pin for the push rod.
4. Remove the air from the brake system and adjust the
brake linkage as described in CHECKS AND ADJUST-
MENTS in this section.

CHECKS AND ADJUSTMENTS

REMOVE AIR FROM THE BRAKE cylinder. Use the fitting at the line connector on the re-
SYSTEM lief valve.

ADJUST THE BRAKE PEDAL

The air must be removed from the brake fluid. Fill the
reservoir of the master cylinder with brake fluid. Put one
end of a rubber hose on the special fitting of the wheel
cylinder. Put the other end of the hose in a container with
brake fluid. Loosen the special fitting. Push slowly on
the brake pedal. Close the fitting at the wheel cylinder.
Repeat the procedure until no air bubbles are seen in the
container. Check the fluid level in the master cylinder.
Keep the master cylinder full of brake fluid during these
procedures. Use the procedures described for the wheel
cylinders to remove air from the relief tube at the master
(See FIGURE 11.)
NOTE: The adjustment procedures for the inching ped-
al are in the section, TWOSPEED POWERSHIFT
TRANSMISSION, REPAIRS, 1300 SRM 325.
1. Adjust the height of the brake pedal above the floor
plate as shown in FIGURE 11. Use the stop screw (2)
and nut (3) behind the pedal to adjust the height.
2. Adjust the push rod (4) for the brake booster (5) so
that there is 5.5 mm (0.2 in) of free travel in the brake
pedal (1).

5 mm (0.2 in)

127 mm (5.0 in)

1. BRAKE PEDAL
2. STOP SCREW
3. NUT
4. PUSH ROD
5. BRAKE BOOSTER

11615

FIGURE 11. BRAKE PEDAL ADJUSTMENT

12
ADJUST THE BRAKE SHOES If the lift truck has a powershift transmission and a
(See FIGURE 7.) Monotrol pedal, make sure the switch is actuated by the
handlever when the parking brake is applied.
The brake shoes will adjust automatically by applying
the brake pedal while traveling in forward or reverse. To
manually adjust the brakes, it is necessary to turn the ad- ADJUST THE PARKING BRAKE SWITCH
juster wheels. Remove the rubber plugs in the adjust- (See FIGURE 5.)
ment slots in the back plate. Put a small screwdriver
through the slot in the back plate. Make sure to install the
1. Apply the parking brake. The link must be at the max-
plugs after the adjustment is complete. See FIGURE 7.
imum limit of travel (top of slot). If the link is not in this
Push the adjuster plate away from the adjuster wheel
position with the parking brake applied, check that the
and turn the adjuster wheel until the brake shoe just
normally closed (NC) circuit of the switch is opened
touches the brake drum. Adjust the brake shoes for the
when the switch lever is actuated by the link. The NC
other wheel using the same method. Remove the blocks
circuit goes through the two terminals at the end of the
and operate the lift truck in the forward and reverse di-
switch.
rections. Make 10 stops in each direction using the
brakes. This action will adjust the brakes automatically.
2. If the switch is open with the brake lever applied, the
NOTE: If the lift truck does not have frequent hard installation is correct. If the circuit remains closed with
braking applications and the position of the brake pedal the brake lever applied, the link for the switch has been
is low, the brakes are not adjusting enough. Change the bent and must be replaced.
shims at the adjuster wheel so that there is a clearance of
0.94 mm (0.037 in) at the arrows (See FIGURE 7.) 3. When the new link is installed check again to make
NOTE: If the lift truck has frequent hard braking ap- sure the normally closed (NC) circuit of the switch is
plications and the brakes are too tight, the brakes are not opened when the parking brake lever is applied.
adjusting correctly. Change the shims at the adjuster
wheel so that there is a clearance of 1.40 mm (0.055 in)
at the arrows (See FIGURE 7.)
CHECK THE RELIEF VALVE ON THE
BRAKE BOOSTER (See FIGURE 10.)
ADJUST THE PARKING BRAKE
(See FIGURE 5.)
The relief valve is adjusted at the factory and is not nor-
Turn the knob on the hand lever to adjust the parking mally adjustable. Shims can be added or removed be-
brake. The brake must hold the lift truck with a capacity tween the spring and the valve stem. The correct relief
load on a 15% grade. pressure is 1205 to 1275 kPa (175 to 185 psi).

13

TROUBLE
The brakes do not operate equally.
One brake assembly does not
release.
Both brakes do not release.
The pedal is hard to push.
The brakes makes noise.
14
TROUBLESHOOTING
POSSIBLE CAUSE
Oil or brake fluid is on the linings.
The linings are worn or hard.
A wheel cylinder is leaking.
The brake linings are not correctly
installed.
The back plate or brake shoes are
damaged.
A brake drum is damaged or not
round.
The shoes are adjusted too tightly.
The back plate or brake shoes are
damaged.
The brake lines have a restriction.
A cable for the parking brake is
damaged.
The parking brake is not released.
The parking brake cables need
adjustment.
There is not enough clearance at
the end of the push rod in the
master cylinder.
The master cylinder is damaged.
The pedal linkage is damaged.
The linings are worn.
Water or oil is on the linings.
The master cylinder is damaged.
The brake booster has a
malfunction.
The seals in the brake booster are
damaged.
Dirt is on the linings.
The linings are worn.
A brake drum is damaged.
PROCEDURE OR ACTION
Repair leak. Install new linings.
Install new linings.
Repair or install new wheel cylinder.
Remove air from the system.
Install brake linings correctly.
Install new parts.
Check to make sure there is
adequate material to allow for
machining. Machine the brake shoe
area to make them round or install
new drums.
Adjust brakes.
Install new parts.
Install new brake lines.
Install new cable.
Release parking brake.
Adjust or install new cables.
Adjust the clearance between the
push rod and the piston.
Install new master cylinder.
Remove air from the system.
Repair linkage.
Install new linings.
Clean or install new linings.
Repair or install new master
cylinder. Remove air from the
system.
Repair or install new brake booster.
Install new seals.
Clean or install new linings.
Install new linings.
Install a new brake drum.

TROUBLE
The brake pedal travel too far.
The brakes do not stop the lift truck. Oil, water or brake fluid is on the
The parking brake will not hold the
lift truck.
The parking brake will not release.
TROUBLESHOOTING
POSSIBLE CAUSE
Air in the brake system.
Brake fluid level low. The brake
system has a leak.
The brake shoes are not adjusted
correctly.
The brake linings are worn.
The linings do not fit the drum.
A wheel cylinder is leaking.
The master cylinder is worn or
damaged.
The pedal return spring is broken.
linings.
The linings are worn.
The wheel cylinders are leaking.
The shoes are not adjusted
correctly.
The master cylinder is worn or
damaged.
The brake booster does not operate Repair or install a new brake
correctly. booster.
Parking brake not adjusted
correctly.
The shoes are not adjusted.
The linkage for brake shoes is
damaged or not connected.
Oil, water, or brake fluid is on the
linings.
The parking brake cables need
adjustment, lubrication, or have
damage.
The parking brake lever is adjusted
too tightly.
The parking brake cables need
adjustment, lubrication, or have
damage.
PROCEDURE OR ACTION
Remove air from the system. Check
for leaks.
Fill brake fluid reservoir to the
correct level. Repair leak. Remove
air from the system.
Check operation of automatic
adjusters. Adjust brakes.
Install new linings.
Adjust the linings.
Repair or install new wheel cylinder.
Remove air from the system.
Repair or install new master
cylinder. Remove air from the
system.
Install new spring.
Clean or install new linings.
Install new linings.
Repair or install new wheel cylinder.
Remove air from the system.
Adjust brakes.
Repair or install new master
cylinder. Remove air from the
system.
Use adjustment knob on parking
brake lever to adjust holding force.
See adjustment procedure for
correct specifications.
Adjust brakes.
Repair linkage.
Clean or install new brake linings.
Install new parts. Lubricate and
adjust cables.
Adjust parking brake. See
adjustment procedure for correct
specifications.
Install new parts. Lubricate and
adjust cables.
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