May 2002 FBR 02-D01

Applied Model : D02 3.2ton model / D01/D02 SERIES

Applied From : Production in April, 2002

Subject : BRAKE SYSTEM (BR)

Introduction:
3.2 ton model UGD02A32PQ (LPG model) and FGD02A32Q (Diesel model) have
been newly added to the D02 series.
At the same time, several specifications have been changed in D01/D02 series.

Modification Notice:
In accordance with this change, Update the following pages in D01/D02 Service
manual with new pages.
The details of this change are described at “Technical Service Note” in next page.

1, “GI” section 8, “HD” section

Update page GI - 4, 5, 6, 8. Update page HD – 3, 4.
2, “MA” section 9, “LM” section
Update page MA - 6, 27. Update page LM – 3, 10, 11, 22.
3, “ER” section 10, “BF” section
Update page ER - 4. Update page BF - 2.
4, “DF” section 11, “BE” section
Update page DF - 2. Update page BE – 5, 6, 11, 20,63.
5, “FA” section
Update page FA - 2, 6.
6, “RA” section
Update page RA - 2.
7, “BR” section
Update all page

The information in this bulletin should not be interpreted as base for claims, unless so designated
Technical Service Notice:

[ For 3.2 ton model]

1, 3.2 Ton model added

1) 3.2 ton model information is added. GI section
DF section
FA section
RA section
HD section
LM section

2, Parts change
1) The size and weight of Counterweight increase. BF section
2) Drive axle is reinforced. ( Hardness is changed. Size is same) Not described
3) Brake is reinforced. (DS31H model <- DS31 model) Not described
4) Mast is reinforced. (Tilt Bracket shape changed and Rib added) Not described
( for 3.0 ton and 3.2ton mast, except 3V mast) Not described
5) Down Safety Valve is changed (Flow rate change 15 <- 22 L/min) Not described
( for 3.0 ton and 3.2ton mast, except 2F mast) Not described
6) Fork capacity mark is changed ( 1600 X 500 <- 1500 X 500) Not described
( for 3.0 ton and 3.2ton mast) Not described

[ For all D01/D02 model]

1, Brake specification change (Brake Booster deleted)

1) Brake Vacuum Booster deleted. ( all D02 ) BR, MA section
2) Pedal link ratio changed. ( all D01/D02 : 4.91 <- 5.14) Not described
3) Pedal stroke changed. ( D01 : 42 <- 44mm, D02 : 68 <- 51mm ) Not described
4) Master cylinder changed. ( D01: no change, D02: 3/4” <- 15/16”) BR section
5) Return Spring changed. ( all D01/D02 : 2.9 <- 5.9 N/mm ) Not described
6) Vacuum Port for Brake booster deleted. ( H20, H25 engine) Not described
7) Vacuum Pump deleted. ( TD27 engine) BR section

2, Temperature sensor for Catalytic muffler deleted (H20, H25 engine)

1) Temperature sensor for Catalytic muffler deleted. BE, BF section
2) Muffler temperature warning lamp in Meter panel deleted. BE section
3) Chassis harness and rear harness changed. (Circuit deleted.) BE section
 BRAKE SYSTEM

SECTION BR
CONTENTS
SERVICE DATA AND SPECIFICATIONS (SDS) ............2
TROUBLE DIAGNOSES AND CORRECTIONS.............3
ADJUSTMENT .................................................................5
Service Brake ..............................................................5 Brake Piping ..............................................................12
Hand Brake..................................................................8 Drive Axle Brake ........................................................13
SERVICE BRAKE..........................................................10 HAND BRAKE ...............................................................14
Brake Pedal and Inching Brake Pedal ......................10 SPECIAL SERVICE TOOL ............................................15
Master Cylinder..........................................................11
 SERVICE DATA AND SPECIFICATIONS (SDS)

GENERAL SPECIFICATIONS TIGHTNING TORQUE

D01 D02 N⋅m kg-m ft-lb in-lb

Drive axle brake Pedal stopper lock nut 12 - 14 1.2 - 1.5 9 - 10 —

Hydraulic, duo-servo drum with Push rod lock nut 16 - 21 1.6 - 2.2 12 - 15 —
Type
auto-adjuster Contact bolt lock nut 19 - 25 1.9 - 2.6 14 - 18
Drum inner diameter Pedal bracket attaching bolt 37 - 50 3.7 - 5.1 27 - 36 —
254 (10) 310 (12-1/5)
mm (in) Master cylinder attaching
9 - 11 0.9 - 1.2 — 79 - 104
Lining mm (in) 48.5 x 4.87 x 279.3 60.0 x 5.67 x 343.6 bolt/nut
(Width x thickness x (1.909 x 0.1917 x (2.362 x 0.2232 x
length) 11.0) 13.53)
Wheel cylinder attaching bolt
Wheel cylinder inner D01 8 - 11 0.8 - 1.2 — 70 - 104
diameter 22.22 (7/8) 28.57 (1-1/8)
mm (in) D02 18 - 26 1.8 - 2.7 13 - 19 —
Back plate attaching nut
Master cylinder
D01 59 - 78 6.0 - 8.0 44 - 57 —
Type Single conventional
D02 98 - 117 10 - 12 73 - 86 —
Inner diameter Brake tube flare nut 15 - 17 1.5 - 1.8 11 - 13 —
17.46 (11/16) 19.05 (3/4)
mm (in)
Brake house flare nut 17 - 19 1.7 - 2.0 13 - 14
Stroke mm (in) 33 (1.30)
Hand brake fixing bolt 9 - 11 0.9 - 1.2 79 - 104
Brake booster — --- Hand brake cable adjusting
19 - 25 1.9 - 2.6 14 - 18 —
lock nut
INSPECTION AND ADJUSTMENT
D01 D02

Brake pedal mm (in)

Pedal free play 1 - 3 (0.04 - 0.12)

Pedal height 105 - 115 (4.13 - 4.53)

Depressed height More than 90 (3.54)

Inching brake pedal

Pedal height mm (in) 105 - 115 (4.13 - 4.53)

Clearance between con-

4.4 - 5.7 (0.173 - 0.224)
tact bolt and brake pedal

Master cylinder
Allowable clearance
between cylinder and Less than 0.15 (0.0059)
piston mm (in)

Drive axle brake

Wear limit of brake lining

1.0 (0.039)
mm (in)

Brake drum mm (in)

Out of roundness Less than 0.03 (0.0012)

Radial runout Less than 0.05 (0.0020)

Repair limit 254.3 (10.01) 310.8 (12.24)

Hand brake

Pulling force
167 - 225 (17 - 23, 37 - 51)
N (kg, lb)

BR-2

SERVICE BRAKE
Condition
Insufficient braking force
Unequal braking (lift truck
veers to one side)
Brake dragging
TROUBLE DIAGNOSES AND CORRECTIONS
Probable cause Corrective action
Oil leakage in brake lines Correct and replenish.
Air in brake lines Bleed air.
Water or oil on linings Clean or replace.
Uneven wear or contact of brake linings Grind or replace.
Worn linings Replace.
Improper functioning of master cylinder or wheel Correct or replace.
cylinder
Clogged oil lines Clean.
Uneven tire pressure Adjust.
Brakes out of adjustment Adjust.
Water or oil on brake linings Clean or replace.
Foreign particles in brake drum Clean.
Deteriorated lining surfaces Grind or replace.
Improper contact of linings Grind or correct.
Worn lining Replace.
Worn, warped, rusted or damaged brake drums Correct or replace.
Improper operation of wheel cylinder Correct or replace.
Improper sliding of shoes Adjust.
Loose back plate bolts Tightening or replace.
Warped back plates Replace.
Improperly adjusted wheel bearings Adjust or replace.
Clogged oil lines Clean.
No free play of brake pedal Adjust.
Improper shoe sliding Adjust.
Improper operation of wheel cylinder Adjust or replace.
Faulty piston cup Replace.
Weak or broken return springs Replace.
Clogged master cylinder return port Clean.
Clogged oil lines Clean.
Wheel bearing out of adjustment Adjust or replace.
BR-3
 TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Brake squeaking Brake drag Refer to above.
Improper returning of piston Replace.
Worn linings Replace.
Deteriorated lining surfaces Grind or replace.
Improper contact of shoes with linings Replace.
Excessively worn shoes or back plates Clean and apply brake grease.
Foreign particles on frictional surfaces of drums Clean.
Frictional surfaces of drum worn runout Replace.
Deformed or improperly installed shoes Replace or correct.
Loose back plate bolts Tighten.
Worn anchors Replace.
Improper contact of linings Correct or replace.
Improperly installed anti-rattle springs Correct.
Brake noise Rough frictional surfaces of drums Grind or replace.
Drum out of center or excessively warped drum Replace.
Rough lining surfaces Grind or replace.
Excessive pedal stroke Brake out of adjustment Adjust.
Air in oil lines Bleed air.
Oil leakage or insufficient oil Check and correct.
Worn linings Replace.
Dislocation or improper returning of shoes Correct.
Improper contact of linings Correct.

HAND BRAKE
Condition Probable cause Corrective action
Insufficient braking force Open or elongated wire Replace.
Water or oil on linings Clean or replace.
Uneven wear or contact of brake linings Grind or replace.
Worn linings Replace.

BR-4
 ADJUSTMENT

Service Brake
BRAKE PEDAL
1. Adjust brake pedal height “H” to the specified value with lock
nut of pedal stopper.
Brake pedal height “H”:
105 - 115 mm (4.13 - 4.53 in)
Pedal stopper lock nut:
: 12 - 14 N⋅m (1.2 - 1.5 kg-m, 9 - 10 ft-lb)

BRM0042

2. Adjust push rod length of master cylinder or brake booster until

pedal free play is within specified value, then tighten lock nut
securely.
Pedal free play:
1 - 3 mm (0.04 - 0.12 in)
Push rod lock nut:
: 16 - 21 N⋅m (1.6 - 2.2 kg-m, 12 - 15 ft-lb)

BRM0043

3. Check depressed height. If it is not as specified, check brake

system.
Depressed height:
More than 90 mm (3.54 in)

BRM0044

4. Depress and release pedal several times to see if it travels

smoothly over its entire stroke without binding, twisting or inter-
fering with adjacent parts.
5. Depress and release pedal several times. make sure stop lamp
switch comes on when pedal is depressed 10 to 20 mm (0.39
to 0.79 in) and goes off when it is released.

BR-5
 ADJUSTMENT
Service Brake (Cont’d)
BRAKE SHOE
The shoe-to-drum clearance automatically adjusts for lining wear
when the foot brake is operated while moving forward.

INCHING BRAKE PEDAL

1. Adjust inching pedal height “H” to the specified value with inch-
ing pedal stopper.
Inching pedal height “H”:
105 - 115 mm (4.13 - 4.53 in)
Pedal stopper lock nut:
: 12 - 14 N⋅m (1.2 - 1.5 kg-m, 9 - 10 ft-lb)

BRM0045

2. Adjust clearance between contact bolt and brake pedal.

Clearance:
4.4 - 5.7 mm (0.173 - 0.224 in)
Contact bolt lock nut:
: 19 - 25 N⋅m (1.9 - 2.6 kg-m, 14 - 18 ft-lb)

BRM0046

BR-6
 ADJUSTMENT
Service Brake (Cont’d)

3. Adjusting the inching cable length using the adjusting nut so

that the inching lever turns to the lock position when the inch-
ing pedal is depressed.

BR-7
 ADJUSTMENT

Hand Brake

BRM0047

Before adjusting hand brake, make sure that drive axle brake is
functioning properly.
1. Park the forklift.
2. Put blocks at the tires (wheels) on the drive side.
3. Adjust nut B until thread length “L” is 15.5 mm (0.610 in) and
then tighten lock nut A.

4. To lock the lever, push the adjusting bolt in direction “Q” to point
“P” where the grip load becomes 167 to 225 N (17 to 23 kg, 37
to 50 lb).
5. Turn the adjusting bolt with a screwdriver. Adjust the opera-
tional force to lock the hand brake lever to the standard value.
Standard value at the tip of the hand brake lever
(point P):
167 - 225 N (17 - 23 kg, 37 - 50 lb)

BRM0063

BR-8
 ADJUSTMENT
Hand Brake (Cont’d)
NOTICE:
I The operational force to lock the hand brake lever
increases by turning the adjusting bolt clockwise.
I The operational force to lock the hand brake lever
decreases by turning the adjusting bolt counterclockwise.

BR-9
SERVICE BRAKE

Brake Pedal and Inching Brake Pedal

BRM0048

CAUTION:
I To avoid splashing brake fluid on painted surfaces and
other parts, always place a container or rag under brake
tubes.
I When removing flare nut, use Tool GG94310000.
Never use open end or adjustable wrench.
I Discard cotter pin after removal; install new one.
I Make sure pedal travels smoothly over its entire stroke
without binding, twisting, etc. and makes no contacting
noise.
I Use DOT 3 (F.M.V.S.S. No. 116) brake fluid only.
INSPECTION
Check the following parts, replace or repair if necessary.
I Pedal bushing for wear, deformation or other damage
I Pedal shaft for bending or other damage
I Pedal arm for bending or other damage
I Return spring for weakness
I Pedal pad for damage

BR-10
SERVICE BRAKE

Master Cylinder

BRM0049

BR-11
 SERVICE BRAKE

Brake Piping

BRM0060

BR-12
SERVICE BRAKE

Drive Axle Brake

BRM0064

BR-13
HAND BRAKE

BRM0062

BR-14
 SPECIAL SERVICE TOOL

Tool number
Description
Tool name
GG94310000
Flare nut torque wrench

NT792

BR-15