INTRODUCTION

GENERAL If a failure occurs in one of the dual circuits, the other

This section has a description and the service
procedures for the parts of the brake system. The brake
system includes the following parts: master cylinder,
brake shoes, wheel cylinders, the parking brake system,
and the seat brake system. A troubleshooting section is
included at the end of this section.
DESCRIPTION AND OPERATION
Service Brakes (See FIGURE 1.)
A service brake assembly is installed on the mounts at
each end of the drive axle. The parts of the service brake
assembly are shown in FIGURE 3. and FIGURE 4.
When the brake pedal is pushed, fluid pressure from the
master cylinder causes the pistons in the wheel cylinders
to extend. The pistons expand the brake shoes against
the drums.
circuit will apply one of the service brakes. This failure
will cause the brake pedal to travel farther when the
brakes are applied, but the service brakes on one drive
wheel will operate. This failure of one of the brake cir-
cuits can cause the lift truck to turn toward the drive
wheel with the good brake when the brakes are applied.
The operator must control the direction of the lift truck
with the steering when the brakes are applied during this
condition.
The reservoir is equipped with an indicator for low fluid
level. A float in the reservoir moves up and down with
the fluid level. When the fluid level is low, a magnet on
the float activates a switch in the bottom of the reservoir.
This switch energizes a warning light on the instrument
cluster.
1

The clearance between the brake shoes and the brake

drum is adjusted automatically. An adjuster linkage 4
turns the adjuster wheel to adjust the clearance. When
the lift truck moves in the REVERSE direction and the
brakes are applied, the rear brake shoe and the adjuster
links move with the drum. This linkage moves the ad-
juster lever to rotate the adjuster wheel. The adjuster 3
wheel can turn only when there is clearance between the 2
lining of the brake shoe and the brake drum. The ad-
juster wheel can also be turned with a tool. A slot in the
back plate gives access to the adjuster wheel.

Master Cylinder

The master cylinder is designed for a dual circuit sys-

tem. The master cylinder has two separate pistons that
operate in the single bore of the master cylinder. The res- 12836

ervoir for the fluid is pressed into the two ports on top of 1. BRAKE PEDAL
the master cylinder and held in position by seals. When 2. MASTER CYLINDER
the brake pedal is pushed, the push rod moves the piston 3. BRAKE ASSEMBLY
4. BRAKE FLUID RESERVOIR
assemblies. The operation of the master cylinder is de-
scribed in FIGURE 2. FIGURE 1. SERVICE BRAKE SYSTEM

1
 BRAKE “OFF” 7 6
When the brakes are “OFF,” the hydraulic fluid
can move freely between the dual circuit system
and the separate chambers of the fluid reservoir.

BRAKE “RELEASED” 9
When the brake pedal is released, the re-
turn springs cause the pistons to retract 8
faster than the fluid. This action causes a 9
vacuum between the fluid in chambers A 8
and C. The vacuum causes the seals (2)
to change shape. When the seals change
shape, they permit the fluid in chambers
B and D to flow through the holes in the
2 5
pistons and past the seals into chambers 4
3
A and C. The supply holes in the cylinder A B C D
2
body supplies fluid as the flow moves 1
from the one chamber to the other cham-
ber. The fluid returns to the reservoir
through the bypass holes when the pis-
tons are fully retracted. FLUID WITH NO PRESSURE
FLUID UNDER PRESSURE

1. SECONDARY SPRING
2. SEAL 6. PRIMARY FLUID CHAMBER
3. SECONDARY PISTON 7. SECONDARY FLUID CHAMBER
4. PRIMARY SPRING 8. BYPASS HOLES
5. PRIMARY PISTON 9. SUPPLY HOLES

BRAKE “APPLIED”
When the brake pedal is pressed, the primary
piston moves in the cylinder bore. This move-
ment creates hydraulic pressure that combines
with the force of the primary spring. These com-
bined forces overcome the secondary spring
force and move the secondary piston in the
bore with the primary piston. The first move-
ment of both pistons pushes the seals (2) past
the bypass holes in the chambers A and C.
This action applies pressure to the fluid in those
chambers and causes fluid to flow to the cham-
bers of the two separate systems. The fluid in
chambers B and D is not effected by movement
of the pistons. This fluid can move freely be-
tween the piston chambers and the chambers
of the fluid reservoir, before and during brake
application. A B C D
12595

FIGURE 2. OPERATION OF MASTER CYLINDER

2
Parking Brake
The parking brake system uses the service brake shoes.
Additional linkage activates the parking brake system.
When the lever is moved to apply the parking brake, the
cables and linkage expand the brake shoes against the
drums. The design of the parking brake linkage adjusts
each cable so that the tension is the same when the lever
is moved to apply parking brake.
SERVICE BRAKES
Removal And Disassembly
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
respirator must be used.
1. See the procedure “HOW TO PUT A LIFT TRUCK
ON BLOCKS” in the PERIODIC MAINTENANCE
section of the service manual or the OPERATING
MANUAL. Tilt the mast fully backward. Put blocks un-
der the mast. Tilt the mast forward until the wheels just
touch the floor. Stop the motor. Put blocks under the
frame of the lift truck.
2. If tilt does not function (N30XMH) use a hydraulic
jack, crane or another lift truck to lift the drive wheels
until they just touch the floor. Put blocks under the frame
of the lift truck.
3. Remove the capscrews that hold the axle shaft to the
hub. Remove the axle shaft.
4. Release the park brake. Bend the lock plate and re-
move the nut that holds the axle bearing. Remove the
washer and the bearing cone.
5. Put grease on the floor so that the wheel assembly will
slide easily from the axle tube. Pull the wheel assembly
from the lift truck. If the wheel assembly cannot be re-
moved easily, use a small screwdriver to push the adjust-
er actuator away from the adjuster wheel. Use a brake
adjustment tool or a screwdriver to turn the adjuster
wheel to loosen the brake shoes. Remove the hub and
drum assembly. Do not damage the grease seal when re-
moving the hub.

4 5
19 1 1. WHEEL CYLINDER
3 2
2. RETURN SPRING
7 3. RETURN SPRING
15 4. ANCHOR
17 5. ANCHOR GUIDE
9 6. BACK PLATE
7. BRAKE SHOE
8 8 8. RETAINER SPRING ASSEMBLY (4)
9. PIVOT PLATE
10. LINK
11. ADJUSTER WHEEL ACTUATOR
12. ADJUSTER WHEEL
13. PARKING BRAKE CABLE
14. ADJUSTER ACTUATOR SPRING
15. BRAKE SHOE
16. LINK, PARKING BRAKE
16 17. SPRING, PARKING BRAKE LINK
10 18. PARKING BRAKE LEVER
6 19. PIVOT PIN, RETAINER, AND SPRING
18 11 WASHER
13 14 12

FIGURE 3. BRAKE ASSEMBLY (LEFT BRAKE ASSEMBLY SHOWN)

3
 1
4
17

16

19
7
23
19
22
9

20
6

18 5
10 2
13
21 15 8
1. WHEEL CYLINDER 3
2. RETURN SPRING
3. RETURN SPRING
4. ANCHOR 12 14 11
5. ANCHOR GUIDE
6. BACK PLATE 12. ADJUSTER WHEEL
7. BRAKE SHOE 13. PARKING BRAKE CABLE 18. PARKING BRAKE LEVER.
8. RETAINER SPRING 14. ADJUSTER ACTUATOR 19. PIVOT PIN, RETAINER,
ASSEMBLY (4) SPRING AND SPRING WASHER
9. PIVOT PLATE 15. BRAKE SHOE 20. WASHER
10. LINK 16. LINK, PARKING BRAKE 21. RETAINER
11. ADJUSTER WHEEL 17. SPRING, 22. ANCHOR
ACTUATOR PARKING BRAKE LINK 23. SPACER

FIGURE 4. PARTS OF THE SERVICE BRAKE

8. Disengage the link (10) from the adjuster wheel ac-

WARNING
When the brake shoes are removed do not create
dust in the air. See the cleaning procedure in this sec-
tion.
6. Make a note of the arrangement of the parts. See
FIGURE 3. and FIGURE 4. Remove the return springs
(2) and (3) with spring pliers.
7. Remove the retainers, springs, and anchor pins (8)
that hold the brake shoes to the back plate.
tuator (11). Remove the link (10), washer (20), and the
pivot plate (9). Remove the anchor guide (5).
9. Move the brake shoes away from each other to disen-
gage the brake shoes from the wheel cylinder. Discon-
nect the parking brake lever (18) from the parking brake
cable (13) as the brake assembly is removed from the
back plate. The parking brake lever has a hook that en-
gages the parking brake cable.
NOTE: The adjuster wheel for the left brake is not the
same as the adjuster wheel for the right brake. The ad-
juster wheel for the right brake has left–hand threads.

4
 1. PUSH ROD (2)
2. DUST COVER (2)
3. PISTON (2)
4. CUP (2)
5. SPRING
6. BODY, WHEEL CYLINDER
7. INLET PORT
8. SPECIAL FITTING
9. DUST COVER
4
3
2
1 6
FIGURE 5. WHEEL CYLINDER
10. Make a note of the arrangement of parts and disas-
semble the brake assembly. Remove the parking brake
link (16) and spring (17) if they are still engaged with
brake shoes. The parking brake link and spring will of-
ten fall from the brake assembly when the brake assem-
bly is removed from the back plate. The adjuster wheel
(12) will also disengage from the brake shoes after the
brake assembly is removed.
11. Remove the spring (14) for the adjuster wheel actua-
tor (11). Remove the adjuster wheel actuator (11) from
the brake shoe. Loosen the nut and remove the anchor
(22) and spacer (23) from the brake shoe.
12. Use a screwdriver or small prybar to move apart the
ends of the retainer (19). Remove the spring washer (19)
and pivot pin (19) to remove the parking brake lever (18)
from the brake shoe (15).
13. Disconnect the brake line from the wheel cylinder
(1). Remove the capscrews that hold the wheel cylinder
to the back plate and remove the wheel cylinder.
14. See FIGURE 5. Remove the push rods, dust covers,
pistons, cups, and spring from the wheel cylinder.
NOTE: The back plate is not normally removed from
the axle housing for brake repairs. Eight special
capscrews are used to fasten the back plate to the axle
1
2
3
4
5
8
9
7
mount and the locking function of the capscrews is re-
duced if they are removed. These capscrews are tight-
ened to 255 N.m (188 lbf ft).
Cleaning
WARNING
DO NOT use an oil solvent to clean the master cylin-
der, wheel cylinder, or the brake linings. Use a sol-
vent approved for cleaning of brake parts. Do not
permit oil or grease in the brake fluid or on the brake
linings. Oil and grease will cause damage and leaks
in the seals of a brake system. The brakes will not op-
erate correctly if oil, grease, or brake fluid is on the
brake linings.
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.
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 of brake parts to
wet the brake lining dust. Follow the instructions and
cautions of the manufacturer for the use of the solvent. If
a solvent spray is used, do not create brake lining dust
with the spray.
5
3. When the brake lining dust is wet, clean the parts. Put
any cloth or towels in a plastic bag or an airtight con-
tainer while they are still wet. Put an “DANGEROUS
FIBERS” warning label on the plastic bag or airtight
container.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the air.
CAUTION
Do not permit oil or grease on the brake linings. Use a
brake cleaning fluid as necessary to clean linings that
will not be replaced.
Inspection
1. Inspect the bore of the wheel cylinder for holes or
scratches. Replace the wheel cylinder assembly if there
is any damage.
2. Inspect the return springs for wear or damage. Inspect
the back plate for wear where the brake shoes touch the
back plate. Remove any grooves or replace a worn or
damaged back plate.
3. Inspect the brake shoes for cracks or damage. If the
linings or shoes are worn or damaged, replace the brake
shoes. Maximum wear is to within 1 mm (0.025 in) of
contact with the rivets, or the metal shoe on bonded lin-
ings. Brake shoes must be replaced in complete sets. In-
spect the brake drums for cracks or damage. Replace
any damaged parts.
WARNING
The brake shoes on both wheels must be replaced if
any shoe is damaged. The brake performance on
both ends of an axle must be equal or the lift truck
can be difficult to steer when the brakes are applied.
4. Inspect the brake drum for deep grooves or other dam-
age.
NOTE: If grooves must be removed from the brake
drums, do not grind more than 1.5 mm (0.060 in) from
the internal diameter of the brake drum. The maximum
limit of the internal diameter of the brake drum is 311.7
mm (12.27 in). If the internal diameter is larger than the
limit, replace the brake drum.
6
5. The teeth of the adjuster wheel must not be worn. The
adjuster wheel must turn freely. Check the adjuster links
for damage.
6. Make sure the parking brake cables are in good condi-
tion.
7. Check the grease seals and the surfaces for the seals
for wear or damage.
Assembly And Installation (See FIGURE 4 )
1. If the wheel cylinder ( 1 ) was disassembled for repair,
assemble the wheel cylinder. See FIGURE 5. Use only
HYSTER APPROVED parts.
2. Install the wheel cylinder on the back plate ( 6 ) and
tighten the two capscrews to 18 to 27 N.m (13 to 20 lbf
ft). Connect the brake line to the wheel cylinder.
3. See FIGURE 4. Install the parking brake lever (18).
Use the pivot pin, spring washer, and retainer (19) to fas-
ten the parking brake lever to the brake shoe (15). Close
the ends of the retainer to fasten the pivot pin in position.
4. Install the anchor (22) and the spacer (23) in the brake
shoe (7). Install the adjuster wheel actuator (11) in the
brake shoe (7).
5. Fasten the adjuster actuator spring (14) to the adjuster
wheel actuator (11) and the brake shoe (15).
6. Put an anti–seize compound on the threads of the ad-
juster wheel. Turn the adjuster wheel into the adjuster
nut so that the adjuster assembly is in its shortest posi-
tion. This action permits the brake drum to be easily in-
stalled over the brake shoes.
7. Install the adjuster wheel (12) between the two brake
shoes. Make sure the adjuster wheel will be toward the
rear of the lift truck. Move the brake shoes apart so that
the adjuster wheel is held in position and the adjuster ac-
tuator spring is in tension.
WARNING
The threads of the adjuster wheel are not the same
for each side. If the adjuster assemblies are installed
on the wrong side, the brake shoe clearance will in-
crease each time the brakes are applied. The ad-
juster wheel for the right brake has left–hand
threads. The adjuster wheel for the left brake has
right–hand threads.
 1

1. LINK, ADJUSTER ACTUATOR

2. RETURN SPRING
3. RETURN SPRING 3 4
2
4. ANCHOR
FIGURE 6. RETURN SPRINGS

8. Lubricate the back plate with a small amount of 15. Make sure the bottom edge of the adjuster wheel ac-
grease where the brake shoes touch. Install the brake tuator is just above the center of the teeth of the adjuster
shoes on the anchor (4) and engage the push rods of the wheel. Check for correct installation if the alignment is
wheel cylinder. Engage the the parking brake lever (18) not correct.
in the slot in the parking brake cable as the brake shoes
are installed on the back plate. 16. Clean the bearings and lubricate them with wheel
bearing grease. Install the bearings and seals in the brake
9. Put an anchor pin that holds the brake shoes through drum. Install the assembly on the axle housing. See
the back plate. Put a spring seat, spring, and retainer (8) FIGURE 7. and FIGURE 8.
on the anchor pin. Push the retainer on to the anchor pin
and rotate the retainer 90 degrees. Make sure the retainer
is in the correct position. Install another retainer spring
assembly. 3 2
1
10. Install the link, parking brake (16) and the spring
(17) between the parking brake lever (18) and the brake
shoe (7).
11. Install the other spring retainers (8) that hold the
brake shoes. Make sure the parking brake link (16) and
the spring (17) are correctly engaged after the spring re-
tainers are installed.
12. Install the anchor guide (5) on the anchor (4). Install
the pivot plate (9) on its anchor (22).
13. Fasten the link (10) to the adjuster wheel actuator
(11) and put the cable around the pivot plate (9). Raise
the adjuster wheel actuator (11) against the spring ten-
sion and connect the link (10) to the anchor (4).
14. Use the correct tools to install the return springs. In-
stall the return spring (3). Install the washer (20) and the
return spring (2). The shape of the return springs permits 1. OUTER SEAL
them to be installed correctly in only one position. The 2. INNER SEAL 3. BRAKE DRUM
arrangement of the return springs on the anchors is
shown in FIGURE 6. FIGURE 7. LOCATION OF THE GREASE SEALS

7

9518
FIGURE 8. INSTALLATION OF THE INNER
GREASE SEAL
NOTE: To prevent damage to the inner oil seal when in-
stalling the hub, the hub and drum assembly can be tem-
porarily fastened to the wheel. Align the height of the
axle housing with hub bearings. Put grease under the
wheel and slide the wheel toward the axle housing. In-
stall the outer bearing and nut.
17. Adjust the hub bearings by tightening the nut to 205
N.m (150 lbf ft) while rotating the hub. Loosen the nut
until the hub turns freely. The torque must be less than
27 N.m (20 lbf ft). Tighten the nut to 34 N.m (25 lbf ft) or
until the first alignment position after 34 N.m (25 lbf ft).
Bend the lock plate over the nut.
18. Adjust the clearance of the brake shoes. Put a brake
adjustment tool or a screwdriver through the slot in the
back plate. Use the tool to rotate the adjuster wheel. The
actuator for the adjuster wheel will only permit rotation
in one direction. Turn the adjuster wheel until the brake
shoes have expanded against the brake drum and the hub
will not turn. Use a small screwdriver to lift the actuator
away from the adjuster wheel and turn the adjuster
wheel approximately 15 teeth in the opposite direction.
The brakes will adjust to the correct clearance when they
are applied while the lift truck is traveling in the RE-
VERSE direction.
NOTE: If the brake shoes were not replaced, loosen the
adjuster wheel approximately 15 teeth.
CAUTION
If there is too much clearance, the automatic adjust-
ers will not operate. If the clearance is too small, the
automatic adjuster cannot turn the adjuster wheel to
increase the clearance and the adjuster wheel will
8
not turn until the brake shoes wear. If the adjuster
wheel does not move for a long operating period, the
adjuster link can wear a spot on the adjuster wheel so
that it will not turn correctly.
19. Put liquid sealant on the flange of the axle shaft. In-
stall the axle shaft and capscrews. Tighten the
capscrews to 90 N.m (66 lbf ft).
Adjustments
1. Remove the air from the brake hydraulic system. See
the procedure “Remove The Air From The Brake Sys-
tem”, under CHECKS AND ADJUSTMENTS.
2. Install the wheel on the hub. Tighten the nuts to 237 to
305 N.m (175 to 225 lbf ft).
3. Tilt the mast backward or lift the truck to remove the
blocks. Push on the brake pedal. The pedal must not
touch the floor plate. Move the lift truck in REVERSE
and push on the brake pedal to permit adjusting mecha-
nism to operate. Repeat this operation several times.
4. The service brakes must be adjusted before the park-
ing brake can be adjusted. See FIGURE 10. and the fol-
lowing paragraphs in this section for the correct adjust-
ment of the parking brake.
PARKING BRAKE
Removal And Disassembly (See FIGURE 10.)
If the lever assembly for the parking brake must be re-
moved from the frame, use the following procedure
(See FIGURE 10.):
a. Use blocks next to the wheels to make sure the lift
truck can not move. Release the parking brake.
b. Turn the adjustment knob (5) so that the link (17)
is at the bottom of the adjustment slot (18).
c. Remove the cotter pin and anchor pin (8) that
connect the bar (4) to the park brake assembly (3).
d. Remove the nuts (10) and washers that hold the
park brake assembly to the bracket (16). Remove
the capscrews (9) and spacers (12).
e. Remove the cotter pin, washer, and anchor pin
(13) from the link (17).
f. The service brake assembly must be removed be-
fore the parking brake cables (2) can be removed
from the back plate of the service brake. A snap
ring (item 21, FIGURE 4.) holds the sheath of the
 parking brake cable in the back plate of the ser-
vice brake. Remove the snap ring and remove the
parking brake cable from the back plate.
Assembly And Installation (See FIGURE 10.)
The parking brake cables must be installed in the back
plate before the service brake is installed. A snap ring
holds the sheath of the parking brake cable in the back
plate of the service brake. Install the parking brake cable
in the back plate and install the snap ring that holds the
sheath of the parking brake cable in the back plate.
If the lever assembly for the parking brake was removed
from the frame, use the following procedure for installa-
tion:
a. Make sure the parking brake lever is in the re-
leased position. Turn the adjustment knob (5) un-
til the link (17) is adjusted to the bottom of the ad-
justment slot (18).
b. Install the ends of the cables into the compensator
(15). Install the anchor pin (13), washer, and cot-
ter pin into the park brake assembly. Make sure
the anchor pin is through the link and compensa-
tor.
c. Install the mounting bolts (9) through the cable
clamps (11) and spacers (12). Mount the assem-
bly to the bracket (16).
d. Before tightening the the mounting capscrews
(9), make sure the park brake assembly is in con-
tact with the frame bracket (19).
e. The following procedure must be used to connect
the bar (4) to the park brake assembly (3) and the
brake pedal assembly (6): put the park brake lever
(3) in the applied position and align the bottom
edge of the brake pedal assembly (6) with the top
edge of the frame bracket. See FIGURE 10. Use
the mounting holes that allow the best alignment
of the bar. Install the cotter pins.
f. With the brake in the applied position, adjust and
tighten the nuts on the end of the cable (20) to re-
move all the free–play from the release handle
(7).
Adjust The Parking Brake (See FIGURE 10.)
Make sure that the service brakes are adjusted and the
operation of the automatic adjuster mechanism is cor-
rect before the parking brake is adjusted.
1. Turn the adjustment knob (5) to raise the link (17) and
tighten the parking brake cables (2). Turn the adjust-
ment knob until the parking brakes are fully applied
when the pedal is used to apply the parking brake.
2. Test the operation of the parking brake. The lift truck
with a capacity load must not move when the parking
brake is applied on a 15% grade, [a slope that increases
1.5 metres in 10 metres (1.5 ft in 10 ft)].
3. With the park brake applied, adjust the nuts (14) to re-
move any free play from the release handle (7).
4. Check the operation of the switches on the parking
brake as described in CHECKS AND ADJUST-
MENTS.
9
 2
3

3.16 in (81 mm) 1

8 5 6

10
9

12836

1. CAPSCREW 6. LOCKNUT
2. BRAKE PEDAL 7. MASTER CYLINDER
3. FLOORPLATE 8. SWITCH
4. LOCKNUT 9. BRAKE ASSEMBLY
5. PUSH ROD 10. BRAKE LINES

FIGURE 9. SERVICE BRAKE

10
 5

20
7
17
6, RELEASED POSITION
6

0 15 13
6, APPLIED POSITION

14

18 12

3
3
4
5 2

9 16
19 11

12837
1 9

1. BRAKE ASSEMBLY 9. MOUNTING CAPSCREW 10

2. BRAKE CABLES 10. NUT 12838
11
3. PARK BRAKE ASSEMBLY 11. CLAMP 12
4. BAR 12. SPACER
5. ADJUSTMENT KNOB 13. ANCHOR PIN 17. LINK
6. PARK BRAKE PEDAL 14. NUT 18. ADJUSTMENT SLOT
7. RELEASE HANDLE 15. COMPENSATOR 19. FRAME BRACKET
8. ANCHOR PIN 16. BRACKET, FRAME 20. CABLE

FIGURE 10. PARK BRAKE

11
MASTER CYLINDER
Removal (See FIGURE 11.)
1. Remove the floor plates from the lift truck for access
to the master cylinder.
2. Loosen and remove the two brake hydraulic lines
from the master cylinder. Disconnect the wire at the
switch on the reservoir.
3. Remove the cotter pin, washer, and pin from the push
rod end that is attached to the brake linkage lever arm.
4. Remove the capscrews, washers, and nuts that hold
the master cylinder to the bracket assembly and remove
the master cylinder from the lift truck.
vent approved for cleaning of brake parts. Do not
permit oil or grease in the brake fluid or on the lin-
ings.
Inspect the bore of the master cylinder for holes or
scratches. Replace the master cylinder assembly if there
is damage.
Repair
See the repair procedures for the master cylinder in
FIGURE 12.

Cleaning And Inspection Installation (See FIGURE 11.)

CAUTION Use the reverse order of Removal to install the master

DO NOT use an oil solvent to clean the master cylin- cylinder. Check the adjustment of the brake pedal as de-
der, wheel cylinder, or the brake linings. Use a sol- scribed in CHECKS AND ADJUSTMENTS.

1. CAP 4. RETURN SPRING 9. SEAL

2. RESERVOIR 5. BODY 10. SPRING
3. SEAL 6. PIN 11. PRIMARY PISTON
1 7. SEAL 12. WASHER
19 8. SECONDARY 13. RETAINER RING
PISTON 14. DUST COVER
15. ROD
18 16. LOCK NUT
17. CLEVIS
2 20
18. PRIMARY FLUID CHAMBER
19. SECONDARY FLUID
13 CHAMBER
21
20. FLOAT
3 21. SWITCH (FLUID LEVEL)
4

7 7 15 16
5 7 6 17
8 10 11 9 12
14 12595

FIGURE 11. MASTER CYLINDER

12
STEP 1.
Remove the fluid reservoir. Apply force in the di-
rection of the arrow and pull the reservoir from the
master cylinder. Install the reservoir by pushing
and turning the reservoir in the opposite direction.
Make sure brake fluid does not leak from the res-
ervoir seals. If there is any leakage, replace the
seals.
STEP 3.
Push the primary piston into the bore as shown in
the illustration. Remove the pin at the the secon-
dary piston through the port for the secondary res-
ervoir. Use the same method to install the pin dur-
ing assembly.
STEP 5.
Remove the snap ring and the primary piston assembly.
WARNING
Keep control of the pistons as they are removed
so that the return springs do not suddenly release
the pistons from the bore with enough force to
cause an injury.
FIGURE 12. MASTER CYLINDER, REPAIR (1 of 2)
STEP 2.
Be careful to not scratch the surfaces. Use a tool
(screwdriver with a flat tip) that has a smooth
and rounded end to remove the reservoir seals.
Always install new seals. Put new seals in clean
brake fluid, then install the seals in the body of
the master cylinder.
STEP 4.
Remove the clevis and nut from the push rod.
Remove the dust cover. Be sure to put the lip of
the dust cover into the recess in the bore of the
cylinder during assembly.
CAUTION
When the piston is removed or installed, make
sure the cylinder bore or piston is not
scratched or damaged.
13
 STEP 6.
Hit the cylinder lightly on a soft or wooden surface
and remove the secondary piston assembly. Lubri-
cate the cylinder bore with clean brake fluid to help
removal.
CAUTION
During disassembly and assembly of the pri-
mary and secondary pistons assembly, make
sure not to scratch or damage the cylinder
bore when the spring is removed.
STEP 7.
During installation of the secondary piston, insert
the piston assembly into the cylinder until the
seal is at the center of the bore opening. Be
careful to not cause a restriction of the seal dur-
ing installation. To make sure the seal enters the
bore correctly, carefully rotate and tilt the piston
until the seal is installed in the bore. Slowly push
the piston assembly into the bore in one continu-
ous motion after the seal fully enters the bore.

STEP 8.
Remove the seal from the piston with a smooth
and rounded tool.
NOTE: Install a new seal when the master cylin-
der is disassembled for repair.

FIGURE 12. MASTER CYLINDER, REPAIR (2 of 2)

14
 1. LEVER 10
2. SPRING ADJUSTMENT
3. BATTERY COMPARTMENT,
FRONT PLATE
4. ROD ADJUSTMENT
5. LEVER 11
6. SPRING, BRAKE
7. JAM NUTS
8. MOTOR
9. BRAKE ASSEMBLY
10. SEAT
11. SCREW, ADJUSTMENT 17
1
12. SPRING
13. BALL JOINT 3
14. ROD 2
15. THRUST BEARING
16. ROD
17. SWITCH
3.9 in (100 mm)
0.039 in (1 mm)
13
2.5 in (65 mm)
6
16
12
4
14 15 5
7

11509 9
8
Lift trucks equipped with a seat brake do not have a switch located in the seat. The brake switch is at-
tached to the front plate of the battery compartment. Also, the power steering timer has been replaced
with a filter.

Lift trucks that are not equipped with a seat brake will still have a switch located in the seat to activate
* the power steering and traction circuits. These units will continue to use a power steering timer.
SEAT BRAKE ADJUSTMENT PROCEDURE
1. Apply the park brake.
2. Put a weight on the seat to release the seat brake. Apply adhesive (Loctite 290) to the threads of item
(11). Adjust the screw, item (11), to set the 2.5 in (65 mm) dimension.
3. With the seat down, use the spring adjustment (item 2) to set the spring (item 12) to a length of 3.9 in
(100 mm). Tighten the jam nut without moving the spring adjustment nut.
4. With the seat down, lift the brake spring (item 6) to remove all the clearance in the brake assembly (item 9).
Adjust the ball joint (item 13) on rod (item 14) to obtain a clearance of 0.039 in (1.0 mm) between the lever
weldment (item 5) the brake spring (item 6). With the seat up and the lever (item 1) against the battery
compartment (item 3), the brake spring (item 6) should be slightly extended to allow for brake wear.
5. With the seat up, adjust the jam nuts (item 7) so that they do not contact the thrust bearing (item 15).
Test the operation of the seat brake to make sure the seat brake is actuated correctly. Make sure the
measurements for the linkage adjustments are correctly done. If the seat brake does not correctly actuate
after the adjustments have been made, make adjustments to the length of the rod (16).

BRAKE SWITCH ADJUSTMENT PROCEDURE

Adjust the switch (item 17) so the switch leaf is actuated when the lever (item 1) contacts the battery
compartment (item 3).
Make sure the capscrew at the center of the brake drum is tightened to 66 N.m (48.7 lbf ft) torque. Make
sure that the pivot nut and capscrew for the brake lever are tightened to 40 N.m (29.5 lbf ft) torque.
FIGURE 13. SEAT BRAKE ASSEMBLY

15
 CHECKS AND ADJUSTMENTS
ADJUST THE SERVICE BRAKES
The following procedure is for newly installed brake
shoes. If the lift truck has been operated for more than 25
hours and has correct pedal height, the brakes normally
will not need adjustment.
1. See the procedure “HOW TO PUT A LIFT TRUCK
ON BLOCKS” in the PERIODIC MAINTENANCE
section of the service manual or the OPERATING
MANUAL. Put the lift truck on blocks so that the drive
wheels can be removed. Remove the drive wheels.
2. Use an adjuster tool to rotate the adjuster wheel so that
the teeth of the wheel move downward. This adjustment
expands the brake shoes. Adjust the brake shoes so that
the brake drum will not rotate.
3. Push the automatic adjuster lever away from the ad-
juster wheel with a small screwdriver. Use the adjuster
tool to loosen the adjuster wheel approximately 15 teeth
(new brake shoes).
NOTE: If the brake shoes were not replaced, loosen the
adjuster wheel approximately 15 teeth.
4. Install the drive wheels. Remove the lift truck from
the blocks. Operate the lift truck in the FORWARD and
REVERSE directions. Stop the lift truck 10 times in
each direction. This procedure causes the brake shoes to
wear a small amount and fit the brake drum better.
ADJUST THE BRAKE PEDAL
(SEE FIGURE 9.)
Adjust the pedal (2) height to 3.16 in (81 mm) by turning
the capscrew (1) at the rear of the pedal assembly. This
measurement is made with the pedal pad mounted on the
pedal. Make sure the locknut (4) is tight.
ADJUST THE MASTER CYLINDER
(SEE FIGURE 9.)
Loosen the locknut (6) on the push rod (5). Turn the push
rod until all of the clearance is removed between the
push rod and the master cylinder. Turn the push rod 1/8 of
a turn counterclockwise (viewed from the rear of the
16
fork lift). This will create the proper clearance which
will allow the piston in the master cylinder to fully re-
turn when the brake pedal is released. Make sure the
locknut is tight.
REMOVE THE AIR FROM THE BRAKE
SYSTEM
Adjust the service brakes before the air is removed from
the brake system.
1. Fill the master cylinder reservoir with brake fluid.
2. Put one end of a rubber hose on the special fitting of
the wheel cylinder. Put the other end of the hose into a
clear container of brake fluid.
3. Loosen the special fitting at the wheel cylinder one
turn so that the air can be removed from the brake sys-
tem. Slowly push the brake pedal and hold it at the end of
its stroke. Close the special fitting.
4. Repeat the procedure in steps 1 through 3 until there
are no air bubbles in the container.
5. Check the level of the brake fluid in the reservoir for
the master cylinder during the procedure. Make sure to
keep the brake fluid at the correct level.
6. Repeat the procedure for the other wheel cylinder. If
there is still air in the system, the air must be removed
from the master cylinder. Push on the brake pedal with a
steady stroke. Release the pedal slowly. Repeat this pro-
cedure until no air bubbles enter the reservoir.
TEST THE “PARKING BRAKE NOT
APPLIED” WARNING
The “Parking Brake Not Applied” system is actuated by
a combination of two switches, one attached to the park
brake mechanism and the other is the seat switch. These
switches actuate an audible buzzer on the instrument
cluster. When the operator leaves the seat for more than
two seconds without applying the parking brake, the
buzzer will be on continuously for 20 seconds. The
buzzer operates whether the key switch is “ON” or
“OFF.”

TROUBLE
The brakes do not correctly stop the lift
truck .
One brake does not release.
The brakes make too much noise.
TROUBLESHOOTING
POSSIBLE CAUSE
Air in the brake system.
The mount for the master cylinder is
loose.
The brake shoes are worn or damaged.
The linings are too hard.
A brake drum is cracked.
A back plate is damaged.
A wheel cylinder is leaking or does not
operate correctly.
The brake linings do not fit the brake
drums.
The master cylinder is damaged.
Water or oil is on the brake linings.
A brake shoe is damaged.
A return spring is wrong.
The brake lines have a restriction.
A parking brake cable is damaged or
needs adjustment.
The wheel cylinder is damaged.
The back plate is worn or damaged.
Dirt, oil, water, or brake fluid is on the
linings.
The brake linings are worn.
The brake drum is damaged.
A brake shoe is worn or damaged.
PROCEDURE OR ACTION
Repair system to prevent air entering.
Remove air from the system.
Tighten fasteners.
Install new brake shoes.
Install new correct lining.
Install new part.
Install new part.
Repair or install new parts. Remove air
from the system.
Install correct linings. Machine brake
drums.
Install new master cylinder. Remove air
from the system.
Clean or install new linings.
Install new parts.
Install new correct spring.
Remove restriction or Install new lines.
Remove air from the system.
Adjust cable or install new parts.
Repair or install new parts. Remove air
from the system.
Repair or install new parts.
Clean or install new linings.
Install new linings.
Repair or install new brake drum.
Install new brake shoe(s).
17

TROUBLE
The brakes do not operate equally.
Both brakes do not release.
The brake pedal travels too far.
18
TROUBLESHOOTING
POSSIBLE CAUSE
Oil or brake fluid is on the linings.
The lining are worn or hard.
A wheel cylinder is leaking.
The brake linings are not correctly in-
stalled.
The back plate or brake shoes are dam-
aged.
The brake drums are not round.
The shoes are adjusted too tight.
The parking brake is not released.
The parking brake cables need adjust-
ment.
There is not enough clearance at the
end of the push rod in the master
cylinder.
The master cylinder is damaged.
The brake shoes are adjusted too tight.
Air in the brake system.
Brake fluid level low. The brake system Fill brake fluid reservoir to the correct
has a leak.
The brake shoes are not adjusted cor-
rectly.
The brake linings are worn.
One of the dual brake circuits is not op- Repair or install new parts.
erating.
There is too much clearance at the end
of the push rod in the master cylin-
der.
The master cylinder is worn or dam-
aged.
PROCEDURE OR ACTION
Repair leak. Clean or install new lin-
ings.
Install new linings.
Repair or install new parts. Remove air
from the system.
Install brake linings correctly.
Repair or Install new parts.
Check to make sure there is adequate
material to allow for machining.
Machine brake drums to make
them round or install new drums.
Adjust brakes. Check self–adjusters.
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.
Check operation of self–adjusters. Ad-
just brakes.
Remove air from the system. Check for
leaks.
level. Repair leak. Remove air
from the system.
Check operation of self–adjusters. Ad-
just brakes.
Install new linings.
Adjust the clearance between the push
rod and the piston.
Repair or install new master cylinder.
Remove air from the system.
 TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE
The parking brake will not hold the lift Parking brake not adjusted correctly.
truck.
Oil, water, or brake fluid is on the lin-
ings.
The parking brake cables need adjust-
ment, lubrication, or have damage.
PROCEDURE OR ACTION
Use adjustment knob on parking brake
lever to adjust holding force. See
adjustment procedure for correct
specifications.
Clean or install new linings.
Install new parts. Lubricate and adjust
cables.

The parking brake will not release.
The parking brake lever is adjusted too
tight.
The parking brake cables need adjust-
ment, lubrication, or have damage.
Adjust parking brake. See adjustment
procedure for correct specifica-
tions.
Install new parts. Lubricate and adjust
cables.

The seat brake will not hold the lift
truck.
The seat brake will not release.
Seat brake not adjusted properly
Oil, water, or brake fluid is on the lin-
ings.
Seat brake not adjusted properly
The seat brake linkage needs adjust-
ment, lubrication, or has damage.
See adjustment procedure for correct
specifications.
Clean or install new linings.
See adjustment procedure for correct
specifications.
Install new parts. Lubricate and adjust
the linkage.

TORQUE SPECIFICATIONS
ITEM SPECIFICATION
Back Plate to Axle Mount Capscrews 225 N.m (188 lbf ft)
Wheel Cylinder Capscrews 18 to 27 N.m ( 13 to 20 lbf ft)
Axle Shaft Capscrews 90 N.m (66 lbf ft)
Wheel Nuts 237 to 305 N.m (175 to 222 lbf ft)

19
 NOTES

20
21