TRANSAXLE

J2.2-3.5XN (J45-70XN) [A276]

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced
technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could
result in damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being
lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS
in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:

 WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
 CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and
property damage.
On the lift truck, the WARNING symbol and word are on orange background. The CAUTION
symbol and word are on yellow background.

TABLE OF CONTENTS
   
General   
Discharging the Capacitors   
Description   
Transaxle Assembly   
Remove   
Install   
Maintenance and Repair   
Wheel Studs   
Removal of Defective Wheel Studs   
Removal of Sheared Off Wheel Stud   
Installation   
Transaxle Output Breathers   
Removal   
Installation   
Speed Sensor Repair   
Removal   
Installation   
Protective Cap   
Removal   
Installation   
Traction Motor   
Removal   
Installation   
Park Brake Actuator   
Removal   
Repair   
O-ring Replacement   
Rotary Shaft Seal Replacement   
Breather Valve Replacement   
Installation   
Service Brake Actuator   
Removal   
Repair   
Installation   
Brake Disc Set and Ball Ramp Actuator   
Removal   
Installation   
Output Assembly   
Removal   
Installation   
First Transmission Stage   
Removal   
Installation   
Brake Pedal and Linkages   
General   
Master Cylinder Repair   
Remove   
Disassemble   
Clean   
Inspect   
Assemble   
Bench Bleed Master Cylinder   
Install and Adjust   
Brake Pedal Components   
Remove   
Disassemble   
Inspect   
Assemble   
Install   
Brake Pedal and Master Cylinder Adjustments   
Brake Pedal Adjustment   
Master Cylinder Adjustment   
Adjust Push Rod   
Parking Brake Valve Repair   
Remove   
Disassemble   
Assemble   
Install   
Tools   

This section is for the following models:

   
J2.2-3.5XN (J45-70XN) [A276]
General
 CAUTION
Use only brake and transmission fluid from approved vendors. Using fluid from unapproved
vendors will void the warranty. Contact Hyster Company Contact Management if you have
questions about warranty status.
This section contains the removal, repair, inspection, and installation instructions for the transaxle
assembly used on these lift truck models.

 WARNING
DO NOT make repairs or adjustments unless you have been properly trained and authorized to do
so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT
operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately.
If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the
battery.
Throughout this section, forward will refer to travel in the direction of the forks and left and right will be
determined by sitting in the seat facing forward. See Figure 1.

C. FORWARD TRAVEL

Figure 1. Truck Orientation (Four-Wheel Trucks)

DISCHARGING THE CAPACITORS
 WARNING
DO NOT make repairs or adjustments unless you have been properly trained and authorized to do
so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT
operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately.
If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the
battery.
Disconnect the battery and allow the capacitors to discharge before opening any compartment
covers or inspecting or repairing the electrical system. DO NOT place tool on top of the battery. If
a tool causes a short circuit, the high current flow from the battery can cause personal injury and
property damage.
 Some checks and adjustments are performed with the battery connected. DO NOT connect the
battery until the procedure instructs you to do so. Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidentally make an electrical connection and cause injury
Before performing any tests or adjustment, block the lift truck to prevent unexpected movement.
The capacitor in the transistor controller(s) can hold an electrical charge for about 10 seconds
after the battery is disconnected. To prevent an electrical shock and personal injury, discharge
the capacitor(s) before inspecting or repairing any component in the drive unit compartment.
Make certain that the battery has been disconnected.
DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

Make certain the Emergency-Disconnect switch has not been activated. This will isolate the
controllers and prevent the capacitors from discharging properly. The proper way to disconnect
the battery is by separating the battery connectors.
1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below.
2. Turn key or keyless switch to OFF position.
3. Disconnect the battery by separating the connectors.
4. Block drive wheels to prevent lift truck from moving.
5. Make sure the Emergency-Disconnect switch HAS NOT been activated. If the Emergency-Disconnect
switch is activated, rotate the switch to the right until it pops up.
6. Press the horn button. Wait at least 30 seconds to be sure that the capacitors are fully discharged.
DESCRIPTION
This transaxle is a modular, rigid axle for use in front-wheel-drive electric balance-weight forklift trucks.
Depending on its application, this drive unit may be fitted to vehicles with a maximum lifting load range of
3,500 kg (7,716 lb). It consists of a centrally located park and service brake system, two asynchronous
traction motors, and two transmissions. The drive unit is joined to the vehicle chassis and to the lift mast
by means of fixtures mounted on the axle. See Figure 2.

A. DIRECTION OF FORWARD MOTION

1. RH TRANSMISSION OUTPUT ASSEMBLY
2. RH TRACTION MOTOR
3. SERVICE BRAKE ACTUATOR
4. LH TRACTION MOTOR
5. LH TRANSMISSION OUTPUT ASSEMBLY
6. PARK BRAKE ACTUATOR
Figure 2. Transaxle
Transaxle Assembly
REMOVE
 WARNING
The lift truck must be put on blocks for some types of maintenance and transaxle repair. The
removal of the battery, mast, transaxle, or counterweight will cause large changes in the center of
gravity. Position additional blocks under the frame when the lift truck is on blocks, so the lift truck
cannot tip over.
1. Remove mast assembly. Refer to Mast Repair, 2-, 3-, and 4-Stage Masts 4000 SRM 1338 for
procedures.
NOTE: DO NOT remove battery.
2. Turn key or keyless switch to the OFF position and disconnect battery connectors.
3. Discharge capacitors. Refer to the section Discharging the Capacitors.
4. Position lift truck on blocks so the drive tires are suspended off the floor. Refer to Periodic
Maintenance 8000 SRM 1372 for instructions for putting lift truck on blocks.
5. Remove drive wheel lug nuts and drive wheels from transaxle. Repeat for both right and left wheels.
NOTE: Perform Step 6 for lift trucks equipped with a sealed transaxle.
6. Remove two button head capscrews and speed sensor shield from lift truck. Repeat for other side.
See Figure 3.
  

A. TOP VIEW
B. BOTTOM VIEW
1. SPEED SENSOR SHIELD
2. CAPSCREW
3. WASHER
4. UPPER SEAL COVER
5. UPPER SEAL
6. MOTOR BAND
7. MOTOR BAND SEAL
8. LOWER SEAL COVER
9. LOWER SEAL
10. BUTTON HEAD CAPSCREWS
11. NUT
Figure 3. Sealed Transaxle
NOTE: Tag all electrical connectors prior to disconnect to aid in assembly.
7. Disconnect parking brake connector from main wiring harness and parking brakes. See Figure 4.
  

1. PARK BRAKE ACTUATOR CONNECTOR

Figure 4. Park Brake Actuator Connector
8. Disconnect thermal sensor connector from main wiring harness on RH motor. See Figure 5.
9. Disconnect speed sensor connector from main wiring harness. See Figure 5.
10. Remove six capscrews and disconnect power cables from the LH/RH traction motors. There are three
capscrews on each traction motor. See Figure 5.
11. Disconnect brake line from master cylinder at the traction motor port. Cap brake line and plug at the
traction motor port to prevent contamination of brake system. See Figure 6.
 CAUTION
Disposal of lubrication must meet local environment regulations.
12. Place a suitable container with the capacity of 3.2 liter (3.4 qt) under the transaxle brake chamber.
NOTE: Each transmission output assembly oil capacity is 0.5 liter (0.5 qt).
13. Remove plugs and washers and drain oil from each outer transmission and brakes. See Figure 7.
  

1. SPEED SENSOR CONNECTOR

2. THERMAL SENSOR CONNECTOR
3. TRACTION MOTOR POWER CABLES AND CAPSCREWS
Figure 5. Electrical Connectors
  

1. BRAKE LINE FROM MASTER CYLINDER

Figure 6. Brake Line From Master Cylinder
  

NOTE: UNSEALED TRANSAXLE SHOWN. SEALED TRANSAXLE IS SIMILAR.

A. LH TRANSMISSION
B. RH TRANSMISSION

C. BRAKE CHAMBER
1. PLUG
2. WASHER
3. TRANSAXLE/TRACTION MOTOR/BRAKE ASSEMBLY
Figure 7. Transaxle Oil Drain/Fill
 CAUTION
The transaxle assembly weighs approximately 303.4 kg (668.9 lb). Make sure lifting device has
enough lift capacity to safely lift the assembly.
NOTE: Use approved lifting device to hold and lift the transaxle assembly during removal.
14. With a suitable lifting device attached, remove four nuts, mounting bolts, washers, and transaxle
assembly from lift truck frame. See Figure 8.
NOTE: Perform Step 15 through Step 19 for lift trucks equipped with a sealed transaxle.
15. Remove two capscrews, washers, upper seal cover, and upper seal from transaxle. See Figure 3.
Discard seal. Repeat for other side.
 16. Remove two capscrews, washers, lower seal cover, and lower seal from transaxle. See Figure 3.
Discard seal. Repeat for other side.
17. Remove any remaining RTV adhesive/sealant from around edges and between slots on transaxle.

NOTE: PORTIONS OF LIFT TRUCK FRAME REMOVED FOR CLARITY.

1. TRANSAXLE ASSEMBLY
2. NUT
3. MOUNTING BOLT
4. WASHER
5. FRAME
Figure 8. Transmission Output Assembly and Traction Motor Mount
18. Remove two button head capscrews and nuts from motor band. See Figure 3. Repeat for other side.
19. Remove motor band and motor band seal. See Figure 3. Discard seal. Repeat for other side.
20. Remove 13 socket head bolts from transmission output assembly. See Figure 9.
  

A. LEFT-HAND SIDE
B. RIGHT-HAND SIDE
1. LH TRANSMISSION OUTPUT ASSEMBLY
2. LH TRACTION MOTOR
3. SOCKET HEAD BOLT
4. CYLINDER PIN
5. RH TRANSMISSION OUTPUT ASSEMBLY
6. RH TRACTION MOTOR
Figure 9. Transmission Output Assembly to Traction Motor Mount
21. Place the pry bar into the recessed area of the transaxle output assembly and pry the transmission output
assembly away from the traction motor. See Figure 10.
  

1. PRY BAR
2. RECESSED AREA
Figure 10. Pry Bar
22. Separate the traction motor and transmission output assembly by slowly moving the transmission output
assembly back and forth while lifting and pulling it away from the traction motor. See Figure 11.
  

Figure 11. Transmission Output Assembly Installation/Removal

23. Remove the two cylinder pins from the transmission output assembly and traction motor casing.
See Figure 12.

 
 Figure 12. Cylinder Pin Removal
24. Repeat Step 20 through Step 23 for the opposite side if required.
INSTALL
NOTE: Before installing transmission output assemblies, clean sealing surfaces thoroughly.
1. Apply surface sealant LOCTITE 574 evenly across all the mating surfaces of the components.
SeeFigure 13.

Figure 13. Sealant

 WARNING
In order to avoid damage, make sure that all gear teeth are engaged before they are joined. If
necessary, use suitable slinging equipment and lifting tackle.
2. Install the transmission output assembly onto the traction motor. See Figure 11.
3. Install two cylinder pins into the transaxle output casing. Using a soft faced hammer and drift countersink
into both assemblies. See Figure 14.
  

Figure 14. Cylinder Pin Installation

4. Install 13 socket head bolts into the transaxle output assembly and tighten to 195 N•m (143 lbf ft).
See Figure 9.
5. Repeat Step 1 through Step 4 for opposite traction motor transmission output assembly.
 NOTE: Perform Step 6 and Step 10 for lift trucks equipped with sealed transaxle.
6. Install new motor band seal and motor band onto transaxle. Repeat for other side.
7. Install two button head capscrews and nuts into motor band. Tighten button head capscrews to 2 N•m
(17.7 lbf in). Repeat for other side.
NOTE: Make sure transaxle upper and lower seal surfaces are clean of any old sealant before
performing Step 8.
8. Apply a 5 to 6 mm (0.20 to 0.24 in.) bead of RTV adhesive/sealant to edges and between slots on
transaxle where upper and lower seals are installed.
9. Install new upper seal, seal cover, two washers and capscrews into seal cover and transaxle.
SeeFigure 15. Tighten capscrews. Repeat for other side.

 
1. MOTOR BAND
2. MOTOR BAND SEAL
3. BUTTON HEAD CAPSCREW
4. NUT
5. CAPSCREWS
6. WASHERS
7. UPPER SEAL COVER
8. UPPER SEAL
9. LOWER SEAL
10. LOWER SEAL COVER
Figure 15. Sealed Transaxle Seal Locations

10. Install new lower seal, seal cover, two washers and capscrews into seal cover and transaxle.
SeeFigure 15. Tighten capscrews. Repeat for other side.

 WARNING
The transaxle assembly weighs approximately 303.4 kg (668.9 lb). Make sure lifting device has
enough lift capacity to safely lift the assembly.
NOTE: Use approved lifting device to hold and lift the transaxle/traction motor/brake assembly during
installation.
NOTE: Ensure that the top surface of the transaxle mounts are contacting the frame.
11. Install four nuts, mounting bolts, washers, and transaxle/traction motor/brake assembly into the lift truck
frame. Tighten the four nuts to 755-830 N•m (557-613 lbf ft). See Figure 8.
12. Remove cap from brake line and plug from the traction motor port. Connect brake line from master
cylinder at the traction motor port. See Figure 6.
13. Fill transaxle with oil. Refer to the manual Periodic Maintenance 8000 SRM 1372.
14. Install six capscrews and connect power cables to the LH/RH traction motors. See Figure 5.
NOTE: Perform Step 15 for lift trucks equipped with Outdoor Protection/Wash-down Package.
15. Spray LH/RH traction motor power cables with rust inhibitor-ignition sealer.
16. Connect speed sensor connector to the main wiring harness. See Figure 5.
17. Connect thermal sensor connector to the main wiring harness. See Figure 5.
18. Connect parking brake connector to the main wiring harness and parking brakes. See Figure 4.
19. Install drive wheels and drive wheel lug nuts onto the transaxle. Tighten lug nuts to 339 to 380 N•m (250
to 280 lbf ft).
20. Remove the lift truck from the blocks. Refer to the manual Periodic Maintenance 8000 SRM 1372.
21. Connect battery connectors.
NOTE: Perform Step 22 for lift trucks equipped with Outdoor Protection/Wash-down Package.
22. Spray battery connectors with rust inhibitor-ignition sealer.
23. Install mast assembly. Refer to the manuals Mast Repair, 2-, 3-, and 4-Stage Masts 4000 SRM 1338
for procedures.
24. Turn key or keyless switch to ON position and test lift truck for proper operation.

Maintenance and Repair

WHEEL STUDS
Removal of Defective Wheel Studs
 WARNING
Always use protective sleeve over jaws of vise. Damage may occur to the gear shaft.
 1. Place the transmission output assembly in vise to secure. Use protective sleeves over jaws of vise.
See Figure 16.
NOTE: For any special tools required in this procedure, refer to Table 2.

1. ADJUSTABLE PLIERS
2. PROTECTIVE SLEEVES
3. VISE
Figure 16. Transmission Output Assembly in Vise
2. Using a set of adjustable grip pliers, unscrew defective wheel stud from the transmission output
assembly. See Figure 16.
Removal of Sheared Off Wheel Stud
1. Center punch the sheared wheel stud. See Figure 17.
  

1. CENTER PUNCH
Figure 17. Center Punch
2. Using a 3 mm twist bit drill into the sheared wheel stud to make a pilot hole for the 7 mm twist drill bit.
See Figure 18.

 
 Figure 18. Small Twist Bit
3. Using a 7 mm twist drill bit drill into the sheared wheel stud. See Figure 19.

Figure 19. Large Twist Bit

4. Using a tap wrench and easy out extract sheared wheel stud. See Figure 20.
  

1. EASY OUT
2. TAP WRENCH
Figure 20. Wheel Stud Extraction
5. Using a tap wrench and M18x1.5 tap, re-tap the threads where the sheared or defective wheel stud was
removed from. See Figure 21.
  

1. TAP
2. TAP WRENCH
Figure 21. Thread Repair
6. Check the threads with a thread plug gauge. If the reject side of the gauge fits, you must replace the
complete transaxle output assembly.
  

1. THREAD PLUG GAUGE

Figure 22. Thread Plug Gauge

Installation
 WARNING
Always use protective sleeve over jaws of vise. Damage may occur to the gear shaft.
NOTE: For any special tools required in this procedure, refer to Table 2.
1. Place the transmission output assembly in vise to secure. Use protective sleeves over jaws of vise.
See Figure 16.
2. Apply LOCTITE No. 270 evenly to wheel stud threads on the transmission output assembly side and
install special tool 6 into the transmission output assembly.
3. Using special tool 6, tighten all wheel studs slowly. See Figure 23.
  

1. SPECIAL TOOL 6
Figure 23. Special Tool 6
4. Using special tool 6, tighten wheel studs to 100 N•m (74 lbf ft). See Figure 24.

 
1. SPECIAL TOOL 6
2. TORQUE WRENCH
Figure 24. Torque Wheel Stud
TRANSAXLE OUTPUT BREATHERS
Removal
NOTE: The lift truck has three breathers; each transmission output assembly has one, and the parking
brake actuator has one.
1. Using a flat tip screw driver, remove the breather cap. See Figure 25.

1. BREATHER
2. FLAT TIP SCREWDRIVER
Figure 25. Breather Cap Removal
2. Remove the spring from breather cap by hand.

 WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel.
Make sure that the path of the compressed air is directed away from all personnel. Wear
protective goggles or a face shield to prevent injury to the eyes.
3. Using an air nozzle with compressed air, blow the breather ball from breather. See Figure 26.
  

1. BREATHER
2. BREATHER BALL
3. COMPRESSED AIR NOZZLE
Figure 26. Breather Ball Removal
4. Remove the steel wool from inside the breather.
5. Slowly screw in extracting tool and remove breather. Discard breather. See Figure 27 and Figure 28.
  

1. EXTRACTOR
Figure 27. Extracting Tool

1. EXTRACTOR
2. BREATHER
Figure 28. Breather Removal

Installation
1. Place new breather into position by hand. See Figure 29.

1. BREATHER
Figure 29. Breather
2. Using special tool 2 and a soft faced hammer, tap the breather into place flush with the housing.
SeeFigure 30.
  

1. SOFT FACED HAMMER

2. SPECIAL TOOL 2
3. BREATHER
Figure 30. Breather Installation
SPEED SENSOR REPAIR
The speed sensor monitors the speed of the transaxle and relays the information to the controller. The
speed sensor can be replaced with the transaxle still on the lift truck.
Removal
1. Park the lift truck on a level surface. Turn the key switch to the OFF position and unplug the battery
connector.
2. Discharge the capacitors. Refer to the section Discharging the Capacitors.
3. Remove floor mat and floor plates from the operator compartment to access the top of the transaxle.
See Frame 100 SRM 1342 for procedures.
NOTE: Perform Step 4 for lift trucks equipped with a sealed transaxle.
4. Remove two capscrews and speed sensor shield from transaxle. See Figure 31.
  

1. CAPSCREWS
2. SPED SENSOR SHIELD
3. SPEED SENSOR
Figure 31. Speed Sensor Shield
5. Disconnect the speed sensor wiring harness from main wiring harness.
 CAUTION
Use a brush to clean around the speed sensor before removing to avoid contaminating the
transaxle.
6. Remove the capscrew securing the speed sensor to the traction, motor using a 6 mm Allen wrench.
See Figure 32.
  

1. CAPSCREW
2. 6 MM ALLEN WRENCH
3. SPEED SENSOR
Figure 32. Capscrew Removal/Installation
7. Remove the speed sensor from the traction motor. See Figure 33.
8. Repeat Step 1 through Step 7 for opposite traction motor if necessary.
Installation
1. Insert the new speed sensor into the traction motor. See Figure 33.
2. Using a 6 mm Allen wrench, install the capscrew and tighten to 6.6 N•m (58 lbf in). See Figure 32.
3. Connect the speed sensor wiring harness to main wiring harness.
NOTE: Perform Step 4 for lift trucks equipped with sealed transaxle.
4. Install speed sensor shield and two capscrews into transaxle. Repeat for other side. See Figure 31.
5. Install floor plates and floor mat. See Frame 100 SRM 1342 for procedures.
6. Reconnect the battery and test lift truck for proper operation.
7. Repeat Step 1 through Step 6 for opposite traction motor if necessary.
  

1. SPEED SENSOR
Figure 33. Speed Sensor Removal/Installation

PROTECTIVE CAP
Removal
1. Remove protective cap from transmission output assembly with flat tip screw driver. See Figure 34.
  

1. FLAT TIP SCREWDRIVER

2. PROTECTIVE CAP
Figure 34. Protective Cap Removal
2. Repeat Step 1 for opposite transmission output assembly if necessary.

Installation
1. Place protective cap on transmission output assembly. See Figure 35.
  

1. PROTECTIVE CAP
Figure 35. Protective Cap Installation
2. Repeat Step 1 for opposite transmission output assembly if necessary.

TRACTION MOTOR
Removal
NOTE: For any special tools required in this procedure, refer to Table 2.
NOTE: Before separating the two traction motors, remove the left and right transmission output
assemblies. Refer to the section Output Assembly, Removal.
1. Place the axle on transmission output flange side of motor.
2. Remove ten retaining bolts. See Figure 36.
  

1. RETAINING BOLTS
Figure 36. Bolt Removal/Installation
3. Remove the two cylinder pins using soft face hammer and drift pin. See Figure 37.

 
1. CYLINDER PINS
Figure 37. Cylinder Pins
4. Install two lift-eye bolts onto RH traction motor. See Figure 38.

1. LIFT-EYE BOLTS
Figure 38. Lift-Eye Bolts
5. Carefully lift and separate the two traction motors. See Figure 39.
  

B. LH MOTOR

Figure 39. Lifting/Lowering Traction Motor

6. Lower the RH traction motor onto work surface, and remove the two lift-eye bolts. See Figure 38.
7. Place the motor on the transmission output flange side.
8. If disassembly of RH traction motor brake disc assembly is required, refer to the section Brake Disc Set
and Ball Ramp Actuator, Removal.
9. If disassembly of LH traction motor brake disc assembly is required, refer to the following repair
procedures:
• Park Brake Actuator, Removal
• Service Brake Actuator, Removal
• Brake Disc Set and Ball Ramp Actuator, Removal
Installation
NOTE: For any special tools required in this procedure, refer to Table 2.
NOTE: Always assemble motors in a vertical position. Place LH traction motor on transmission output
flange side of motor.
1. If LH traction motor brake disc were disassembled, refer to the following repair procedures:
• Brake Disc Set and Ball Ramp Actuator, Installation
• Service Brake Actuator, Installation
• Park Brake Actuator, Installation
2. If RH traction motor brake disc were disassembled, refer to the section Brake Disc Set and Ball Ramp
Actuator, Installation.
3. Install special tool 1 and special tool 4 as shown in Figure 40 onto the shaft of the RH traction motor. This
allows for the RH traction motor to be rotated during the assembly process to seat the brake disc sets into
the disc housing.
  

2. SPECIAL TOOL 1

Figure 40. Special Tool Installation

4. Attach the two lift-eye bolts to RH traction motor and lift RH traction motor. See Figure 38.
5. Install O-ring in groove on RH traction motor. Apply grease to O-ring for installation. See Figure 41.
  

1. O-RING
Figure 41. O-ring
6. Place LH traction motor on work surface with the transmission output flange side down. Lower RH
traction motor, while rotating the motor shaft with special tool 4. This will seat the brake disc set into the
brake disc housing. See Figure 39.
7. With the traction motors seated together ensure that the terminal boards on the traction motors face the
same direction. See Figure 42.
  

1. TERMINAL BOARDS
Figure 42. Terminal Boards.
8. Install the two cylinder pins and counter sink with soft faced hammer and drift pin. See Figure 37.
9. Install the ten retaining bolts and tighten to 79 N•m (58 lbf ft). See Figure 36.
10. Remove lift-eye bolts and special tool assembly from RH traction motor assembly. See Figure 38.
PARK BRAKE ACTUATOR
Removal
 WARNING
Due to high spring tension, there is risk of injury during the removal of the park brake actuator.
Release park brake actuator before removal.
1. Carefully remove two retaining bolts. See Figure 43.
  

1. RETAINING BOLTS
Figure 43. Retaining Bolts Removal/Installation
2. Remove park brake actuator from LH traction motor. See Figure 44.
  

1. PARK BRAKE ACTUATOR

2. BREATHER VALVE
Figure 44. Park Brake Actuator and Breather Valve

Repair
O-ring Replacement
1. Remove and discard the old O-ring from parking brake actuator. See Figure 45.
  

1. O-RING
2. PARK BRAKE ACTUATOR
Figure 45. O-ring Removal/Installation
2. Grease new O-ring and install onto parking brake actuator. See Figure 45.
Rotary Shaft Seal Replacement
1. Remove and discard old rotary shaft seal. See Figure 46.
2. Slide new rotary shaft seal onto park brake actuator until flush with piston. If necessary use a suitable
sleeve for installation. See Figure 46.
Breather Valve Replacement
1. Using a flat tip screw driver, remove the breather valve from the park brake actuator. See Figure 44.
2. Remove the spring from breather cap by hand.

 WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel.
Make sure that the path of the compressed air is directed away from all personnel. Wear
protective goggles or a face shield to prevent injury to the eyes.
3. Using an air nozzle with compressed air, blow the breather ball from breather. See Figure 26.
4. Remove steel wool from inside the breather.
5. Slowly screw in extracting tool and remove breather. Discard breather. See Figure 27 and Figure 28.
6. Place new breather into position by hand. See Figure 29.
7. Using special tool 2 and a soft faced hammer, tap the breather into place flush with the housing.
SeeFigure 30.
  

1. ROTARY SHAFT SEAL

2. ROTARY SHAFT
Figure 46. Rotary Shaft Seal Removal/Installation
 Installation
1. Place axle in position shown in Figure 47.

Figure 47. Axle Position

2. Install park brake actuator into LH traction motor housing. Ensure that breather valve is facing upward.
See Figure 48.
  

A. THE PARK BRAKE ACTUATOR WILL SEAT INTO THIS WEDGE WHEN CORRECTLY INSTALLED.
Figure 48. Park Brake Actuator Installation and Alignment Position
3. Align park brake actuator with the wedge faces of the ball ramp actuator. The wedge face can be seen
through the opening in the LH traction motor housing. See Figure 48 and Figure 49.
  

A. ACTUATOR ON WEDGE FACE

1. PARK BRAKE ACTUATOR
2. SERVICE BRAKE ACTUATOR
3. BALL RAMP ACTUATOR
4. LH MOTOR HOUSING
Figure 49. Park Brake Actuator Alignment

 WARNING
Due to high spring tension, there is risk of injury during the installation of the park brake actuator.
Make sure the park brake actuator is securely attached to the motor casing.
4. Install two retaining bolts and tighten to 23 N•m (17 lbf ft). See Figure 43.

SERVICE BRAKE ACTUATOR

Removal
1. Remove two retaining bolts. See Figure 50.
  

1. RETAINING BOLTS
Figure 50. Retaining Bolts
2. Remove the service brake actuator from LH traction motor. See Figure 51.

 
1. SERVICE BRAKE ACTUATOR
2. LH MOTOR
Figure 51. Service Brake Actuator Removal/Installation

Repair
1. Remove the bleed screw from service brake actuator. See Figure 52.

1. BLEED SCREW
Figure 52. Bleed Screw
2. Remove the piston from the cylinder of the service brake actuator.
NOTE: During removal of the seal, note the seal lip orientation to aid in the proper installation of the new
seal.
3. Remove and discard old seal, and install new one, as shown in Figure 53.
  

A. SEAL
Figure 53. Seal
NOTE: Prior to installing the new O-ring, coat it with a light coat of grease.
 4. Remove and discard old O-ring from cylinder of the service brake actuator and install new one.
SeeFigure 54.
5. Coat piston with a light coat of oil and install piston into the cylinder of the service brake actuator, as
shown in Figure 55.
6. Install retaining ring onto piston as shown in Figure 55.
7. Install bleed screw into service brake actuator, as shown in Figure 52. Tighten bleed screw to 12 to
16 N•m (9 to 11 lbf ft).

1. O-RING
Figure 54. O-ring
  

3. CYLINDER

Figure 55. Piston and Retaining Ring Installation

Installation
1. Grease O-ring on service brake actuator. See Figure 54.
2. Position transaxle as shown in Figure 47.
3. Position service brake actuator with bleed screw facing upward. See Figure 56.
  

1. BLEED SCREW
2. HYDRAULIC CONNECTOR
Figure 56. Service Brake Actuator Position
4. Align piston with the wedge faces of the ball ramp actuator. See Figure 57.
5. Install service brake actuator into LH traction motor. See Figure 58.
6. Install two retaining bolts, and tighten to 23 N•m (17 lbf ft). See Figure 50.
  

A. ALIGNMENT OF SERVICE BRAKE ACTUATOR ON THE BALL RAMP ACTUATOR

1. SERVICE BRAKE ACTUATOR
2. PARK BRAKE ACTUATOR
3. BALL RAMP ACTUATOR
4. LH MOTOR HOUSING
Figure 57. Service Brake Actuator Alignment To On The Ball Ramp Actuator
  

1. SERVICE BRAKE ACTUATOR

2. LH MOTOR
Figure 58. Service Brake Actuator Installation

BRAKE DISC SET AND BALL RAMP ACTUATOR

Removal
NOTE: Before the brake disc set and ball ramp actuator can be removed, first separate the two traction
motors. Refer to the section Traction Motor, Removal.
NOTE: Always replace brake disc sets in pairs.
1. Position RH traction motor vertically on the transaxle output flange side of the traction motor as shown
in Figure 59.
2. Remove the first snap ring and first brake disc set. See Figure 59.
  

1. FIRST BRAKE DISC SET

2. FIRST SNAP RING
Figure 59. First Snap Ring and First Brake Disc Set Removal/Installation
3. Position the LH traction motor vertically on the transaxle output flange side of the traction motor as shown
in Figure 60.
4. Remove any shims lying on top of the ball ramp actuator, if any are present. See Figure 60.
  

1. SHIM
Figure 60. Shim Removal
5. Remove ball ramp actuator from motor. See Figure 61.
  

1. BALL RAMP ACTUATOR

Figure 61. Ball Ramp Actuator Removal/Installation
6. Remove any shims lying under the ball ramp actuator, if any are present. See Figure 62.

1. SHIM
 Figure 62. Shims Under Ball Ramp Actuator
7. Remove second snap ring and second brake disc set. See Figure 63.

1. SECOND SNAP RING

2. SECOND BRAKE DISC SET
Figure 63. Second Snap Ring and Brake Disc Set Removal/Installation
Installation
1. Position the LH traction motor vertically on transaxle output flange side of the traction motor as
shown Figure 64.
2. Place the second brake disc set and second snap ring into the housing. See Figure 64.
  

1. SECOND BRAKE DISC SET

Figure 64. Second Brake Disc Set
3. Install the ball ramp actuator into the motor housing.
4. Position the ball ramp actuator so that the service and park brake actuators can engage from the
openings in the LH traction motor housing. See Figure 61.
5. Install first disc brake set and measure the air-gap clearance by first measuring the distance between the
transmission flange and outer top brake disc on the LH traction motor. This will give you dimension A.
See Figure 65..
  

A. DIMENSION A
1. SECOND DISC BRAKE SET
2. FIRST DISC BRAKE SET
Figure 65. Dimension A LH Traction Motor
6. For dimension B measure the distance between the motor flange and the contact surface for the outer
disc on the RH traction motor. This will give you dimension B. See Figure 66.

A. DIMENSION B
Figure 66. Dimension B RH Traction Motor
7. Use the measurements acquired in Step 5 and Step 6, (see Table 1) to calculate the number of shims
required to obtain the proper air-gap clearance.
NOTE: In order to adjust the specified air-gap clearance of the disc set correctly, use shim rings. Arrange
shims symmetrically on either side of the ball ramp actuator. If an odd number of shim rings is required,
this will result in asymmetry. The maximum asymmetry may be 0.5 mm (0.02 in.).
8. Insert a shim ring on either side of the ball ramp actuator.
9. If the air-gap clearance is correct continue to Step 10.
If air-gap clearance is not correct, repeat Step 5 through Step 6.
10. Remove the first brake disc set and ball ramp actuator.
11. Install bottom shim ring, ball ramp actuator and top shim ring.
12. Place first brake disc set on motor shaft and using snap ring pliers, install snap ring onto motor shaft.
See Figure 59.
13. Assemble both traction motors as shown in section Traction Motor, Installation.
Table  1.   Air-Gap Equation
Example A = 28.10 mm
B = 22.50 mm

A (28.1 mm) - B (22.5 mm) = X (5.60 mm)

Shim rings must be applied to obtain correct air-gap clearance. The shims are 0.5 mm thickness.

Calculation:

Actual clearance between brake disc set and RH motor is 5.60 mm.

Clearance should be between 4.25 to 4.75 mm.

Actual clearance subtracted from "MIN" allowed 5.60 mm – 4.25 mm = 1.35 mm which calls for
clearance. three shims at 0.5 mm and will make the clearance
below "MIN".

Actual clearance subtracted from "MAX" allowed 5.60 mm – 4.75 mm = 0.85 mm which calls for two
clearance. shims at 0.5 mm and will make the clearance 4.60
mm and will fall in clearance range.

Two shims will be added to make the air gap clearance 4.60 mm.

OUTPUT ASSEMBLY
Removal
NOTE: The procedures below apply to both traction motor transmission output assemblies.
1. Remove 13 socket head bolts from the transmission output assembly. See Figure 67.
  

A. LH TRANSMISSION
B. RH TRANSMISSION
1. LH TRANSMISSION OUTPUT ASSEMBLY
2. LH TRACTION MOTOR
3. SOCKET HEAD BOLT
4. CYLINDER PIN
5. RH TRANSMISSION OUTPUT ASSEMBLY
6. RH TRACTION MOTOR
Figure 67. Transmission Output Assembly to Traction Motor Mount

2. Place pry bar into the recessed area of the transmission output assembly and pry assembly away from traction
motor. See Figure 68.
  

1. PRY BAR
2. RECESSED AREA
Figure 68. Pry Bar
3. Separate traction motor and transmission output assembly by slowly moving assembly back and forth
while lifting and pulling it away from the traction motor. See Figure 69.
  

Figure 69. Transmission Output Assembly Removal/Installation

4. Remove two cylinder pins from transmission output assembly and traction motor casing. SeeFigure 70.

 
 Figure 70. Cylinder Pin Removal.
5. Repeat Step 1 through Step 4 for both traction motors transmission output assemblies.
Installation
NOTE: The procedures below apply to both traction motor transmission output assemblies.
NOTE: Before installing transaxle output assemblies, clean sealing surfaces thoroughly.
1. Apply surface sealant LOCTITE 574 evenly across all the mating surfaces of the components.
SeeFigure 71.

Figure 71. Sealant

 WARNING
In order to avoid damage, make sure that all gear teeth are engaged before they are joined. If
necessary, use suitable slinging equipment and lifting tackle.
2. Install the transaxle output assembly onto the traction motor. See Figure 69.
3. Install two cylinder pins into the transaxle output casing. Using a soft faced hammer and drift countersink
into both assemblies. See Figure 72.
  

Figure 72. Cylinder Pin Installation

4. Install 13 socket head bolts into the transaxle output assembly and tighten to 195 N•m (143 lbf ft).
See Figure 67.
FIRST TRANSMISSION STAGE
 Removal
NOTE: For any special tools required in this procedure, refer to Table 2.
NOTE: Before the first transmission stage can be removed, remove the output assembly. Refer to the
section Output Assembly.
NOTE: Always replace the spur gear and pinion gear as a set. Never replace one gear without replacing
the other gear.
NOTE: The procedures below apply to both traction motors.
1. Remove spur gear and sun gear from traction motor casing. See Figure 73.

1. SPUR AND SUN GEAR

Figure 73. Spur and Sun Gear Removal
2. Remove hex-head pinion bolt and plate from the input pinion. See Figure 74.
  

Figure 74. Pinion Bolt Removal

3. Thread special tool 4 into the input pinion first by hand. Slowly insert special tool 4 into the input pinion.
This will help press the pinion out for disassembly. See Figure 75.

 
1. SPECIAL TOOL 4
2. PNEUMATIC WRENCH
Figure 75. Input Pinion Removal
4. Use a pneumatic wrench to press input pinion out of pinion gear. See Figure 75.
5. Remove the input pinion, phonic wheel, and flange bushing from motor. See Figure 76.
  

Figure 76. Pinion and Phonic Wheel Removal

 WARNING
 When pressing phonic wheel, DO NOT place hands in area between plunger and tool, injury may
occur.
NOTE: The lever press plunger, tool, and input pinion must align vertically with no offset. See Figure 77.
Use special tool 3.

Figure 77. Pressing The Input Pinion

6. Using special tool 3, press phonic wheel out of input pinion and flange bushing. Discard flange bushing.
See Figure 78.

Figure 78. Phonic Wheel

Installation
  WARNING
When pressing in input pinion, DO NOT place hands in area between plunger and tool, injury may
occur.
NOTE: The procedures below apply to both traction motors.
NOTE: For any special tools required in this procedure, refer to Table 2.
NOTE: Carry out press-in process carefully and slowly to avoid damaging the flange bushing. The press
in pressure is not to exceed 25 kN (224 lbf) or damage may occur.
NOTE: The lever press plunger, tool, and input pinion must align vertically with no offset. See Figure 77.
Use special tool 3.
1. Press input pinion and new flange bushing into phonic wheel. See Figure 78.

 WARNING
Death or serious injury can occur if brakes are inoperable. The bore hole to receive the input
pinion in the motor shaft and the input pinion ball must be absolutely free from oil and grease. Be
sure to use only motorshaft without any damage to machined taper surface.
2. Thoroughly clean bore hole to receive input pinion in motor shaft. See Figure 79.

Figure 79. Bore Cleaning

3. Install input pinion with flange bush and phonic wheel on motor shaft. See Figure 80.
  

Figure 80. Input and Phonic Wheel Installation

4. Measure the distance between the input pinion top surface and the traction motor casing flange surface
and note dimension. See Figure 81.
  

Figure 81. Measurement

5. Screw special tool 5 by hand in bore hole of input pinion. See Figure 82.

 
1. SPECIAL TOOL 5
Figure 82. Special Tool 5
6. Install special tool 7 using special tool 5 and secure using special tool 1. See Figure 83.

1. SPECIAL TOOL 1
2. SPECIAL TOOL 5
3. SPECIAL TOOL 7
Figure 83. Special Tool 7

 WARNING
Death or serious injury can occur if brakes are inoperable.
NOTE: Ensure that the press-in depth of the motor pinion is 4.5 to 6 mm (0.18 to 0.24 in.) in the motor
shaft. If the necessary press-in depth is not reached, do not use the axle any more. Contact ZF Customer
Service.
7. Apply pressure to special tool 7 using special tool 8. Press input pinion to flange bush and phonic wheel
in motor shaft. Measure distance at regular intervals between input pinion top surface and motor casing
flange surface. See Figure 83.
NOTE: Remove all special tools specified in Step 5 through Step 7.
8. Insert hex bolt and washer in input pinion and tighten to 200 N•m (147 lbf ft). See Figure 84.
  

Figure 84. Pinion Bolt Installation

9. Clean bearing seat to receive spur gear into the traction motor casing. See Figure 85.

 
 Figure 85. Clean Bearing Seat
10. Install spur gear and sun gear into bearing seat and hammer slightly with a soft faced hammer, until
correct seat is reached. See Figure 86.

 
 Figure 86. Spur and Sun Gear Installation
NOTE: Before installing outputs, clean sealing surfaces thoroughly.
11. Apply surface sealant LOCTITE 574 evenly across all the mating surfaces of the components.
SeeFigure 87.

Figure 87. Sealant

12. Install transaxle output assembly onto the traction motor casing. See Figure 88.

 
 Figure 88. Transaxle Output Assembly Installation
13. Install two cylinder pins into output casing. Using a soft faced hammer and drift, countersink cylinder
pins into both assemblies. See Figure 89.

 
 Figure 89. Cylinder Pins
14. Install 13 socket head bolts into the transaxle output assembly and tighten to 195 N•m (143 lbf ft).
See Figure 90.

Figure 90. Retaining Bolts

Brake Pedal and Linkages
GENERAL
This section has service procedures for the following: brake pedal, master cylinder, and park brake
release. See Figure 91.
  

1. BRAKE PEDAL
2. PARK BRAKE RELEASE HANDLE
3. PARK BRAKE CABLE

4. PARK BRAKE ACTUATOR

5. MASTER CYLINDER
Figure 91. Brake System

MASTER CYLINDER REPAIR

Remove
1. Block front and rear sides of wheels to make sure lift truck cannot move.
2. Remove floor mat and floor plates from lift truck to access master cylinder. See Frame 100 SRM 1342 for
procedures.
NOTE: Tag all electrical connections prior to removal to aid in installation.
3. Disconnect wire at brake sensor and bottom of master cylinder. Remove brake sensor. SeeFigure 92.
4. Disconnect reservoir level sensor switch from cowl harness.
5. Remove tube assembly from master cylinder. Plug master cylinder and tube to prevent foreign material
from entering the brake system. See Figure 92.
NOTE: Perform the following step only if the tube is damaged.
6. Remove tube assembly from brake fitting. Plug fitting to prevent foreign material from entering brake
system. Lay tube assembly aside until ready for bench bleed. See Figure 92.
7. Remove cotter pin, washer, and pin from plate at bottom of brake pedal assembly. See Figure 92.
8. Remove two nuts, two capscrews, and master cylinder from mounting plate. See Figure 92.
  

1. MASTER CYLINDER
2. BRAKE SENSOR
3. TUBE ASSEMBLY
4. BRAKE FITTING
5. COTTER PIN
6. WASHER
7. PIN
8. MOUNTING PLATE
9. NUT
10. CAPSCREW
11. PLATE
Figure 92. Master Cylinder
Disassemble
 CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
1. Drain master cylinder into drain pan. Dispose of brake fluid.
2. Remove push rod and boot from cylinder. See Figure 93.

 WARNING
Use care when removing snap ring to avoid possible injury.
3. Remove snap ring from cylinder. See Figure 93.
 CAUTION
When the piston is removed, make sure the cylinder bore and piston are not scratched or
damaged.
NOTE: DO NOT disassemble piston assembly.
4. Remove piston assembly from cylinder. See Figure 93.
5. Remove gasket and cap from reservoir. See Figure 93.
  

NOTE: ITEM 12, PISTON ASSEMBLY (INCLUDES ITEMS 1 THROUGH 6), SHOULD NOT BE

DISASSEMBLED. ILLUSTRATION CREATED FROM MANUFACTURER’S DOCUMENTATION.
1. SECONDARY CUP
2. PISTON
3. SPACER
4. PRIMARY CUP
5. RETAINER
6. SPRING
7. SNAP RING
8. BOOT
9. PUSH ROD
10. NUT
11. CLEVIS
12. PISTON ASSEMBLY
13. PIN
14. WASHER
15. COTTER PIN
16. REPAIR KIT
17. MASTER CYLINDER ASSEMBLY
18. GASKET
19. CAP
20. CYLINDER
21. CLAMP
22. RESERVOIR
Figure 93. Master Cylinder Assembly
Clean
 CAUTION
DO NOT use an oil solvent to clean the master cylinder. Use Dexron® III transmission fluid from a
sealed container only.
1. Clean components paying particular attention to those areas highlighted in Figure 94 with Dexron® III
transmission fluid only.
  

Figure 94. Cleaning Components

Inspect
1. Inspect exterior of master cylinder assembly for damage. Replace assembly if damaged.
2. Inspect bore of master cylinder for holes or scratches. Replace master cylinder assembly if damaged.
Assemble
 CAUTION
When piston is installed, make sure the cylinder bore and piston are not scratched or damaged.
1. Install piston assembly into cylinder. See Figure 93.

 WARNING
Use care when installing snap ring to avoid possible injury.
2. Install snap ring into cylinder. See Figure 93.
3. Install boot and push rod into cylinder. See Figure 93.
 Bench Bleed Master Cylinder
NOTE: Master cylinder must be bench bled before installing it on lift truck.
1. Place master cylinder, horizontally, in a soft-jawed vise.
2. Remove plugs from tube assembly ends. Connect tube assembly to master cylinder.
3. Place the other end of tube assembly in a clear contain of brake fluid.
4. Fill reservoir with Dexron® III transmission fluid, as needed.
5. Stroke master cylinder until all air is purged from master cylinder.
6. Install gasket and cap to reservoir. See Figure 93.
Install and Adjust
1. Remove plugs from master cylinder and tube assembly. Install tube assembly to master cylinder.
See Figure 92.
2. Install master cylinder with tube assembly attached, two capscrews, and two nuts onto mounting plate.
Tighten nuts to 19 N•m (168 lbf in). See Figure 92.
3. Install pin, washer, cotter pin, and the back of master cylinder onto plate at the bottom of brake pedal
assembly. See Figure 92.
4. Remove plug from brake fitting. Install tube assembly into brake fitting. See Figure 92.
5. Install brake sensor. Tighten to 23 to 28 N•m (203 to 247 lbf in). Connect wire from sensor to bottom of
master cylinder. See Figure 92.
6. Connect reservoir level sensor switch to cowl harness.
7. Adjust brake pedal height to 96 +3 mm (3.78 +0.11 in.) by adjusting capscrew. Tighten locknuts.
SeeFigure 95.
8. Adjust master cylinder per following procedure:
     a. Loosen locknut on master cylinder push rod and adjust by turning push rod counterclockwise (as
viewed from rear of lift truck) to remove all slack between master cylinder and brake pedal. DO NOT allow
rubber boot to be twisted while adjusting the rod length. See Figure 95.
     b. Turn push rod one-eighth turn clockwise (as viewed from rear of lift truck) allowing master cylinder to
fully return when brake pedal is released. Tighten locknut to 15 to 17 N•m (133 to 150 lbf in).
SeeFigure 95.
9. Flush with Dexron® III transmission fluid and air bleed system.
10. Adjust fluid level until at MAX line on reservoir.
11. Verify all connections are leak-free.
12. Install floor plates and floor mat to lift truck. See Frame 100 SRM 1342 for procedures.
13. Check adjustment of brake pedal as described in Brake Pedal Adjustment section of this manual.
BRAKE PEDAL COMPONENTS
Remove
1. Block front and rear sides of wheel to make sure lift truck cannot move.
2. Remove floor mat and floor plates from lift truck. See Frame 100 SRM 1342 for procedures.
3. Remove tube assembly from master cylinder. Plug master cylinder and tube assembly to prevent foreign
material from entering brake system.
4. Disconnect wire at brake sensor and bottom of master cylinder.
5. Disconnect reservoir level sensor switch from cowl harness.
6. Remove nut and capscrew from bracket and plate attached to bulkhead; remove two nuts and two
capscrews from bracket and plate attached to cowl. Remove bracket with brake pedal assembly and
master cylinder.
7. Remove cotter pin, washer, and pin from plate at bottom of brake pedal assembly.
8. Remove two nuts, two capscrews, and master cylinder from mounting plate.
Disassemble
1. Disconnect spring from bracket and brake pedal assembly. See Figure 95.
2. Remove capscrew and two locknuts from mount bracket. See Figure 95.
3. Remove nut, capscrew, washer, two bushings, tube, and brake pedal from bracket. See Figure 95.
4. Remove brake pad from brake pedal. See Figure 95.
  

7. BUSHING
8. TUBE
9. LOCKNUT
10. MOUNT BRACKET
11. BRAKE PAD Figure 95. Brake Pedal Assembly
Inspect
1. Inspect components for damage. Replace if damaged.
2. Spring free length measurement should be 133 to 160 mm (5 to 6 in.). Replace spring if length is beyond
specification.
Assemble
1. Assemble brake pedal and brake pad. See Figure 95.
2. Assemble brake pedal, two bushings, tube, washer, capscrew, and nut on bracket. See Figure 95.
Tighten capscrews to 165 N•m (122 lbf ft).
3. Assemble two locknuts and one capscrews on mount bracket. See Figure 95.
4. Adjust brake pedal as indicated in Brake Pedal Adjustment section.
5. Connect spring to brake pedal and bracket. See Figure 96.
Install
1. Install master cylinder, two capscrews, and two nuts onto mounting plate. Tighten nuts to 19 N•m
(168 lbf in).
2. Install pin, washer, and cotter pin onto plate at bottom of brake pedal assembly.
3. Install bracket, brake pedal assembly, master cylinder, two capscrews, and two nuts onto plate attached
to cowl; install capscrews, nut, and bracket onto plate attached to bulkhead.
 4. Connect brake sensor wire to sensor on master cylinder.
5. Connect reservoir level sensor switch to cowl harness.
6. Remove plugs from master cylinder and tube assembly.
7. Install tube assembly onto master cylinder.
8. Install floor plates and floor mat. See Frame 100 SRM 1342 for procedures.
9. Remove blocks from front and rear side of wheels.
BRAKE PEDAL AND MASTER CYLINDER ADJUSTMENTS
Brake Pedal Adjustment
Adjust pedal height to 96 +3 mm (3.78 +0.11 in.) by adjusting capscrew at the rear of the pedal assembly.
Measurement if from the bottom of the brake pedal to the top of the bracket. See Figure 96.

1. BRAKE PEDAL LEVER

2. CAPSCREW
3. LOCKNUT
4. MASTER CYLINDER PUSH ROD
5. RUBBER BOOT
Figure 96. Brake Pedal and Master Cylinder Adjustment
Master Cylinder Adjustment
Adjust Push Rod
 1. Loosen locknut on master cylinder push rod and adjust by turning push rod counterclockwise (as viewed
from rear of list truck) to remove all slack between master cylinder and brake pedal. DO NOT allow rubber
boot to be twisted while adjusting the rod length. See Figure 96.
2. Turn push rod one-eighth turn clockwise allowing master cylinder to fully return when brake pedal is
released. Tighten locknut to 15 to 17 N•m (133 to 150 lbf in). See Figure 96.
Parking Brake Valve Repair
REMOVE
 WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some types of maintenance and repair. The removal of the
mast, drive axle, battery, or counterweight assemblies will cause large changes in the center of
gravity. Use additional blocks next to the tires as necessary to prevent movement of the lift truck.
See the Operators Manual or Periodic Maintenance section for your lift truck model, for
procedures to put the lift truck on blocks.
 CAUTION
DO NOT permit dirt to enter the hydraulic system during the steps of this procedure. Dirt can
cause damage to the components of the hydraulic system.
1. Place lift truck on blocks. See Operators Manual or Periodic Maintenance 8000 SRM 1372 for
procedures.
2. Discharge capacitors as specified in Discharging the Capacitors in General section of this manual.
3. Remove battery from lift truck. The procedure for removing the battery may be found in the Operators
Manual or Periodic Maintenance 8000 SRM 1372.
4. To bleed the hydraulic oil pressure from the accumulator prior to service, perform the following steps:
     a. Loosen locknut. See Figure 97.
     b. Turn adjuster screw counterclockwise to bleed pressure from accumulator. See Figure 97.
     c. Close adjuster screw fully clockwise and tighten locknut to 5 to 7 N•m (44 to 62 lbf in).
  

1. LOCKNUT
2. ADJUSTER SCREW
Figure 97. Hydraulic Pressure Bleed
 CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
NOTE: Tag hoses prior to disconnect to aid in connection. Plug hoses and fittings to prevent foreign
material from entering the hydraulic system.
5. Place a container below parking brake valve. Disconnect brake return hose assembly, brake supply hose
assembly, and park brake hose assembly from parking brake valve fittings. See Figure 98.
6. Remove two capscrews and parking brake valve from lift truck frame. See Figure 98.
NOTE: Plug openings to prevent foreign material from entering the hydraulic system.
7. Remove fittings from parking brake valve. Plug openings in valve. Remove and discard O-rings from
fittings. See Figure 99.
  

NOTE: FRAME NOT SHOWN FOR CLARITY.

1. DRIVE AXLE
2. PARK BRAKE ACTUATOR
3. CONTROL VALVE
4. PARKING BRAKE VALVE
5. BRAKE SUPPLY HOSE ASSEMBLY
6. BRAKE RETURN HOSE ASSEMBLY
7. PARK BRAKE HOSE ASSEMBLY
8. FITTING
9. CAPSCREW
Figure 98. Parking Brake Valve With Drive Axle
  

Figure 99. Parking Brake Valve Fittings

Legend for Figure 99

1. PARKING BRAKE VALVE
2. FITTING
3. O-RING

DISASSEMBLE
1. Remove accumulator from fitting. See Figure 100.
NOTE: Plug openings in housing to prevent foreign material from entering the hydraulic system.
2. Remove fitting from housing. Plug opening in housing. Remove and discard O-rings from fitting.
SeeFigure 100.
3. Remove pressure relief valve from housing. Plug opening in housing. See Figure 100.
4. Remove pressure switch from housing. Plug opening in housing. Remove and discard O-ring from
pressure switch. See Figure 100.
5. Remove two capscrews and solenoid valve from housing. Plug opening in housing. See Figure 100.
6. Remove flow control valve from housing. Plug opening in housing. See Figure 100.
ASSEMBLE
NOTE: Remove plugs in openings as components are installed onto housing.
1. Install flow control valve onto housing. Tighten valve to 33.9 N•m (25 lbf ft). See Figure 100.
 2. Install solenoid valve and two capscrews onto housing. Tighten capscrews to 2 to 3 N•m (17.7 to
26.5 lbf in). See Figure 100.
3. Lubricate new O-ring with clean hydraulic oil and install onto pressure switch. Install pressure switch onto
housing. See Figure 100.
4. Install pressure relief valve onto housing. See Figure 100.

1. HOUSING
2. ACCUMULATOR
3. FITTING
4. O-RING
5. FLOW CONTROL VALVE
6. SOLENOID VALVE
7. CAPSCREW
8. PRESSURE SWITCH
9. PRESSURE RELIEF VALVE
Figure 100. Parking Brake Valve
5. Lubricate two new O-rings with clean hydraulic oil and install onto fitting. Install fitting into housing.
See Figure 100.
6. Install accumulator onto fitting. See Figure 100.
INSTALL
NOTE: Remove plugs from openings when fittings are installed onto valve.
1. Lubricate new O-rings and install onto fittings. Install fittings onto parking brake valve. See Figure 99.
2. Install parking brake valve and two capscrews onto lift truck frame. See Figure 98.
3. Connect park brake hose assembly, brake supply hose assembly, and brake return hose assembly to
parking brake valve fittings as tagged during removal. See Figure 98.
4. Install battery into lift truck. The procedure for installing the battery may be found in the Operators
Manual or Periodic Maintenance 8000 SRM 1372.
5. Remove lift truck from blocks. See Operators Manual or Periodic Maintenance 8000 SRM 1372for
procedures.
Tools
Table 2.   Special Tools
Too Tool Part Illustration
l Name No.
No.

1 Cylinder Hyster
Pressure P/N
Nut 401065
3
2 Breather Hyster
Installatio P/N
n Tool 401065
4
3 Phonic Hyster
Wheel P/N
Puller 401065
6
4 Phonic Hyster
Wheel P/N
Stud 401065
7
5 Wheel Hyster
Stud P/N
Driver 401066
0
6 Hydraulic Hyster
Cylinder P/N
401065
9
 7 Hand Hyster
Pump P/N
401065
8

Table 3.   Wear Parts and Consumables

Designation Use

LOCTITE No. 270 To secure grooved nuts and wheel bolts.

LOCTITE No. 574 To seal flange surfaces between transmission and

motor.

Multipurpose grease Shell Alvania RL3 or To grease O-rings and rotary shaft seals.
equivilant

Oil for transmission output assemblies Lubricate with SAE 80W-90

Oil for brake system Lubricate with Dexron III

LOCTITE No. 7061 To clean components.

RTV adhesive/sealant #0280472 To seal upper and lower transaxle seals.

Rust inhibitor-ignition sealer To seal electrical circuit from moisture.

   
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