BRAKE SYSTEM

Description

207074

Automatic Adjusting Device

This device adjusts the drum-to-lining clearance to reposition the shoes closer to the drum. This
automatically. As the clearance increases due to adjustment corresponds to 1/24 of one rotation
lining wear, the lever mechanism of this device or 15°. In the course of usage, the adjusting
turns the adjusting screw by one notch or tooth process repeats itself at long intervals.

Brake Pedal and Assembly

This clutch pedal is the one used in the Direct-
Drive lift truck.

Stop lamp switch

Brake pedal

Clutch pedal
Stop lamp switch 2 mm
(0.08 in.)
204923
204965

8-1
BRAKE SYSTEM

Disassembly and Reassembly

Master Cylinder
Disassembly

6
7
5 *
*
4
3 *
2
**

204924

Sequence
1 Clevis, Lock nut, Push rod 5 Spring seat, Primary cup, Cup spacer
2 Boot 6 Return spring
3 Stopper ring 7 Cylinder body
4 Secondary cup, Piston 8 Fluid reservoir, Wire band

NOTE
The parts (*) to be changed periodically are
involved in the Brake Repair Kit.

8-2
 BRAKE SYSTEM

Inspection after Disassembly

1. Brake fluid level sensor
(1) Connect the level sensor at the bottom of fluid
reservoir, and turn the starter switch to ON.
(2) The sensor is satisfactory if the brake fluid
level warning lamp of OK monitor glows
when the filler of the reservoir is positioned
upward and goes out when it is positioned
downward. ON OFF
2. Cylinder body
200270
(1) Check the bore of the cylinder for rusting, ero-
sion and scoring.
(2) Check the inlet port and relief port for cleanli-
ness. Also, check the threads of screw con-
nection of each joint for damage. Make sure
that the boot is free from any defects.
3. Piston A = Assembly standard
Replace the piston if it is damaged. Check the pis- B = Repair or service limit Unit: mm (in.)
ton clearance in the cylinder body. Replace the Clearance 0.020 to 0.105
A
cylinder body and piston if the clearance is in between piston (0.00079 to 0.00413)
excess of the service limit. and cylinder B 0.2 (0.008)
4. Return spring
Replace the return spring every 1 year.
5. Primary cup, secondary cup and valve
Check these rubber parts for swelling, tearing and
deterioration due to aging. Replace them every 1
year.
Reassembly
To reassemble, follow the reverse of disassembly
procedure, and proceed as follows
(1) Wash all metal parts clean with a volatile
cleaning solvent, and dry them with pressure
air.
(2) Apply a thin coat of rubber grease or brake
fluid to the piston cups and the bore of the
cylinder.

8-3
BRAKE SYSTEM

Wheel Brakes
Disassembly

10 9
9

3
11

* 5

8 7

* 2

3
5 4
207208

Sequence
1 Return spring 7 Strap and Anti-rattle spring
2 Fitting cable 8 Shoe and lining (primary), Parking brake
3 Hold-down spring, Cup, Pin lever, Retainer, Spring washer
4 Adjusting lever, Adjusting spring and 9 Wheel cylinder
Return spring 10 Parking brake cable
5 Cable guide, Sheave, Adjusting screw, 11 Backing plate
Pin, Washer
6 Shoe guide plate, Shoe and lining, (sec-
ondary)

NOTE Start by:

1. Remove the front wheel.
The part (*) to be changed periodically are
2. Remove the wheel hub and brake drum.
involved in the Brake Repair Kit.
3. Separate the parking brake lever and cable
at the bottom of wheel brake.
4. Disconnect the brake pipe from the wheel
brake assembly.

8-4
 BRAKE SYSTEM

Suggestions
1. Removing return springs
Use a special tool to remove the return springs.
Special tool needed
Spring remover 64309-15411

200271

2. Hold-down springs removal

Use a special tool to remove the hold-down
springs.
Special tool needed
Spring retainer 64309-15412

200272

Inspection after Disassembly

1. Backing plate Tightening torque for 157 N·m
(1) Check the backing plate for cracks. backing plate mounting (16 kgf·m)
(2) Tighten the backing plate mounting bolts to bolts [116 lbf·ft]
the specified torque.

2. Shoes and linings

(1) Check each shoe and lining for cracks.
(2) Replace the lining if it is fouled with grease
matter, burnt or glazed.
(3) Check the thickness of the lining, and replace
the lining if it is worn to the service limit.

A = Assembly standard
B = Repair or service limit Unit: mm (in.)
1 to 1.8 ton 2 to 3.5 ton
models models 203005
A 4.87 (0.19) 6 (0.24)
Thickness of
linings 2.5 (0.10) 3 (0.12)
B
maximum maximum

8-5
BRAKE SYSTEM

3. Brake drums
Check the inside (friction) surface of the drum for A = Assembly standard
abnormal wear, grooving and other defects. Minor B = Repair or service limit Unit: mm (in.)
grooving can be removed by grinding, provided 1 to 1.8 ton 2 to 3.5 ton
that the inside diameter does not exceed the ser- models models
vice limit. +0.13
25400 +0.15
31000
Inside +0 +0
diameter A
(10.2+0.005
+0
1
) (12.2 +0.005
+0
9
)
of brake
drum B 256 (10.08) 312 (12.28)

4. Adjusting screws
Check the wheel teeth for wear. Turn the screw by
hand to see if its rotating parts turn smoothly.

200274

5. Parking brake cable

Replace the cable if it shows stretch, rust or dam-
age.

6. Others
(1) Check the return springs for cracks or fatigue.
(2) Check the adjusting springs for cracks or
fatigue.
(3) Check the fitting cables for stretching.

8-6
 BRAKE SYSTEM

Reassembly

4 3 7 5 12 10 1 2 12 8 13 6
A

11
•

A 14 Section A-A

203586

Sequence
1 Wheel cylinder 9 Hold-down spring, Cup, Pin
2 Backing plate 10 Shoe guide plate
3 Shoe and lining (primary) 11 Fitting cable
4 Parking brake lever 12 Return spring
5 Retainer, Washer 13 Cable guide, Sheave, Pin, Washer
6 Shoe and lining (secondary) 14 Adjusting lever, Adjusting screw, Adjust-
7 Strap ing spring
8 Anti-rattle spring

8-7
BRAKE SYSTEM

Suggestions
1. Wheel cylinder installation
Apply the liquid packing to the mounting face of
the wheel cylinder before positioning the cylinder
in place; and secure it by tightening to the speci-
fied torque:

A = Assembly standard
B = Repair or service limit Unit: N·m (kgf·m) [lbf·ft]
1 to 1.8 ton 2 to 3.5 ton
models models 200275
8 to 12 18 to 26
Tightening torque
(0.8 to 1.2) (1.8 to 2.7)
for wheel cylinder
[6 to 9] [13 to 20]

2. Greasing
Apply the specified brake grease to the following
parts, forming a thin coat of grease at each:
(1) Shoe ledges (6 places)
The ledges are those portions of the backing
plate in contact with the shoe.
(2) Anchor pin surface in contact with the shoe
ends

3. Shoe and lining installation

Check to be sure that each push rod of the wheel
cylinder is snugly fitted to its shoe web.

4. Return spring installation

Use a special tool to install the return springs to the
backing plate pins.
Special tool needed
Spring installer 65309-15413

200276

8-8
 BRAKE SYSTEM

5. Automatic adjusting device installation

(1) Clean the adjusting screw and associated parts
and apply a thin cost of grease to the screw
threads and screw socket. Check that the
screw turns smoothly when rotated by hand.
If the screw is hard to turn, replace it by a new
one.
(2) Discriminate the right-hand adjusting screw
and lever from the left-hand ones by the color:
Right-hand adjusting screw and lever
200277
(left-hand thread)
Yellowish color
Left-hand adjusting screw and lever
(right-hand thread)
Whitish color

NOTE
After reassembly, bleed air out of the brake
fluid lines. (Refer to Inspection and
Adjustment.)

8-9
BRAKE SYSTEM

Wheel Cylinders
Disassembly

1
2
*
4 3
5 *
*
6

4
*
3
2
*
1

200278

200279

Sequence
1 Connector link 5 Return spring
2 Boot 6 Bleeder screw, Cap
3 Piston 7 Cylinder body
4 Piston cup

NOTE
The parts (*) to be changed periodically are
involved in the Brake Repair Kit.

8-10
 BRAKE SYSTEM

Inspection after Disassembly

1. Cylinder bodies
(1) Check the bore for rusting, erosion and scor-
ing.
(2) Check the threads of bleeder screw and oil
pipe for damage.
2. Pistons
(1) Check the sliding surface for rusting and
scratching.
(2) Check the piston clearance in the cylinder
body. Replace the cylinder body and piston if
the clearance is in excess of the service limit.
A=Assembly standard
B=Repair or service limit Unit: mm (in.)
1 to 1.8 ton 2 to 3.5 ton
models models 200280
0.040 to 0.020 to
Clearance 0.125 0.125
A
between piston (0.00157 to (0.00079 to
and cylinder 0.00492) 0.00413)
B 0.15 (0.0059)

3. Piston cups
Check for swelling or other defects. Replace the
cups at the time of overhaul and every 1 year.
4. Boots
Replace the boots if they are hardened, damaged
or otherwise deteriorated.
Reassembly
To reassemble, follow the reverse of disassembly.
Do the following steps:
(1) Coat the piston cups and the cylinder bore
with brake fluid.
(2) Be careful not to damage the lips of the cups.

8-11
BRAKE SYSTEM

Inspection and Adjustment

Automatic Adjusting Device
1. Assemble the wheel brake. Adjust the drum-
to-lining clearance to the specification. Push
the cable by thumb to pull the adjusting lever.
Observe the lever turns the adjusting screw by
one tooth, and remove the push to observe the
adjusting screw returns to the original posi-
tion.

200281

2. If the lever fails or is sluggish to turn the

adjusting screw in the above test, the likely
cause is that the lever is not properly posi- A
tioned relative to the toothed wheel. Be sure
that the lever is so positioned that its actuating
tip touches the toothed wheel at a level about
9 mm (0.35 in.) under the center line of the
screw, as shown. 9 mm
(0.35 in.)
3. Where the automatic adjusting device is sus-
pected of malfunctioning during normal use of 200282
the machine, the following possible causes
Adjusting toothed wheel and lever positions
must be considered:
(1) Adjusting spring is not correctly hooked to
primary shoe.
(2) Any of these parts is in bad condition to
require replacement:
a) fitting cable, b) adjusting lever, and c)
adjusting screw.

Manual Adjustment
The drum-to-lining clearance can be adjusted by
rotating the adjusting screw with a screwdriver put
to the toothed wheel. The hole thorough which the
screwdriver tip can be inserted is provided in the
backing plate.

200283

8-12
 BRAKE SYSTEM

Brake Pedal Adjustment

1. Set the height A (from the frame to the top of C
pad ) of the pedal to the specified value.
2. Set the length B of push rod to the specified
value, and push in the rod into the master A
cylinder.
3. Make sure that the pedal stroke C (to a point Stopper bolt
where the brakes are applied ) is correct.

Unit: mm (in.)
1 to 1.8 ton 2 to 3.5 ton
models models
Pedal height A 220 (8.7)
Push rod length B 103.2 (4.06)
40 to 61 49 to 95 B
Pedal stroke C 207076
(1.57 to 2.4) (1.93 to 3.74)

Bleeding Air Out of the Brake Fluid Line

Whenever any part of the brake fluid line was dis-
connected in servicing work, an air bleeding oper-
ation must be carried out to complete the work.
With air trapped in any part of the fluid line, the
pedal will “feel” spongy.
The procedure for air bleeding operation is as fol-
lows:
1. Connect a flexible tube, such as a clear plastic
pipe, to the bleeder screw on wheel cylinder. 200285
Pour enough clean brake fluid in to the jar, and
imnevse the end of pipe.
2. Pump the brake pedal and depress the pedal all
the way. While keeping the pedal depressed,
loosen the bleeder screw and, when air bub-
bles cease to come out (as seen in the jar),
tighten the screw. Repeat this process until
nothing but brake fluid flows into the vessel.
3. Carry out the foregoing steps at each wheel
brake, and fill up the brake fluid reservoir to
level.
Brake Test
NOTE After completion of necessary adjustments, test
1) Be sure that, at no time during the the brake force by traveling the truck at a speed
bleeding operation, the reservoir of 10 km/h (6.2 mph).
becomes empty of fluid. Refer to Manual Adjustment for necessary
readjustment.
2) Use the specified brake fluid, and avoid
different brands of brake fluid getting
mixed before and after filling up the
reservoir.

8-13
BRAKE SYSTEM

Troubleshooting
Complaints Possible causes Remedies
Lack of braking a) Oil leaks over primary cup in master *Replace piston cup if
force cylinder, or oil leaks over cups in cylinder is worn.
wheel cylinders Replace the cup and
fluid if the cup is
distorted.
b) Oil leaking from oil pipe connection Replace pipe and
connector and retighten.
c) Shoe linings excessively worn Replace.
d) Linings fauled with oil or grease Clean or replace.
Pedal stroke is too long a) Air trapped in brake oil line Bleed air at brake boost-
er and wheel cylinder.
b) Piston cup defective in master cylinder Replace.
c) Not enough fluid in reservoir Refill.
d) Push rod to piston clearance too large in Readjust.
master cylinder See page 8-13.
e) Brake fluid leakage Replace piston cup if
cylinder is worn. Replace
the cup and fluid if the
cup is distorted.
f) Automatic adjusting device out of order Check cable guide and
adjusting spring installa-
tion. If they are defec-
tive, replace fitting cable,
lever and adjusting screw.
See page 8-12.
Uneven braking a) Lining or drum fauled with oil or grease in less Clean or replace.
(Wheel brake is more effective brake
effective on one side b) Wobbly or loose-mounted drum in less Replace drum.
than on the other.) effective brake Readjust and retighten.
Tightening torque of
drum nut.
1 ton class 59 N·m
(6 kgf·m) [431 lbf·ft]
2,3 ton class 181 N·m
(18.5 kgf·m) [134 lbf·ft]
Brake squeals a) Linings glazed Sand.
b) Linings worn Replace shoe and lining
assembly.
c) Backing-plate securing bolts loose Retighten.
Tightening torque
215 N·m (21.9 kgf·m)
[158 lbf·ft]
d) Wheel bearings loose Readjust preload and
retighten.
Preload for hub bearing
0.5 to 4.9 N·m
(5 to 50 kgf·cm)
e) Brake drum fauled [0.4 to 3.6 lbf·ft] Clean.
Brake chatters or a) Anchored ends of shoes rattling on anchor Repair or replace.
clatters b) Shoes ledges worn Replace shoes.
c) Piston worn in wheel cylinder Replace.

8-14
 BRAKE SYSTEM

Complaints Possible causes Remedies

Lever stroke is too Lining to drum clearance too small Readjust.
short Clearance
1 ton class 0.5 to 1.0 mm
(0.02 to 0.04 in.)
2,3 ton class
0.2 to 0.7 mm
(0.01 to 0.03 in.)
Will squeal during a) Lining to drum clearance too small Readjust.
traveling b) Brake drum distorted Repair or replace.
Will not apply a) Parking brake cable longer than is specified Check drum to lining
clearance, readjust cable
length if necessary.
Replace shoe and lining
b) Linings worn to the service limit assembly.
Readjust.
c) Lining to drum clearance too large 245 to 294 N (25 to 30
d) Lever lacks operating force kgf) [55 to 66 lbf]

8-15
BRAKE SYSTEM
Service Data A = Assembly standard B = Repair or service limit
Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
Height of pedal 1 A 220 (8.7)
Stroke (to a point where brakes start 40 to 61 49 to 95
A
to apply) 2 (1.57 to 2.4) (1.93 to 3.74)
Free play of pedal 3 A 10 to 16 (0.4 to 0.6)
Set length of push rod 4 A 103.2 (4.06)
Projection of stop lamp switch 5 A 2 (0.08)
2
3

5
4 204944

Inside diameter of cylinder body 1 A 19.05 +0.052

+0
+0.002 05
(0.7500 +0 )

Diameter of piston 2 A 19.05 –0.020 –0.000 79

–0.053 (0.7500 –0.002 09 )

A 0.020 to 0.105 (0.000 79 to 0.004 13)

Clearance between cylinder and piston
B 0.2 (0.008)
0 0
A 20 – 0.3 (0.79 – 0.012 )
Diameter of primary cup (lip side) 3
B (Replace every year)
A 20.2 ± 0.2 (0.795 ± 0.008)
Diameter of secondary cup (lip side) 4
B (Replace every year)
A 46.8 (1.843)
Free length of return spring 5
B (Replace every year)
4 2 5

1 3 207077

8-16
 BRAKE SYSTEM
A = Assembly standard B = Repair or service limit
Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K
+0.052 +0.052
22.220000
+0 28.580000
+0
Inside diameter of cylinder body 1 A (0.874 8 +0.002 05 ) (1.125 2 +0.002 05 )
+0 +0
–0.040 –0.020
22.220000 28.580000
Diameter of piston 2 A (0.874 8 –0.078
–0.001 57 ) (1.125
–0.058
2 –0.000 79
–0.003 07 –0.002 28 )
0.040 to 0.125 0.020 to 0.125
Clearance between cylinder and piston A (0.001 57 to 0.004 92) (0.0007 9 to 0.004 13)
B 0.15 (0.005 9)
Diameter of piston cup (lip side ) 3 23.7 ± 0.2 30.5 ± 0.25
A (0.933 ± 0.007 9) (1.201 ± 0.0098)
B (Replace every year)
Free length A 49.5 (1.95) 58 (2.28)
Length under test force A 20 (0.79) 22 (0.91)
Return
spring 4 12 ± 1 (1.2 ± 0.1) 13 ± 1 (1.3 ± 0.1)
Test force A [2.6 ± 0.2] [2.9 ± 0.2]
N (kgf)[lbf] B (Replace every year)
Tightening 8 to 12 (0.8 to 1.2) 18 to 26 (1.8 to 2.7)
torque Wheel cylinder bolts 5 A [6 to 9] [13 to 20]
N·m (kgf·m)
[lbf·ft] Bleeder screw 6 A 6 to 9 (0.6 to 0.9) [4 to 7]
1 6 5

2 3 4 200426
+0.13
254000
–0
A 310–+0.15 +0.005 9
0 (12.20 – 0 )
Inside diameter of brake drum 1 (10.00 +0.005
–0
1
)
B 256 (10.08) 312 (12.28)
A 4.87 (0.19) 6 (0.24)
Thickness of lining 2
B 2.5 (0.098) 3 (0.118)
Clearance between drum and 0.5 to 1.0 0.2 to 0.7
lining 3 (one side) A (0.02 to 0.04) (0.01 to 0.03)
Primary: 120 (4.72)
Free length A 102 (4.02) Secondary: 139.3 (5.48)
Return Primary: 134 (5.28)
spring 4 Length under test force A 111(4.37) Secondary: 145.4 (5.72)
157 ± 16 (16 ± 1.6) 226 ± 23 (23 ± 2.3)
Test force N (kgf) [lbf] A [35 ± 3.5] [51 ± 5.1]
Adjusting Free length A 79 (3.11) 104.5 (4.11)
spring 5 Length under test force A 98.5 (3.88) 122 (4.80)
Test force 137 ± 14 (14 ± 1.4) 78 ± 8 (8 ± 0.8)
N (kgf) [lbf] A [31 ± 3] [18 ± 2]
Tightening torque for backing plate bolt 6
N·m (kgf·m) [lbf·ft] A 157 (16) [116]

8-17
BRAKE SYSTEM

A = Assembly standard
Unit: mm (in.)
Truck Models GP/DP15K GP/DP20K GP/DP30K
Items GP/DP18K GP/DP25K GP/DP35K

1
4

4 Secondary spring
2 6

Free length

5
204962

Lever swing angle A A 71° to 76°

Lever operating effort F
A 245 to 294 (25 to 30) [55 to 66]
N (kgf) [lbf]

F
A

204967

8-18