YM15180001E

Brake System
GP/GTP/GLP/GDP15-18MX, 20SMX [E812];
GP/GTP/GLP/GDP20-35MX [D871]

Safety Precautions Maintenance

and Repair
• 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 ground cable on internal combustion lift trucks.
• 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 YALE 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), 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
 Disclaimer
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
Yale® 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.
 GENERAL
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, and
parking brake system.

[1] Service Brakes

A service brake assembly is installed on the

mounts at each end of the drive axle. See
Figure 1-1. The parts of the service brake
assembly are shown in Figure 2-2 for 2.0 ~
3.5 ton lift trucks and Figure 2-4 for 1.5 ~ 2.0
ton. When the brake pedal is pushed, fluid
pressure from the master cylinder causes the
pistons in the wheel cylinder to extend. The
pistons expand the brake shoes against the
drums.
The clearance between the brake shoes and
the brake drum is adjusted automatically. An
adjuster linkage 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 adjuster lever to rotate the adjuster wheel.
The adjuster wheel can turn only when there
is clearance between the lining of the brake
shoe and the brake drum. The adjuster wheel
can also be turned with a tool. A slot in the
back plate gives access to the adjuster wheel.

[2] Master Cylinder

The master cylinder is designed for a single-

circuit system. The master cylinder has a
piston that operates in the bore of the master
cylinder. See Figure 1-2. 1. PARKING BRAKE LEVER
2. ADJUSTMENT KNOB
3. PARKING BRAKE CABLE
NOTE: The reservoir is located to the right of the
4. INCHING/BRAKE PEDAL
park brake and is attached to the cowl. 5. MASTER CYLINDER
6. BRAKE ASSEMBLY
7. PARK BRAKE SENSOR
[3] Brake Position Sensor

This sensor senses the park brake hand Figure 1-1. Brake System
lever position. The sensor is located on the
left hand side of the park brake handle. See
Figure 1-1.

—1—
 1. YOKE 10. PISTON
2. NUT 11. SPACER
3. PUSH ROD 12. PISTON CUP
4. BOOT 13. RETAINER
5. SNAP RING 14. SPRING
6. CYLINDER HOUSING 15. CHECK VALVE
7. SEAL 16. VALVE SEAT
8. FITTING 17. BLEEDER VALVE
9. PISTON SEAL 18. CAP

Figure 1-2. Master Cylinder

[4] 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 the parking brake. The
park brake sensor is located on the left side of the park brake handle.

—2—
 SERVICE BRAKES REPAIR

[1] Remove and Disassemble

WARNING
Brake linings can contain dangerous fibers. Breathing 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 follow
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. Remove the capscrews that hold the axle shaft to the hub. Remove the axle shaft.
2. See the procedure How to Put Lift Truck on Blocks in the section Periodic Maintenance
or the Operating Manual. Start the engine and tilt the mast fully backward. Put blocks under
the mast. Tilt the mast forward until the wheels just touch the floor. Stop the engine. Put
blocks under the frame of the lift truck.
3. Remove the set screw and remove the nut that holds the axle bearing. Remove the washer
and the bearing cone.

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

Figure 2-1. Brake Assembly (Left-Hand Shown), 2.0 ~ 3.5 ton

—3—
 WARNING
When the brake shoes are removed, do not create dust in the air. See the Clean procedure
in this section.

4. 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 removed easily, use
a small screwdriver to push the adjuster 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

NOTE: Right-hand brake assembly shown.

1. WHEEL CYLINDER 12. ADJUSTER ASSEMBLY

2. RETURN SPRING 13. PRIMARY BRAKE SHOE
3. RETURN SPRING 14. PARKING BRAKE LEVER
4. ANCHOR 15. PARKING BRAKE LINK
5. ANCHOR GUIDE 16. PARKING BRAKE SPRING
6. BACK PLATE 17. RETAINER, AND SPRING WASHER
7. SECONDARY BRAKE SHOE 18. ADJUSTER ACTUATOR SPRING
8. ADJUSTER WHEEL ACTUATOR 19. SPRING
9. PIVOT PLATE 20. RETAINING PIN
10. ADJUSTER ACTUATOR LINK 21. RETAINING WASHER
11. ADJUSTER WHEEL 22. PARKING BRAKE CABLE

Figure 2-2. Service Brake Parts, 2.0 ~ 3.5 ton

—4—
 the hub and drum assembly. Do not damage the grease seal when removing the hub.
5. Make a note of the arrangement of the parts. See Figure 2-1 and Figure 2-2 for 2.0 ~ 3.5
ton lift trucks. See Figure 2-3 and Figure 2-4 for 1.5 ~ 2.0 ton lift trucks. Remove the return
springs with spring pliers.
6. Remove the retainers, springs, and anchor pins that hold the brake shoes to the back plate.
7. Disengage the link from the adjuster wheel actuator. Remove the link, washer, and pivot
plate. Remove the anchor guide.
8. Move the brake shoes away from each other to disengage the brake shoes from the wheel
cylinder. Disconnect the parking brake lever from the parking brake cable as the brake
assembly is removed from the back plate. The parking brake lever has a hook that engages
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
adjuster wheel for the left brake has left-hand threads.

9. Make a note of the arrangement of parts and disassemble the brake assembly. Remove the
parking brake link and spring if they are still engaged with brake shoes. The parking brake
link and spring will often fall from the brake assembly when the brake assembly is removed
from the back plate. The adjuster wheel will also disengage from the brake shoes after the
brake assembly is removed.
10. Remove the spring for the adjuster wheel actuator. Remove the adjuster wheel actuator from
the brake shoe.
11. Use a screwdriver or small pry bar to move apart the ends of the retainer. Remove the spring
washer and pivot pin to remove the parking brake lever from the brake shoe.
12. Disconnect the brake line from the wheel cylinder. Remove the capscrews that hold the wheel
cylinder to the back plate and remove the wheel cylinder.

1. BACKING PLATE
2. RETAINING RING
3. LEVER PIN
4. GUIDE PLATE
5. WHEEL CYLINDER
6. PAWL LEVER STOPPER
7. SPRING (ANTI-RATTLE)
8. RETURN SPRING
9. SPRING (ACTUATOR)
10. ADJUSTER WHEEL
ACTUATOR
11. SECONDARY BRAKE SHOE
12. ADJUSTER ASSEMBLY
13. ADJUSTER SPRING
14. PARK BRAKE LEVER
15. PRIMARY BRAKE SHOE
16. STRUT

Figure 2-3. Brake Assembly (Left Hand Side), 1.5 ~ 2.0 ton

—5—
 1. BOLT 13. ADJUSTER WHEEL ACTUATOR
2. WHEEL CYLINDER 14. PARK BRAKE CABLE
3. STRUT 15. ADJUSTER ASSEMBLY
4. SPRING 16. RETAINING RING
5. SECONDARY BRAKE SHOE 17. SPRING (ADJUSTER)
6. GUIDE PLATE 18. PRIMARY BRAKE SHOE
7. RETURN SPRING 19. PARK BRAKE LEVER
8. PAWL LEVER STOPPER 20. LEVER PIN
9. SPRING (ACTUATOR) 21. PLUG
10. WASHER 22. BACKING PLATE
11. SPRING (SHOE HOLD DOWN) 23. PIN
12. WASHER

Figure 2-4. Service Brake Parts, 1.5 ~ 2.0 ton

NOTE: For 2.0 ~ 3.5 ton lift trucks, 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 mount, and the locking
function of the capscrews is reduced if they are removed. The capscrews are tightened to 255 to 306 N·m
(2600 to 3120 kgf·cm).
NOTE: For 1.5 ~ 2.0 ton lift trucks, the back plate is not normally removed from the axle housing for brake
repairs. Six special capscrews are used to fasten the back plate to the axle mount, and the locking function
of the capscrews is reduced if they are removed. The capscrews are tightened to 152 to 167 N·m (1550 to
1700 kgf·cm).

13. Remove the push rods, dust covers, pistons, cups, and spring from the wheel cylinder. See
Figure 2-5.

—6—
 1. PUSH ROD (2) 6. WHEEL CYLINDER BODY
2. DUST COVER (2) 7. INLET PORT
3. PISTON (2) 8. PRESSURE BLEEDER
4. CUP (2) 9. DUST COVER
5. SPRING

Figure 2-5. Wheel Cylinder

[2] Clean

WARNING
DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or brake linings. Use
a solvent 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 operate 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 solvents, always follow the safety instructions of the solvent 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, spray at a distance so that the dust is not released into the air.
3. When the brake lining dust is wet, clean the parts. Put any cloth or towels in a plastic bag or
an airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on
the plastic bag or airtight container.

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.

—7—
 4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into
the air.

[3] Inspect

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 and 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.

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.

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 of contact with the rivets, or the
metal shoe on bonded linings. Brake shoes must be replaced in complete sets. Inspect the
brake drums for cracks or damage. Replace any damaged parts.
4. Inspect the brake drum for deep grooves or other damage.

NOTE: On 2.0 ~ 3.5 ton lift trucks, if grooves must be removed from the brake drums, do not grind more
than 1.5 mm from the internal diameter of the brake drum. The maximum limit of the internal diameter of the
brake drum is 312 mm. If the internal diameter is larger than the limit, replace the brake drum.
NOTE: On 1.5 ~ 2.0 ton lift trucks, if grooves must be removed from the brake drums, do not grind more
than 1.5 mm from the internal diameter of the brake drum. The maximum limit of the internal diameter of the
brake drum is 255.5 mm. If the internal diameter is larger than the limit, replace the brake drum.

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 condition.
7. Check the grease seals and the surfaces of the seals for wear or damage.

[4] Assemble and Install

1. If the wheel cylinder was disassembled for repair, assemble the wheel cylinder. See Figure
2-5. Use only YALE APPROVED parts.
2. Install the wheel cylinder on the back plate and tighten the two capscrews to 18 to 26 N·m
(180 to 260 kgf·cm) for 2.0 ~ 3.5 ton and 15 to 23 N·m (150 to 230 kgf·cm) for 1.5 ~ 2.0 ton.
Connect the brake line to the wheel cylinder.
3. Install the parking brake lever. Use the spring washer, and retainer to fasten the parking
brake lever to the brake shoe. Close the ends of the retainer to fasten the pivot pin in position.
See Figure 2-2 for 2.0 ~ 3.5 ton and Figure 2-4 for 1.5 ~ 2.0 ton lift trucks.
4. Fasten the adjuster actuator spring to the lever and the brake shoe.
5. Put antiseize compound on the threads of the adjuster wheel. Turn the adjuster wheel into
the adjuster nut so that the adjuster assembly is in its shortest position. This action permits
the brake drum to be easily installed over the brake shoes.

—8—
 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 increase each time the brakes
are applied. The adjuster wheel for the right brake has right-hand threads. The adjuster
wheel for the left brake has left-hand threads.

6. Install the adjuster wheel 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 actuator spring is in tension.
7. Lubricate the back plate with a small amount of lithium grease where the brake shoes touch.
Install the brake shoes on the anchor and engage the push rods of the wheel cylinder.
Engage the parking brake lever in the slot in the parking brake cable as the brake shoes are
installed on the back plate.
8. Put an anchor pin that holds the brake shoes through the back plate. Put a spring seat,
spring, and retainer on the anchor pin. Push the retainer onto the anchor pin and rotate the
retainer 90 degrees. Make sure the retainer is in the correct position.
9. Install the link, parking brake, and spring between the parking brake lever and the brake
shoe.
10. Install the other spring retainer that holds the brake shoes. Make sure the parking brake link
and the spring are correctly engaged after the spring retainers are installed.
11. Install the anchor guide on the anchor. Install the pivot plate on its anchor.
12. Lubricate the adjuster cable where it slides in the pivot plate groove.
13. Fasten the link to the adjuster wheel actuator and put the cable around the pivot plate. Raise
the adjuster wheel actuator against the spring tension and connect the link to the anchor.

CAUTION
2.0 ~ 3.5 ton: Be sure to install the white return spring first and then the black return spring.
See Figure 2-7. Improper assembly can result in brake failure and/or component damage.

1. RETURN SPRING 4. SPRING AND CABLE ASSEMBLY

2. ANCHOR GUIDE 5. PIVOT PLATE
3. RETURN SPRING

Figure 2-6. Return Springs, 2.0 ~ 3.5 ton

—9—
 1. WHITE SPRING
2. BLACK SPRING

Figure 2-7. Proper Installation of Return Springs, 2.0 ~ 3.5 ton

NOTE: The shape of the return springs permits them to be installed correctly in only one position. The
arrangement of the return springs on the anchors is shown in Figure 2-6 and Figure 2-7.

14. 2.0 ~ 3.5 ton: Using the correct tools, install the return springs as follows (see Figure 2-7):
a. Install the white spring.
b. Install the black spring.

1. RETURN SPRING
2. GUIDE PLATE
3. RETURN SPRING
4. SPRING ACTUATOR

Figure 2-8. Return Springs, 1.5 ~ 2.0 ton

— 10 —
 1. INNER SEAL
2. OUTER SEAL
3. BRAKE DRUM
4. INNER BEARING
5. OUTER BEARING

Figure 2-9. Grease Seals and Bearing Locations

15. 2.0 ~ 3.5 ton: Verify that the return springs

are properly installed as shown in Figure
2-7
16. 1.5 ~ 2.0 ton: Use the correct tools to
install the return springs. Install the return
spring. Install the washer and the return
spring. The shape of the return springs
permits them to be installed correctly in
only one position. The arrangement of the
return springs on the anchors is shown in
Figure 2-8.

NOTE: Seal and bearings are to be installed flush

with the hub. Seal is to be installed with no grease Figure 2-10. Inner Grease Seal Installation
or oil on outside surface.

17. Clean the bearings and lubricate them with wheel bearing grease. Install the bearings and
seals in the brake drum. Install the assembly on the axle housing. See Figure 2-9 and Figure
2-10.

NOTE: To prevent damage to the inner oil seal when installing the hub, the hub and drum assembly can be
temporarily 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. Install the outer bearing and nut.

18. Adjust the hub bearings by tightening the nut until the hub cannot be rotated. Loosen the nut
30 to 60 degree and fix at hub rotating torque 3.0 to 3.4 N·m (30 to 35 kgf·cm).
19. Apply the loctite on the thread of the set screw and fasten to the thread where aligned to the
V-groove on the washer. See Figure 2-11

— 11 —
 CAUTION
If there is too much clearance, the automatic
adjusters 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 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.

NOTE: If the brake shoes were not replaced,

loosen the adjuster wheel approximately 20 teeth.

20. A d j u s t t h e c l e a r a n c e o f t h e b r a k e
1. WASHER
shoes. Put a brake adjustment tool or a 2. BRAKE DRUM ASSEMBLY
screwdriver through the slot in the back 3. WHEEL ADJUSTMENT NUT
plate. Use the tool to rotate the adjuster 4. SET SCREW
wheel. The actuator for the adjuster wheel
will only permit rotation in one direction.
Turn the adjuster wheel until the brake Figure 2-11. Lock Plate
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 20 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 reverse direction.
21. Put liquid sealant, Yale Part Number
520042831, on the flange of the axle
shaft. Install the axle shaft and capscrews.
Tighten the capscrews in cross pattern to
a torque specified below for your lift truck.
a. For 2.0 ~ 3.5 ton lift trucks, tighten
between 90 to 108 N·m (920 to 1100
kgf·cm).
b. For 1.5 ~ 2.0 ton lift trucks, tighten
b e t w e e n 52 t o 62 N · m (530 t o 630
kgf·cm). See Figure 2-12.

Figure 2-12. Axle Shaft Tightening Sequence

[5] Adjust

1. Remove the air from the brake hydraulic system. See Brake System Air Removal.
2. Install the wheel on the hub. Tighten the wheel nuts to the torque specified below for your lift
truck.
a. For 2.0 ~ 3.5 ton lift trucks, tighten between 196 to 216 N·m (2000 to 2200 kgf·cm) for
2-2.5 ton, 294 to 343 N·m (3000 to 3500 kgf·cm) for 3-3.5 ton.
b. For 1.5 ~ 2.0 ton lift trucks, tighten between 196 to 216 N·m (2000 to 2200 kgf·cm).

— 12 —
 1. PARKING BRAKE LEVER
2. ADJUSTMENT KNOB
3. PARKING BRAKE CABLES
4. CONNECTING PINS
5. COTTER PINS
6. WASHER
7. SLIDER
8. CLAMP

Figure 2-13.

3. Start the engine and tilt the mast backward 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 mechanism to operate. Repeat this operation several times.
4. The service brakes must be adjusted before the parking brake can be adjusted. See Figure
3-1 and the following paragraphs in this section for the correct adjustment of the parking
brake.

— 13 —
 PARKING BRAKE REPAIR

[1] Remove and Disassemble

If the lever assembly for the parking brake must be removed from the cowl, use the following
procedure (see Figure 3-1):

1. Use blocks next to the wheels to make sure the lift truck cannot move. Release the parking
brake lever.
2. Remove the two capscrews that fasten the parking brake to the cowl. Remove the parking
brake lever assembly.
3. Turn the adjuster knob counterclockwise until the brake cables are loosened. Remove the
cotter pins, the washers and the connecting pins and the cables from the slider.
4. Loosen the nuts that fasten the threaded ends of the brake cables to the parking brake lever
assembly.
5. The service brake assembly must be removed before the parking brake cable can be
removed from the back plate of the service brake. A snap ring holds the sheath of the parking
brake cable in the back plate of the service brake. Remove the snap ring and remove the
parking brake cable from the back plate.

[2] Assemble and Install

1. Loosen the two capscrews on the parking lever assembly and install the bracket to the
parking lever assembly by using the capscrews loosened.
2. Make sure the parking brake lever is in the released position. Turn the adjustement knob
counterclockwise until the slider is adjusted to the bottom of the adjustment slot.
3. Adjust the nuts on the ends of the cable assemblies so that the threads of the cable sheaths
extend to 11 mm above the support plate in the lever assembly.
4. Install the cable ends to the slider with connecting pins, cotter pins and washers. Tighten the
upper nut to hold the sheath of the parking brake cables to the parking brake lever with the
support plate.
5. Install the parking brake lever to the cowl and tighten two capscrews.

[3] Adjust

Make sure the service brakes are adjusted and the operation of the automatic adjuster
mechanism is correct before the parking brake is adjusted.

1. Turn the adjustment knob to raise the slider and tighten the parking brake cables. Turn the
adjustment knob until the parking brakes are fully applied with 167 N (15 kgf) of the lever
effort at the top of the lever when the lever 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 percent grade [a slope that increases 1.5 m in 10 m].

[4] Inspection

Inspect each part by the following procedure. If there are any damages, replace the new parts.

1. Inspect the pin (30) for wear and damage.

2. Inspect the O-ring (3) for wear and damage. Replace if the o-ring is worn or damaged and

— 14 —
 does not hold the adjustment knob in position.
3. Inspect any link (13), plate (40) (41) and pins (10) (39) for damage.
4. Inspect the threads on the inner collar (6) and outer collar (5) for damage.
5. Make sure the parking cables are in good condition.

1. GRIP 22. RETAINING RING

2. RELEASE BUTTON 23. CAPSCREW
3. O-RING 24. PUSH NUT
4. PLATE 25. CAPSCREW
5. ADJUSTMENT KNOB 26. SPACER
6. INNER COLLAR 27. RUBBER
7. LEVER 28. SPACER
8. HOOK 29. NUT
9. SPRING 30. PIN
10. PIN 31. NUT
11. PIN 32. SLIDER
12. RETAINING RING 33. PIN
13. LINK 34. PUSH NUT
14. SPACER 35. PIN
15. SWITCH 36. WASHER
16. CAPSCREW 37. NUT
17. GUIDE PLATE 38. CAPSCREW
18. GUIDE PLATE 39. SPACER
19. BRACKET 40. PLATE
20. CAPSCREW 41. PLATE
21. CAPSCREW 42. COTTER PIN

Figure 3-1. Parking Brake Lever Adjustment (Left Hand Side Shown)

— 15 —
 MASTER CYLINDER REPAIR

[1] Remove

1. Remove the floor plate, and kick plate, from the lift truck for access to the master cylinder.
2. Remove the brake hydraulic line from the master cylinder. See Figure 4-1.
3. Disconnect the brake fluid supply hose from the master cylinder. Plug hose to prevent
reservoir from draining.
4. Remove the brake fluid reservoir and supply hose from the lift truck.
5. Remove the cotter pin and rod end pin that is attached to the brake linkage lever arm.
6. Remove capscrews that hold master cylinder to bracket assembly.





 


1. RESERVOIR

2. CAPSCREWS
3. BRAKE FLUID SUPPLY HOSE
4. CAPSCREWS 
5. MASTER CYLINDER 
6. BRAKE HOSE 
7. PUSH ROD
8. NUT 
9. YOKE
10. ROD END PIN
11. COTTER PIN
12. STOP LAMP SWITCH 
13. BRACKET
14. CAPSCREWS 
15. CLAMP

Figure 4-1. Master Cylinder and Reservoir Assembly

[2] Disassemble

CAUTION
When the piston is removed or installed, make sure the cylinder bore and piston are not
scratched or damaged.

1. Remove yoke, push rod, nut, boot, fitting, seal and bleeder valve. See Figure 4-2.

— 16 —
 1. YOKE 10. PISTON
2. NUT 11. SPACER
3. PUSH ROD 12. PISTON CUP
4. BOOT 13. RETAINER
5. SNAP RING 14. SPRING
6. CYLINDER HOUSING 15. CHECK VALVE
7. SEAL 16. VALVE SEAT
8. FITTING 17. BLEEDER VALVE
9. PISTON SEAL 18. CAP

Figure 4-2. Master Cylinder

2. Remove snap ring, piston seal, and piston.

3. Remove spacer, piston cup, retainer, spring, check valve, and valve seat.

NOTE: Install new seals when the master cylinder is disassembled for repair.

— 17 —
[3] Clean and Inspect

CAUTION
DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or brake linings. Use
a solvent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid
or on the linings.

Inspect the bore of the master cylinder for holes or scratches. Replace the master cylinder
assembly, if there is damage.

[4] Assemble

1. Install valve seat, check valve, spring, retainer, piston cup, and spacer.
2. Install the piston, piston seal, and snap ring.
3. Install bleeder valve seal, fitting, boot, nut, push rod, and yoke.

[5] Install and Adjust

1. Install brake fluid reservoir, supply hose and master cylinder on lift truck as an assembly. See
Figure 4-1.
2. Install brake hydraulic line on master cylinder.
3. Orient master cylinder side of brake hose assembly.
4. Tighten fitting nuts at each end of brake pipe and hose assembly to 13 to 18 N·m (130 to 185
kgf·cm).
5. Apply a layer of multipurpose grease to the rod end pin and, with twisting motion, insert
through yoke and the inching/brake pedal. Install cotter pin into the rod end pin.
6. Adjust free pedal per the following procedure:
a. Loosen nut and screw it away from yoke.
b. Turn push rod counterclockwise, as viewed from top, until push rod can be moved from
side to side.
c. Turn push rod clockwise until it can no longer be moved from side to side.
d. Turn push rod counterclockwise 1/3 to 2/3 turns.
e. Tighten nut to lock the push rod and the yoke.
f. Verify free pedal is 2 to 4 mm. See Figure 5-1.
7. Flush with brake fluid and air bleed system. See Brake System Air Removal.
8. Adjust fluid level until level is within 2.5 mm of MAX line.
9. Verify all connections are leak-free.
10. Check adjustment of brake pedal as described in Brake Pedal Adjustment.
11. Install floor plate, and kick plate, on lift truck.

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 SERVICE BRAKES ADJUSTMENT
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 Lift Truck on Blocks in the Periodic Maintenance section for
your lift truck or the Operating Manual for your lift truck. 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.

NOTE: If the brake shoes were not replaced, loosen the adjuster wheel approximately 20 teeth.

3. Push the automatic adjuster lever away from the adjuster wheel with a small screwdriver. Use
the adjuster tool to loosen the adjuster wheel approximately 20 teeth (new brake shoes).
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.

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 BRAKE SYSTEM AIR REMOVAL
There are two commonly used methods to remove air from the brake system. The preferred
method is using a pressure bleed system. The other method is by applying pressure using the
brake pedal.

[1] Using Pressure Bleed System

NOTE: Adjust the service brakes before the air is removed from the brake system.

1. Fill the brake fluid reservoir with brake fluid.

2. Place one end of a rubber hose on the bleeder screw of each wheel cylinder. Place the other
end of each hose into a clear container of brake fluid.
3. Connect a pressure bleeder to the brake fluid reservoir.
4. Loosen the bleeder screws at the wheel cylinders one turn.

NOTE: While applying air pressure to the pressure bleeder, check the level of the brake fluid in the reservoir
for the master cylinder. Make sure to obtain the brake fluid at the correct level to avoid forcing more air into
the brake system.

5. Apply 34.5 kPa (0.4kgf/cm2) of air pressure to the pressure bleeder, forcing fluid through the
lines until all air is removed from the system. Close the bleeder screws.
6. Check the level of the brake fluid in the reservoir for the master cylinder. Fill the brake fluid
reservoir to the correct level.

[2] Using Brake Pedal Pressure

Perform the following procedure to remove used brake fluid from the remainder of the brake
system.

1. Ensure that the master cylinder reservoir is filled with brake fluid and the appropriate free
play exists between the push rod and the piston.
2. Put one end of a rubber hose on the bleeder valve of the master cylinder. Put the other end
of the hose into a empty container.
3. Loosen the bleeder valve at the master cylinder one turn so that the used brake fluid can be
removed from the brake system and close the bleeder valve.
4. Slowly push the brake pedal and hold it at the end of its stroke. Loosen the bleeder valve
so that the air in the master cylinder can be removed with the fluid. Close the bleeder valve
when the fluid flow stops. Release the brake pedal.

NOTE: The new brake fluid will be easily recognized, as the color will be more clear than the used fluid
which will be darker.

5. Repeat Step 4 until there is new brake fluid in the container and no air exists in the fluid
coming out of master cylinder.
6. Repeat Step 1 through Step 5 for the wheel cylinder.
7. 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.
8. Repeat the procedure for the other wheel cylinder.

— 20 —
 BRAKE PEDAL ADJUSTMENT, 1-PEDAL OPTION
Check and adjust the inching/brake pedal by the following procedure if the control valve on the
transmission, the master cylinder, the service brakes and the pedal linkage are repaired and re-
installed. See Figure 5-1.

1. Adjust the pedal height to 156 to 166 mm from the top surface of the floor plate (147 to 157
mm from the top of the floor mat) by the capscrew (3).
2. Adjust the inching/brake pedal stroke for actuating the bell crank (4) (overlap stroke of inching
and brake) to 17 to 21 mm by the STOPPER SCREW (11).
3. Adjust the free play on the pedal for actuating the master cylinder (6). See INSTALL AND
ADJUST of MASTER CYLINDER REPAIR.
4. Adjust the free play on the pedal for actuating the inching cable (7) to 2.5 to 7.5 mm by the
adjustment nut on the inching cable (8). Ensure the bell crank on the inching valve (9) does
not push the spool (10) when the pedal (2) in released.
5. Adjust height of the stop lamp switch so that it can be torned on when the pedal is stepped.

147 to 157 mm

156 to 166 mm

1. BRACKET
2. INCHING/BRAKE PEDAL
3. CAPSCREW
4. BELL CRANK
5. STOP LAMP SWITCH
6. MASTER CYLINDER
7. INCHING CABLE
8. ADJUSTMENT NUTS
9. BELL CRANK
10. SPOOL
11. STOPPER SCREW

Figure 5-1.

— 21 —
 BRAKE PEDAL ADJUSTMENT, 2-PEDAL OPTION
See Figure 6-1.

1. Adjust the inching pedal height to 149 to 159 mm from the top surface of the floor plate (140
to 150 mm from the top of the floor mat) by the capscrew (3).
2. Adjust the inching pedal stroke for actuating the brake pedal (4) (overlap stroke of inching
and brake) to 17 to 21 mm by the STOPPER SCREW (11).
3. Ensure the brake pedal height is 149 to 159 mm from the top surface of the floor plate (140
to 150 mm from the top of the floor mat). Repeat Step 1 through Step 3 if the measurement
is out of the range.
4. Adjust the free play on the brake pedal for actuating the master cylinder (6). See INSTALL
AND ADJUST of MASTER CYLINDER REPAIR.
5. Adjust the free play on the inching pedal for actuating the inching cable (7) to 2.5 to 7.5 mm
by the adjustment nut on the inching cable (8). Ensure the bell crank on the inching valve (9)
does not push the spool (10) when the inching pedal (2) is released.
6. Adjust height of the stop lamp switch so that it can be torned on when the pedal is stepped.

140 to 150 mm

149 to 159 mm

1. BRACKET
2. INCHING/BRAKE PEDAL
3. CAPSCREW
4. BELL CRANK
5. STOP LAMP SWITCH
6. MASTER CYLINDER
7. INCHING CABLE
8. ADJUSTMENT NUTS
9. BELL CRANK
10. SPOOL
11. STOPPER SCREW

Figure 6-1.

— 22 —
 TORQUE SPECIFICATIONS

Back Plate to Axle Mount Capscrews

2.0 ~ 3.5 ton

   255 to 306 N·m (2600 to 3120 kg·cm)
1.5 ~ 2.0 ton
   152 to 167 N·m (1550 to 1700 kg·cm)

Wheel Cylinder Capscrews

2.0 ~ 3.5 ton

   18 to 26 N·m (133 to 195 kg·cm)
1.5 ~ 2.0 ton
   15 to 23 N·m (150 to 230 kg·cm)

Axle Shaft Capscrews

2.0 ~ 3.5 ton

   90 to 108 N·m (920 to 1100 kg·cm)
1.5 ~ 2.0 ton
   59 to 70 N·m (600 to 715 kg·cm)

Wheel Nuts

2.0 ~ 3.5 ton

   440 to 490 N·m (4490 to 5000 kg·cm)
1.5 ~ 2.0 ton
   196 to 216 N·m (2000 to 2200 kg·cm)

— 23 —