BRAKE SYSTEM

E2.00-3.20XM (E45-65XM, E45-65XM 2) [F108];

N30XMH, N30XMH 2 [A210, C210];
V30ZMD [D210/E210];
E2.00-3.20XM (E45-65Z) [G108]

PART NO. 897669 1800 SRM 574

 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 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 back-
ground. The CAUTION symbol and word are on yellow background.
Brake System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Service Brakes ............................................................................................................................................... 1
Master Cylinder............................................................................................................................................. 2
Parking Brake................................................................................................................................................ 3
Service Brakes Repair ....................................................................................................................................... 3
Remove and Disassemble .............................................................................................................................. 3
Clean .............................................................................................................................................................. 7
Inspect ............................................................................................................................................................ 7
Assemble and Install ..................................................................................................................................... 7
Adjust ............................................................................................................................................................. 10
Parking Brake Repair........................................................................................................................................ 12
Remove and Disassemble .............................................................................................................................. 12
Assemble and Install ..................................................................................................................................... 12
Adjust ............................................................................................................................................................. 13
Master Cylinder Repair ..................................................................................................................................... 17
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 18
Clean and Inspect .......................................................................................................................................... 20
Assemble ........................................................................................................................................................ 20
Install ............................................................................................................................................................. 23
Seat Brake Assembly ......................................................................................................................................... 23
Seat Brake, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
N30XMH, and N30XMH 2 (A210, C210), V30ZMD (D210).......................................................................... 23
Brake Switch, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
N30XMH, and N30XMH 2 (A210, C210), V30ZMD (D210).......................................................................... 23
Electric Seat Brake, Adjust for Lift Truck Model E2.00-3.20XM (E45-65Z) (F108/G108), V30ZMD
(D210/E210) ................................................................................................................................................... 24
Electric Seat Brake Adjustment With Handle For Lift truck Models E2.00-3.20XM (E45-65Z)
(G108), V30ZMD (E210) ................................................................................................................................ 26
Remove....................................................................................................................................................... 26
Clean .......................................................................................................................................................... 26
Inspect........................................................................................................................................................ 26
Install ......................................................................................................................................................... 28
Adjustments ................................................................................................................................................... 28
Solenoid Adjustment ................................................................................................................................. 28
Traction cutoff Switch Adjustment........................................................................................................... 28
Cable Adjustment...................................................................................................................................... 30
Service Brakes Adjustment ............................................................................................................................... 32
Brake Pedal Adjustment ................................................................................................................................... 32
Master Cylinder Adjustment............................................................................................................................. 32
Brake System Air Removal ............................................................................................................................... 32
Parking Brake Not Applied Switch Test........................................................................................................... 33
Torque Specifications ......................................................................................................................................... 33
Troubleshooting.................................................................................................................................................. 33

©2008 HYSTER COMPANY i

Table of Contents Brake System

TABLE OF CONTENTS (Continued)

This section is for the following models:

E2.00-3.20XM (E45-65XM, E45-65XM 2) [F108];

N30XMH, N30XMH 2 [A210, C210];
V30ZMD [D210/E210];
E2.00-3.20XM (E45-65Z) [G108]

ii
1800 SRM 574 Description and Operation

General
This section has a description and the service pro- brake shoes, wheel cylinders, parking brake system,
cedures for the parts of the brake system. The brake and seat brake system. A troubleshooting section is
system includes the following parts: master cylinder, included at the end of this section.

Description and Operation

SERVICE BRAKES
A service brake assembly is installed on the mounts
at each end of the drive axle. The parts of the service
brake assembly are shown in Figure 4 and Figure 5.
When the brake pedal is pushed, fluid pressure from
the master cylinder causes the pistons in the wheel
cylinders to extend. The pistons expand the brake
shoes against the drums. See Figure 1.

The clearance between the brake shoes and the brake

drum is adjusted automatically. An adjuster link-
age turns the adjuster wheel to adjust the clearance.
When the lift truck moves in the REVERSE direc-
tion 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 ad-
juster 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.

1. BRAKE PEDAL
2. MASTER CYLINDER
3. BRAKE ASSEMBLY
4. BRAKE FLUID RESERVOIR

Figure 1. Service Brake System

1
Description and Operation
MASTER CYLINDER
The master cylinder is designed for a dual circuit sys-
tem. The master cylinder has two separate pistons
that operate in the single bore of the master cylin-
der. The reservoir for the fluid is pressed into the
two ports on top of the master cylinder and held in
position by seals. When the brake pedal is pushed,
the push rod moves the piston assemblies. The oper-
ation of the master cylinder is as follows:
When the brakes are OFF, the hydraulic fluid can
move freely between the dual circuit system and the
separate chambers of the fluid reservoir. See Fig-
ure 2.
When the brake pedal is released, the return springs
cause the pistons to retract faster than the fluid. This
action causes a vacuum between the fluid in cham-
bers A and C. The vacuum causes the seals to change
shape. When the seals change shape, they permit
the fluid in chambers B and D to flow through the
holes in the pistons and past the seals into chambers
1. SECONDARY SPRING
2. SEAL
3. SECONDARY PISTON
4. PRIMARY SPRING
5. PRIMARY PISTON
Figure 2. Master Cylinder Brake OFF and Brake RELEASED
2
1800 SRM 574
A and C. The supply holes in the cylinder body supply
fluid as the flow moves from one chamber to the other
chamber. The fluid returns to the reservoir through
the bypass holes when the pistons are fully retracted.
See Figure 2.
When the brake pedal is pressed, the primary pis-
ton moves in the cylinder bore. This movement cre-
ates hydraulic pressure that combines with the force
of the primary spring. These combined forces over-
come the secondary spring force and move the sec-
ondary piston in the bore with the primary piston.
The first movement of both pistons pushes the seals
past the bypass holes in the chambers A and C. This
action applies pressure to the fluid in those cham-
bers and causes fluid to flow to the chambers of the
two separate systems. The fluid in chambers B and
D is not affected by movement of the pistons. This
fluid can move freely between the piston chambers
and the chambers of the fluid reservoir before and
during brake application. See Figure 3.
6. PRIMARY FLUID CHAMBER
7. SECONDARY FLUID CHAMBER
8. BYPASS HOLES
9. SUPPLY HOLES
1800 SRM 574
Figure 3. Master Cylinder Brake APPLIED
If a failure occurs in one of the dual circuits, the other
circuit will apply one of the service brakes. This fail-
ure will cause the brake pedal to travel farther when
the brakes are applied, but the service brakes on one
drive wheel will operate. This failure of one of the
brake circuits can cause the lift truck to turn toward
the drive wheel with the good brake when the brakes
are applied. The operator must control the direction
of the lift truck with the steering when the brakes
are applied during this condition.
The reservoir is equipped with an indicator for low
fluid level. A float in the reservoir moves up and
down with the fluid level. When the fluid level is low,
Service Brakes Repair
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.
Service Brakes Repair
a magnet on the float activates a switch in the bot-
tom of the reservoir. This switch energizes a warning
light in the instrument cluster.
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 the
tension is the same when the lever is moved to apply
the parking brake.
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 re-
stricted area with special ventilation. Protec-
tive clothing and a respirator must be used.
1. If the lift truck must be put on blocks for mainte-
nance or repair, see How to Put Lift Truck on
Blocks in the Operating Manual or Periodic
Maintenance of your vehicle. Tilt mast fully
backward. Put blocks under mast. Tilt mast for-
ward until wheels just touch the floor. Stop mo-
tor. Put blocks under frame of lift truck.
3
Service Brakes Repair 1800 SRM 574

NOTE: On N30XMH, N30XMH 2 (C210) and
V30ZMD (D210/E210) lift trucks, the tilt func-
tion is not installed.
2. If tilt does not function, use a hydraulic jack,
crane, or another lift truck to lift drive wheels
until they just touch the floor. Put blocks under
frame of lift truck.
lift truck. If wheel assembly cannot be removed
easily, use a small screwdriver to push adjuster
actuator away from adjuster wheel. Use a brake
adjustment tool or a screwdriver to turn adjuster
wheel to loosen brake shoes. Remove hub and
drum assembly. Do not damage grease seal when
removing hub.

3. Remove capscrews that hold axle shaft to hub. WARNING

Remove axle shaft.
4. Release parking brake. Bend lock plate and
remove nut that holds axle bearing. Remove
washer and bearing cone.
5. Put grease on floor so wheel assembly will slide
easily from axle tube. Pull wheel assembly from
When the brake shoes are removed, do not cre-
ate dust in the air. See the cleaning procedure
in this section.
6. Make a note of the arrangement of the parts. See
Figure 4 and Figure 5. Remove return springs
with spring pliers.

1. WHEEL CYLINDER 11. ADJUSTER WHEEL ACTUATOR

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

Figure 4. Brake Assembly (Left Brake Assembly Shown)

4
1800 SRM 574 Service Brakes Repair

1. WHEEL CYLINDER 13. PARKING BRAKE CABLE

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

Figure 5. Service Brake Parts

7. Remove retainers, springs, and anchor pins that
hold brake shoes to back plate.
8. Disengage cable from adjuster wheel actuator.
Remove cable, washer, and cable guide. Remove
anchor guide.
9. Move brake shoes away from each other to dis-
engage brake shoes from wheel cylinder. Dis-
connect parking brake lever from parking brake
cable as brake assembly is removed from back
plate. The parking brake lever has a hook that
engages parking brake cable.

5
Service Brakes Repair 1800 SRM 574

NOTE: The adjuster wheel for the left brake is not 12. Use a screwdriver or small pry bar to move apart
the same as the adjuster wheel for the right brake. the ends of the retainer. Remove spring washer
The adjuster wheel for the right brake has left-hand and pivot pin to remove parking brake lever from
threads. brake shoe.

10. Make a note of the arrangement of parts and
disassemble brake assembly. Remove 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 disen-
gage from the brake shoes after the brake assem-
bly is removed.
11. Remove spring for adjuster wheel actuator. Re-
move adjuster wheel actuator from brake shoe.
Loosen nut and remove anchor and spacer from
brake shoe.
13. Disconnect brake line from wheel cylinder. Re-
move capscrews that hold wheel cylinder to back
plate and remove wheel cylinder.
14. Remove push rods, dust covers, pistons, cups,
and spring from wheel cylinder. See Figure 6.
NOTE: The back plate is not normally removed from
the axle housing for brake repairs. Eight special cap-
screws are used to fasten the back plate to the axle
mount and the locking function of the capscrews is
reduced if they are removed. These capscrews are
tightened to 255 N•m (188 lbf ft).

1. PUSH ROD (2) 6. WHEEL CYLINDER BODY

2. DUST COVER (2) 7. INLET PORT
3. PISTON (2) 8. SPECIAL FITTING
4. CUP (2) 9. DUST COVER
5. SPRING

Figure 6. Wheel Cylinder

6
1800 SRM 574
CLEAN
WARNING
DO NOT use an oil solvent to clean the mas-
ter cylinder, wheel cylinder, or the brake lin-
ings. 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 brake lin-
ings into air when brake drum is removed.
2. Use a solvent approved for cleaning of brake
parts to wet brake lining dust. Follow instruc-
tions and cautions of manufacturer for use of
solvent. If a solvent spray is used, do not create
brake lining dust with spray.
3. When brake lining dust is wet, clean parts. Put
any cloth or towels in a plastic bag or an airtight
container while they are still wet. Put a DAN-
GEROUS FIBERS warning label on 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.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the
air.
INSPECT
1. Inspect bore of wheel cylinder for holes or
scratches. Replace wheel cylinder assembly if
there is any damage.
2. Inspect return springs for wear or damage. In-
spect back plate for wear where brake shoes
touch back plate. Replace a worn or damaged
back plate.
Service Brakes Repair
WARNING
The brake shoes on both wheels must be re-
placed if any shoe is damaged. The brake per-
formance 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 brake shoes for cracks or damage. If
linings or shoes are worn or damaged, replace
brake shoes. Maximum wear is to within 1 mm
(0.025 in.) of contact with rivets or metal shoe on
bonded linings. Brake shoes must be replaced in
complete sets. Inspect brake drums for cracks or
damage. Replace any damaged parts.
NOTE: If grooves must be removed from the brake
drums, do not grind more than 1.5 mm (0.060 in.)
from the internal diameter of the brake drum. The
maximum limit of the internal diameter of the brake
drum is 311.7 mm (12.27 in.). If the internal diame-
ter is larger than the limit, replace brake drum.
4. Inspect brake drum for deep grooves or other
damage.
5. The teeth of the adjuster wheel must not be worn.
The adjuster wheel must turn freely. Check ad-
juster links for damage.
6. Make sure parking brake cables are in good con-
dition.
7. Check grease seals and surfaces of seals for wear
or damage.
ASSEMBLE AND INSTALL
1. If wheel cylinder was disassembled for repair, as-
semble wheel cylinder. See Figure 6. Use only
HYSTER APPROVED parts.
2. Install wheel cylinder on back plate and tighten
two capscrews to 18 to 27 N•m (13 to 20 lbf ft).
Connect brake line to wheel cylinder.
3. Install parking brake lever. See Figure 5. Use
pivot pin, spring washer, and retainer to fasten
parking brake lever to brake shoe. Close the ends
of the retainer to fasten the pivot pin in position.
4. Install anchor and spacer in brake shoe. Install
adjuster wheel actuator in brake shoe.
5. Fasten adjuster actuator spring to adjuster
wheel actuator and brake shoe.
7
Service Brakes Repair
6. Put an antiseize compound on threads of adjuster
wheel. Turn adjuster wheel into adjuster nut so
adjuster assembly is in its shortest position. This
action permits brake drum to be easily installed
over the brake shoes.
WARNING
The threads of the adjuster wheel are not the
same for each side. The adjuster wheel for the
right brake has left-hand threads. The adjuster
wheel for the left brake has right-hand threads.
If the adjuster assemblies are installed on
the wrong side, the brake shoe clearance will
increase when the brakes are applied. This
would result in a loss of braking ability.
7. Install adjuster wheel between two brake shoes.
Make sure adjuster wheel will be toward rear of
lift truck. Move brake shoes apart so adjuster
wheel is held in position and adjuster actuator
spring is in tension.
8. Lubricate back plate with a small amount of
grease where brake shoes touch. Install brake
shoes on anchor and engage push rods of wheel
cylinder. Engage parking brake lever in slot in
parking brake cable as brake shoes are installed
on back plate.
1. ADJUSTER ACTUATOR LINK
2. RETURN SPRING
Figure 7. Return Springs
8
1800 SRM 574
9. Put an anchor pin that holds brake shoes through
back plate. Put a spring seat, spring, and re-
tainer on anchor pin. Push retainer on to anchor
pin and rotate retainer 90 degrees. Make sure
retainer is in correct position. Install another re-
tainer spring assembly.
10. Install link, parking brake, and spring between
parking brake lever and brake shoe.
11. Install other spring retainers that hold brake
shoes. Make sure parking brake link and spring
are correctly engaged after spring retainers are
installed.
12. Install anchor guide on anchor. Install cable
guide on its anchor.
13. Fasten cable to adjuster wheel actuator and put
cable around cable guide. Raise adjuster wheel
actuator against spring tension and connect ca-
ble to anchor.
14. Use the correct tools to install the return springs.
Install return spring. Install washer and return
spring. The shape of the return springs permits
them to be installed correctly in only one posi-
tion. The arrangement of the return springs on
the anchors is shown in Figure 7.
3. RETURN SPRING
4. ANCHOR
1800 SRM 574 Service Brakes Repair

15. Make sure bottom edge of adjuster wheel actua- alignment position at or above 3 N•m (25 lbf in),
tor is just above center of teeth of adjuster wheel. bend lock plate over nut.
Check for correct installation if alignment is not
correct.

16. Clean bearings and lubricate them with wheel

bearing grease. Install bearings and seals in
brake drum. Install assembly on axle housing.
See Figure 8, Figure 9, and Figure 10.

1. OUTER SEAL
2. INNER SEAL
3. BRAKE DRUM

Figure 9. Oil Seal Location E2.00-3.20XM

(E45-65XM, E45-65XM 2) (F108), E2.00-3.20XM
(E45-65Z) (G108)

1. OUTER SEAL 3. BRAKE DRUM

2. INNER SEAL

Figure 8. Grease Seals Location N30XMH,

N30XMH 2 (A210, C210), V30ZMD (D210, E210)

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 wheel and slide wheel toward axle
housing. Install outer bearing and nut.

17. Adjust hub bearings by tightening nut to 68 N•m

(50 lbf ft) while rotating hub. Loosen nut until
hub turns freely with no end play. Tighten nut
to 3 N•m (25 lbf in) and lock in place at first Figure 10. Inner Grease Seal Installation

9
Service Brakes Repair 1800 SRM 574

applied while the lift truck is traveling in the

CAUTION REVERSE direction.
If there is too much clearance, the automatic
adjusters will not operate. If the clearance is 19. Put liquid sealant on flange of axle shaft. Install
too small, the automatic adjuster cannot turn axle shaft and capscrews. Tighten capscrews to
the adjuster wheel to increase the clearance 90 N•m (66 lbf ft).
and the adjuster wheel will not turn until
the brake shoes wear. If the adjuster wheel ADJUST
does not move for a long operating period, the
1. Remove air from brake hydraulic system. See
adjuster link can wear a spot on the adjuster
Brake System Air Removal.
wheel so that it will not turn correctly.
2. Install wheel on hub. Tighten nuts to 237 to
NOTE: If the brake shoes were not replaced, loosen
305 N•m (175 to 225 lbf ft).
adjuster wheel approximately 15 teeth.
3. Tilt mast backward or lift the truck to remove
18. Adjust clearance of brake shoes. Put a brake
blocks. Push on brake pedal. The pedal must
adjustment tool or a screwdriver through slot in
not touch floor plate. Move lift truck in RE-
back plate. Use the tool to rotate adjuster wheel.
VERSE and push on brake pedal to permit ad-
The actuator for the adjuster wheel will only
justing mechanism to operate. Repeat this oper-
permit rotation in one direction. Turn adjuster
ation several times.
wheel until brake shoes have expanded against
brake drum and hub will not turn. Use a small 4. The service brakes must be adjusted before the
screwdriver to lift actuator away from adjuster parking brake can be adjusted. See Figure 11
wheel and turn adjuster wheel approximately and the following paragraphs in this section for
15 teeth in opposite direction. The brakes will the correct adjustment of the parking brake.
adjust to the correct clearance when they are

10
1800 SRM 574 Service Brakes Repair

1. CAPSCREW 6. LOCK NUT

2. BRAKE PEDAL 7. MASTER CYLINDER
3. FLOOR PLATE 8. SWITCH
4. LOCK NUT 9. BRAKE ASSEMBLY
5. PUSH ROD 10. BRAKE LINES

Figure 11. Service Brake Adjustment

11
Parking Brake Repair
Parking Brake Repair
REMOVE AND DISASSEMBLE
1. Use blocks next to the wheels to make sure the
lift truck cannot move. Release the parking
brake. See Figure 13.
2. Turn the adjustment knob so that the link is at
the bottom of the adjustment slot.
3. Remove the cotter pin and anchor pin that con-
nect the bar to the parking brake assembly. Dis-
card the cotter pin.
4. Remove the nuts and washers that hold the park-
ing brake assembly to the bracket. Remove the
capscrews and spacers.
5. Remove the cotter pin, washer, and anchor pin
from the link.
6. The service brake assembly must be removed be-
fore the parking brake cables can be removed
from the backplate of the service brake. A snap
ring ( Figure 5) holds the sheath of the parking
brake cable in the backplate of the service brake.
Remove the snap ring and remove the parking
brake cable from the backplate.
ASSEMBLE AND INSTALL
The parking brake cables must be installed in the
backplate before the service brake is installed. A
snap ring holds the sheath of the parking brake ca-
ble in the backplate of the service brake. Install the
parking brake cable in the backplate and install the
snap ring that holds the sheath of the parking brake
cable in the backplate. See Figure 13.
If the lever assembly for the parking brake was re-
moved from the frame, use the following procedure
for installation:
1. Make sure the parking brake lever is in the re-
leased position. Turn the adjustment knob until
12
1800 SRM 574
the link is adjusted to the bottom of the adjust-
ment slot.
2. Install the ends of the cables into the compen-
sator. Install the anchor pin, washer, and new
cotter pin into the parking brake assembly. Make
sure the anchor pin is through the link and com-
pensator.
3. Install the mounting bolts through the cable
clamps and spacers. Mount the assembly to the
bracket.
4. Before tightening the mounting capscrews, make
sure the parking brake assembly is in contact
with the frame bracket.
NOTE: Perform the adjustment in Step 5 on lift
trucks built before March 7, 2000, and Step 6 on lift
trucks built after March 7, 2000.
5. The following procedure must be used to connect
the bar to the parking brake assembly and the
brake pedal assembly: put the parking brake
lever in the applied position and align the bot-
tom edge of the brake pedal assembly with the
top edge of the frame bracket. See Figure 13. Use
the mounting holes that allow the best alignment
of the bar. Install the cotter pins.
6. Loosen the socket head screw located on the park
brake pedal adjustment plate. The socket head
screw can be loosened from the access port lo-
cated on front of the cowl. See Figure 12. Adjust
the park brake pedal adjustment plate to achieve
a 5 to 6 mm (0.20 to 0.24 in.) clearance between
the park brake pedal adjustment plate and the
park brake pedal assembly. See Figure 14.
7. With the brake in the applied position, adjust
and tighten the nuts on the end of the cable to
remove all the free-play from the release handle.
1800 SRM 574 Parking Brake Repair

ADJUST
Make sure that the service brakes are adjusted and
the operation of the automatic adjuster mechanism
is correct before the parking brake is adjusted. See
Figure 13.

1. Turn the adjustment knob to raise the link and

tighten the parking brake cables. Turn the ad-
justment knob until the parking brakes are fully
applied when the pedal is used to apply the park-
ing brake.

2. Test the operation of the parking brake. The

parking brake, when in good condition and cor-
rectly adjusted, will hold a lift truck with a capac-
ity load on a 15% grade, [a slope that increases
1.5 m in 10 m (1.5 ft in 10 ft)].

3. With the parking brake applied, adjust the nuts

to remove any free play from the release handle.

1. COWL 4. Check the operation of the switches on the park-

2. ACCESS PORT ing brake as described in Parking Brake Not Ap-
plied Switch Test.
Figure 12. Adjusting Plate Access

13
Parking Brake Repair 1800 SRM 574

Figure 13. Parking Brake Assembly For Lift Trucks Built Before March 7, 2000

14
1800 SRM 574 Parking Brake Repair

Legend for Figure 13

1. BRAKE ASSEMBLY 10. NUT
2. BRAKE CABLES 11. CLAMP
3. PARKING BRAKE ASSEMBLY 12. SPACER
4. BAR 13. ANCHOR PIN
5. ADJUSTMENT KNOB 14. NUT
6. PARKING BRAKE PEDAL 15. COMPENSATOR
A. RELEASED POSITION 16. FRAME BRACKET
B. APPLIED POSITION 17. LINK
7. RELEASE HANDLE 18. ADJUSTMENT SLOT
8. ANCHOR PIN 19. FRAME BRACKET
9. MOUNTING CAPSCREW 20. CABLE

15
Parking Brake Repair 1800 SRM 574

1. PARK BRAKE RELEASE HANDLE 7. PARK BRAKE PEDAL CABLE ADJUSTMENT

2. MOUNTING BRACKET PLATE
3. CAPSCREW 8. ADJUSTMENT KNOB
4. COWL 9. SPRING
5. PARK BRAKE PEDAL CABLE 10. PARKING BRAKE LEVER ASSEMBLY
6. PARK BRAKE PEDAL ASSEMBLY 11. PARKING BRAKE CABLE
A. RELEASED POSITION 12. SWITCH
B. APPLIED POSITION 13. SWITCH MOUNTING PLATE

Figure 14. Parking Brake Assembly For Lift Trucks Built After March 7, 2000

16
1800 SRM 574 Master Cylinder Repair

Master Cylinder Repair

REMOVE
1. Remove floor plates from lift truck for access to
master cylinder. See Figure 15.
2. Loosen and remove two brake hydraulic lines
from master cylinder. Disconnect wire at switch
on reservoir.
3. Remove cotter pin, washer, and pin from push
rod end that is attached to the brake linkage
lever arm. Discard the cotter pin.
4. Remove capscrews, washers, and nuts that hold
the master cylinder to the bracket assembly and
remove master cylinder from lift truck.

1. CAP 12. WASHER

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

Figure 15. Master Cylinder

17
Master Cylinder Repair 1800 SRM 574

DISASSEMBLE
The disassembly procedures for the master cylinder are in the following steps:

STEP 1.
Remove the fluid reservoir. Apply force in the direc-
tion of the arrow and pull the reservoir from the mas-
ter cylinder.

STEP 2.
Be careful to not scratch the surfaces. Use a tool
(screwdriver with a flat tip) that has a smooth and
rounded end to remove the reservoir seals.

STEP 3.
Push the primary piston into the bore as shown in the
illustration. Remove the pin at the secondary piston
through the port for the secondary reservoir.

18
1800 SRM 574 Master Cylinder Repair

STEP 4.
Remove the clevis and nut from the push rod. Re-
move the dust cover.

WARNING
Keep control of the pistons as they are removed so that the return springs do not suddenly release
the pistons from the bore with enough force to cause an injury.

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

STEP 5.
Remove the snap ring and the primary piston assem-
bly.

CAUTION
During disassembly of the primary and secondary piston assemblies, make sure not to scratch or
damage the cylinder bore when the spring is removed.

STEP 6.
Hit the cylinder lightly on a soft or wooden surface
and remove the secondary piston assembly. Lubri-
cate the cylinder bore with clean brake fluid to help
removal.

19
Master Cylinder Repair 1800 SRM 574

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

STEP 7.
Remove the seal from the piston with a smooth and
rounded tool.

CLEAN AND INSPECT
CAUTION
DO NOT use an oil solvent to clean the master
cylinder, wheel cylinder, or the 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.

ASSEMBLE
The assembly procedures for the master cylinder are in the following steps:

NOTE: Install a new seal when the master cylinder is assembled for repair.

STEP 1.
Install the seal into the piston.

20
1800 SRM 574 Master Cylinder Repair

CAUTION
During assembly of the primary and secondary piston assemblies, make sure not to scratch or dam-
age the cylinder bore when the spring is removed.

STEP 2.
During installation of the secondary piston, insert
the piston assembly into the cylinder until the seal
is at the center of the bore opening. Be careful to not
cause a restriction of the seal during installation. To
make sure the seal enters the bore correctly, carefully
rotate and tilt the piston until the seal is installed
in the bore. Slowly push the piston assembly into
the bore in one continuous motion after the seal fully
enters the bore.

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

STEP 3.
Install the snap ring and primary piston assembly.

STEP 4.
Install the clevis and nut from the push rod. Install
the dust cover. Be sure to install the dust cover lip
into the recess in the bore of the cylinder.

21
Master Cylinder Repair 1800 SRM 574

STEP 5.
Install the primary piston into the bore as shown in
the illustration. Install the pin at the secondary pis-
ton through the port for the secondary reservoir.

NOTE: Always install new seals.

STEP 6.
Put new seals in clean brake fluid, then install the
seals in the body of the master cylinder.

STEP 7.
Install the reservoir by pushing and turning the
reservoir in the direction shown by the arrow. Make
sure brake fluid does not leak from the reservoir
seals. If there is any leakage, replace the seals.

22
1800 SRM 574
INSTALL
1. Install the capscrews, washers, and nuts that
hold the master cylinder to the bracket assem-
bly and install the master cylinder into the lift
truck.
2. Install the new cotter pin, washer, and pin into
the push rod end that is attached to the brake
linkage lever arm. See Figure 15.
Seat Brake Assembly
SEAT BRAKE, ADJUST - LIFT TRUCK
MODELS E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108), N30XMH, AND
N30XMH 2 (A210, C210), V30ZMD (D210)
NOTE: Lift trucks equipped with a seat brake do not
have a switch located in the seat. The brake switch
is attached to the front plate of the battery compart-
ment. Also, the power steering timer has been re-
placed with a filter.
Lift trucks that are not equipped with a seat brake
will still have a switch located in the seat to activate
the power steering and traction circuits. These units
will continue to use a power steering timer.
1. Apply park brake.
2. Put a weight on seat to release seat brake. Apply
adhesive (Loctite® 290) to threads of screw. Ad-
just screw to set 65 mm (2.5 in.) dimension. See
Figure 16.
3. With seat down, use spring adjustment to set
spring to a length of 100 mm (3.9 in.). Tighten
jam nut without moving spring adjustment nut.
4. With seat down, lift brake spring to remove all
the clearance in brake assembly. Adjust ball joint
Seat Brake Assembly
3. Install and tighten the two brake hydraulic lines
onto the master cylinder. Connect the wire at the
switch on the reservoir.
4. Install the floor plates onto the lift truck.
5. Check the adjustment of the brake pedal as de-
scribed in Brake Pedal Adjustment.
on rod to obtain a clearance of 1.0 mm (0.039 in.)
between lever weldment the brake spring. With
seat up and lever against battery compartment,
brake spring should be slightly extended to allow
for brake wear.
5. With seat up, adjust jam nuts so they do not
contact thrust bearing. Test operation of seat
brake to make sure seat brake is actuated cor-
rectly. Make sure measurements for linkage ad-
justments are correctly done. If seat brake does
not correctly actuate after the adjustments have
been made, make adjustments to the length of
the rod.
BRAKE SWITCH, ADJUST - LIFT TRUCK
MODELS E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108), N30XMH, AND
N30XMH 2 (A210, C210), V30ZMD (D210)
1. Adjust switch so switch leaf is actuated when
lever contacts battery compartment.
2. Make sure capscrew at center of brake drum is
tightened to 66 N•m (48.7 lbf ft). Make sure pivot
nut and capscrew for brake lever are tightened to
40 N•m (29.5 lbf ft).
23
Seat Brake Assembly 1800 SRM 574

1. LEVER 10. SEAT

2. SPRING ADJUSTMENT ROD 11. ADJUSTMENT SCREW
3. FRONT PLATE BATTERY COMPARTMENT 12. SPRING
4. JAM NUT 13. BALL JOINT
5. LEVER 14. ROD
6. BRAKE SPRING 15. THRUST BEARING
7. JAM NUT 16. ADJUSTING ROD
8. MOTOR 17. SWITCH
9. BRAKE ASSEMBLY

Figure 16. Seat Brake Assembly, Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
N30XMH, and N30XMH 2 (A210, C210), V30ZMD (D210)

ELECTRIC SEAT BRAKE, ADJUST FOR
LIFT TRUCK MODEL E2.00-3.20XM
(E45-65Z) (F108/G108), V30ZMD
(D210/E210)
NOTE: The spring must be fully set before any ad-
justments can be done.
1. Turn the plunger counterclockwise to pull it out
and clockwise to push it in, so that there is a
10 mm (0.40 in.) distance between the solenoid
plunger face and the lip of the solenoid housing.
See Figure 17.
2. Turn the lift truck power ON and release the
brake.
3. Rotate the brake drum. If brake drum turns
freely, go to Step 7.
4. If the brake drum does not turn freely, turn the
truck power OFF and turn the solenoid plunger
counterclockwise.

24
1800 SRM 574 Seat Brake Assembly

5. Repeat Step 3 and Step 4 until brake drum is

CAUTION
If brake drum is not fully released, the brakes
will drag and cause damage to the brakes and
can cause the traction motor to overheat. Make
sure brake drum fully releases before using the
truck.
fully released.
6. Turn solenoid plunger 1/8 turn past the point of
full brake drum release.
7. Tighten jam nut against the clevis to complete
the adjustment procedure.

A. FRONT VIEW B. SIDE VIEW

1. SPRING 7. BRAKE DRUM
2. BRAKE 8. CONTROLLER SOLENOID PLUG
3. PIN ROD END 9. SOLENOID HOUSING
4. JAM NUT 10. CLEVIS (PLUNGER)
5. COTTER PIN 11. TRACTION MOTOR
6. SPACER

Figure 17. Electric Seat Brake Adjustment for Lift Truck Model E2.00-3.20XM (E45-65Z)
(F108/G108), V30ZMD (D210/E210)

25
Seat Brake Assembly 1800 SRM 574

ELECTRIC SEAT BRAKE ADJUSTMENT
WITH HANDLE FOR LIFT TRUCK MODELS
E2.00-3.20XM (E45-65Z) (G108), V30ZMD
(E210)
NOTE: Remove the battery from the lift truck before
removing the seat brake. See the Operating Man-
ual or the section Periodic Maintenance 8000
SRM 1060 for the procedures.
Remove
1. Loosen brake drum capscrew. Pull manual re-
lease lever up to release the compression spring.
Remove capscrew, washer, and lockwasher from
brake drum. Remove brake drum from brake as-
sembly. Remove spacer from motor shaft.
2. Put manual release lever down. Disconnect
guide pipe and brake cable. Disconnect electri-
cal connections. See Figure 18.
3. Loosen the compression spring. Remove pin se-
curing clevis and stud to brake assembly. Re-
move brake assembly from traction motor.
1. Do not release brake lining dust from the brake
linings into the air when 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 solvents. If a solvent spray is
used, do not create brake lining dust with the
spray.
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 DANGEROUS FIBERS warning labels 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
brake linings that will be installed again.
4. Any cleaning cloths that will be washed must be
cleaned so that the fibers are not released into
the air.

4. Remove two capscrews from seat brake mounting

bracket. Remove seat brake mounting bracket
and solenoid.
5. Remove two rod end pins from seat brake mount-
ing bracket to disconnect the solenoid.
Clean
Inspect
1. Inspect the brake shoes for cracks or damage. If
the lining or shoes are worn or damaged, install
new brake shoes. Brake shoes must be installed
in complete sets.
2. Inspect the brake drum and all other parts for
cracks or damage.

WARNING 3. If any parts are damaged or cracked, install new

Cleaning solvents can be flammable and toxic parts.
and can cause skin irritation. When using
cleaning solvents, always follow the safety
instructions of the solvent manufacturer.

Legend for Figure 18

1. CAPSCREW 10. BRAKE CABLE 19. SPACER
2. BRACKET 11. CONTROLLER 20. BRAKE DRUM
3. NUT 12. FITTING 21. BRAKE ASSEMBLY
4. WASHER 13. GUIDE PIPE 22. COTTER PIN
5. LOCKWASHER 14. CABLE LINK 23. CLEVIS
6. DISC SPRING 15. THUMB NUT 24. MOUNTING BRACKET
7. MANUAL RELEASE LEVER 16. COMPRESSION SPRING 25. SWITCH
8. PIN 17. CUP 26. SOLENOID
9. WIRE STOP 18. STUD

26
1800 SRM 574 Seat Brake Assembly

Figure 18. Seat Brake Assembly With Handle for Lift Truck Models E2.00-3.20XM (E45-65Z) (G108),
V30ZMD (D210/E210)

27
Seat Brake Assembly
Install
1. Install and connect the solenoid to seat brake
mounting bracket using two rod end pins.
2. Install seat brake mounting bracket to traction
motor with two capscrews.
3. Install Brake assembly to traction motor.
4. Install pin to connect clevis and stud to brake
assembly. Tighten nuts on compression spring.
5. Connect the electrical connections, brake cable,
and guide pipe.
6. Install spacer on motor shaft. Install lockwasher,
washer, and capscrew into brake drum and in-
stall brake drum onto brake assembly. Tighten
brake drum capscrew.
ADJUSTMENTS
Solenoid Adjustment
NOTE: The solenoid is energized when the brake is
released and de-energized when the brake is applied.
1. With the brake fully assembled and the solenoid
de-energized, adjust the adjusting nut so the
compression spring plus cup is 70 mm (2.75 in.)
in length. Tighten Lock nut. See Figure 20.
NOTE: The stroke is the amount the plunger pro-
trudes from the solenoid body when it is de-ener-
gized.
2. Loosen lock nut. Screw the plunger in or out
of the clevis to adjust plunger stroke to 4 mm
(0.016 in.). Tighten lock nut. See Figure 20.
3. Energize the solenoid to release the seat brake
and check for drag by rotating the brake drum
by hand.
Legend for Figure 19
1. MOUNTING BRACKET
2. CUTOFF SWITCH MOUNTING CAPSCREWS
3. COMPRESSION SPRING
4. CUP
5. TRACTION CUTOFF SWITCH
6. PAN HEAD SCREW
7. BRAKE ASSEMBLY
28
1800 SRM 574
4. If the brake drags with the solenoid energized,
increase the plunger stroke by 1/2 a turn and re-
peat Step 3 and Step 4 until the brake does not
drag.
5. Tighten the clevis lock nut.
NOTE: The solenoid is correctly adjusted when the
brake fully releases with the minimum possible sole-
noid stroke.
Traction cutoff Switch Adjustment
1. On older models, mount switch to bracket leaving
both screws loose enough to rotate the switch.
See Figure 18
2. Mount the bracket and switch to the brake as-
sembly and apply loctite part number 251099
to the screws and install washers and nuts as
shown in Figure 19.
3. With the brake fully assembled, energize the so-
lenoid.
4. On later models, slide the bracket on the cap-
screws until the switch lever arm contacts the
lever arm on the brake. Adjust until there is a
1 mm (0.039 in.) gap between the switch lever
and the switch body. Once the correct position is
determined the mounting screws should be tight-
ened to 4 N•m (36 lbf in). See Figure 19
5. Once switch is correctly adjusted the manual re-
lease handle will need to be readjusted to ensure
that the minimum 1 mm (0.039 in.) clearance
is maintained between the switch lever and the
switch body.
8. CAPSCREW
9. LOCKING RING COTTER PIN
10. PIN
11. SOLENOID
12. CLEVIS JAM NUT
13. COMPRESSION SPRING NUT
14. COMPRESSION SPRING JAM NUT
1800 SRM 574 Seat Brake Assembly

Figure 19. Traction Cutoff Switch Adjustment

29
Seat Brake Assembly 1800 SRM 574

Cable Adjustment 2. Move the handle to the DOWN position.

NOTE: The Solenoid and Traction Cutoff Switch ad- 3. Pull the handle back into the UP position, and
justment must be completed before adjusting the re- check for drag by rotating the brake drum by
lease cable. hand.

NOTE: When handle is in the UP position, brake is
released. When handle is in the DOWN position,
brake is applied.
NOTE: The solenoid must NOT be energized when
performing this procedure.
NOTE: When the handle is in the UP position, the air
gap between the leaf and the switch housing must be
0.5 mm (0.019 in.) minimum.
1. With brake fully assembled, and the handle in
the UP position. Pull the cable tight through the
wire stop. Insert excess cable into the handle.
See Figure 20.
4. If the brake drags while the handle is in the
UP position, lower the handle, loosen the wire
stop, pull cable through, and retighten the wire
stop. Repeat Step 3 and Step 4 until the brake
no longer drags. Lower the handle to the DOWN
position.
5. Adjust handle by tightening nut to 0.85 N•m (7.5
lbf in) so that the washers clamp onto the handle
but allows handle to pivot easily.

Legend for Figure 20

1. BRACKET 10. WASHER
2. LOCK NUT 11. LOCKWASHER
3. ADJUSTING NUT 12. CAPSCREW
4. CUP 13. BRAKE DRUM
5. COMPRESSION SPRING 14. TRACTION MOTOR
6. CLEVIS 15. CABLE-BRAKE
7. SOLENOID 16. NUT
8. HANDLE 17. WASHER
9. SCREW 18. WIRE STOP

30
1800 SRM 574 Seat Brake Assembly

Figure 20. Seat Brake Adjustment With Handle for Lift Truck Models E2.00-3.20XM (E45-65Z)
(G108), V30ZMD (D210/E210)

31
Brake System Air Removal 1800 SRM 574

Service Brakes Adjustment

The following procedure is for newly installed brake 3. Push automatic adjuster lever away from ad-
shoes. If the lift truck has been operated for more juster wheel with a small screwdriver. Use
than 25 hours and has correct pedal height, the adjuster tool to loosen adjuster wheel approxi-
brakes normally will not need adjustment. mately 15 teeth (new brake shoes).

1. If the lift truck must be put on blocks for mainte-
nance or repair, see How to Put Lift Truck on
Blocks in the Operating Manual or Periodic
Maintenance of your vehicle. Put lift truck on
blocks so drive wheels can be removed. Remove
the drive wheels.
2. Use an adjuster tool to rotate adjuster wheel so
teeth of wheel move downward. This adjustment
expands brake shoes. Adjust brake shoes so
brake drum will not rotate.
NOTE: If the brake shoes were not replaced, loosen
adjuster wheel approximately 15 teeth.
4. Install drive wheels. Remove lift truck from
blocks. Operate lift truck in FORWARD and
REVERSE directions. Stop lift truck 10 times
in each direction. This procedure causes the
brake shoes to wear a small amount and fit the
brake drum better.

Brake Pedal Adjustment

Adjust pedal height to 81 mm (3.16 in.) by turning the capscrew at the rear of the pedal assembly. This mea-
surement is made with the pedal pad mounted on the pedal. Make sure lock nut is tight. See Figure 11.

Master Cylinder Adjustment

Loosen lock nut on push rod. Turn push rod until will create the proper clearance, which will allow the
all of the clearance is removed between push rod and piston in the master cylinder to fully return when the
master cylinder. Turn push rod 1/8 of a turn counter- brake pedal is released. Make sure lock nut is tight.
clockwise (viewed from the rear of the fork lift). This See Figure 11.

Brake System Air Removal

Adjust the service brakes before the air is removed 4. Repeat the procedure in Step 1 through Step 3
from the brake system. until there are no air bubbles in the container.

1. Fill the master cylinder reservoir with brake
fluid.
2. Put one end of a rubber hose on the special fitting
of the wheel cylinder. Put the other end of the
hose into a clear container of brake fluid.
3. Loosen the special fitting at the wheel cylinder
one turn so that the air can be removed from the
brake system. Slowly push the brake pedal and
hold it at the end of its stroke. Close the special
fitting.
5. Check the level of the brake fluid in the reser-
voir for the master cylinder during the procedure.
Make sure to keep the brake fluid at the correct
level.
6. Repeat the procedure for the other wheel cylin-
der. If there is still air in the system, the air
must be removed from the master cylinder. Push
on the brake pedal with a steady stroke. Release
the pedal slowly. Repeat this procedure until no
air bubbles enter the reservoir.

32
1800 SRM 574 Troubleshooting

Parking Brake Not Applied Switch Test

NOTE: This test is for the E2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108) model lift trucks only.
The Parking Brake Not Applied system is actuated
by a combination of two switches, one attached to the
parking brake mechanism and the other is the seat
switch. These switches actuate an audible buzzer
on the instrument cluster. When the operator leaves
the seat for more than two seconds without applying
the parking brake, the buzzer will be on continuously
for 20 seconds. The buzzer operates whether the key
switch is ON or OFF.

Torque Specifications
Back Plate to Axle Mount Capscrews Axle Shaft Capscrews
225 N•m (166 lbf ft) 90 N•m (66 lbf ft)

Wheel Cylinder Capscrews Wheel Nuts

18 to 27 N•m (13 to 20 lbf ft) 237 to 305 N•m (175 to 225 lbf ft)

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The brakes do not correctly Air in the brake system. Repair system to prevent air enter-
stop the lift truck. ing. Remove air from system.

The mount for the master cylinder is Tighten fasteners.

loose.

The brake shoes are worn or dam- Install new brake shoes.
aged.

The linings are too hard. Install new correct lining.

A brake drum is cracked. Install new part.

A backplate is damaged. Install new part.

A wheel cylinder is leaking or does Repair or install new parts. Remove

not operate correctly. air from system.

The brake linings do not fit the brake Install correct linings.
drums.

The master cylinder is damaged. Install new master cylinder. Remove

air from system.

Water or oil is on the brake linings. Install new linings.

33
Troubleshooting 1800 SRM 574

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

One brake does not release. A brake shoe is damaged. Install new parts.

Wrong return spring. Install new correct spring.

The brake lines have a restriction. Remove restriction or Install new

lines. Remove air from system.

A parking brake cable is damaged or Adjust cable or install new parts.

needs adjustment.

The wheel cylinder is damaged. Repair or install new parts. Remove

air from system.

The backplate is worn or damaged. Repair or install new parts.

The brakes make too much Dirt, oil, water, or brake fluid is on Clean or install new linings.
noise. the linings.

The brake linings are worn. Install new linings.

The brake drum is damaged. Install new brake drum.

A brake shoe is worn or damaged. Install new brake shoe(s).

The brakes do not operate Oil or brake fluid is on the linings. Repair leak. Clean or install new lin-
equally. ings.

The linings are worn or hard. Install new linings.

A wheel cylinder is leaking. Repair or install new parts. Remove

air from system.

The brake linings are not correctly Install brake linings correctly.
installed.

The backplate or brake shoes are Repair or Install new parts.

damaged.

The brake drums are not round. Check to make sure there is adequate
material to allow for machining. Ma-
chine brake drums to make them
round or install new drums.

The shoes are adjusted too tight. Adjust brakes. Check self-adjusters.

34
1800 SRM 574 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Both brakes do not release. The parking brake is not released. Release parking brake.

The parking brake cables need ad- Adjust or install new cables.
justment.

There is not enough clearance at the Adjust clearance between push rod
end of the push rod in the master and piston.
cylinder.

The master cylinder is damaged. Install new master cylinder. Remove

air from system.

The brake shoes are adjusted too Check operation of self-adjusters.

tight. Adjust brakes.

The brake pedal travels too Air in the brake system. Remove air from system. Check for
far. leaks.

Brake fluid level low. The brake sys- Fill brake fluid reservoir to correct
tem has a leak. level. Repair leak. Remove air from
system.

The brake shoes are not adjusted cor- Check operation of self-adjusters.
rectly. Adjust brakes.

The brake linings are worn. Install new linings.

One of the dual brake circuits is not Repair or install new parts.
operating.

There is too much clearance at the Adjust clearance between push rod
end of the push rod in the master and piston.
cylinder.

The master cylinder is worn or dam- Repair or install new master cylin-
aged. der. Remove air from system.

35
Troubleshooting 1800 SRM 574

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The parking brake will not Parking brake not adjusted correctly. Use adjustment knob on parking
hold the lift truck. brake lever to adjust holding force.
See adjustment procedure for correct
specifications.

Oil, water, or brake fluid is on the lin- Install new linings.

ings.

The parking brake cables need ad- Install new parts. Lubricate and ad-
justment, lubrication, or have dam- just cables.
age.

The parking brake will not The parking brake lever is adjusted Adjust parking brake. See adjust-
release. too tight. ment procedure for correct specifica-
tions.

The parking brake cables need ad- Install new parts. Lubricate and ad-
justment, lubrication, or have dam- just cables.
age.

The seat brake will not hold Seat brake not adjusted properly. See adjustment procedure for correct
the lift truck. specifications.

Oil, water, or brake fluid is on the lin- Install new linings.

ings.

The seat brake will not re- Seat brake not adjusted properly. See adjustment procedure for correct
lease. specifications.

The seat brake linkage needs adjust- Install new parts. Lubricate and ad-
ment, lubrication, or has damage. just linkage.

36
 TECHNICAL PUBLICATIONS

1800 SRM 574 4/08 (3/07)(10/06)(1/06)(7/05)(5/04)(11/03)(11/94)(6/94) Printed in U.S.A.