BRAKE SYSTEM

S6.0FT, S7.0FT (S135FT, S155FT) [D024, E024];

S4.0, 4.5, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [G004];
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) [N005, P005]

PART NO. 1624741 1800 SRM 1247

 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Brake System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Dry Brake System ......................................................................................................................................... 1
Wet Brake System ......................................................................................................................................... 1
Service Brakes Repair (Dry Brake)................................................................................................................... 2
Remove and Disassemble .............................................................................................................................. 3
Clean .............................................................................................................................................................. 5
Inspect ............................................................................................................................................................ 6
Assemble and Install ..................................................................................................................................... 6
Adjust ............................................................................................................................................................. 10
Parking Brake Repair........................................................................................................................................ 10
Remove and Disassemble .............................................................................................................................. 10
Assemble and Install ..................................................................................................................................... 15
Adjust ............................................................................................................................................................. 15
Dry Brake System ..................................................................................................................................... 15
Wet Brake System ..................................................................................................................................... 15
Lift Trucks With a MONOTROL® Pedal or Forward Reverse Lever...................................................... 16
Master Cylinder Repair ..................................................................................................................................... 16
Remove ........................................................................................................................................................... 16
Disassemble ................................................................................................................................................... 19
Clean and Inspect .......................................................................................................................................... 19
Assemble ........................................................................................................................................................ 20
Install and Adjust .......................................................................................................................................... 21
Accumulator ....................................................................................................................................................... 22
Precharge Check ............................................................................................................................................ 22
Remove ........................................................................................................................................................... 22
Install ............................................................................................................................................................. 24
Service Brakes Adjustment (Dry Brake) .......................................................................................................... 25
Service Brakes Adjustment........................................................................................................................... 25
Brake System Air Removal ............................................................................................................................... 25
Using Pressure Bleed System ....................................................................................................................... 25
Using Brake Pedal Pressure ......................................................................................................................... 26
Brake Pedal Adjustment ................................................................................................................................... 27
Free Pedal Adjustment ...................................................................................................................................... 28
Torque Specifications ......................................................................................................................................... 29

This section is for the following models:

S6.0FT, S7.0FT (S135FT, S155FT) [D024, E024];

S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [G004];
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) [N005, P005]

©2008 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1800 SRM 1247 General

General
DRY BRAKE SYSTEM WET BRAKE SYSTEM
NOTE: The dry brake system is used only on lift NOTE: The wet brake system is used on all lift truck
truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, models covered in this SRM.
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; The wet brake system in this section includes the fol-
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005). lowing parts: master cylinder and parking brake sys-
tem. See Figure 2 and Figure 3.
This section has service procedures for the dry brake
system. The dry brake system includes the follow-
ing parts: master cylinder and parking brake system
(see Figure 1) and brake shoes and wheel cylinders
(see Figure 4).

NOTE: LIFT TRUCK MODEL S4.0, 4.5, 5.5FT,

S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004) SHOWN.
1. PARK BRAKE HANDLE ASSEMBLY
2. INCH/BRAKE PEDAL
3. BOOSTER ASSEMBLY
4. PARK BRAKE LEVERS
5. PLANETARY CARRIER HOUSING (LEFT-HAND
SIDE SHOWN)
6. WET DISC BRAKE HOUSING
7. PARK BRAKE CABLES
1. PARK BRAKE HANDLE ASSEMBLY 8. ADJUSTMENT KNOB
2. ADJUSTMENT KNOB 9. BRAKE POSITION SENSOR (LEFT-HAND SIDE
3. PARK BRAKE CABLES SHOWN)
4. INCHING/BRAKE PEDAL 10. MASTER CYLINDER
5. MASTER CYLINDER AND BOOSTER 11. CYLINDER BLOCK
6. BRAKE ASSEMBLY
7. BRAKE POSITION SENSOR (RIGHT-HAND Figure 2. Wet Brake System for Lift Truck
SIDE) Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
Figure 1. Dry Brake System (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005)

1
Service Brakes Repair (Dry Brake) 1800 SRM 1247

The wet disc brakes are a component of the wet

brake drive axle. The brake discs are located inside
the planetary carrier housing at each end of the
drive axle. See Drive Axle and Differential As-
sembly Repair, (Wet Brake) 1400 SRM 1246 for
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005),
Drive Axle and Differential Assembly Repair,
(Wet Brake) 1400 SRM 1318 for lift truck models
S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) or
Drive Axle and Differential Assembly Repair,
(Wet Brake) 1400 SRM 1344 for lift truck models
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) for
the removal, assembly and installation procedures.

NOTE: LIFT TRUCK MODEL S6.0FT, S7.0FT (S135FT,

S155FT) (D024, E024) SHOWN
1. PARK BRAKE HANDLE ASSEMBLY
2. INCH/BRAKE PEDAL
3. BOOSTER ASSEMBLY
4. ADJUSTMENT KNOB
5. PLANETARY CARRIER HOUSING (LEFT-HAND
SIDE SHOWN)
6. WET DISC BRAKE HOUSING
7. PARK BRAKE CABLES
8. BRAKE POSITION SENSOR
9. MASTER CYLINDER
10. CYLINDER BLOCK
11. PARK BRAKE LEVERS

Figure 3. Wet Brake System for Lift Truck

Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)

Service Brakes Repair (Dry Brake)

NOTE: The procedures in this section apply on to lift (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) equipped with the dry brake system.

2
1800 SRM 1247
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 re-
stricted area with special ventilation. Protec-
tive clothing and a respirator must be used.
1. See the procedure How to Put Lift Truck on
Blocks in the section Periodic Maintenance
8000 SRM 1248 or the Operating Manual.
Start the engine and tilt the mast fully back-
ward. 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.
2. Remove the capscrews that hold the axle shaft to
the hub. Remove the axle shaft.
3. Bend the lock plate tab and remove the nut, lock-
plate, washer and bearing cone.
4. Put grease on the floor so that the wheel assem-
bly 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
Service Brakes Repair (Dry Brake)
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 the hub and
drum assembly. Do not damage the grease seal
when removing the hub.
NOTE: During disassembly, note the arrangement of
parts to aid in re-assemble of the brake system.
5. Remove the primary, secondary return springs
and tension spring with spring pliers and remove
the anchor pin from the primary brake shoe. See
Figure 4.
6. Remove the pressure springs that hold the brake
shoes to the backing plate.
7. Disconnect the parking brake cable from park
brake lever. See Figure 4.
WARNING
When the brake shoes are removed, do not cre-
ate dust in the air. See the Clean procedure in
this section.
8. Remove brake shoes.
9. Remove the auto adjuster assembly from the
backing plate. See Figure 5.
10. Disconnect the brake line from the wheel cylin-
der. Remove wheel cylinder from backing plate.
See Figure 5.
11. If damaged, remove the backing plate from the
axle housing. Discard the eight mounting lock
bolts.
3
Service Brakes Repair (Dry Brake) 1800 SRM 1247

1. RETAINER 9. TENSION SPRING

2. SECONDARY RETURN SPRING 10. PRIMARY BRAKE SHOE
3. SECONDARY BRAKE SHOE 11. PARK BRAKE LEVER
4. PRESSURE SPRING 12. STRUT
5. AUTO ADJUSTER LINK 13. PRIMARY RETURN SPRING
6. ADJUSTER WHEEL 14. ANCHOR PIN
7. AUTO ADJUSTMENT ASSEMBLY 15. BACKING PLATE
8. PARKING BRAKE CABLE 16. WHEEL CYLINDER

Figure 4. Brake Assembly (Left-Hand Shown)

4
1800 SRM 1247 Service Brakes Repair (Dry Brake)

damage and leaks in the seals of a brake sys-

tem.

Small amounts of water in the brake system

can cause reduced braking if the water reaches
the wheel cylinders and is subject to high tem-
peratures. DO NOT allow water entry into the
brake system. If water is present, remove all
water and refill the system with Dexron III
from a sealed container. Unfiltered shop air
can contain substantial amounts of water. DO
NOT use unfiltered shop air to blow out brake
components.

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.

CAUTION
Do not permit brake cleaning fluid to contact
the master cylinder or wheel cylinder. Brake
cleaning fluid will cause damage and leaks in
seals of the brake system.

1. Do not release brake lining dust from the brake

linings into the air when the brake drum is re-
moved.

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.
1. WHEEL CYLINDER CAPSCREWS 2. Use a solvent approved for cleaning of brake
2. AUTO ADJUSTER CAPSCREW parts to wet the brake lining dust. Follow the
3. ADJUSTER WHEEL ACCESS PLUGS
4. BRAKE LINE instructions and cautions of the manufacturer
for the use of the solvent. If a solvent spray is
Figure 5. Auto Adjuster and Wheel Cylinder used, spray at a distance so that the dust is not
Mount Location released into the air.

CLEAN 3. When the brake lining dust is wet, clean the

WARNING
DO NOT use an oil solvent to clean the brake
linings, use a solvent approved for cleaning of
brake parts. Do not permit oil or grease on the
brake linings, the brakes will not operate cor-
rectly if oil, grease, or brake cleaning fluid is
on the brake linings. Oil and grease will cause
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.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the
air.

5
Service Brakes Repair (Dry Brake) 1800 SRM 1247

INSPECT 5. Inspect the brake shoes for cracks or damage. If

the linings or shoes are worn or damaged, replace
WARNING the brake shoes. Maximum wear is to within
1 mm (0.039 in.) of contact with the rivets, or
Small amounts of water in the brake system
the metal shoe on bonded linings. Brake shoes
can cause reduced braking if the water reaches
must be replaced in complete sets. Inspect the
the wheel cylinders and is subject to high tem-
brake drums for cracks or damage. Replace any
peratures. DO NOT allow water entry into the
damaged parts.
brake system. If water is present, remove all
water and refill the system with Dexron III 6. Inspect the brake drum for deep grooves or other
from a sealed container. Unfiltered shop air damage.
can contain substantial amounts of water. DO
NOT use unfiltered shop air to blow out brake NOTE: If grooves must be removed from the brake
components. drums, do not grind more than 1.5 mm (0.060 in.)
from the internal diameter of the brake drum. The
Cleaning solvents can be flammable and toxic maximum limit of the internal diameter of the brake
and can cause skin irritation. When using drum is 317.5 mm (12.4 in.). If the internal diameter
cleaning solvents, always follow the safety is larger than the limit, replace the brake drum.
instructions of the solvent manufacturer.
7. The teeth of the adjuster wheels must not be
CAUTION worn. The adjuster wheel must turn freely.
Check the adjuster links for damage. See Fig-
Do not permit brake cleaning fluid to contact
ure 4 and Figure 5. Replace the auto adjuster
the master cylinder or wheel cylinder. Brake
assembly if there is any damage.
cleaning fluid will cause damage and leaks in
seals of the brake system. 8. Make sure the parking brake cables are in good
condition. Replace parking brake cables if worn
1. Inspect the bore of the wheel cylinder for holes or
or damaged.
scratches. Replace the wheel cylinder assembly
if there is any damage. 9. Check the grease seals and the surfaces of the
seals for wear or damage. Replace damaged
2. Inspect wheel cylinder parts for dirt or water.
seals.
Clean any dirt or water present in the wheel
cylinder parts using a lint free cloth.
ASSEMBLE AND INSTALL
3. Inspect the primary, secondary and tension
1. If removed, install backing plate using eight new
springs for wear and damage. Inspect the back
lock bolts to the axle housing using tightening
plate for wear where the brake shoes touch the
sequence, see Figure 6. Tighten bolts to 340 to
back plate. Remove any grooves or replace a
375 N•m (251 to 277 lbf ft).
worn or damaged back plate.
NOTE: Replace wheel cylinder if there is any damage
4. Inspect the park brake lever and strut. If dam-
or it is not working properly.
aged, replace primary and secondary brake shoe
assembly. 2. Install the wheel cylinder on the backing plate
and tighten capscrews to 20 to 25 N•m (15 to
WARNING 19 lbf ft). Connect the brake line to the wheel
The brake shoes on both wheels must be re- cylinder. See Figure 5.
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.

6
1800 SRM 1247
NOTE: Replace auto adjuster assembly if there is any
damage or it is not working properly.
3. Install the auto adjuster assembly on the backing
plate between the two brake shoes and tighten
capscrew to 120 to 140 N•m (89 to 103 lbf ft). See
Figure 4 and Figure 5.
4. Lubricate the backing plate with small amount
of lithium grease where the brake shoes touch.
Figure 6. Backing Plate to Axle Housing
Tightening sequence
NOTE: The park brake lever and strut are a compo-
nent of the primary brake shoe. If damaged, replace
primary and secondary brake shoe assembly.
5. Install the primary and secondary brake shoes on
the push rod of wheel cylinder and auto adjuster
link. See Figure 4.
6. Connect the parking brake cable to park brake
lever.
Service Brakes Repair (Dry Brake)
7. Install pressure springs to hold the brake shoes
to the backing plate.
8. Install the primary and secondary return
springs, and tension spring to the brake shoe.
See Figure 4.
9. Coat threads of the adjuster wheels with anti-
seize compound. Turn the adjuster wheels so
that the adjuster assembly is in its shortest po-
sition. This action permits the brake drum to be
easily installed over the brake shoes.
NOTE: Seal and bearings are to be installed flush
with the hub. Seal is to be installed with no grease
or oil on outside surface.
10. Clean the bearings and lubricate them with
wheel bearing grease. Install the bearings and
seals in the wheel hub. Install the assembly on
the axle housing. See Figure 7 and Figure 8.
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.
11. Install the washer, lock plate and wheel adjust-
ment nut. See Figure 9. To align the bearing
rollers, tighten the wheel adjustment nut to 28
to 32 N•m (21 to 24 lbf ft) and rotate the hub 2
revolutions in both directions. To seat the wheel
bearings, tighten the wheel adjustment nut to
400 to 480 N•m (295 to 354 lbf ft). Back off the
wheel adjustment nut to zero end play. Preload
the wheel bearings by tightening the wheel ad-
justment nut to 28 to 32 N•m (21 to 24 lbf ft). Ro-
tate the hub 3 complete revolutions in both direc-
tions. Verify the wheel adjustment nut torque is
28 to 32 N•m (21 to 24 lbf ft) and that the torque
stabilizes at that specification.
7
Service Brakes Repair (Dry Brake)
1. INNER SEAL
2. OUTER SEAL
3. BRAKE DRUM
Figure 7. Grease Seals and Bearing Locations
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
8
1800 SRM 1247
4. INNER BEARING
5. OUTER BEARING
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 two adjuster wheels equally, approximately 20
teeth.
1800 SRM 1247 Service Brakes Repair (Dry Brake)

13. 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 pro-
cedure causes the brake shoes to wear a small
amount and fit the brake drum better.

Figure 8. Inner Grease Seal Installation

1. ADJUSTER LEVER
2. ADJUSTER WHEEL
3. ADJUSTER LINK

Figure 10. Auto Adjuster Assembly

14. Coat the flange of the axle shaft with liquid

sealant, Hyster Part Number 264159. Install
the axle shaft and capscrews. Tighten the cap-
1. AXLE SHAFT
2. WHEEL ADJUSTMENT NUT screws in the sequence shown in Figure 11 to 90
3. LOCK PLATE to 99 N•m (66 to 73 lbf ft).
4. WASHER
5. HUB

Figure 9. Wheel Adjustment

12. To manually adjust the brakes, it is necessary to

turn the adjuster wheels. See Figure 4. Remove
the two access plugs in the adjustment slots lo-
cated on the back side of the backing plate. Place
an adjuster tool and screwdriver through the slot
in the backing plate. See Figure 5. Push the ad-
juster lever away from the adjuster wheel, in the
direction indicated in Figure 10 and turn the ad-
juster wheel until the brake shoe just touches the
brake drum. Use the adjuster tool to loosen the
adjuster wheel approximately 20 teeth. Adjust
the brake shoe for the other adjuster wheel us-
ing the same method. See Figure 10. Make sure
to install the access plugs after the adjustment is
complete. See Figure 5. Figure 11. Axle Shaft Tightening Sequence

9
Parking Brake Repair 1800 SRM 1247

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 610 to 680 N•m (450 to 502 lbf ft).
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 13
and the following paragraphs in this section for
the correct adjustment of the parking brake.

Parking Brake Repair

REMOVE AND DISASSEMBLE
NOTE: For removal and disassembly procedures for
a dry brake system use Step 1 through Step 5. For
the wet brake system use Step 1 through Step 4 and
Step 6.

If the handle assembly for the parking brake must be

removed from the cowl, use the following procedure.
For dry brake system see Figure 13 and for wet brake
system see Figure 14 and Figure 15.

1. Block the front and rear side of the wheels to

make sure the lift truck cannot move. Release
the parking brake handle assembly.

2. Remove the four capscrews that fasten the

bracket for the parking brake to the cowl. Re-
move the bracket and parking brake handle
assembly.

3. Loosen the jam nuts that fasten the threaded

1. PARKING BRAKE CABLE
ends of the parking brake cables to the parking 2. SHEATH
brake handle assembly. 3. SNAP RING
4. SERVICE BRAKE ASSEMBLY
4. Turn the adjustment knob counterclockwise un- 5. BACK PLATE
til the parking brake cables are loosened. Dis-
connect the cables from the equalizer links. Figure 12. Parking Brake Cable Removal for
Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS
5. The service brake assembly must be removed be- (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
fore the parking brake cable can be removed from S120FTPRS) (G004) and H4.0FT5/FT6;
the back plate of the service brake. See Fig- H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
ure 12. A snap ring holds the sheath of the park- 120FT) (N005, P005) With Dry Brake System
ing brake cable in the back plate of the service
brake. Remove the snap ring and remove the 6. The cotter pin, clevis pin, and cable clamps must
parking brake cable from the back plate. See Fig- be removed from the parking brake levers before
ure 12. the parking brake cables can be removed. See
Figure 14 and Figure 15.

10
1800 SRM 1247 Parking Brake Repair

Figure 13. Parking Brake Lever Adjustment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Dry Brake System

11
Parking Brake Repair 1800 SRM 1247

Legend for Figure 13

A. RIGHT HAND SIDE B. LEFT HAND SIDE
1. PARKING BRAKE HANDLE ASSEMBLY 8. ADJUSTMENT SLOT (UNDERNEATH SPRING)
2. ADJUSTMENT KNOB 9. EQUALIZER LINK
3. PARKING BRAKE CABLES 10. NUT
4. INCHING/BRAKE PEDAL 11. CAPSCREW
5. MASTER CYLINDER AND BOOSTER 12. PARKING BRAKE BRACKET
6. BRAKE ASSEMBLY 13. JAM NUTS
7. BRAKE POSITION SENSOR 14. PARKING BRAKE CABLE BRACKET

Legend for Figure 14

A. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT B. S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
(H80, 90, 100, 120FT) (N005, P005) 100FTBCS; S120FTS; S120FTPRS) (G004)
1. PARKING BRAKE HANDLE ASSEMBLY 9. INCHING/BRAKE PEDAL
2. ADJUSTMENT KNOB 10. MASTER CYLINDER AND BOOSTER
3. EQUALIZER LINKS 11. CLEVIS PIN
4. PARKING BRAKE CABLES 12. COTTER PIN
5. NUT 13. PARKING BRAKE LEVER
6. CAPSCREW 14. CABLE CLAMPS
7. BRAKE POSITION SENSOR (RIGHT SIDE 15. PARKING BRAKE BRACKET
SHOWN) 16. JAM NUTS
8. ADJUSTMENT SLOT (UNDERNEATH SPRING) 17. PARKING BRAKE CABLE BRACKET

12
1800 SRM 1247 Parking Brake Repair

Figure 14. Parking Brake Lever Adjustment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Wet Brake System

13
Parking Brake Repair 1800 SRM 1247

Figure 15. Parking Brake Lever Adjustment for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) (Wet Brake System)

14
1800 SRM 1247
Legend for Figure 15
A. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
1. PARKING BRAKE HANDLE ASSEMBLY
2. ADJUSTMENT KNOB
3. EQUALIZER LINKS
4. PARKING BRAKE CABLES
5. NUT
6. CAPSCREW
7. BRAKE POSITION SENSOR
8. ADJUSTMENT SLOT (UNDERNEATH SPRING)
ASSEMBLE AND INSTALL
NOTE: For assemble and install procedures for a dry
brake system use Step 1, Step 3, Step 4, Step 6 and
Step 7. For the wet brake system use Step 2, Step 3,
and Step 5 through Step 7.
If the lever assembly for the parking brake was re-
moved from the cowl, use the following procedure for
installation:
1. The parking brake cables must be installed in the
back plate before the service brake is installed.
See Figure 12. A snap ring holds the sheath of
the parking brake cable in the back plate of the
service brake. Install the parking brake cable
in the back plate and install the snap ring that
holds the sheath of the parking brake cable in
the back plate. See Figure 12.
2. The parking brake cables must be installed on
the parking brake levers located on the wet brake
drive axle and the cables loosely clamped to the
frame and axle in the correct position before con-
necting cables to the equalizer links located on
the parking brake handle assembly. See Fig-
ure 14 and Figure 15.
3. Make sure the parking brake handle is in the re-
leased position. Turn the adjustment knob until
the equalizer link is adjusted to the bottom of the
adjustment slot. For Dry Brake system, see Fig-
ure 13. For Wet Brake system, see Figure 14 and
Figure 15.
4. Adjust the jam nuts on the ends of the cable as-
semblies so that the threads of the cable sheaths
extend 23 to 26 mm (0.90 to 1.02 in.) above their
support plate in the lever assembly. See Fig-
ure 13.
5. Adjust the jam nuts on the ends of the parking
cables so that the threads of the cable are level
Parking Brake Repair
B. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
9. INCHING/BRAKE PEDAL
10. MASTER CYLINDER AND BOOSTER
11. CLEVIS PIN
12. COTTER PIN
13. PARKING BRAKE LEVER
14. CABLE CLAMPS/MOUNTING BRACKET
15. JAM NUTS
in the parking brake handle assembly and not
pulling on the equalizer links with the parking
brake handle assembly in the released position.
See Figure 14 and Figure 15.
6. Install the round ends of the parking brake ca-
bles in their slots in the equalizer link. Tighten
the upper jam nuts to hold the sheaths of the
parking brake cables in the parking brake cable
bracket.
7. Use the four capscrews, washers, and nuts and
fasten the bracket to the inside of the cowl.
Tighten park brake cable clamps on frame and
axle.
ADJUST
Dry Brake System
Make sure the service brakes are adjusted and the
operation of the automatic adjuster mechanism is
correct before the parking brake cables are adjusted.
Wet Brake System
Make sure the park brake levers are adjusted be-
fore the parking brake cables are adjusted. See
Drive Axle and Differential Assembly Repair,
(Wet Brake) 1400 SRM 1246 for lift truck models
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004) and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005), Drive
Axle and Differential Assembly Repair, (Wet
Brake) 1400 SRM 1318 for lift truck models S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024) or Drive
Axle and Differential Assembly Repair, (Wet
Brake) 1400 SRM 1344 for lift truck models H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006) for park
brake lever adjustment procedures.
15
Master Cylinder Repair
Lift Trucks With a MONOTROL® Pedal or
Forward Reverse Lever
The switch energizes the seat warning circuit when
hand lever is released. This switch puts the trans-
mission in NEUTRAL by de-energizing the direction
solenoid. There is also a switch on the left-hand side
of bracket. This switch prevents engine from start-
ing unless parking brake is applied.
CAUTION
On lift trucks equipped with the wet brake sys-
tem, check the dash display to verify the trans-
mission oil is at operating temperature, 49 to
66 C (120 to 150 F) before adjusting the park-
ing brake adjustment knob.
1. To adjust the parking brake, turn the adjustment
knob to raise the equalized link and tighten the
parking brake cables shown in Figure 13, Fig-
ure 14 and Figure 15. Do not tighten the adjust-
ment so that the brake is applied when the lever
is released. The lever for the parking brake has a
lock. Use your thumb or finger to release the lock
on the lever when the parking brake is released.
Master Cylinder Repair
REMOVE
NOTE: The removal procedure in this section is the
same for both dry and wet brake systems.
1. Remove the floor plate, kick plate, and seal plate
from the lift truck for access to the master cylin-
der and booster assembly.
2. Remove master cylinder hoses and brake pres-
sure transducer:
a. For lift truck models S4.0, 4.5, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, S100FT-
BCS; S120FTS; S120FTPRS) (G004)
and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005), remove and tag the brake
16
1800 SRM 1247
NOTE: Before doing Step 2 and Step 3, make sure
the parking brake is correctly adjusted. The parking
brake is correctly adjusted when it takes 125 N
(28 lbf) force (6 clicks) to fully apply the parking
brake for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and 200 N (45 lbf) force (6
clicks) to fully apply the parking brake for lift
truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005),
S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) and
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006).
2. For new brakes, test the operation of the parking
brake. The lift truck, with a capacity load, must
not move when parking brake is applied on a 7.5
percent grade [a slope that increases .75 m in
10 m (9 in. in 10 ft)].
3. For burnished brakes, test the operation of the
parking brake. The lift truck, with a capacity
load, must not move when parking brake is ap-
plied on a 15 percent grade [a slope that increases
1.5 m in 10 m (1.5 ft in 10 ft)].
booster supply and return hoses from the
master cylinder and booster assembly. Plug
hoses to prevent hoses from draining. Dis-
connect the connector at the brake pressure
transducer, and remove brake pressure
transducer. See Figure 16.
b. For lift truck models S6.0FT, S7.0FT
(S135FT, S155FT) (D024, E024), remove
and tag the accumulator to booster hose,
the booster and accumulator supply hose,
the brake hose, and booster return hose.
Plug hoses to prevent hoses from draining.
Disconnect the connector at the brake pres-
sure transducer, and remove brake pressure
transducer. See Figure 17.
1800 SRM 1247 Master Cylinder Repair

1. CAPSCREW 11. BRAKE PRESSURE TRANSDUCER

2. BRAKE OIL RESERVOIR 12. BOOSTER SUPPLY HOSE
3. CLAMP 13. BOOSTER ASSEMBLY
4. UPPER BRAKE OIL SUPPLY HOSE 14. MOUNTING BOLT
5. CYLINDRICAL BLOCK 15. MANIFOLD MOUNT
6. MOUNT 16. BRACKET
7. LOWER BRAKE OIL SUPPLY HOSE 17. COTTER PIN
8. INSERT 18. ROD END PIN
9. FITTING FOR BOOSTER RETURN HOSE 19. MASTER CYLINDER
10. BRAKE HOSE 20. NIPPLE

Figure 16. Master Cylinder and Reservoir Assembly, Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)

17
Master Cylinder Repair 1800 SRM 1247

1. BOOSTER
2. MASTER CYLINDER
3. BOOSTER RETURN HOSE
4. MANIFOLD
5. BOOSTER AND ACCUMULATOR SUPPLY HOSE
6. ACCUMULATOR TO BOOSTER HOSE
7. ELBOW FITTING
8. ACCUMULATOR
9. MOUNTING CLAMP/BRACKET 1. BOOSTER
10. BRAKE HOSE 2. BOOSTER RETURN HOSE
11. BRAKE PRESSURE TRANSDUCER 3. MANIFOLD
4. MASTER CYLINDER
Figure 17. Accumulator and Boosted Master 5. ACCUMULATOR TO BOOSTER LINE
Cylinder, Lift Truck Models S6.0FT, S7.0FT 6. BOOSTER AND ACCUMULATOR SUPPLY HOSE
7. TEE FITTING
(S135FT, S155FT) (D024, E024) 8. MOUNTING CLAMP/BRACKET
9. ACCUMULATOR
c. For lift truck models H6.0FT, H7.0FT 10. BRAKE HOSE
(H135FT, H155FT) (H006, J006), remove 11. BRAKE PRESSURE TRANSDUCER
and tag the accumulator to booster line, the
booster and accumulator supply hose and Figure 18. Accumulator and Boosted Master
the brake hose. Plug hoses to prevent hoses Cylinder, Lift Truck Models H6.0FT, H7.0FT
from draining. Disconnect the connector at (H135FT, H155FT) (H006, J006)
the brake pressure transducer, and remove
brake pressure transducer. See Figure 18.

18
1800 SRM 1247
3. Disconnect and cap the lower brake oil supply
hose from nipple at the master cylinder. See Fig-
ure 16.
4. Remove the cotter pin and rod end pin from the
clevis that is attached to the brake linkage lever
arm.
5. Remove capscrews and nuts that hold master
cylinder and booster assembly to bracket assem-
bly.
DISASSEMBLE
CAUTION
When the piston is removed or installed, make
sure the cylinder bore and piston are not
scratched or damaged.
1. Place master cylinder and booster assembly into
a soft jawed vise.
2. Remove three mounting capscrews and master
cylinder from booster. See Figure 19.
WARNING
Piston is under extreme pressure. Use care
when removing snap ring to avoid possible
injury.
3. Remove the snap ring holding the piston.
4. Remove Piston.
5. Remove the spring and retainer from the bore.
6. Remove and discard the pressure seal from the
spring end of the piston.
Master Cylinder Repair
7. Remove the washer between the pressure seal
and the piston.
8. Remove and discard the retaining seal from the
piston. Note the position of the seal.
CLEAN AND INSPECT
WARNING
Small amounts of water in the brake system
can cause reduced braking performance if
the water reaches the wheel cylinders and is
subject to high temperatures. DO NOT allow
water entry into the brake system. If water is
present, remove all water and refill the sys-
tem with Dexron III from a sealed container.
Unfiltered shop air can contain substantial
amounts of water, therefore, DO NOT use un-
filtered shop air to blow out components.
CAUTION
DO NOT permit brake cleaning fluid to con-
tact master cylinder. Brake cleaning fluid will
cause damage and leaks in seals of the brake
system.
Inspect the bore of the master cylinder for holes and
scratches. Replace the master cylinder and booster
assembly if there is damage. See Figure 19.
Inspect master cylinder parts for dirt or water. Clean
any dirt or water present in master cylinder parts
using a clean lint free cloth.
19
Master Cylinder Repair 1800 SRM 1247

1. BOOSTER ASSEMBLY 6. PRESSURE SEAL

2. HOUSING (MASTER CYLINDER) 7. WASHER
3. SNAP RING 8. RETAINER
4. PISTON 9. SPRING
5. RETAINING SEAL 10. CAPSCREW

Figure 19. Master Cylinder and Booster

ASSEMBLE 3. Install the new pressure seal and retainer over

NOTE: Install new seals when the master cylinder is
being assembled.
1. Install the new retaining seal on the piston, as
noted during removal.
the spring end of the plunger.
4. Install the spring and piston into the bore of the
master cylinder.
5. Install the snap ring holding the piston.

2. Install the washer between the pressure seal and 6. Install the master cylinder on the booster assem-
the piston. bly with three capscrews and tighten to 49 to
59 N•m (36 to 43 lbf ft).

20
1800 SRM 1247
INSTALL AND ADJUST
WARNING
Small amounts of water in the brake system
can cause reduced braking performance if
the water reaches the wheel cylinders and is
subject to high temperatures. DO NOT allow
water entry into the brake system. If water is
present, remove all water and refill the sys-
tem with Dexron III from a sealed container.
Unfiltered shop air can contain substantial
amounts of water, therefore, DO NOT use un-
filtered shop air to blow out components.
NOTE: The install and adjust procedure is the same
for both dry and wet brake systems.
NOTE: The master cylinder uses Dexron III brake oil.
For the correct amount oil used see the Maintenance
Schedule.
1. Using capscrews and nuts, install the master
cylinder and brake booster assembly on the
bracket assembly. See Figure 16.
2. Attach the clevis to the bracket using the rod end
pin and cotter pin.
3. Uncap and install the lower brake oil supply hose
onto the nipple at the master cylinder.
4. Connect hoses to master cylinder booster assem-
bly:
a. For lift truck models S4.0, 4.5, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, S100FT-
BCS; S120FTS; S120FTPRS) (G004)
and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005), connect the brake booster sup-
ply and return hoses to the master cylinder
and booster assembly. See Figure 16.
b. For lift truck models S6.0FT, S7.0FT
(S135FT, S155FT) (D024, E024), connect the
accumulator to booster hose, the booster and
accumulator supply hose, the brake hose,
and booster return hose. See Figure 17.
c. For lift truck models H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006), connect
the accumulator to booster line, the booster
and accumulator supply hose and the brake
hose. See Figure 18.
Master Cylinder Repair
5. Install the brake pressure transducer into mas-
ter cylinder and tighten to 23 to 28 N•m (16.9
to 20.6 lbf ft). See Figure 16, Figure 17, or Fig-
ure 18.
6. Orient master cylinder side of brake supply and
return lines parallel with brake pressure trans-
ducer.
7. Tighten fitting nuts at each end of brake hose
assembly to 13 to 18 N•m (84 to 117 lbf in).
8. Apply a layer of multipurpose grease to the
rod end pin and, with twisting motion, insert
through clevis and the inching/brake pedal. In-
stall cotter pin into the rod end pin.
9. 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 1.5 to 1.75
turns.
e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft).
f. Verify free pedal is 10 to 12 mm (0.39 to
0.47 in.). See Figure 26.
10. Flush with Dexron III brake oil from a sealed
container, and air bleed system. See Brake Sys-
tem Air Removal.
11. Adjust oil level until level is within 2.5 mm
(0.098 in.) of MAX line or 5 to 7.5 mm (0.19 to
0.29 in.) above large rib on reservoir if MAX line
is not present.
12. Verify all connections are leak-free.
13. Install floor plate, kick plate, and seal plate on
lift truck.
14. Check adjustment of brake pedal as described in
Brake Pedal Adjustment.
21
Accumulator 1800 SRM 1247

Accumulator
The accumulator is used on the S6.0FT, S7.0FT
(S135FT, S155FT) (D024, E024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006) lift trucks only.
4. Remove the cap from the accumulator. See Fig-
ure 20.
5. Connect a 0 to 34 bar (0 to 500 psi) gauging as-
sembly to the accumulator check valve. See Fig-
ure 20.

6. Apply brake pedal ten times until the pressure

stabilizes and observe the gauge reading. This
reading in pressure represents the precharge of
the accumulator.

7. Recharge with nitrogen gas to the required

precharge pressure of 4 ±0.35 bar (58 ±5 psi).

8. Disconnect gauging assembly and install cap.

REMOVE

WARNING
The accumulator has a pressure charge and
can cause an injury if the pressure is released
too fast. Follow the manufacturer’s instruc-
tions during removal and installation.
1. CAP Before disconnecting any hydraulic lines,
2. O-RING release pressure from hydraulic circuit as fol-
3. CHECK VALVE
4. ACCUMULATOR lows:

Figure 20. Accumulator
PRECHARGE CHECK
NOTE: During service, the precharge pressure will
decrease as a result of the natural diffusion of nitro-
gen gas. Therefore, the precharge pressure must be
checked every 12 months and recharged if required.
NOTE: For checking of the precharge value, proceed
as follows:
1. Lower the forks completely.
2. Switch the engine OFF.
3. For lift truck models S6.0FT, S7.0FT (S135FT,
S155FT) (D024, E024), remove the floor mats,
floor plates and raise the hood for access to
the accumulator. For lift truck models H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006) remove
the floor mats and floor plates for access to the
accumulator.
• Shut OFF the engine and completely lower
the forks. Install blocks at the wheels to pre-
vent the lift truck from moving.
• Operate the lift/lower lever and the brake
pedals until the hydraulic pressure is re-
leased.
1. Perform the following step that applies to your
lift truck.
a. For S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024) lift trucks, release pressure
from the accumulator by slowly disconnect-
ing the elbow fitting on the accumulator
from the hose between the accumulator and
booster. See Figure 21.
b. For H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006) lift trucks, to release system
pressure, slowly disconnect the line between
the booster and accumulator from the tee fit-
ting on the accumulator. Slowly disconnect
the hose between the manifold on the drive
axle and accumulator from the tee fitting on
the accumulator. See Figure 22.

22
1800 SRM 1247 Accumulator

1. BOOSTER
2. MASTER CYLINDER
3. BOOSTER RETURN HOSE
4. MANIFOLD
5. BOOSTER AND ACCUMULATOR SUPPLY HOSE
6. ACCUMULATOR TO BOOSTER HOSE
7. ELBOW FITTING
8. ACCUMULATOR
9. MOUNTING CLAMP/BRACKET 1. BOOSTER
2. BOOSTER RETURN HOSE
Figure 21. Accumulator and Boosted Master 3. MANIFOLD
Cylinder, S6.0FT, S7.0FT (S135FT, S155FT) 4. MASTER CYLINDER
5. ACCUMULATOR TO BOOSTER LINE
(D024, E024) 6. BOOSTER AND ACCUMULATOR SUPPLY HOSE
7. TEE FITTING
2. Place caps on all disconnected lines and hoses. 8. MOUNTING CLAMP/BRACKET
9. ACCUMULATOR
3. Loosen the nut on the accumulator mounting
clamp/bracket and remove accumulator. See Figure 22. Accumulator and Boosted Master
Figure 23. Cylinder, H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
4. If necessary, remove the elbow or tee fitting from
the accumulator. See Figure 23.

23
Accumulator 1800 SRM 1247

A. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) B. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
1. ACCUMULATOR 4. NUT
2. ELBOW FITTING 5. TEE FITTING
3. CLAMP/BRACKET

Figure 23. Accumulator and Mounting Clamp/Bracket

INSTALL b. For H6.0FT, H7.0FT (H135FT, H155FT)

(H006, J006) lift trucks, connect the line
1. If removed, install the elbow or tee fitting to ac- between the booster and accumulator to the
cumulator. See Figure 23. tee fitting on the accumulator. Connect the
hose between the manifold on the drive axle
2. Place the accumulator in position in the mount-
and accumulator to the tee fitting on the
ing clamp/bracket and tighten nut to 17 N•m
accumulator. See Figure 22.
(13 lbf ft).
4. For lift truck models S6.0FT, S7.0FT (S135FT,
3. Perform the following step that applies to your
S155FT) (D024, E024), install the floor mats,
lift truck.
floor plates and close the hood. For lift truck
a. For S6.0FT, S7.0FT (S135FT, S155FT) models H6.0FT, H7.0FT (H135FT, H155FT)
(D024, E024) lift trucks, connect the hose (H006, J006) install the floor mats and floor
between the booster and accumulator to the plates.
elbow fitting on the accumulator. See Fig-
5. Operate the system and check for leaks.
ure 21.

24
1800 SRM 1247 Brake System Air Removal

Service Brakes Adjustment (Dry Brake)

SERVICE BRAKES ADJUSTMENT 3. Install the drive wheels. Remove the lift truck
from the blocks. Operate the lift truck in the
The following procedure is for newly-installed brake FORWARD and REVERSE directions. Stop the
shoes. If the lift truck has been operated for more lift truck 10 times in each direction. This pro-
than 25 hours and has correct pedal height, the cedure causes the brake shoes to wear a small
brakes normally will not need adjustment. amount and fit the brake drum better.
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 the
drive wheels can be removed. Remove the drive
wheels.

2. To manually adjust the brakes, it is necessary to

turn the adjuster wheels. Remove the two ac-
cess plugs in the adjustment slots located on the
back side of the backing plate. Place an adjuster
tool and screwdriver through the slot in the back-
ing plate. See Figure 5. Push the adjuster lever
away from the adjuster wheel and turn the ad-
juster wheel, in the direction indicated in Fig-
ure 24 until the brake shoe just touches the brake
drum. Use the adjuster tool to loosen the ad-
juster wheel approximately 20 teeth. Adjust the
brake shoe for the other adjuster wheel using
1. ADJUSTER LEVER
the same method. See Figure 24. Make sure to 2. ADJUSTER WHEEL
install the access plugs after the adjustment is 3. ADJUSTER LINK
complete.
Figure 24. Auto Adjuster Assembly
NOTE: If the brake shoes were not replaced, loosen
the adjuster wheel approximately 20 teeth.

Brake System Air Removal

There are two commonly used methods to remove air
from the brake system. The preferred method is us-
ing a pressure bleed system. The other method is by
applying pressure using the brake pedal.
NOTE: Two people are required for the two proce-
dures below to properly bleed the brake system.
USING PRESSURE BLEED SYSTEM
WARNING
On lift trucks with wet brake and dry brake
drive axles, only use Dexron III oil in the mas-
ter cylinder.
NOTE: Adjust the service brakes before the air is re-
moved from the brake system.
1. Fill the brake oil reservoir with Dexron III brake
oil from a sealed container.
2. Place one end of a rubber hose on the bleeder
screw of each wheel cylinder for lift trucks
equipped with dry brakes and place one end of
rubber hose on the bleeder screws located on
the drive axle for lift trucks equipped with wet
brakes. Place the other end of each hose into a
clear container of Dexron III brake oil.

25
Brake System Air Removal
3. Connect a pressure bleeder to the brake oil reser-
voir.
NOTE: While applying air pressure to the pressure
bleeder, check the level of the brake oil in the reser-
voir for the master cylinder. Make sure to maintain
the brake oil at the correct level to avoid forcing more
air into the brake system.
4. Apply 103.5 kPa (15 psi) of air pressure to the
pressure bleeder, forcing oil through the lines un-
til all air is removed from the system. Close the
bleeder screws.
5. Loosen the bleeder screw at the wheel cylinder
for lift trucks equipped with dry brakes and
loosen the bleeder screw on the drive axle for
lift trucks equipped with wet brakes one turn
so that the air can be removed from the brake
system.
6. For lift truck models S6.0FT, S7.0FT (S135FT,
S155FT) (D024, E024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006) equipped with
a Basic Powershift (2-speed) transmission,
loosen the bleed port fitting on the inching actu-
ator and allow oil to run out until it is air free.
See Figure 25.
7. Check the level of the brake oil in the reservoir
for the master cylinder. Fill the brake oil reser-
voir to the correct level.
1. CAP 4. INCHING
2. BLEED PORT ACTUATOR
FITTING 5. TRANSMISSION
3. CONTROL VALVE
Figure 25. Bleeding The Transmission
26
1800 SRM 1247
USING BRAKE PEDAL PRESSURE
WARNING
On lift trucks with wet brake and dry brake
drive axles, only use Dexron III oil in the mas-
ter cylinder.
NOTE: Adjust the service brakes before the air is re-
moved from the brake system.
1. Fill the brake oil reservoir with Dexron III brake
oil from a sealed container.
2. Place one end of a rubber hose on the bleeder
screw of the wheel cylinder furthest from the
master cylinder for lift trucks equipped with
dry brakes and place one end of rubber hose on
the bleeder screws located on the drive axle for
lift trucks equipped with wet brakes. Place the
other end of the hose into a clear container of
Dexron III brake oil.
NOTE: Check the level of the brake oil in the reser-
voir for the master cylinder during the procedure.
Make sure to obtain the brake oil at the correct level.
3. Loosen the bleeder screw at the wheel cylinder
for lift trucks equipped with dry brakes and
loosen the bleeder screw on the drive axle for
lift trucks equipped with wet brakes 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 bleeder screw.
4. Repeat the procedures in Step 1 through Step 3
until there are no air bubbles in the container.
5. Repeat the procedures in Step 1 through Step 4
for the remaining wheel cylinder for lift trucks
equipped with dry brakes and repeat the proce-
dures Step 1 through Step 4 for the other side
of drive axle for lift trucks equipped with wet
brakes.
NOTE: Both wheel cylinders (for lift trucks equipped
with dry brakes), or both sides of the drive axle (for
lift trucks equipped with wet brakes) must be com-
pleted before doing Step 6.
6. For lift truck models S6.0FT, S7.0FT (S135FT,
S155FT) (D024, E024) and H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006) equipped with
a Basic Powershift (2-speed) transmission only,
slowly push the brake pedal and hold it at the
end of its stroke. Loosen the bleed port fitting
1800 SRM 1247 Brake Pedal Adjustment

on the inching actuator and allow oil to run out 7. Check the level of the brake oil in the reservoir
until it is air free. See Figure 25. for the master cylinder. Fill the brake oil reser-
voir to the correct level.

Brake Pedal Adjustment

NOTE: The brake pedal adjustment procedure for
this section is the same for both dry and wet brake
systems.
2. Depress arm V until it stops. Verify gap S be-
NOTE: Measurements are made with the floor mats
removed.
1. Adjust the height (dimension R) of the inch-
ing/brake pedal to 31 ±0.4 mm (1.22 ±0.01 in.).
Use the upstop bolt to change the pedal height.
Tighten the nut while keeping the upstop bolt
fixed. See Figure 26.
tween arm V and tab W is 1.5 to 2.0 mm (0.06 to
0.08 in.) for wet brake, and 3.0 to 3.5 mm (0.11
to 0.13 in.) for dry brake. If it is not, then Tab W
may require bending to obtain the proper gap of
S. See Figure 26.

1. INCH/BRAKE PEDAL 5. SENSOR MOUNT

2. UPSTOP BOLT 6. BRAKE POSITION SENSOR
3. NUT 7. BUMPER
4. PEDAL PAD

Figure 26. Brake Pedal Adjustment

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Free Pedal Adjustment 1800 SRM 1247

Free Pedal Adjustment

NOTE: The free pedal adjustment procedure is the
same for both dry and wet brake systems.

After the brake pedal adjustment is completed, see

Brake Pedal Adjustment. Perform the following pro-
cedure for the free pedal adjustment.

1. Loosen nut and screw it away from clevis. See

Figure 27.

2. Turn push rod counterclockwise, as viewed from

the top of the push rod, until push rod can be
moved from side to side.

3. Turn push rod clockwise until it just begins to no

longer be moved from side to side.

4. Turn push rod counterclockwise 1.5 to 1.75 turns.

5. Tighten nut to 17 to 23 N•m (13 to 17 lbf ft).

6. Verify the free pedal is 10 to 12 mm (0.39 to

0.47 in.). See Figure 26.

NOTE: DRY BRAKE SYSTEM SHOWN

1. ROD END PIN
2. COTTER PIN
3. CLEVIS
4. NUT
5. PUSH ROD
6. MASTER CYLINDER AND BOOSTER

Figure 27. Free Pedal Adjustment

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1800 SRM 1247 Torque Specifications

Torque Specifications
Backing Plate to Axle Mount Capscrews Wheel Nuts

340 to 375 N•m (251 to 277 lbf ft) 610 to 680 N•m (450 to 502 lbf ft)

Wheel Cylinder Capscrews Wheel Adjustment Nut

20 to 25 N•m (15 to 19 lbf ft) Initial 400 to 480 N•m (295 to 354 lbf ft)
Final 28 to 32 N•m (21 to 24 lbf ft)
Axle Shaft Capscrews
Master Cylinder to Booster Capscrews
90 to 99 N•m (66 to 73 lbf ft)
49 to 59 N•m (36 to 43 lbf ft)
Auto Adjuster Assembly Capscrew

120 to 140 N•m (89 to 103 lbf ft)

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 NOTES

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 TECHNICAL PUBLICATIONS

1800 SRM 1247 7/08 (12/07)(6/07)(3/07)(9/06)(8/06)(6/06)(3/06) Printed in U.S.A.