INTRODUCTION

GENERAL brake assembly has a single wheel cylinder at the top of each
back plate. The support flange has an anchor for each shoe.
When the wheel cylinder is actuated by fluid pressure from
This section has the repair procedures for the service brakes. the master cylinder, the shoes touch the drum. The primary
The pedal adjustments are also shown. Instructions for re- shoe starts to turn with the drum. This action pushes the
pair of the master cylinder are found in the section THE secondary shoe right against the drum and the anchor. This
MASTER CYLINDER, 1800 SRM 13. The parking brake is a servo action increases the force applied to the brake drums.
separate system. See the section THE PARKING BRAKE, When the lift truck is traveling in reverse, the primary shoe is
1800 SRM 205. pushed against the anchor and the drum by the secondary
shoe.
DESCRIPTION AND OPERATION
The service brake assembly is the same for the “BS” and
Different brake assemblies are used on later model trucks “BH” lift trucks. The hub and brake drum assembly is differ-
than on early models. The early brake assemblies were used ent because the clearances needed for cushion tires (BS) and
through the following truck serial numbers: pneumatic tires (BH) is different.
E20BS, B l14V 4591D, B114T 1622D, and
B114A 2825E An electric switch is actuated by the hydraulic pressure in
E20BH, B159A 2138E the brake system. This brake switch is found in the brake line
near the master cylinder. The purpose of the brake switch is
to prevent the traction motor from working against the brakes.
The later brake assemblies were used after the above serial The brake switch is normally open. When the brake pedal is
numbers. pushed, the hydraulic pressure closes the switch and stops
the power to the traction motor.

A service brake assembly is used at each end of the housing

for the drive axle housing. Each service

REPAIRS

REMOVAL AND DISASSEMBLY

Drive Axle

The axles must be removed for access to the brake assembly.

See the section DRIVE AXLE SPEED REDUCER, AND DIF-
FERENTIAL, 1400 SRM 209 for information on removal and
installation of the drive axles. Remove the brake drum and
hub assembly. Put a cover over the inner bearing cone to
protect it from dirt. If the brake drum cannot be easily re-
moved, loosen the brake shoes by turning the adjuster.
1. BRAKE SHOE
2. WHEEL BEARING
3. SHOE RETURN SPRING
4. WHEEL CYLINDER

FIGURE 1. BRAKE ASSEMBLY

Brake Assembly E. Remove the two capscrews from the wheel cylinder and
remove the wheel cylinder.

DISASSEMBLY, EARLY MODELS (See Figure 2)

CLEANING

A. Put a clamp on the wheel cylinder to hold the pistons in

the wheel cylinder. CAUTION
Do not use solvent to clean the wheel cylinder or
the brake lings. Use alcohol to clean the linings
B. Use spring pliers to remove the shoe return spring. and the wheel cylinders.

C. Remove the two “C” washers and flat washers that hold
the shoes to the shoe adjusting cam. Remove the anchor Clean the parts of the brake assembly.
spring. Remove the shoes.

WARNING
D. If the wheel cylinder must be repaired or replaced, discon- Asbestos is used in the brake lining. Do not use
nect the brake line from the wheel cylinder. compressed air to clean the brake assembly.

FIGURE 2. BRAKE ASSEMBLY, EARLY MODELS

DISASSEMBLY, LATE MODELS (See Figure 3)

A. Remove the spring and adjuster linkage from the brake B. Disconnect the brake line at the wheel cylinder. Remove
shoes. Remove the spring assemblies that hold the brake the capscrews that hold the back plate to the axle mount.
shoes to the back plate. Remove the brake shoes. Discon- Remove the back plate.
nect the parking brake cable from the lever.
C. Remove the wheel cylinder.

FIGURE 3. BRAKE ASSEMBLY, LATER MODELS

ASSEMBLY, EARLY MODELS and and shoe return spring. Install the flat washers and “C”
washers. Make sure both shoes are in the correct position
against the pistons of the wheel cylinder, against the anchor,
A. Install the wheel cylinder on the back plate. Connect the and against the shoe adjusting cams.
brake line.

D. Install the brake drum and hub assembly. See the section
B. Set the shoe adjusting cams so that the shoes will have the DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL,
lease expansion. 1400 SRM 209.

C. Install the brake shoes. Install the anchor spring

ASSEMBLY, LATER MODELS

A. Install the wheel cylinder on the back plate. Connect the C. Turn the adjuster wheel into the adjuster nut so that the
brake line. adjuster assembly is in the shortest position.

B. Install the brake shoes, adjuster parts, springs, and other D. Install the brake drum and hub assembly. See the section
parts as shown in Figure 3. Put NEVER SEEZ on the threads DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL, 1400
of the adjuster wheel. SRM 209.

CHECKS AND ADJUSTMENTS

CHECKS Brake Shoes, Later Models

Check that the drums are not damaged. Make sure that the Use a brake adjuster tool to adjust the brake shoes so that the
drums are round. Use emery cloth to make the surface rough. brake drum will not rotate. Push the automatic adjuster lever
The drums must not have large grooves. away from the adjuster wheel with a small screwdriver. Use
the brake adjuster tool to loosen the adjuster wheel approxi-
mately 20 teeth.
Check that the lining on the shoes is not worn or loose.
Check that the shoes do not have cracks. Check that there is
no oil or brake fluid on the linings. 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.
Check that the springs do not have defects.

Removing the Air From The Brake System

Check that the bearings and seal surfaces have no defects.

The air must be removed from the brake fluid. Fill the reservoir
Check for leaks in the wheel cylinders. Replace the wheel of the master cylinder with brake fluid. Put one end of a rubber
cylinder assembly if it has defects. Check for cracks in the hose on the special fitting of the wheel cylinder. Put the other
brake lines. end in a container with brake fluid. Loosen the special fitting
one turn.
Check the adjuster screw wheel for wear. Make sure the
adjuster screw turns. Push slowly on the brake pedal. Repeat the procedure until no
air bubbles are seen in the container. Check the fluid level in
ADJUSTMENTS the master cylinder. If necessary, close the special fitting and
push on the pedal. Quickly release the pedal and repeat until
there is resistance. Loosen the special fitting to remove the
Put the lift truck on blocks so that the drive wheels are clear air bubbles. Repeat the procedure on the other wheel cylinder.
of the floor or ground.

Brake Shoes, Early Models

Turn the adjusting cams until the wheel will not turn. Back
off the adjusting cam just enough so the wheel will turn
freely.
TROUBLESHOOTING