BRAKE SYSTEM

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]

PART NO. 1580513 1800 SRM 1135

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 .............................................................................................................................. 2
Clean .............................................................................................................................................................. 7
Inspect ............................................................................................................................................................ 8
Assemble and Install ..................................................................................................................................... 8
Adjust ............................................................................................................................................................. 15
Parking Brake Repair........................................................................................................................................ 16
Remove and Disassemble .............................................................................................................................. 16
Assemble and Install ..................................................................................................................................... 16
Adjust ............................................................................................................................................................. 19
Master Cylinder Repair ..................................................................................................................................... 19
Remove (Dry Brake) ...................................................................................................................................... 19
Disassemble (Dry Brake) .............................................................................................................................. 20
Clean and Inspect (Dry Brake) ..................................................................................................................... 22
Assemble (Dry Brake) ................................................................................................................................... 22
Bench Bleed Master Cylinder (Dry Brake) .................................................................................................. 22
Install and Adjust (Dry Brake) ..................................................................................................................... 22
Remove (Wet Brake) ...................................................................................................................................... 23
Disassemble (Wet Brake) .............................................................................................................................. 24
Clean and Inspect (Wet Brake) ..................................................................................................................... 25
Assemble (Wet Brake) ................................................................................................................................... 25
Install and Adjust (Wet Brake) ..................................................................................................................... 25
Service Brakes Adjustment (Dry Brake) .......................................................................................................... 26
Brake System Air Removal ............................................................................................................................... 27
Using Pressure Bleed System ....................................................................................................................... 27
Using Brake Pedal Pressure ......................................................................................................................... 27
Brake Pedal Adjustment ................................................................................................................................... 28
Free Pedal Adjustment ...................................................................................................................................... 29
Torque Specifications ......................................................................................................................................... 30

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]

©2006 HYSTER COMPANY i

1800 SRM 1135 General

General
DRY BRAKE SYSTEM WET BRAKE SYSTEM
This section has service procedures for the dry brake The wet brake system in this section includes the fol-
system. The dry brake system includes the following lowing parts: master cylinder and parking brake sys-
parts: master cylinder, brake shoes, wheel cylinders, tem. See Figure 2.
and parking brake system.
The wet disc brakes are a component of the wet brake
drive axle. The brake discs are located inside the
planetary carrier housing on the left side of the drive
axle. See Drive Axle Repair, (Wet Brake) 1400
SRM 1215 for Remove, Assemble and Install proce-
dures. See Figure 2.

1. PARK BRAKE 7. BRAKE OIL

HAND LEVER SUPPLY HOSE
2. INCH/BRAKE 8. ADJUSTMENT
1. PARK BRAKE LEVER PEDAL KNOB
2. ADJUSTMENT KNOB 3. MASTER 9. BRAKE POSITION
3. PARK BRAKE CABLES CYLINDER AND SENSOR
4. INCHING/BRAKE PEDAL BOOSTER 10. BRAKE POSITION
5. MASTER CYLINDER 4. PARK BRAKE SENSOR
6. BRAKE ASSEMBLY LEVER CONNECTOR
7. BRAKE POSITION SENSOR (RIGHT HAND 5. WET DISC BRAKE 11. BRAKE OIL
SIDE) HOUSING RESERVOIR
6. PLANETARY 12. PARKING BRAKE
Figure 1. Brake System CARRIER CABLE BRACKET
HOUSING (RIGHT 13. PARKING BRAKE
SIDE SHOWN) CABLE

Figure 2. Wet Brake System for Lift Truck

Model H2.0-3.5FT (H40-70FT) (L177)

1
Service Brakes Repair (Dry Brake) 1800 SRM 1135

Service Brakes Repair (Dry Brake)

REMOVE AND DISASSEMBLE 5. Make a note of the arrangement of the parts. See
Figure 3 and Figure 4 for S2.0-3.5FT (S40-70FT,
WARNING S55FTS) [F187] and H2.0-3.5FT (H40-70FT)
[L177] lift trucks. See Figure 5 and Figure 6
Brake linings can contain dangerous fibers.
for S30FT, S35FT, S40FTS (E010) and H1.6FT,
Breathing the dust from these brake linings
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
is a cancer or lung disease hazard. Do not
[F001] lift trucks. Remove the return springs
create dust! Do not clean brake parts with
with spring pliers.
compressed air or by brushing. Use vacuum
equipment approved for brake dust or follow 6. Remove the retainers, springs, and anchor pins
the cleaning procedure in this section. When that hold the brake shoes to the back plate.
the brake drums are removed, do not create
dust. 7. Disengage the link from the adjuster wheel actu-
ator. Remove the link, washer, and pivot plate.
Do not sand, grind, chisel, hammer, or change Remove the anchor guide.
linings in any way that will create dust. Any
changes to brake linings must be done in a re- 8. Move the brake shoes away from each other to
stricted area with special ventilation. Protec- disengage the brake shoes from the wheel cylin-
tive clothing and a respirator must be used. der. Disconnect the parking brake lever from the
parking brake cable as the brake assembly is re-
1. Remove the capscrews that hold the axle shaft to moved from the back plate. The parking brake
the hub. Remove the axle shaft. lever has a hook that engages the parking brake
cable.
2. See the procedure How to Put Lift Truck on
Blocks in the section Periodic Maintenance NOTE: The adjuster wheel for the left brake is not
8000 SRM 1150, or the Operating Manual. the same as the adjuster wheel for the right brake.
Start the engine and tilt the mast fully back- The adjuster wheel for the left brake has left-hand
ward. Put blocks under the mast. Tilt the mast threads.
forward until the wheels just touch the floor.
Stop the engine. Put blocks under the frame of 9. Make a note of the arrangement of parts and dis-
the lift truck. assemble the brake assembly. Remove the park-
ing brake link and spring if they are still engaged
3. Bend the lock plate and remove the nut that with brake shoes. The parking brake link and
holds the axle bearing. Remove the washer and spring will often fall from the brake assembly
the bearing cone. when the brake assembly is removed from the
back plate. The adjuster wheel will also disen-
WARNING gage from the brake shoes after the brake assem-
When the brake shoes are removed, do not cre- bly is removed.
ate dust in the air. See the Clean procedure in
10. Remove the spring for the adjuster wheel actu-
this section.
ator. Remove the adjuster wheel actuator from
4. Put grease on the floor so that the wheel assem- the brake shoe.
bly will slide easily from the axle tube. Pull the
11. Use a screwdriver or small pry bar to move apart
wheel assembly from the lift truck. If the wheel
the ends of the retainer. Remove the spring
assembly cannot be removed easily, use a small
washer and pivot pin to remove the parking
screwdriver to push the adjuster actuator away
brake lever from the brake shoe.
from the adjuster wheel. Use a brake adjustment
tool or a screwdriver to turn the adjuster wheel 12. Disconnect the brake line from the wheel cylin-
to loosen the brake shoes. Remove the hub and der. Remove the capscrews that hold the wheel
drum assembly. Do not damage the grease seal cylinder to the back plate and remove the wheel
when removing the hub. cylinder.

2
1800 SRM 1135 Service Brakes Repair (Dry Brake)

1. WHEEL CYLINDER 11. ADJUSTER WHEEL

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

Figure 3. Brake Assembly (Left-Hand Shown), S2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-3.5FT
(H40-70FT) [L177]

3
Service Brakes Repair (Dry Brake) 1800 SRM 1135

NOTE: RIGHT-HAND BRAKE ASSEMBLY SHOWN.

1. WHEEL CYLINDER 12. ADJUSTER ASSEMBLY
2. RETURN SPRING 13. PRIMARY BRAKE SHOE
3. RETURN SPRING 14. PARKING BRAKE LEVER
4. ANCHOR 15. PARKING BRAKE LINK
5. ANCHOR GUIDE 16. PARKING BRAKE SPRING
6. BACK PLATE 17. PIVOT PIN, RETAINER, AND SPRING WASHER
7. SECONDARY BRAKE SHOE 18. ADJUSTER ACTUATOR SPRING
8. LEVER 19. SPRING
9. PIVOT PLATE 20. RETAINING PIN
10. ADJUSTER ACTUATOR LINK 21. RETAINING WASHER
11. ADJUSTER WHEEL 22. PARKING BRAKE CABLE

Figure 4. Service Brake Parts, S2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-3.5FT (H40-70FT)
[L177]

4
1800 SRM 1135 Service Brakes Repair (Dry Brake)

1. BACKING PLATE 9. SPRING (ACTUATOR)

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

Figure 5. Brake Assembly (Left Hand Side), S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001]

5
Service Brakes Repair (Dry Brake) 1800 SRM 1135

1. BOLT 13. PAWL LEVER

2. WHEEL CYLINDER 14. PARK BRAKE CABLE
3. STRUT 15. ADJUSTER ASSEMBLY
4. SPRING 16. PLUG
5. SECONDARY BRAKE SHOE 17. SPRING (ADJUSTER)
6. PLATE 18. PRIMARY BRAKE SHOE
7. SPRING 19. PARK BRAKE LEVER
8. LEVER (STOP) 20. PIN
9. SPRING 21. PLUG
10. WASHER 22. BACKING PLATE
11. SPRING (SHOE HOLD DOWN) 23. PIN
12. WASHER

Figure 6. Service Brake Parts, S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) [F001]

6
1800 SRM 1135 Service Brakes Repair (Dry Brake)

NOTE: For S2.0-3.5FT (S40-70FT, S55FTS) [F187] CLEAN

and H2.0-3.5FT (H40-70FT) [L177] lift trucks, the
back plate is not normally removed from the axle WARNING
housing for brake repairs. Eight special capscrews
DO NOT use an oil solvent to clean the master
are used to fasten the back plate to the axle mount,
cylinder, wheel cylinder, or brake linings. Use
and the locking function of the capscrews is reduced
a solvent approved for cleaning of brake parts.
if they are removed. The capscrews are tightened to
Do not permit oil or grease in the brake fluid or
255 to 306 N•m (188 to 226 lbf ft).
on the brake linings. Oil and grease will cause
NOTE: For S30FT, S35FT, S40FTS (E010) and damage and leaks in the seals of a brake sys-
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) tem. The brakes will not operate correctly if
[F001] lift trucks, the back plate is not normally re- oil, grease, or brake fluid is on the brake lin-
moved from the axle housing for brake repairs. ings.
Six special capscrews are used to fasten the back
Cleaning solvents can be flammable and toxic
plate to the axle mount, and the locking function of
and can cause skin irritation. When using
the capscrews is reduced if they are removed. The
cleaning solvents, always follow the safety
capscrews are tightened to 152 to 167 N•m (112 to
instructions of the solvent manufacturer.
123 lbf ft).
1. Do not release brake lining dust from the brake
13. Remove the push rods, dust covers, pistons, cups,
linings into the air when the brake drum is re-
and spring from the wheel cylinder. See Figure 7.
moved.

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

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

Figure 7. Wheel Cylinder

7
Service Brakes Repair (Dry Brake) 1800 SRM 1135

2. Use a solvent approved for cleaning of brake NOTE: On S2.0-3.5FT (S40-70FT, S55FTS) [F187]
parts to wet the brake lining dust. Follow the and H2.0-3.5FT (H40-70FT) [L177] lift trucks, if
instructions and cautions of the manufacturer grooves must be removed from the brake drums, do
for the use of the solvent. If a solvent spray is not grind more than 1.5 mm (0.060 in.) from the
used, spray at a distance so that the dust is not internal diameter of the brake drum. The maximum
released into the air. limit of the internal diameter of the brake drum is
312 mm (12.28 in.). If the internal diameter is larger
3. When the brake lining dust is wet, clean the than the limit, replace the brake drum.
parts. Put any cloth or towels in a plastic bag
or an airtight container while they are still wet. NOTE: On S30FT, S35FT, S40FTS (E010) and
Put a DANGEROUS FIBERS warning label on H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
the plastic bag or airtight container. [F001] lift trucks, 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
CAUTION drum. The maximum limit of the internal diameter
Do not permit oil or grease on the brake linings. of the brake drum is 255.5 mm (10.06 in.). If the
Use a brake cleaning fluid as necessary to clean internal diameter is larger than the limit, replace
linings that will not be replaced. the brake drum.
4. Any cleaning cloths that will be washed must be 5. The teeth of the adjuster wheel must not be worn.
cleaned so that fibers are not released into the The adjuster wheel must turn freely. Check the
air. adjuster links for damage.
INSPECT 6. Make sure the parking brake cables are in good
condition.
1. Inspect the bore of the wheel cylinder for holes or
scratches. Replace the wheel cylinder assembly 7. Check the grease seals and the surfaces of the
if there is any damage. seals for wear or damage.
2. Inspect the return springs for wear and damage. ASSEMBLE AND INSTALL
Inspect the back plate for wear where the brake
shoes touch the back plate. Remove any grooves 1. If the wheel cylinder was disassembled for repair,
or replace a worn or damaged back plate. assemble the wheel cylinder. See Figure 7. Use
only HYSTER APPROVED parts.
WARNING 2. Install the wheel cylinder on the back plate and
The brake shoes on both wheels must be re- tighten the two capscrews to 18 to 27 N•m (13
placed if any shoe is damaged. The brake per- to 20 lbf ft). Connect the brake line to the wheel
formance on both ends of an axle must be equal, cylinder.
or the lift truck can be difficult to steer when
the brakes are applied. 3. Install the parking brake lever. Use the pivot
pin, spring washer, and retainer to fasten the
3. Inspect the brake shoes for cracks or damage. If parking brake lever to the brake shoe. Close the
the linings or shoes are worn or damaged, replace ends of the retainer to fasten the pivot pin in
the brake shoes. Maximum wear is to within position. See Figure 4 for S2.0-3.5FT (S40-70FT,
1 mm (0.039 in.) of contact with the rivets, or S55FTS) [F187] and H2.0-3.5FT (H40-70FT)
the metal shoe on bonded linings. Brake shoes [L177] and Figure 6 for S30FT, S35FT, S40FTS
must be replaced in complete sets. Inspect the (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
brake drums for cracks or damage. Replace any H35FT, H40FTS) [F001] lift trucks.
damaged parts.
4. Fasten the adjuster actuator spring to the ad-
4. Inspect the brake drum for deep grooves or other juster wheel actuator and the brake shoe.
damage.

8
1800 SRM 1135 Service Brakes Repair (Dry Brake)

5. Put antiseize compound on the threads of the ad- 13. Fasten the link to the adjuster wheel actuator
juster wheel. Turn the adjuster wheel into the and put the cable around the pivot plate. Raise
adjuster nut so that the adjuster assembly is in the adjuster wheel actuator against the spring
its shortest position. This action permits the tension and connect the link to the anchor.
brake drum to be easily installed over the brake
shoes. CAUTION
2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-
WARNING 3.5FT (H40-70FT) [L177]: Be sure to install the
The threads of the adjuster wheel are not the white return spring first and then the black re-
same for each side. If the adjuster assemblies turn spring. See Figure 9. Improper assembly
are installed on the wrong side, the brake shoe can result in brake failure and/or component
clearance will increase each time the brakes damage.
are applied. The adjuster wheel for the right
brake has right-hand threads. The adjuster NOTE: The shape of the return springs permits them
wheel for the left brake has left-hand threads. to be installed correctly in only one position. The
arrangement of the return springs on the anchors is
6. Install the adjuster wheel between the two brake shown in Figure 8 and Figure 9.
shoes. Make sure the adjuster wheel will be to-
ward the rear of the lift truck. Move the brake 14. 2.0-3.5FT (S40-70FT, S55FTS) [F187] and
shoes apart so that the adjuster wheel is held H2.0-3.5FT (H40-70FT) [L177]: Using the cor-
in position and the adjuster actuator spring is in rect tools, install the return springs as follows
tension. (see Figure 9):

7. Lubricate the back plate with a small amount a. Install the white spring.
of lithium grease where the brake shoes touch.
b. Install the black spring.
Install the brake shoes on the anchor and engage
the push rods of the wheel cylinder. Engage the 15. 2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-
parking brake lever in the slot in the parking 3.5FT (H40-70FT) [L177]: Verify that the return
brake cable as the brake shoes are installed on springs are properly installed as shown in Fig-
the back plate. ure 9.
8. Put an anchor pin that holds the brake shoes 16. S30FT, S35FT, S40FTS (E010) and H1.6FT,
through the back plate. Put a spring seat, spring, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
and retainer on the anchor pin. Push the retainer [F001]: Use the correct tools to install the return
onto the anchor pin and rotate the retainer 90 springs. Install the return spring. Install the
degrees. Make sure the retainer is in the correct washer and the return spring. The shape of
position. the return springs permits them to be installed
correctly in only one position. The arrangement
9. Install the link, parking brake, and spring be-
of the return springs on the anchors is shown in
tween the parking brake lever and the brake
Figure 10.
shoe.
NOTE: Seal and bearings are to be installed flush
10. Install the other spring retainer that holds the
with the hub. Seal is to be installed with no grease
brake shoes. Make sure the parking brake link
or oil on outside surface.
and the spring are correctly engaged after the
spring retainers are installed. 17. Clean the bearings and lubricate them with
wheel bearing grease. Install the bearings and
11. Install the anchor guide on the anchor. Install
seals in the brake drum. Install the assembly on
the pivot plate on its anchor.
the axle housing. See Figure 11 and Figure 12.
12. Lubricate the adjuster cable where it slides in the
pivot plate groove.

9
Service Brakes Repair (Dry Brake) 1800 SRM 1135

1. RETURN SPRING 4. ADJUSTER ACTUATOR LINK

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

Figure 8. Return Springs, S2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-3.5FT (H40-70FT) [L177]

10
1800 SRM 1135 Service Brakes Repair (Dry Brake)

1. WHITE SPRING 2. BLACK SPRING

Figure 9. Proper Installation of Return Springs, 2.0-3.5FT (S40-70FT, S55FTS) [F187] and
H2.0-3.5FT (H40-70FT) [L177]

11
Service Brakes Repair (Dry Brake) 1800 SRM 1135

1. RETURN SPRING 3. RETURN SPRING

2. GUIDE PLATE 4. SPRING ACTUATOR

Figure 10. Return Springs, S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) [F001]

12
1800 SRM 1135 Service Brakes Repair (Dry Brake)

1. INNER SEAL 4. INNER BEARING

2. OUTER SEAL 5. OUTER BEARING
3. BRAKE DRUM

Figure 11. Grease Seals and Bearing Locations

13
Service Brakes Repair (Dry Brake) 1800 SRM 1135

too small, the automatic adjuster cannot turn

the adjuster wheel to increase the clearance,
and the adjuster wheel will not turn until
the brake shoes wear. If the adjuster wheel
does not move for a long operating period, the
adjuster link can wear a spot on the adjuster
wheel so that it will not turn correctly.

NOTE: If the brake shoes were not replaced, loosen

the adjuster wheel approximately 20 teeth.

20. Adjust the clearance of the brake shoes. Put a

brake adjustment tool or a screwdriver through
the slot in the back plate. Use the tool to rotate
the adjuster wheel. The actuator for the adjuster
Figure 12. Inner Grease Seal Installation wheel will only permit rotation in one direction.
Turn the adjuster wheel until the brake shoes
NOTE: To prevent damage to the inner oil seal when
have expanded against the brake drum and the
installing the hub, the hub and drum assembly can
hub will not turn. Use a small screwdriver to lift
be temporarily fastened to the wheel. Align the
the actuator away from the adjuster wheel and
height of the axle housing with hub bearings. Put
turn the adjuster wheel approximately 20 teeth
grease under the wheel and slide the wheel toward
in the opposite direction. The brakes will adjust
the axle housing. Install the outer bearing and nut.
to the correct clearance when they are applied
18. Install the washer, lock plate and wheel adjust- while the lift truck is traveling in the reverse di-
ment nut. To align the bearing rollers, tighten rection.
the wheel adjustment nut to 14 to 18 N•m (10 to
13 lbf ft) and rotate the hub 2 revolutions in both
directions. To seat the wheel bearings, tighten
the wheel adjustment nut to 175 to 215 N•m (129
to 159 lbf ft) for S2.0-3.5FT (S40-70FT, S55FTS)
[F187] and H2.0-3.5FT (H40-70FT) [L177] lift
trucks and to 120 to 145 N•m (89 to 107 lbf ft)
for S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
[F001] lift trucks. Back off the wheel adjustment
nut to zero end play. Preload the wheel bearings
by tightening the wheel adjustment nut to 14
to 18 N•m (10 to 13 lbf in). Rotate the hub 3
complete revolutions in both directions. Verify
the wheel adjustment nut torque is 14 to 18 N•m
(10 to 13 lbf ft) and that the torque stabilizes at
that specification.

19. Bend the lock plate over the lock nut. See Fig-
ure 13.
1. LOCK PLATE
2. HUB/BRAKE DRUM ASSEMBLY
CAUTION 3. DOWEL PIN
If there is too much clearance, the automatic Figure 13. Lock Plate
adjusters will not operate. If the clearance is

14
1800 SRM 1135 Service Brakes Repair (Dry Brake)

21. Put liquid sealant, Hyster Part Number 264159, 2. Install the wheel on the hub. Tighten the wheel
on the flange of the axle shaft. Install the axle nuts to the torque specified below for your lift
shaft and capscrews. Tighten the capscrews in truck.
cross pattern to a torque specified below for your
lift truck. a. For S2.0-3.5FT (S40-70FT, S55FTS) [F187]
lift trucks, tighten between 340 to 380 N•m
a. For S2.0-3.5FT (S40-70FT, S55FTS) [F187] (251 to 280 lbf ft).
lift trucks, tighten between 90 to 99 N•m (66
to 73 lbf ft). See Figure 14. b. For H2.0-3.5FT (H40-70FT) [L177] lift
trucks, tighten between 450 to 500 N•m
b. For H2.0-3.5FT (H40-70FT) [L177] lift (332 to 369 lbf ft).
trucks, tighten between 90 to 108 N•m
(66 to 80 lbf ft). See Figure 15. c. For S30FT, S35FT, S40FTS (E010) and
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
c. For S30FT, S35FT, S40FTS (E010) and H40FTS) [F001] lift trucks, tighten between
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 155 to 175 N•m (115 to 130 lbf ft).
H40FTS) [F001] lift trucks, tighten between
52 to 62 N•m (39 to 46 lbf ft). See Figure 14. 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 16
and the following paragraphs in this section for
the correct adjustment of the parking brake.

Figure 14. Axle Shaft Tightening Sequence,

S2.0-3.5FT (S40-70FT, S55FTS) [F187], S30FT,
S35FT, S40FTS (E010) and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001]

ADJUST
1. Remove the air from the brake hydraulic system.
See Brake System Air Removal. Figure 15. Axle Shaft Torque Sequence,
H2.0-3.5FT (H40-70FT) [L177]

15
Parking Brake Repair 1800 SRM 1135

Parking Brake Repair

REMOVE AND DISASSEMBLE If the lever assembly for the parking brake was re-
moved from the cowl, use the following procedure for
NOTE: For removal and disassembly procedures for installation:
a dry brake system use Step 1 through Step 5. For
a wet brake system use Step 1 through Step 4 and 1. The parking brake cables must be installed in the
Step 6. back plate before the service brake is installed.
See Figure 16. A snap ring holds the sheath of
If the lever assembly for the parking brake must be the parking brake cable in the back plate of the
removed from the cowl, use the following procedure. service brake. Install the parking brake cable
For the dry brake system see Figure 16 and for the in the back plate and install the snap ring that
wet brake system see Figure 17. holds the sheath of the parking brake cable in
the back plate.
1. Block wheels front and rear side of the wheels to
make sure the lift truck cannot move. Release 2. For H2.0-3.5FT (H40-70FT) (L177) lift trucks
the parking brake lever. that are equipped with a wet brake system. The
parking brake cable must be installed on the
2. Remove the four capscrews that fasten the
parking brake lever located on the wet brake
bracket for the parking brake to the cowl. Re-
drive axle and the cable loosely clamped to the
move the bracket and brake lever assembly.
parking brake cable bracket in the correct posi-
3. Loosen the jam nuts that fasten the threaded tion before connecting the parking brake cable
ends of the brake cables to the brake lever as- to the equalized link located on the park brake
sembly. assembly. See Figure 17.

4. Turn the adjuster knob counterclockwise until 3. Make sure the parking brake lever is in the re-
the brake cables are loosened. Disconnect the ca- leased position. Turn the adjustment knob until
bles from the link. the link is adjusted to the bottom of the adjust-
ment slot.
5. The service brake assembly must be removed be-
fore the parking brake cable can be removed from 4. Lift trucks equipped with a dry brake system.
the back plate of the service brake. A snap ring Adjust the jam nuts on the ends of the cable as-
holds the sheath of the parking brake cable in the semblies so that the threads of the cable sheaths
back plate of the service brake. Remove the snap extend 13 to 16 mm (0.51 to 0.63 in.) above their
ring and remove the parking brake cable from support plate in the lever assembly. See Fig-
the back plate. ure 16.

6. For H2.0-3.5FT (H40-70FT) (L177) lift trucks 5. Lift trucks equipped with a dry brake system. In-
equipped with a wet brake system. Remove the stall the round ends of the parking brake cables
cotter pin and clevis pin from the parking brake in their slots in the link. Tighten the upper jam
lever. Remove the capscrew, insert and cable nuts to hold the sheaths of the parking brake ca-
clamps from the parking brake cable bracket bles in their support. See Figure 16.
before removing the park brake cable from lift
6. For H2.0-3.5FT (H40-70FT) (L177) lift trucks
truck.
that are equipped with a wet brake system.
Install the clevis end of the parking brake cable
ASSEMBLE AND INSTALL
in the slot in the equalized link and install the
NOTE: For Assemble and install procedures for a dry clevis pin and lock ring cotter pin. Tighten lower
brake system use Step 1, Step 3 through Step 5 and parking brake cable bracket to 19 to 21 N•m (14
Step 7. For a wet brake system use Step 2, Step 3, to 15.5 lbf ft) See Figure 17.
Step 6 and Step 7.
7. Use the four capscrews, washers, and nuts and
fasten the bracket to the inside of the cowl.

16
1800 SRM 1135 Parking Brake Repair

1. PARKING BRAKE LEVER 6. BRAKE ASSEMBLY

2. ADJUSTMENT KNOB 7. BRAKE POSITION SENSOR
3. PARKING BRAKE CABLES 8. ADJUSTMENT SLOT
4. INCHING/BRAKE PEDAL 9. EQUALIZED LINK
5. MASTER CYLINDER 10. NUTS

Figure 16. Parking Brake Lever Adjustment With Dry Brake (Left Side Shown)

17
Parking Brake Repair 1800 SRM 1135

Figure 17. Parking Brake Lever Adjustment With Wet Brake for Lift Truck H2.0-3.5FT (H40-70FT)
(L177)

18
1800 SRM 1135 Master Cylinder Repair

Legend for Figure 17

A. REAR VIEW SHOWN B. REAR RIGHT SIDE SHOWN
1. PARKING BRAKE LEVER HANDLE 11. PARK BRAKE LEVER
2. BRAKE POSITION SENSOR CONNECTOR 12. UPPER PARKING BRAKE CABLE BRACKET
3. BRAKE POSITION SENSOR 13. CABLE CLAMP
4. ADJUSTMENT KNOB 14. CAPSCREW
5. EQUALIZED LINK 15. INSERT
6. CLEVIS PIN 16. MASTER CYLINDER AND BOOSTER
7. LOCK RING COTTER PIN 17. INCHING/BRAKE PEDAL
8. BRAKE OIL SUPPLY HOSE 18. LOWER PARKING BRAKE CABLE BRACKET
9. DRAIVE AXLE (WET BRAKE) 19. PARKING BRAKE CABLE
10. CLEVIS (PARKING BRAKE CABLE)

ADJUST Check the dash display to verify the transmis-

sion oil is at operating temperature, 49 to 66 C
Lift trucks equipped with a dry brake system. Make (120 to 150 F) before adjusting the parking
sure the service brakes are adjusted and the opera- brake adjustment knob.
tion of the automatic adjuster mechanism is correct
before the parking brake is adjusted. 1. To adjust the parking brake, Turn the adjust-
ment knob to raise the equalized link and tighten
Lift trucks equipped with a wet brake system. For the parking brake cables shown in Figure 16 and
lift truck models H2.0-3.5FT (H40-70FT) (L177) Figure 17. Do not tighten the adjustment so that
equipped with a wet brake system, make sure the the brake is applied when the lever is released.
wet disc brakes are adjusted before the parking The lever for the parking brake has a lock. Use
brake is adjusted. See Drive Axle Repair, (Wet your thumb or finger to release the lock on the
Brake) 1400 SRM 1215. lever when the parking brake is released.
Lift trucks with a MONOTROL® pedal the switch 2. For new brakes, test the operation of the parking
energizes the seat warning circuit when hand lever is brake. The lift truck with a capacity load must
released. This switch puts the transmission in NEU- not move when parking brake is applied on a 7.5
TRAL by de-energizing the direction solenoid. There percent grade [a slope that increases .75 m in
is also a switch on the left side of bracket. This switch 10 m (9 in. in 10 ft)].
prevents engine from starting unless parking brake
is applied. 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 applied on
CAUTION a 15 percent grade [a slope that increases 1.5 m
For Lift truck models H2.0-3.5FT (H40-70FT) in 10 m (1.5 ft in 10 ft)].
(L177) equipped with the wet brake system.

Master Cylinder Repair

REMOVE (DRY BRAKE) 3. Disconnect the brake supply hose from the mas-
ter cylinder. Plug hose to prevent reservoir from
1. Remove the floor plate, kick plate, and seal plate draining.
from the lift truck for access to the master cylin-
der. 4. Remove the brake fluid reservoir and supply hose
from the lift truck.
2. For lift trucks equipped with a dry brake system.
Remove the brake hydraulic line from the master 5. Remove the cotter pin and clevis pin that is at-
cylinder. Disconnect the wire at the brake pres- tached to the brake linkage lever arm.
sure transducer, which is connected to the bot-
tom of the master cylinder and remove pressure 6. Remove capscrews and nuts that hold master
transducer. See Figure 18. cylinder to bracket assembly.

19
Master Cylinder Repair 1800 SRM 1135

1. RESERVOIR 7. BRAKE PRESSURE 12. BRACKET

2. RESERVE TANK HOLDER TRANSDUCER 13. COTTER PIN
3. BRAKE SUPPLY HOSE 8. MASTER CYLINDER 14. CLEVIS PIN
4. CAPSCREW 9. PUSH ROD 15. CAPSCREW
5. CAPSCREW 10. NUT 16. CAPSCREW
6. BRAKE HOSE 11. CLEVIS

Figure 18. Master Cylinder and Reservoir Assembly (Dry Brake)

DISASSEMBLE (DRY BRAKE) 1. Remove clevis, push rod, nut, boot, fitting, and
seal. See Figure 19.
CAUTION 2. Remove snap ring, piston seal, and piston.
When the piston is removed or installed, make
sure the cylinder bore and piston are not 3. Remove spacer, piston cup, retainer, spring,
scratched or damaged. check valve, and valve seat.

20
1800 SRM 1135 Master Cylinder Repair

1. CLEVIS 7. SEAL 13. RETAINER

2. NUT 8. FITTING 14. SPRING
3. PUSH ROD 9. PISTON SEAL 15. CHECK VALVE
4. BOOT 10. PISTON 16. VALVE SEAT
5. SNAP RING 11. SPACER
6. CYLINDER HOUSING 12. PISTON CUP

Figure 19. Master Cylinder (Dry Brake)

21
Master Cylinder Repair 1800 SRM 1135

NOTE: Install new seals when the master cylinder is Install capscrews and nuts that hold master
disassembled for repair. cylinder to bracket assembly. See Figure 18.

CLEAN AND INSPECT (DRY BRAKE) 2. Install brake hydraulic line on master cylinder.

3. Screw assembly of brake pressure transducer

CAUTION into master cylinder and tighten to 23 to 28 N•m
DO NOT use an oil solvent to clean the master (16.9 to 20.6 lbf ft).
cylinder, wheel cylinder, or brake linings. Use
a solvent approved for cleaning of brake parts. 4. Orient master cylinder side of brake hose assem-
Do not permit oil or grease in the brake fluid bly parallel with brake pressure transducer.
or on the linings. 5. Tighten fitting nuts at each end of brake hose
Inspect the bore of the master cylinder for holes or assembly to 13 to 18 N•m (84 to 117 lbf in).
scratches. Replace the master cylinder assembly, if 6. Apply a layer of multipurpose grease to the cle-
there is damage. vis pin and, with twisting motion, insert through
clevis and the inching/brake pedal. Install cotter
ASSEMBLE (DRY BRAKE) pin into the clevis pin.
1. Install valve seat, check valve, spring, retainer, 7. Adjust free pedal per the following procedure:
piston cup, and spacer.
a. Loosen nut and screw it away from clevis.
2. Install the piston, piston seal, and snap ring.
b. Turn push rod counterclockwise, as viewed
3. Install seal, fitting, boot, nut, push rod, and cle- from top, until push rod can be moved from
vis. side to side.
BENCH BLEED MASTER CYLINDER (DRY c. Turn push rod clockwise until it can no longer
BRAKE) be moved from side to side.

NOTE: Master cylinder must be bench bled before in- d. Turn push rod counterclockwise 1.5 to 1.75
stalling it on the lift truck. turns.

1. Place the master cylinder horizontally in a soft- e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft).
jawed vise.
f. Verify free pedal is 10 to 12 mm (0.39 to
2. Connect the brake fluid reservoir supply hose to 0.47 in.). See Figure 22.
the master cylinder.
8. Flush with brake fluid and air bleed system. See
3. Connect hoses to the pressure ports of the mas- Brake System Air Removal.
ter cylinder. Place other end of hoses in a clear
container of brake fluid. 9. Adjust fluid level until level is within 2.5 mm
(0.098 in.) of MAX line or 5 to 7.5 mm (0.19 to
4. Fill the reservoir with brake SAE J-1703 (DOT 0.29 in.) above large rib on reservoir if MAX line
3) brake fluid. is not present.

5. Stroke the master cylinder until all air is purged 10. Verify all connections are leak-free.
from the master cylinder.
11. Install floor plate, kick plate, and seal plate on
INSTALL AND ADJUST (DRY BRAKE) lift truck.

1. Install brake fluid reservoir, supply hose, and 12. Check adjustment of brake pedal as described in
master cylinder on lift truck as an assembly. Brake Pedal Adjustment.

22
1800 SRM 1135 Master Cylinder Repair

REMOVE (WET BRAKE)

NOTE: The removal procedure in this section is for
H2.0-3.5FT (H40-70FT) (L177)lift trucks equipped
with 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 and tag the brake booster supply and re-

turn hoses from the master cylinder and booster
assembly. Plug hoses to prevent hoses from
draining. Disconnect the connector at the brake
pressure transducer, and remove brake pressure
transducer. See Figure 20.

3. Disconnect the upper brake oil supply hose from

the manifold. Plug hose to prevent brake oil
reservoir from draining.

4. Remove the brake oil reservoir and upper brake

oil supply hose from the lift truck.

5. Remove the lower brake oil supply hose from the

manifold and the master cylinder and booster as-
sembly.

6. Remove the manifold from the manifold mount.

7. Remove the cotter pin and rod end pin from the
clevis that is attached to the brake linkage lever
arm.

8. Remove capscrews and nuts that hold master

cylinder and booster assembly to bracket assem-
bly.
1. CAPSCREW
2. BRAKE FLUID RESERVOIR
3. CLAMP
4. UPPER BRAKE OIL SUPPLY HOSE
5. MANIFOLD
6. MOUNT
7. LOWER BRAKE OIL SUPPLY HOSE
8. INSERT
9. BOOSTER RETURN HOSE
10. BRAKE HOSE
11. BRAKE PRESSURE TRANSDUCER
12. BOOSTER SUPPLY HOSE
13. MASTER CYLINDER AND BOOSTER ASSEMBLY
14. MOUNTING BOLT
15. MANIFOLD MOUNT
16. BRACKET
17. COTTER PIN
18. PIN

Figure 20. Master Cylinder and Reservoir

Assembly (Wet Brake)

23
Master Cylinder Repair 1800 SRM 1135

DISASSEMBLE (WET BRAKE) 1. Place master cylinder and booster into a soft
jawed vise.
CAUTION 2. Remove three mounting bolts and the master
When the piston is removed or installed, make cylinder from booster. See Figure 21.
sure the cylinder bore and piston are not
scratched or damaged.

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 21. Master Cylinder and Booster With Wet Brake for Lift Truck Models H2.0-3.5FT
(H40-70FT) (L177)

24
1800 SRM 1135 Master Cylinder Repair

1. Install the new retaining seal on the piston, as

WARNING noted during removal.
Piston is under extreme pressure. Use care
when removing snap ring to avoid possible 2. Install the washer between the pressure seal and
injury. the piston.

3. Remove the internal snap ring holding the pis- 3. Install the new pressure seal and retainer over
ton. the spring end of the plunger.

4. Remove Piston. 4. Install the retainer spring and piston into the
bore of the master cylinder.
5. Remove the spring and retainer from the bore.
5. Install the internal snap ring holding the piston.
6. Remove and discard the pressure seal from the
spring end of the piston. 6. Install the master cylinder on the booster assem-
bly with three bolts and tighten to 49 to 59 N•m
7. Remove the washer between the pressure seal (36 to 43 lbf ft).
and the piston.
INSTALL AND ADJUST (WET BRAKE)
8. Remove and discard the retaining seal from the
piston. Note the position of the seal.
WARNING
CLEAN AND INSPECT (WET BRAKE) Small amounts of water in the brake system
can cause reduced braking performance if
the water reaches the wheel cylinders and is
WARNING
subject to high temperatures. DO NOT allow
Small amounts of water in the brake system
water entry into the brake system. If water is
can cause reduced braking performance if
present, remove all water and refill the sys-
the water reaches the wheel cylinders and is
tem with Dexron III from a sealed container.
subject to high temperatures. DO NOT allow
Unfiltered shop air can contain substantial
water entry into the brake system. If water is
amounts of water, therefore, DO NOT use un-
present, remove all water and refill the sys-
filtered shop air to blow out components.
tem with Dexron III from a sealed container.
Unfiltered shop air can contain substantial NOTE: The master cylinder uses Dexron III oil. For
amounts of water, therefore, DO NOT use un- the correct amount oil used see the Maintenance
filtered shop air to blow out components. Schedule.

1. Install brake oil reservoir, supply hose, and mas-

CAUTION ter cylinder and booster assembly on lift truck
DO NOT permit brake cleaning fluid to con- as an assembly. Install capscrews and nuts that
tact master cylinder or wheel cylinders. Brake hold master cylinder and booster to bracket as-
cleaning fluid will cause damage and leaks in sembly. See Figure 20.
seals of the brake system.
2. Install brake supply and return lines to booster
Inspect the bore of the master cylinder and the bore assembly.
of the Booster Assembly for holes and scratches. Re-
place the master cylinder and booster assembly if 3. Install the brake pressure transducer into mas-
there is damage. See Figure 21. ter cylinder and tighten to 23 to 28 N•m (16.9 to
20.6 lbf ft). See Figure 20.
Inspect wheel and master cylinder parts for dirt or
water. Clean any dirt or water present in wheel and 4. Orient master cylinder side of brake supply and
master cylinder parts using a clean lint free cloth. return lines parallel with brake pressure trans-
ducer.
ASSEMBLE (WET BRAKE)
5. Tighten fitting nuts at each end of brake hose
NOTE: Install new seals when the master cylinder is assembly to 13 to 18 N•m (84 to 117 lbf in).
being assembled.

25
Service Brakes Adjustment (Dry Brake) 1800 SRM 1135

6. Apply a layer of multipurpose grease to the f. Verify free pedal is 10 to 12 mm (0.39 to

rod end pin and, with twisting motion, insert 0.47 in.). See Figure 22.
through yoke and the inching/brake pedal. In-
stall cotter pin into the rod end pin. 8. Flush with brake oil and air bleed system. See
Brake System Air Removal.
7. Adjust free pedal per the following procedure:
9. Adjust oil level until level is within 2.5 mm
a. Loosen nut and screw it away from yoke. (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
b. Turn push rod counterclockwise, as viewed is not present.
from top, until push rod can be moved from
side to side. 10. Verify all connections are leak-free.

c. Turn push rod clockwise until it can no longer 11. Install floor plate, kick plate, and seal plate on
be moved from side to side. lift truck.

d. Turn push rod counterclockwise 1.5 to 1.75 12. Check adjustment of brake pedal as described in
turns. Figure 22.

e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft).

Service Brakes Adjustment (Dry Brake)

The following procedure is for newly-installed brake NOTE: If the brake shoes were not replaced, loosen
shoes. If the lift truck has been operated for more the adjuster wheel approximately 20 teeth.
than 25 hours and has correct pedal height, the
brakes normally will not need adjustment. 3. Push the automatic adjuster lever away from the
adjuster wheel with a small screwdriver. Use the
1. See the procedure How to Put Lift Truck on adjuster tool to loosen the adjuster wheel approx-
Blocks in the Periodic Maintenance section imately 20 teeth (new brake shoes).
for your lift truck or the Operating Manual for
your lift truck. Put the lift truck on blocks so the 4. Install the drive wheels. Remove the lift truck
drive wheels can be removed. Remove the drive from the blocks. Operate the lift truck in the
wheels. FORWARD and REVERSE directions. Stop the
lift truck 10 times in each direction. This pro-
2. Use an adjuster tool to rotate the adjuster wheel cedure causes the brake shoes to wear a small
so that the teeth of the wheel move downward. amount and fit the brake drum better.
This adjustment expands the brake shoes. Ad-
just the brake shoes so that the brake drum will
not rotate.

26
1800 SRM 1135 Brake System Air Removal

Brake System Air Removal

There are two commonly used methods to remove air 6. Check the level of the brake fluid in the reservoir
from the brake system. The preferred method is us- for the master cylinder. Fill the brake fluid reser-
ing a pressure bleed system. The other method is by voir to the correct level.
applying pressure using the brake pedal.
USING BRAKE PEDAL PRESSURE
NOTE: Two people are required for the two proce-
dures below to properly bleed the brake system.
WARNING
USING PRESSURE BLEED SYSTEM On lift trucks with wet brake drive axles, only
use Dexron III oil in the master cylinder. On
lift trucks with dry brake drive axles, only use
WARNING SAE J-1703 (DOT 3) brake fluid in the master
On lift trucks with wet brake drive axles, only cylinder.
use Dexron III oil in the master cylinder. On
lift trucks with dry brake drive axles, only use NOTE: Adjust the service brakes before the air is re-
SAE J-1703 (DOT 3) brake fluid in the master moved from the brake system.
cylinder.
1. Fill the brake fluid reservoir with brake fluid.
NOTE: Adjust the service brakes before the air is re-
moved from the brake system. 2. Place one end of a rubber hose on the bleeder
screw of the wheel cylinder furthest from the
1. Fill the brake fluid reservoir with brake fluid. master cylinder. Place the other end of the hose
into a clear container of brake fluid.
2. Place one end of a rubber hose on the bleeder
screw of each wheel cylinder. Place the other end NOTE: Check the level of the brake fluid in the reser-
of each hose into a clear container of brake fluid. voir for the master cylinder during the procedure.
Make sure to obtain the brake fluid at the correct
3. Connect a pressure bleeder to the brake fluid level.
reservoir.
3. Loosen the bleeder screw at the wheel cylinder
4. Loosen the bleeder screws at the wheel cylinders one turn so that the air can be removed from the
one turn. brake system. Slowly push the brake pedal and
hold it at the end of its stroke. Close the bleeder
NOTE: While applying air pressure to the pressure
screw.
bleeder, check the level of the brake fluid in the reser-
voir for the master cylinder. Make sure to obtain the 4. Repeat the procedures in Step 1 through Step 3
brake fluid at the correct level to avoid forcing more until there are no air bubbles in the container.
air into the brake system.
5. Repeat the procedures in Step 1 through Step 4
5. Apply 34.5 kPa (5 psi) of air pressure to the pres- for the remaining wheel cylinder.
sure bleeder, forcing fluid through the lines un-
til all air is removed from the system. Close the 6. Check the level of the brake fluid in the reservoir
bleeder screws. for the master cylinder. Fill the brake fluid reser-
voir to the correct level.

27
Brake Pedal Adjustment 1800 SRM 1135

Brake Pedal Adjustment

NOTE: Measurements are made with the floor mats 2. Depress arm V until it stops. Verify gap S be-
removed. tween arm V and tab W is 3.0 to 3.5 mm (0.11
to 0.13 in.). If it is not, then Tab W may require
1. Adjust the height (dimension R) of the inch- bending to obtain the proper gap of S. See Fig-
ing/brake pedal to 31 ±0.4 mm (1.22 ±0.01 in.). ure 22.
Use the upstop bolt to change the pedal height.
Tighten the nut while keeping the upstop bolt
fixed. See Figure 22.

1. INCH/BRAKE PEDAL 5. SENSOR MOUNT

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

Figure 22. Brake Pedal Adjustment

28
1800 SRM 1135 Free Pedal Adjustment

Free Pedal Adjustment

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 23.

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 22.

NOTE: DRY BRAKE SYSTEM SHOWN

1. COTTER PIN
2. WELDMENT
3. PIN
4. MASTER CYLINDER
5. PUSH ROD
6. NUT
7. CLEVIS

Figure 23. Free Pedal Adjustment

29
Torque Specifications 1800 SRM 1135

Torque Specifications
Back Plate to Axle Mount Capscrews Wheel Nuts
S2.0-3.5FT (S40-70FT, S55FTS) [F187]
S2.0-3.5FT (S40-70FT, S55FTS) [F187] and 340 to 380 N•m (251 to 280 lbf ft)
H2.0-3.5FT (H40-70FT) [L177]
255 to 306 N•m (188 to 226 lbf ft) H2.0-3.5FT (H40-70FT) [L177]
450 to 500 N•m (332 to 369 lbf ft)
S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, S30FT, S35FT, S40FTS (E010) and H1.6FT,
H40FTS) [F001] H1.8FT, H2.0FTS (H30FT, H35FT,
152 to 167 N•m (112 to 123 lbf ft) H40FTS) [F001]
155 to 175 N•m (115 to 130 lbf ft)
Wheel Cylinder Capscrews
18 to 26 N•m (13 to 19 lbf ft) Upper Parking Brake Cable Bracket
Capscrews (Wet Brake)
Axle Shaft Capscrews H2.0-3.5FT (H40-70FT) [L177]
S2.0-3.5FT (S40-70FT, S55FTS) [F187] 38 to 42 N•m (28 to 31 lbf ft)
90 to 99 N•m (66 to 73 lbf ft)
Upper Parking Brake Cable Bracket
H2.0-3.5FT (H40-70FT) [L177] Capscrews (Wet Brake)
90 to 108 N•m (66 to 80 lbf ft) H2.0-3.5FT (H40-70FT) [L177]
38 to 42 N•m (28 to 31 lbf ft)
S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, Brake Pressure Transducer to Master
H40FTS) [F001] Cylinder (Wet Brake)
52 to 62 N•m (39 to 46 lbf ft) H2.0-3.5FT (H40-70FT) [L177]
23 to 28 N•m (16.9 to 20.6 lbf ft)

Master Cylinder to Booster Capscrews

(Wet Brake)
H2.0-3.5FT (H40-70FT) [L177]
49 to 59 N•m (36 to 43 lbf ft)

30