INTRODUCTION
GENERAL DESCRIPTION AND OPERATION
A service brake assembly is installed at each end of the
This section has a description and the service drive axle. The parts of the brake system are shown in
procedures for the brake system. The parts of the brake Figures 1 and 2. When the brake pedal is pushed,fluid
system include the brake shoes, the wheel cylinders and pressure from the master cylinder causes the pistons in
the parking brake system. A troubleshooting section is the wheel cylinders to move out. The pistons cause the
include the end of this section. brake shoes to expand against the drum.
NOTE: BRAKE ASSEMBLY SHOWN IS
FOR S60 120E MODELS
3
2
1
4
21
22
19
8
5 18
1 1 20
23 18
18
6
7
16
15
8
10
9 11
1. SNAP RING
12 17
2. ANCHOR PIN
14
3. BACK PLATE
12. PIVOT PLATE
4. CABLE
13. SPRING (BROWN)
13
5. CABLE GUIDE
14. SPRING (GREEN)
6. SPECIAL CAPSCREW
15. SPECIAL CAPSCREW
19. FRONT BRAKE SHOE
7. CAPSCREWS
16. LINK (PINK)
20. SPRING (YELLOW)
8. PARKING BRAKE LEVER
17. LINK (LH = YELLOW
21. ADJUSTER NUT
9. WHEEL CYLINDER
RH = ORANGE)
22. ADJUSTER NUT
10. STUD
18. ANCHOR SPRING
23. AUTOMATIC ADJUSTER
11. REAR BRAKE SHOE
ASSEMBLY
FIGURE 1. BRAKE ASSEMBLY, RIGHT SIDE (S60 120E)
1
NOTE: BRAKE ASSEMBLY SHOWN IS FOR THE
S30 50E, S60ES, AND S40 50F MODELS
2
1
3
4
21
20
5
7
18
23
19
17
22
17
17
6
15
7
14
13
9
8
11
16
10
12
1. CRANK 13. SPRING (MAROON)
2. ANCHOR PLATE 14. SPECIAL CAPSCREW
3. BACK PLATE 15. LINK (BLUE)
4. CABLE 16. LINK (RH = GREY, LH = MAROON)
5. SPECIAL CAPSCREW 17. ANCHOR SPRING ASSEMBLY
6. CAPSCREWS 18. REAR BRAKE SHOE
7. PARKING BRAKE LEVER 19. SPRING (RED)
8. WHEEL CYLINDER 20. ADJUSTER NUT
9. STUD 21. ADJUSTER WHEEL
10. FRONT BRAKE SHOE 22. AUTOMATIC ADJUSTER
11. PIVOT PLATE 23. SNAP RING
12. SPRING (GREY)
FIGURE 2. BRAKE ASSEMBLY, LEFT SIDE (S30 60ES, S40 50F)
2
The parking brakes uses the service brake shoes. rotation causes the cable guide to pull on the cable that is
Additional linkage activates the parking brake system connected to the levers for the brake shoes. The levers
when the lever for the parking brake is pushed down. push the brake shoes against the brake drum. The design
The parts of the parking brake system are shown in of the system permits the tension of each cable to be the
Figures 3 and 4. When the pedal for the parking brakes is same during application of the parking brake.
pushed, the cables cause the cranks to rotate. This
1. PARKING BRAKE LEVER ASSEMBLY
2. RELEASE LEVER
3. PEDAL
4. SWITCH 1
5. CABLE
6. TO RIGHT HAND BRAKE ASSEMBLY
7. LEVER
4
8. SPRING
2
9. CABLE
10. CABLE
11. SPECIAL CAPSCREW 3
12. CRANK
13. CABLE GUIDE
14. PARKING BRAKE LEVERS
15. BACK PLATE
5
7
8
11
6
8
10
5631
9
12
14
13
15
14
NOTE: PARKING BRAKE SYSTEM
SHOWN IS FOR THE S60 120E
FIGURE 3. PARKING BRAKE SYSTEM (S60 120E)
3
NOTE: SYSTEM SHOWN IS FOR
S30 50E, S60ES AND S40 50F MODELS
1. PARKING BRAKE LEVER ASSEMBLY
2. RELEASE LEVER
3. PEDAL
4. SWITCH
5. CABLE
6. PARKING BRAKE LEVERS
7. CRANK
8. CABLE
9. LEVER
10. PIVOT
11. TO RH BRAKE ASSEMBLY
FIGURE 4. PARKING BRAKE SYSTEM (S30 60E, S40 50F)
4
The clearance between the brake shoes and the brake adjuster screw wheel. The adjuster screw wheel can
drum is adjusted automatically. The adjuster linkage only turn when there is clearance between the lining and
turns the adjuster wheel to adjust the clearance. The the brake drum. The adjuster screw wheel can also be
primary shoe and the adjuster links move with the drum turned manually. A hole in the drum is used to get access
during a stop when the lift truck is moving in reverse. to the adjuster screw wheel.
The linkage permits the adjuster lever to rotate the
REPAIRS
2. Start the engine and tilt the mast fully backward. Put
WARNING
blocks under the outer mast channels. Tilt the mast
Brake linings contain asbestos or other fibers.
forward on the truck frame.
Breathing the dust from these linings is a cancer or
3. Put some grease on the floor under the wheel. Tilt the
lung disease hazard. Do not create dust! Do not clean
mast backward until the wheels just touch the floor.
brake parts with compressed air or by brushing. Use
vacuum equipment for asbestos or follow the
cleaning procedure in this section. When the brake
drums are removed, do not create dust.
1
2
Do not sand, grind, chisel, hammer or change linings
7
in any way that will create dust. Any changes to
linings must be done in a restricted area with special
ventilation. Protective clothing and a respirator
must be used.
CLEANING PROCEDURES
1. Do not release brake lining dust from the brake
linings into the air when the brake drum is removed.
9 5601
3
2. Use a solvent approved for cleaning of brake parts
to wet the brake lining dust. Follow the instructions
8
4
and cautions of the manufacturer for the use of the
5
5
6
solvent. If a solvent spray is used, spray at a distance
so that the dust is not released into the air.
1. ADJUSTER WHEEL
2. ADJUSTER SCREW NUT
3. When the brake lining dust is wet, clean the parts.
3. PARKING BRAKE LEVER
Put any rags or towels in a plastic bag or an airtight
4. REAR BRAKE SHOE
container while they are still wet. Put a
5. RETURN SPRING
 DANGEROUS FIBERS warning label on the
6. WHEEL CYLINDER
7. AUTOMATIC ADJUSTER MECHANISM
plastic bag or airtight container.
8. FRONT BRAKE SHOE
9. PARKING BRAKE LEVER
4. Any cleaning rags that will be washed must be
cleaned so that fibers are not released into the air.
FIGURE 5. BRAKE ASSEMBLY, LEFT SIDE
REMOVAL AND DISASSEMBLY
4. Remove the nuts (inner) that hold the wheel and the
1. Loosen the nuts (inner) that hold the wheel and the drum to the spindle assembly. Remove the wheel and the
drum to the spindle assembly. drum assembly. If necessary, turn the adjuster wheel to
5
loosen the brake shoes. Use the hole in the drive wheel to 9. Remove the boots, the piston, the cups and the springs
get access to the adjuster wheel. from the wheel cylinder.
10. Remove the parking brake assembly as described in
5. Use spring pliers to remove the return springs for the
THE BRAKE SYSTEM, 1800 SRM 87.
brake shoes.
11. Remove the back plate.
CAUTION
The springs are not the same. Make sure the springs
INSPECTION
are installed to the same positions as during removal.
1. Check the bore of the wheel cylinder for wear,
6. Remove the spring assemblies that hold the brake
damage, and holes caused by corrosion. Replace a
shoes to the back plate. Remove the brake shoes. Inspect
damaged wheel cylinder.
the brake shoes for cracks or damage. If the linings are
badly worn or damaged or the shoes are damaged,
2. Check the return springs for damaged. Inspect the
replace the brake shoes. It is recommended that if one
back plate for wear where the brake shoes touch the back
brake shoe is replaced, both shoes on that wheel be
plate. Grind the back plate if it is not smooth.
replaced.
3. Replace the brake shoes if they are cracked, damaged,
7. Remove the snap rings that hold the parking brake
or have more than 50% wear. If one brake shoe is
levers to the back plate. Remove both of the levers and
replaced both shoes on that wheel must be replaced.
the cable assemblies.
4. Inspect the brake drum for deep grooves or other
8. Remove the brake lines from the wheel cylinder. damage. Use sandpaper on the surface for the brake
Remove the wheel cylinder from the back plate. shoes.
4
4
1
2
5
7
3
6
8 8
1. PORT FOR SPECIAL FITTING
2. INLET PORT
3. BRAKE SHOE
4. BOOT
5. WHEEL CYLINDER
6. SPRING
7. CUP
8. PISTON ASSEMBLY
4
FIGURE 6. WHEEL CYLINDER
6
NOTE: If the brake drums require grinding do not grind
ASSEMBLY (See Figures 6, 7, 8)
more than 1.5 mm (0.060 in) from the inner diameter of
1. Use clean brake fluid during the assembly of the
the brake drum. The maximum drum diameter including
wheel cylinder. Assemble the wheel cylinder as shown
wear is 263 mm (10.35 in) S30 60E/F and 320 mm
in Figure 6.
(12.6 in) S60 120E. If the inner diameter is greater than
the maximum limit, replace the drum.
2. Install the back plate to the hub. Tighten the four
regular capscrews to a torque of 175 N.m (130 lbf ft).
5. The teeth of the adjuster wheel must not be worn. The
Tighten the two special capscrews to a torque of 80 lbf ft
adjuster wheel must turn freely. Check the adjuster links
(108 N.m) for S30 60E and S40 50F models. For the
for damage.
S60 120E models, tighten the two special capscrews to
6. Make sure the parking brake levers move freely.
150 N.m (110 foot pounds).
7. Check the surfaces of the seals for wear or damage. 3. Install the wheel cylinder and the brake lines.
FRONT
4
2
6
5
4
2
1 1
RIGHT SIDE
FRONT
3
2
6
5
2
3
9524
1
LEFT SIDE
1
4. LOWER LINK (GREY)
1. SPRING (GREY)
5. UPPER LINK (BLUE)
2. SPRING (MAROON)
6. SPRING (RED)
3. LOWER LINK (MAROON)
FIGURE 7. INSTALLATION (S30 60ES, S40 50F)
7
FRONT
4
2
6
5
4
2
1
1
LEFT SIDE
FRONT
3
2
6
5
2
3
9524
1
RIGHT SIDE
1
4. LOWER LINK (YELLOW)
1. SPRING (BROWN)
5. UPPER LINK (PINK)
2. SPRING (GREEN)
6. SPRING (YELLOW)
3. LOWER LINK (ORANGE)
FIGURE 8. INSTALLATION (S60 120E)
8
7. Install the automatic adjuster linkage. Install the
return springs for the brake shoes.
8. Put some grease on the floor under the brake
assembly. Slide the wheel and drum assembly on the
spindle. During installation, start the engine and tilt the
mast as necessary to raise or lower the axle.
9. Install the tapered thimbles, the washers and the nuts.
Tighten the nuts evenly to 122 N.m (90 lbf ft) in the
sequence shown in Figure 9. Tighten the nuts that hold
the brake drum to the wheel to a torque of 160 N.m (120
lbf ft) for the S30 60E and S40 50F models. Tighten
FIGURE 9. TIGHTENING SEQUENCE
the nuts to a torque of 270 N.m (200 lbf ft) for the
S60 120E models. Tighten the nuts in the sequence
4. Install the actuator levers for the parking brakes.
shown in Figure 9.
Install the cable and the linkage.
10. Remove the air from the brake fluid as described in
5. Install the brake shoes. Install the spring assemblies
Checks and Adjustments in this section.
that hold the brake shoes to the back plate.
6. Lubricate the adjuster screw with Never Seeze. Turn K. Adjust the service brakes and the parking brakes as
the adjuster screw in for installation of the drum. described in the Checks and Adjustments in this section.
CHECKS AND ADJUSTMENTS
the tension of the cable for the parking brake lever can
ADJUSTING THE SERVICE BRAKES
be adjusted. Loosen the lock nut (3) and then turn the
The brake shoes are adjusted automatically in normal
adjustment screw (4) to adjust the cable. See Figure 10.
operation by applying the service brakes while moving
in reverse. To manually adjust the brakes after replacing
the shoes or other repair work, put a small screw driver
REMOVING THE AIR FROM THE BRAKE
through the hole in the wheel. Push the adjuster spring
SYSTEM
lever away from the adjuster wheel. Use a brake adjuster
tool to turn the star wheel until the brake shoes contact
The air must be removed from the brake system. Fill the
the drum, then back off the star wheel 39 clicks. Move
reservoir of the master cylinder with brake fluid. Put one
the truck forward and reverse and apply the brakes until
end of a rubber hose on the special fitting of the wheel
the pedal assumes a normal position and becomes
cylinder. Put the other end of the hose into a clear
stabilized.
container of brake fluid. Loosen the special fitting one
turn. Slowly push the brake pedal and hold it at the end
ADJUSTING THE PARKING BRAKE
of its stroke. Close the special fitting. Repeat the
Make sure that the service brakes are adjusted and that procedure until there are no bubbles in the container.
the operation of the automatic adjuster mechanism is Check the level of the brake fluid in the master cylinder
correct. Test the operation of the parking brake. The lift during the procedure. Make sure to keep the brake fluid
truck with a capacity load must not move when the at the correct level. Repeat the procedure for the other
parking brake is applied on a 15% grade. If necessary, wheel cylinder.
9
ADJUSTING THE SERVICE BRAKE
PEDAL (See Figure 11)
Adjust the height of the brake pedal. Loosen the locknut
(1) and turn the adjustment nut (2) to adjust the height of
1 the pedal. For models that have a powershift
transmission, adjust the height so that dimensions  A is
108 mm (4.25 in). For models that have an oil clutch
transmission, adjust the height so that dimension  A is
2
76 mm (3 in).
Adjust the stroke of the push rod to get free movement of
the pedal. Loosen the locknut (3) and turn the
adjustment nut (4) to adjust the stroke. Adjust the stroke
of the push rod so that the free movement of the pedal
(dimension  B ) is 6 mm (0.25 in).
4
3
DIMENSION  B
8958
DIMENSION  A
5141
1
5
2
5
1. RELEASE LEVER
2. PEDAL
3. LOCKNUT
3
4. ADJUSTMENT NUT
4
5. CABLE
FIGURE 10. ADJUSTMENT OF THE
1. LOCKNUT
PARKING BRAKE
2. ADJUSTMENT CAPSCREW
3. LOCKNUT
NOTE: On trucks that have a powershift transmission,
4. ADJUSTMENT NUT
remove the air from the line for the inching valve. Do the
5. STOP
same procedure as described in Removing the Air from
FIGURE 11. ADJUSTMENT OF THE
the Brake System. The special fitting for removing the
BRAKE PEDAL
air from the system is on the side of the inching valve.
10
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE
The brakes do not operate equally Oil or brake fluid is on the linings.
The linings are worn or hard.
The wheel cylinders are damaged.
The brake lines have a restriction.
The brake shoes or back plates are damaged.
The drum is not round.
One brake does not release The shoes are adjusted too tight.
A shoe is damaged.
A return spring is damaged.
The brake lines have a restriction.
The parking cable is damaged.
The wheel bearings are adjusted too tight.
The wheel cylinder is damaged.
The back plate is damaged.
Both brakes do not release The parking brake is not released.
The pedal push rod clearance is not enough.
The master cylinder is damaged.
The shoes are adjusted too tight.
The seals are damaged because of oil in the brake fluid.
The pedal is hard to push. There is not enough clearance for the push rod.
The linings are too hard.
Water or oil is on the linings.
The master cylinder is damaged.
The wheel cylinders are damaged.
The pedal return spring is damaged
The pedal does not have enough resis- Air is in the brake system.
tance.
The master cylinder mount is loose.
The shoes are damaged.
A drum is cracked.
A back plate is damaged.
A wheel cylinder is damaged.
The linings do not fit the drums.
The pedal travels too far. Air is in the brake system.
The shoes are adjusted wrong.
The linings are worn.
The clearance at the push rod is too much.
11
The pedal moves to the floor. Air is in the brake system.
The master cylinder is damaged.
The brake system has a leak.
The brakes make too much noise. Oil, water or brake fluid is on the linings.
The linings are worn.
The drum is damaged.
A shoe is damaged.
Dirt is on the linings.
The brakes do not stop the truck. Oil, water or brake fluid is on the linings.
The linings are worn.
The wheel cylinders are damaged.
The shoes are not adjusted correctly.
The master cylinder is damaged.
The parking brake will not hold. Oil, water or brake fluid is on the linings.
The parking cables are not adjusted correctly.
A parking cable is damaged.
The brake linings are worn.
The parking brake will not release. The parking brake handle is adjusted too tight.
The parking brake cables are damaged.
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