INTRODUCTION GENERAL This section has the description and repairs for the brake system. These parts include the park brake, service brake and master cylinder, the disassembly and assembly of the service brakes and the park brakes. The electrically released park brake is also described in this section. Checks and Adjustments are described at the end of this section.
DESCRIPTION The J30XMT, J35XMT, J40XMT J1.60XMT, J1.80XMT and J2.00XMT lift trucks feature dual hydraulically operated service disc brakes and mechanically operated park disc brakes. Both brake systems operate independently of each other although they both use a single disc mounted on the bevel gear shaft of the transaxle for braking. The location provides a mechani-
cal advantage for effective braking. The service brake master cylinder and separate reservoir are sealed. The reservoir has a level sensor connected to a warning light in the instrument panel, which displays when the brake fluid is low. The service brake is actuated by the large pedal located in the operator’s compartment. The pedal can be operated with either the left or right foot. The park brake is set by a pedal operated by the operator’s left foot. The park brake is released by operating the release lever located on the left side of the instrument panel. Both a warning buzzer and indicator light are used to remind the operator to set and release the park brake. The lift truck may also be furnished with an optional electrically operated park brake. When furnished, the park brake applies when the operator leaves the seat of the lift truck. The park brake mechanism is attached to the park brake linkage at the front of the lift truck and replaces the standard park brake linkage.
REPAIRS SERVICE BRAKE PADS (See FIGURE 1 AND FIGURE 2) Removal
4. Remove the pins and the brake pads. NOTE: The original brake pad installed in the carrier side of the service brake is affixed to the carrier side with hot glue. Use a screwdriver to pry the pad from the carrier side. Clean the carrier side before installing a replacement pad.
To access the brakes, the mast and carriage must be raised and a safety chain installed. Follow the instructions in section PERIODIC MAINTENANCE, 8000 SRM 528 or 8000 SRM 584, SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.
Installation
1. Move the lift truck to a safe, level area. Block the tires. Raise the carriage high enough to chain the carriage so that it does not move. Disconnect the battery.
3. Install the spring clips to retain the pins.
2. Remove the capscrews retaining the disc brake shield and remove the disc brake shield.
5. Remove the air from the brake system. See REMOVE AIR FROM BRAKE SYSTEM.
3. Remove the spring clips retaining the pins on both ends of the service brake caliper.
6. Connect the battery. Remove the safety chain and lower the mast. Remove the blocks from the tires.
1. Install the brake pads in both the carrier side and the cam side of the caliper. 2. Install the pins to retain the pads.
4. Install the disc brake shield.
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