This document provides instructions for servicing various parts of the frame on a lift truck, including the counterweight assembly, overhead guard, hydraulic tank, access panels, and decal positions. It describes the components and their functions. The procedures covered include removing and installing the overhead guard, counterweight, hydraulic tank repairs, hood and seat assembly, and replacing decals. Safety warnings are provided throughout.

1. SERVICE REPAIR
J25B J30B J35B [B160]

2. GENERAL
This section has a description and the service proce-
dures for the parts of the frame. These parts include
thecounterweightassembly,overheadguard,hydraulic
tank, access panels, and decal positions.
INTRODUCTION
DESCRIPTION
Theframeisasingleweldment.Theframehasmounts
forthecounterweight,overheadguard,upright,steer-
ing trunnion, and transaxle assembly. The hy-
draulic tank is part of the frame weldment and is
found in the steering compartment behind the
FIGURE 1. FRAME AND CONNECTED PARTS

3. battery compartment. A hood is the access cover
over the battery compartment, hydraulic tank, and
thetopofthesteeringtrunnion.Thehoodisfastened
to the counterweight with a hinge. An access panel
on the right side of the frame protects the electronic
controllerfromdirtandwater.
Threesizesofbatterycompartmentsareavailablefor
theJ25-35Aseriesoflifttrucks.Theframesaresimi-
larindesign,buthavethreedifferentlengthsbecause
of the different battery compartments. The three
lengths of the battery compartments are 42.5 cm
(16.75 in), 60 cm (23.5 in), and 67.3 cm (26.5 in).
The remainder of the frame parts is the same.
Theweightofthebatteryisthemainpartofthecoun-
terweightsystemonanelectriclifttruck.The
WARNING
Do not operate the lift truck without the
overhead guard correctly fastened to the
lift truck.
Removal
A. Remove the battery as described in the section
PERIODIC MAINTENANCE.
B. Access to the capscrews that hold the overhead
guard to the counterweight is from the battery com-
partment. Remove the two capscrews and washers.
C. Remove the four capscrews (two each side) that
hold the overhead guard to the cowl.
D.Usealiftingdevicetolifttheoverheadguardfrom
thelifttruck.
Installation
Puttheoverheadguardonthelifttuck.ApplyLoctite
290 or equivalent to the two capscrews that hold the
overhead guard to the counterweight. Install the six
capscrewsandwashersthatholdtheoverheadguard
to thelift truck.Tightenthefourcapscrewsthathold
the overhead guard to the cowl to 85 N.m ( 63 lf ft)
torque.Tightenthetwocapscrewsthatholdtheover-
headguardtothecounterweightto300N.m(220lbf
ft) torque. Install the battery.
J25A, J30A, and J35A lift trucks have a cast-iron
counterweightfastenedtothebackoftheframe.When
the lifting capacity of the lift truck is increased, the
size of the battery is increased. The increased size of
thebatteryrequiresalargerbatterycompartment.The
counterweight has a weight of 340 kg (750 lb).
The J30AS lift truck uses the same battery and short
frameastheJ25A.Aheaviercounterweight[580kg
(1275 lb)] is installed on the J30AS.
A slot in the overhead guard permits the removal of
the battery without removing the overhead guard.
Accesspanelsbehindthedrivewheelsgiveaccessto
the traction motors. The floor plate gives access to
thehydraulicandelectriccomponents.
DISASSEMBLY AND ASSEMBLY
HOOD AND SEAT ASSEMBLY
The hood has several functions. It protects the bat-
tery, protects the operator, and is the mount for the
operator seat. A latch in the front of the hood con-
nects to the frame. This latch must be in good condi-
tion so that the hood can prevent the battery from
coming into the operator area if an accident occurs.
Agascontrolledspringmakeseasyraisingofthehood
for access to the battery compartment.
Removal and Installation
Theseatassemblycanstayfastenedtothehoodwhen
the hood is removed from the lift truck. The wire to
the seat switch must be disconnected if the seat or
the hood is removed from the lift truck. A plug for
disconnecting the wire is found under the hood.
Disconnect the gas controlled spring. Make a
noteoftheconnectionofthegascontrolledspringto
thehood:
front hole for the 67.3 cm (26.6 in) battery
compartment,
rear hole for the other two sizes of battery
compartments.
Removethehoodfromthecounterweightbyremov-
ing the capscrewsthat hold the hinge to the counter-
weight. When the hood is installed again,
OVERHEAD GUARD

4. makesurethehoodisalignedwiththecounterweight
and frame. Tighten the capscrews for the hinge and
installthegascontrolledspring.
COUNTERWEIGHT
WARNING
PUTTING THE LIFT TRUCK ON
BLOCKS
The lift truck must be put on blocks for
some types of maintenance and repair.
The removal of the following assemblies
will cause large changes in the center of
gravity: battery, upright, transaxle, and
counterweight. When the lift truck is put
on blocks, put additional blocks in the
following positions:
1. If the battery and drive axle are re-
moved, put blocks under the counter-
weight.
2. If the battery and counterweight are
removed, put blocks under the upright
assembly.
Removal Of The Counterweight
CAUTION
If the battery is not removed for this pro-
cedure, use an insulator cover over the
battery to protect the battery.
A. Remove the overhead guard as described in the
paragraph for the removal of the overhead guard.
B. Disconnect the wire to the set switch under the
hood. Use a support to hold the hood open and dis-
connect the gas controlled spring. Remove the two
capscrews that hold the hood to the counterweight.
Remove the hood and the seat.
C. Remove the bottom 1/2 UNC x 1 in capscrew
andwashersthatholdthecounterweighttotheframe.
Thiscapscrewisfoundontheleftsideoftheopening
forthesteeringwheel.
D.Installeyeboltsinthethreadedholesfortheover-
head guard. Connect a crane and sling with a mini-
mum capacity of 1000 kg (2000 lb) to the eyebolts.
Raisethecraneuntiltheweightofthecounterweight
is held by the crane.
E. Remove the four 1/2 UNC x 3-1/2 in bolts, nuts,
andwashersthatholdthecounterweighttotheframe.
Make a note of the arrangement of the washers. The
washers are used for the alignment of the counter-
weightontheframe.
F.Removethecounterweightfromthelifttruck.
Installation Of The Counterweight
A.Installeyeboltsinthethreadedholesfortheover-
head guard. Connect a crane and sling with a
mimimum capacity of 1000 kg (2000 lb) to the eye-
bolts.Raisethecraneuntiltheweightofthecounter-
weightisheldbythecrane.Movethecounterweight
tothelifttruckforinstallation.
B.Installthefour1/2UNCx3-1/2inboltsandnuts
that hold the counterweight to the frame. Use wash-
ersforshimstoalignthecounterweightandtheframe
for the capscrew that holds the counterweight at the
bottom. Tighten the bolts to 75-80 N.m (55-60 lbf
ft).
C. Install the 1/2 UNC x I in capscrew and washers
inthebottomholeinthecounterweight.
D.Installtheseatandhood.Installthegascontrolled
spring. Connect the wire for the seat switch.
E.Installtheoverheadguardasdescribedinthepara-
graph for the overhead guard.
HYDRAULIC TANK REPAIRS
Small Leaks
Small leaks can be sealed as follows:
A. Use steam to clean the area around the leak. Re-
move all paint and dirt around the leak.
WARNING
Do not use tools that can make sparks,
heat or static electricity. The vapors in
the tank can cause an explosion.
B.ApplyLoctite 290tothe leak.Followthe instruc-
tionsofthemanufacturer.

5. Large Leaks
WARNING
Special procedures must be followed
when large leaks or other repairs need
welding or cutting. Special procedures
must be followed. All work must be done
by authorized personnel. If the tank is
cleaned inside of a building, make sure
there is enough ventilation. See the fol-
lowingmanualsforadditionalinformation:
• “Safe Practices For Welding And Cut-
tingContainersThatHaveHeldCombus-
tibles” by the American Welding Society,
A6.0-65.
• “Safety In Welding And Cutting”,
American National Standard, ANSI Z
49.1 -1973.
Whencleaningthetank,donotusesolutionsthatmake
dangerous gases at normal temperatures or when
heated. Wear a device for the protection of the eyes.
Protect the body from burns.
When cleaning with steam, use a hose with a mini-
mumdiameterof19mm(0.75inch).Controlthepres-
sureof thesteambyavalveinstalledatthe nozzle of
thehose.Ifametalnozzleisused,itmustbemadeof
a material that does not make sparks. Make an elec-
tricalconnectionbetweenthenozzleandthetank.To
preventstaticelectricity,connectagroundwiretothe
tank.
Steam Method Of Cleaning
Cleanthetankasfollows:
A.Removeallthepartsfromthetank.Installthedrain
plug.
B. Fill the tank 1 /4 full with a solution of water and
sodium bicarbonate or sodium carbonate. Mix 0.5
kg (1 lb) per 4 litres (1 gal) of water.
C. Mix the solution in the tank using air pressure.
Make sure all the surfaces on the inside of the tank
areflushedwiththesolution.Drainthetank.
D. Put steam into the tank until the tank does not
have odors and the metal is hot. Steam vapors must
comefromalltheopenings.
E.Flushtheinsideofthetankwithboilingwater.Make
surealltheloosematerialisremovedfromtheinside
of the tank.
F.Makeaninspectionoftheinsideofthetank.Ifitis
not clean, repeat steps D and E and make another
inspection.Whenmakinginspections,usealightthat
isapprovedforlocationswithflammablevapors.
G. Put plugs in all the openings in the tank. Wait 15
minutes,thenremovetheinletandoutletplugs.Testa
sample of the vapor with a special indicator for gas
vapors. If the amount of flammable vapors is above
thelowerflammablelimit,repeatthecleaningproce-
dures.
Chemical Solution Method of Cleaning
Ifthetankcannotbecleanedwithsteam,usethefol-
lowingprocedure:
A. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Follow
theinstructionsgivenbythemanufacturer.
B. Fill the tank with the cleaning solution. Use com-
pressed air to mix the solution in the tank.
C. Drain the tank. Flush the inside of the tank with
hot (boiling) water. Make sure all the cleaning com-
pound is removed.
D.Makeaninspectionoftheinsideofthetank.Ifthe
tank is not clean, repeat steps A to C. Make another
inspectionofthetank.Whenmakinginspections,use
alightthatisapprovedforlocationswithflammable
vapors.
E.Checkthetankforflammablevaporsusingspecial
indicatorforgasvapors.Ifthe amountofflammable
vaporsisnotbelowthelowerflammablelimit,repeat
thecleaningprocedures.
Other Methods
Ifnitrogengasorcarbondioxidegasisavailable,pre-
pare the tank for welding using these gases. See the
manual “Safe Practices For Welding and Cutting
Containers That Have Held Combustibles” by the
American Welding Society, A6.0-65. If these gases
arenotavailable,anothermethodusingwatercanbe
usedasfollows:

6. A. Fill the tank with water to just below the point
where the work will be done. Make sure the space
above the level of the water has a vent.
B.Useacceptableweldingpracticestorepairthetank.
DECAL REPLACEMENT (SEE
FIGURE 2)
WARNING
Decals that have WARNINGS or
CAUTIONS must be replaced if they are
damaged.
If an upright of a different size or an
accessory carriage is installed, the
capacity rating can change. Changes in
types of tires can change the capacity
rating. See a Hyster Dealer for a
replacement nameplate. The nameplate
information is a safety item and must be
correct.
NOTE
The nameplate is installed using rivets.
The old rivets must be removed before
installing a new nameplate.
If the decals or information plates are
missing or have damage, they must be
replaced.
A. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean the
surfaceofoldpaintusingacleaningsolvent.
B. Remove the paper from the back of the decal. Do
not touch the adhesive surface.
C. Carefully hold the decal in the correct position
close to the surface. The decal can not be moved
after it touches the surface. Put the decal on the sur-
face. Make sure all air is removed from under the
decal and the corners and edges are tight.

7. FIGURE 2. DECAL POSITIONS

8. GENERAL
This section describes the disassembly and assem-
bly of the service brakes and the parking brake for
repairs. The optional seat brake is also described
in this section. Checks and Adjustments are de-
scribed at the end of this section. See the section
THE MASTER CYLINDER, 1800 SRM 13 for
additional information on the master cylinder.
INTRODUCTION
DESCRIPTION
Service Brakes
This series of lift trucks is equipped with disc
brakes for the service brakes. See Figure 2. This
brake system has a master cylinder, two caliper
and disc assemblies, and the connecting brake
lines. There are no adjustments on the caliper as-
semblies.
FIGURE 1. LOCATION OF BRAKE SYSTEM COMPONENTS

9. There is a brake switch that contacts the arm of the
brake pedal. The brake switch interrupts the coil
circuit for the “FORWARD” and “REVERSE”
contactors. This action opens the contactors and
prevents the traction motors from operating when
the brakes are applied.
Parking Brake
The parking brake has separate sets of caliper as-
semblies actuated by a hand lever. See Figure 4.
The caliper assemblies for the parking brake use
the same brake discs as the service brakes. Cables
are connected between the hand lever and the cali-
per assemblies and operate the caliper assemblies
through a cam arrangement. A knob on the hand
lever can be turned to adjust the pressure for
SERVICE BRAKES
Replacement of the Friction Pads (See
Figure 2)
A. Disconnect the battery and separate the battery
connector. Remove the floor plates. Loosen the
mounting strap that holds the power steering mo-
tor to the frame. Move the power steering pump
and motor so that you have access to the brake
calipers.
B. Remove the bracket that holds the parking brake
cable to the transaxle housing. Move the bracket
so that you have access to the calipers for the ser-
vice brakes.
C. Use a small prybar to slowly and carefully push
the caliper pistons into the housing. Additional
clearance will be needed to install new friction
pads. Remove the clips (1) that hold the pins (2).
Slide the pins from the caliper casting. Remove
the friction pads.
D. Insert and align the new friction pads in the
caliper housing. Install the pins through the cali-
per casting and the friction pads. Install the clips
on the
application of the parking brakes. Additional ad-
justments are described in the section Checks and
Adjustments.
Optional Seat Brake
Some lift trucks with power steering are equipped
with an optional seat brake. See Figure 5 and Fig-
ure 7. The seat brake mechanism is connected to
the cam levers of the parking brake calipers. When
the operator is not on the seat, the power steering
motor does not operate and a spring in the seat
brake mechanism applies the parking brakes. A
small hydraulic piston is actuated by the power
steering pump and releases the parking brake cali-
pers. See the section Checks and Adjustments for
a description of the adjustments.
REPAIRS
E. Install the bracket for the parking brake cables.
Install the power steering motor on the mount. In-
stall the floor plates.
Removal and Disassembly
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for
some types of maintenance and repair.
The removal of the following assemblies
will cause large changes in the center of
gravity: battery, upright, drive axle, and
the counterweight. When the lift truck is
put on blocks, put additional blocks in the
following positions:
1. If the battery and drive axle are to be
removed: Put blocks under the counter-
weight so that the lift truck can not fall
backward.
2. If the battery and counterweight are to
be removed: Put blocks under the upright
assembly so that the lift truck can not fall
forward.

10. NOTE
Do not remove a caliper assembly while
the brake assembly is installed in the lift
truck. Remove the service brake and
parking brake calipers as an assembly be-
fore making repairs on one caliper.
FIGURE 2. CALIPER ASSEMBLY, SERVICE BRAKES
A. Disconnect the battery. Remove the floor plates.
Put the lift truck on blocks so that you have access
to the brake assemblies under the lift truck.
B. Move the power steering motor and pump from
its mount so that you have access to the bracket for
the parking brake cables. Disconnect the parking

11. Assembly and Installation
A. Install a new O-ring in the bore. Install a new
dust cover in the groove on the piston. Lubricate
the parts with brake fluid and carefully install the
piston into the bore of the caliper. Make sure that
you do not cut the O-ring. Install the dust cover in
the groove in the caliper. See Figure 3 for the ar-
rangement.
B. Assemble the caliper assembly as shown in Fig-
ure 2. The concave surface of the curved washers
(3) must be towards the bushings Tighten the
through bolts to 50 N.m (351bf ft) after the caliper
is installed in the mount bracket.
C. Put the complete caliper assembly into position
on the transaxle housing. Measure the distance be-
tween the friction pad in the fixed position and the
brake disc. The maximum clearance is 1.78 mm
(0.070 in). Use shims to adjust the clearance be-
tween the mount bracket and the transaxle case.
D. Tighten the capscrews that fasten the mount
bracket to the transaxle housing to 55 N.m (401bf
ft).
E. Connect the parking brake linkage to the levers
for the caliper cams.
F. Connect the brake lines. Use the special fittings
(4) to remove the air from the brake system.
G. Remove the lift truck from blocks. Install the
powersteeringmotorandpumpontheframemount.
Install the floor plates.
PARKING BRAKE
There is a parking brake caliper for each drive
wheel. (See Figure 4.) When the cam lever is ac-
tuated by the hand lever, a pin is pushed in the
caliper casting. This pin pushes against the fric-
tion pad and increases the friction against the brake
disc. The reaction of the caliper casting also causes
the friction pad in the fixed position to press against
the brake disc and increase the friction. A castle
nut at the cam lever permits adjustment for wear
of the friction pads.
FIGURE 3. OPERATION OF THE
CALIPER PISTON
brake linkage from both levers of the calipers. Both
parking brake calipers must be disconnected so
that you have clearance to remove a bracket from
its mount. A bracket with the service brake and
parking brake calipers fastened to it is removed as
a unit.
C. Disconnect the brake lines and put caps on the
open fittings.
D. Remove the capscrews that fasten the brake
mount to the transaxle housing. Remove the brake
mountwiththecaliperassembliesfromthelifttruck.
E. Remove the caliper assembly that needs repair
from the mount. Remove the clips and pins and
remove the friction pads. Remove the through bolts
to remove the caliper assembly from the bracket.
F. Apply a low pressure air hose to the port for the
brake line to push the piston from the housing. Re-
move and discard the dust cover and O-ring.
G. Use an alcohol solvent to clean the parts of the
caliper assembly. If the bore of the caliper for the
piston has damage, use a new caliper part.

12. Removal and Disassembly
The parking brake calipers are fastened to the same
bracket as the calipers for the service brakes. The
parking brake calipers and the service brake cali-
pers must be removed from the lift truck as a unit
before disassembly. See the Removal and Disas-
sembly
FIGURE 4. CALIPER ASSEMBLY, PARKING BRAKE
procedure for the service brakes to remove the
parking brake calipers.
The friction pads for the parking brake must be
replaced when the castle nut moves beyond the
space where the cotter pin can lock the castle nut.

13. Assembly and Installation
A. Use tape to temporarily hold the friction pads
in the housings while the caliper assembly is as-
sembled.
B. Install the caliper housings and spacer in the
bracket. Make sure the concave side of the curved
washers is towards the bushings. Tighten the nut
on the through bolt to 45 N.m (351bf ft). Make
sure that the caliper assembly moves freely on the
bushings.
C. Apply a thin coat of NEVER-SEEZE to the pin
that is actuated by the cam lever. Install the pin in
the housing. Install the spring, spring cup, cam le-
ver, flat washer, and castle nut. Tighten the castle
nut only enough to install the cotter pin. Do not
bend the cotter pin until the adjustments are com-
plete.
D. Put the complete caliper assembly into position
onthetransaxlehousing.Removethetapethatholds
the friction pads for the parking brake as you in-
stall the caliper assembly on the brake disc. Mea-
sure the distance between the friction pad in the
fixed position and the brake disc. The maximum
clearance is 1.78 mm (0.070 in). Use shims to ad-
just the clearance between the mount bracket and
the transaxle case.
E. Tighten the capscrews that fasten the mount
bracket to the transaxle housing to 55 N.m (401bf
ft).
F. Connect the parking brake linkage to the levers
for the caliper cams. See the Checks and Adjust-
ments to adjust the parking brakes.
G. Connect the brake lines. Use the special fittings
to remove the air from the brake system.
H. Remove the lift truck from blocks. Install the
powersteeringmotorandpumpontheframemount.
Install the floor plates.
SEAT BRAKE
MANUAL RELEASE OF THE SEAT BRAKE
If the power steering system is disabled, the seat
brake can not be released to move the lift truck.
This procedure describes a method to release the
seat brake to move the lift truck for repairs.
A modification was made in the seat brake actua-
tor beginning with serial number A 160 E 2213Z.
If the lift truck has a serial number lower than the
indicated serial number, use the procedure A. de-
scribed in the following paragraph. If the lift truck
has a serial number higher than the indicated se-
rial number, use procedure B.
A. Lift Trucks with a serial number less than A
160 E 2213Z.
1. If possible, tilt the upright forward to have
a maximum access to the cowl area.
WARNING
DO NOT reach through the upright
to do the following procedure. If pos-
sible, make arrangements so that the
upright and carriage can not move.
2. Reach between the upright and the cowl
and disconnect the hydraulic hose to the cyl-
inder that releases the seat brake. See Fig-
ure 5 and Figure 7. Put a cap on the hose.
3. Remove the 90° fitting from the cylinder.
Install a special 7/16 UNF x 20 inch
capscrew into the threaded hole in the cyl-
inder. The capscrew must have a minimum
of 38 mm (1.5 in) of thread length.
4. Turn the capscrew clockwise until the
parking brake is released. Make sure the
hand lever for the parking brake is released.
B. Procedure for lift trucks with a serial number
greater than A 160 E 2213Z.
1. Disconnect the battery. Release the hand
lever for the parking brake.
2. Remove the center floor plate. Use a 9/16
in wrench to turn the release cam 90°. See
Figure 5.
3. Put a tag on the steering wheel to indicate
the cam has been turned. The release cam
must be returned to normal before operating
the lift truck.

14. FIGURE 5. SEAT BRAKE LINKAGE

15. approximately 6-13 mm (1/4-1/2 in) before the
master cylinder begins to apply the brakes. In both
measurements are correct, the brake pedal is ad-
justed correctly.
B. The height of the brake pedal is adjusted by
adjustment of the pedal stop.
C. The linkage between the pedal and the master
cylinder is adjusted as follows: loosen the jam nut
and adjust the length of the push rod to the master
cylinder. The piston in the master cylinder must
return to the stop in the end of the bore. Tighten the
fam nut when adjustments are complete.
D. Adjust the brake switch so that you can hear the
switch open within the first 13 mm (1/2 in) of pedal
travel.
ADJUSTMENT OF THE
PARKING BRAKE LINKAGE
A. Move the hand lever for the parking brake to
the Off (down) position. Turn the adjustment knob
counterclockwise until it stops.
B. Use the adjusting nuts on the transaxle bracket
to adjust the cable. Adjust the cable so that ap-
proximately 9 kg (20 lb) is required to pull the
hand lever to the On position. Make sure that the
cable shield does not prevent the complete release
of the parking brake.
C. Make fine adjustments to pull the hand lever
with the adjustment knob. If the adjustment knob
will not cause the parking brake to be applied cor-
rectly, adjust the friction pads as described in this
section.
ADJUSTMENT OF THE SEAT
BRAKE
A. Put the lift truck on blocks to have access to the
brake assemblies. Remove the floor plates.
B. See Figure 7. Adjust the four through bolts for
the spring evenly for dimension “X” dimension
“X” is.
CHECKS AND ADJUSTMENTS
REMOVING THE AIR FROM THE
SERVICE BRAKES
Fill the reservoir of the master cylinder with brake
fluid. Put one end of a rubber hose on the special
fitting of the caliper cylinder. Put the other end in a
container with brake fluid. Loosen the special fit-
ting one turn. Push slowly on the brake pedal. Re-
peat the procedure until air bubbles are not seen
coming from the end of the hose in the in the con-
tainer. Check the fluid level in the master cylinder.
Close the special fitting if necessary. Quickly push
and release the pedal until there is resistance.
Loosen the special fitting to remove the air bubbles.
Repeat the procedure on, the the other caliper cyl-
inder.
BRAKE PEDAL ADJUSTMENT
A. Check for the correct pedal height as shown in
Figure 6. Check that the pedal can be pushed down
FIGURE 6. BRAKE PEDAL ADJUSTMENT

16. 101.6 mm (4.00 in). Dimension “X” for this ad-
justment is when the spring has expanded and ap-
plied the parking brake.
C. Adjust both sets of clevis nuts so that both cam
levers for the parking brake calipers are in the re-
leased position.
D. Make sure your hands and tools are away from
the linkage. Have another person sit in the
operator’s seat so that the power steering motor
will operate. Apply the service brakes and turn
the key switch to the ON position.
E. Adjust the clevis for each cam lever for a cali-
per and the castle nut on the cam lever so that di-
mension “X” is 83.5 to 86.6 mm (3.29 to 3.41 in).
See Figure 7. Dimension “X” for this adjustment
is when the piston has compressed the spring and
released the parking brake.
F. If the parking brake calipers do not correctly
apply the parking brake, adjust the friction pads as
described in the following paragraphs.
ADJUSTMENT OF THE
FRICTION PADS
The friction pads for the service brakes do not need
adjustment. Replace the friction pads before the
friction material is worn so that the back plate car
touch the brake disc.
The following procedure is for the parking brake
calipers:
A. Put the lift truck on blocks to have access to the
brake assemblies.
B. Make sure the parking brake and the seat brake
has released the parking brake calipers. Remove
the cotter pins and adjust the castle nuts on the cam
levers.
C. Tighten the castle nut until the friction pad is
tight against the brake disc. Loosen the castle nut
until there is a maximum clearance of 1.5 mm
(0.060 in). Install the cotter pins.
FIGURE 7. ADJUSTMENT FOR THE
PARKING BRAKE LINKAGE

17. TROUBLESHOOTING

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