Maintaining A Master Cylinder On A Toyota Forklift

Proper braking is essential for any type of moving vehicle whether it is an automobile or a forklift. When an operator presses down on the pedal of a hydraulic brake of a forklift, he is applying pressure to liquid, which causes friction on the lift’s wheelbase. The pressure converts into heat energy, which causes the forklift to slow down. That’s how a hydraulic brake system on a forklift works.

A master cylinder of a Toyota forklift.
(Courtesy: Toyota Material Handling)

The braking system itself includes two parts –- the wheel brake mechanism and the master cylinder. Ensuring that a master cylinder on a Toyota forklift is working properly is vital for the proper operation of the brakes. So checking it out and making sure it is properly filled with hydraulics should be a major part of any forklift maintenance program.

Master Cylinder 101

A master cylinder on a Toyota forklift has two subsystems that combine to control the braking of the forklift when engaged by the brake pedal. The two subsystems offer redundancy so that if one doesn’t work because of a leak or some other reason, then the second system performs. The fluid for the two systems comes from the same reservoir or from two different reservoirs based on the model of the brake system.

Inspecting A Master Cylinder On A Toyota Forklift

In order to ensure proper operation of the braking system, a master cylinder on a Toyota forklift should be inspected periodically. Elements that must be thoroughly checked out include:

· Cleaning. Study all surfaces of the master cylinder for any contaminants. This inspection should include all elements of the cylinder including the pistons and piston rod. Make certain that all contaminants are cleaned off of the cylinder.
· Leaks. If during your inspection you notice that the fittings of the cylinder are leaking, be sure to tighten them. If the leak continues, then replace them. If the cylinder is leaking from the piston rod, then the inspector should remove the cylinder and perform a more extensive inspection.
· Proper Pressure. For the braking system to work properly, pressure should be held and maintained by the master cylinder as long as the pedal is pressed. If this is not occurring, then it will be necessary to bleed the brakes.

Repairing A Master Cylinder On A Toyota Forklift

If after the inspection, some issues are discovered, then the inspector will have to remove the cylinder. A master cylinder on a Toyota forklift is removed by following these three steps:

1. Loosen the breeder valve to drain or bleed the brake fluid from the braking system.
2. Remove the hydraulic lines from the cylinder and cap and close them to guard against contamination.
3. Disconnect the top and bottom bolts and then remove the cylinder.

Next you will have to dismantle the master cylinder on a Toyota forklift. The process of dismantling the cylinder and then maintaining and repairing it should be performed on a flat, smooth surface. The dismantling process can be achieved in these seven steps.

1. Use pliers to remove the retaining ring from the cylinder.
2. Discharge the pressure over the piston rod slowly.
3. Move down the compression spring, piston rod and other attached parts from the body of the cylinder.
4. Use pliers to loosen the spring guide from the piston rod.
5. Remove the nut and clevis pin from the piston rod.
6. Move the rod support from the rod’s upper end.
7. Remove the O rings from the rod support, piston rod and pistons.

Once a master cylinder of a Toyota forklift has been dismantled, you can make any repairs that you have discovered are necessary.

· Examine the body of the cylinder for slashing, nicks, cracks, or corrosion. If found, replace the component.
· Look for brittleness, wear or other damage to the O-rings. If found, or if the O-rings do not appear as good as new, replace them.
· Use solvent to clean all metallic parts and dry them with compressed air.
· Reassemble the cylinder and return to the forklift.

*These are not guidelines nor a “Do It Yourself” piece. Always consult with your owner’s manual and a certified Toyota Forklift mechanic prior to any work on your Toyota Forklift. It is strongly recommended to use only certified Toyota Forklift mechanics to service your Toyota Forklift.

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