1800458, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}INTRODUCTIONGENERALThis section has a description and the serviceprocedures for the brake system. The brake systemincludes the following parts: master cylinder, mastercylinder with brake booster [only available lift truckmodels H2.00–3.00XL (H40–60XL)], brake shoes,wheel cylinders, a single inching/brake pedal andlinkage, and the parking brake system.Two sizes of service brakes are used on the H3.00XL(H60XL) lift trucks: a 260 mm (10.25 in) or a 310 mm(12.20 in). New drive wheels and tires are required forthe larger diameter service brake. Both sizes of servicebrakes are described in this section. A troubleshootingsection is included at the end of this section.SERVICE BRAKES AND PARKING BRAKEDESCRIPTION AND OPERATIONService BrakesA service brake assembly is installed on the brackets ateach end of the drive axle. The parts of the service brakeassembly for the 260 mm (10.25 in) brake are shown inFIGURE 2. The parts of the service brake assembly forthe 310 mm (12.20 in) brake are shown in FIGURE 13.When the brake pedal is pushed, fluid pressure from themaster cylinder causes the pistons in the wheel cylinderto extend. The pistons expand the brake shoes againstthe drum.The clearance between the brake shoes and the brakedrum is adjusted automatically. An adjuster linkageturns the adjuster wheel to adjust the clearance. Whenthe lift truck moves in theREVERSEdirection and thebrakes are applied, the rear brake shoe and the adjusterlinks move with the drum. This linkage moves the ad-juster lever to rotate the adjuster wheel. The adjusterwheel can turn only when there is clearance between thelining of the brake shoe and the brake drum. The ad-juster wheel can also be turned with a tool. A hole in thedrum is used for access to the adjuster wheel in the 260mm (10.25 in) brake. A slot in the back plate gives ac-cess to the adjuster wheel in the 310 mm (12.20 in)brake.1.2.3.4.5.6.7.8.9.10.11.LEVER, PARKING BRAKEPEDAL, SERVICE BRAKEBRAKE RODBRAKE BOOSTER *MASTER CYLINDERBRAKE LINE, RHBRAKE LINE, LHCABLE, LHCABLE, RHBRAKE ASSEMBLYDRIVE WHEEL*AVAILABLE ONLY ON MODELSH2.00–3.00XL (H40–60XL)12604FIGURE 1. BRAKE SYSTEM1Parking BrakeThe parking brake system uses the service brake shoes.Additional linkage activates the parking brake system.When the lever is moved to apply the parking brake, thecables and linkage expand the brake shoes against thedrum. The design of the parking brake linkage adjustseach cable so that the tension is the same when the leveris moved to apply parking brake.4. Put grease on the floor so that the wheel assembly willslide easily from the axle tube. Pull the wheel assemblyfrom the lift truck.WARNINGWhen the brake shoes are removed do not createdust in the air. See the cleaning procedure in this sec-tion.5. If the wheel assembly cannot be removed easily, re-move the wheel from the hub. Align the hole in the brakedrum with the adjuster wheel. Pull the adjuster actuatoraway from the adjuster wheel. Use an adjuster tool or ascrewdriver to turn the adjuster wheel to loosen thebrake shoes. Remove the hub and drum assembly. Donot damage the seal when removing the hub.6. See FIGURE 2. Remove the return springs (2) (15)with spring pliers.NOTE:The return springs (2) (15) are not the same partnumber. Make sure the springs are installed in the samepositions from which they were removed.7. Remove the retainers, springs and retainer pins thathold the brake shoes to the back plate. See FIGURE 4.Remove the brake shoes and adjuster assembly.NOTE:The adjuster wheel for the left brake is not thesame as the adjuster wheel for the right brake. The ad-juster wheel for the right brake has left–hand threads.8. The back plate must be removed from the axle hous-ing for access to the capscrews for the wheel cylinder.Remove the brake line from the wheel cylinder. Removethe capscrews that hold the back plate to the axle hous-ing.9. Remove the dust covers, pistons, cups and springsfrom the wheel cylinder. See FIGURE 3.10. Remove the snap rings from the brake levers. Re-move the parking brake levers from the back plate.REMOVAL AND DISASSEMBLY OF THE260 mm (10.25 in) SERVICE BRAKESWARNINGBrake linings can contain dangerous fibers. Breath-ing the dust from these brake linings is a cancer orlung disease hazard. Do not create dust! Do not cleanbrake parts with compressed air or by brushing. Usevacuum equipment approved for asbestos dust orfollow the cleaning procedure in this section. Whenthe brake drums are removed, do not create dust.Do not sand, grind, chisel, hammer or change liningsin any way that will create dust. Any changes tobrake linings must be done in a restricted area withspecial ventilation. Protective clothing and arespirator must be used.1. See the procedure “HOW TO PUT A LIFT TRUCKON BLOCKS” in the MAINTENANCE section or theOPERATING MANUAL.Start the engine and tilt themast fully backward. Put blocks under the mast. Tilt themast forward until the wheels just touch the floor. Stopthe engine. Put blocks under the frame of the lift truck.2. Remove the capscrews that hold the axle shaft to thehub. Remove the axle shaft.3. Bend the lock plate and remove the nut that holds theaxle bearing. Remove the washer and the bearing cone.2122131141531.2.3.4.5.6.7.8.9.10.11.WHEEL CYLINDERRETURN SPRING, LEFTPIVOT PLATELINKRETAINER PINACTUATOR FOR ADJUSTERWHEELADJUSTER WHEELADJUSTER NUTCABLESPRING RETAINER(SPRING NOT SHOWN)LEVERS FORPARKING BRAKELINING FOR BRAKE SHOEBRAKE SHOEANCHORRETURN SPRING, RIGHTBACK PLATE114109871669524512.13.14.15.16.FIGURE 2. THE 260 mm (10.25 in) BRAKE ASSEMBLY1. PORT FOR SPECIALFITTING2. INLET PORT3. BRAKE SHOE4. DUST COVER5. WHEEL CYLINDER6. SPRING7. CUP8. PISTON ASSEMBLY1025FIGURE 3. WHEEL CYLINDER351381.2.3.4.5.6.7.8.9.10.11.12.SNAP RINGANCHOR PINBACK PLATECABLECABLE GUIDESPECIAL CAPSCREWCAPSCREWSPARKING BRAKE LEVERWHEEL CYLINDERPIVOT PINBRAKE SHOEPIVOT PLATE413. RETURN SPRING (GRAY)14. RETURN SPRING15. SPECIAL CAPSCREW(SPRING ANCHOR) AND WASHER16. LINK21.17. LINK22.18. RETAINER SPRING ASSEMBLY23.19. BRAKE SHOE24.20. SPRING24ADJUSTER NUTADJUSTER WHEELACTUATOR, ADJUSTER WHEELCRANK, PARKING BRAKEFIGURE 4. PARTS FOR THE 260 mm (10.25 in) BRAKE SYSTEMParking Brakeb. Remove the four capscrews that fasten the brack-et for the parking brake lever to the cowl. Removethe bracket and lever assembly.If the lever assembly for the parking brake must be re-moved from the cowl, use the following procedure (seeFIGURE 11.):a. Use blocks next to the wheels to make sure the lifttruck can not move. Release the parking brake le-ver.c. Loosen the jam nuts that fasten the threaded endsof the parking brake cables to the bracket assem-bly.d. Turn the adjuster knob counterclockwise until thebrake cables are loosened. Disconnect the park-ing brake cables from the link.4CLEANINGWARNINGDO NOT use an oil solvent to clean the master cylin-der, wheel cylinder, or the brake linings. Use a sol-vent approved for cleaning of brake parts. Do notpermit oil or grease in the brake fluid or on the brakelinings. Oil and grease will cause damage and leaksin the seals of a brake system. The brakes will not op-erate correctly if oil, grease, or brake fluid is on thebrake linings.2. Inspect the return springs for defects. Inspect the backplate for wear where the brake shoes touch the backplate. remove any grooves worn into the back plate.3. Inspect the brake shoes for cracks or damage. If thelinings or shoes are worn or damaged, replace the brakeshoes. Maximum wear is to within 1 mm (0.039 in) ofcontact with the rivets, or the metal shoe on bonded lin-ings. Brake shoes must be replaced in complete sets. In-spect the brake drums for cracks or damage. Replaceany damaged parts.WARNINGThe brake shoes on both wheels must be replaced ifany shoe is damaged. The brake performance onboth ends of an axle must be equal or the lift truckcan be difficult to steer when the brakes are applied.4. Inspect the brake drum for deep grooves or other dam-age.NOTE:If grooves must be removed from the brakedrums, do not grind more than 1.5 mm (0.060 in) fromthe internal diameter of the brake drum. The maximumlimit of the internal diameter of the brake drum is 262.7mm (10.35 in). If the internal diameter is larger than thelimit, replace the brake drum.5. The teeth of the adjuster wheel must not be worn. Theadjuster wheel must turn freely. Check the adjuster linksfor damage.6. Make sure the parking brake levers and crank movefreely.7. Check the grease seals and the surfaces for the sealsfor wear or damage.WARNINGCleaning solvents can be flammable and toxic, andcan cause skin irritation. When using cleaning sol-vents, always follow the safety instructions of the sol-vent manufacturer.1. Do not release brake lining dust from the brake liningsinto the air when the brake drum is removed.2. Use a solvent approved for cleaning of brake parts towet the brake lining dust. Follow the instructions andcautions of the manufacturer for the use of the solvent. Ifa solvent spray is used, do not create brake lining dustwith the spray.3. When the brake lining dust is wet, clean the parts. Putany cloth or towels in a plastic bag or an airtight con-tainer while they are still wet. Put an “ASBESTOS”warning label on the plastic bag or airtight container.4. Any cleaning cloths that will be washed must becleaned so that fibers are not released into the air.CAUTIONDo not permit oil or grease on the brake linings be-cause the brakes will not operate correctly. Use abrake cleaning fluid as necessary to clean brake lin-ings that will be installed again.ASSEMBLY AND INSTALLATION OF THE260 mm (10.25 in) SERVICE BRAKES1. Assemble the wheel cylinder. See FIGURE 3. Useonly HYSTER APPROVED parts.2. Install the wheel cylinder on the back plate. Make surethe special fitting for removing the air is in the top hole.Put LoctiteR271 on the threads of the capscrews.Tighten the two capscrews that are near the top of thewheel cylinder to 78 to 85 N.m (58 to 66 lbf ft). Tightenthe two larger capscrews to 80 to 102 N.m (67 to 75 lbfft).INSPECTION1. Inspect the bore of the wheel cylinder for holes orscratches. Replace the wheel cylinder assembly if thereis any damage.5

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