1800570, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}INTRODUCTIONGENERALThis section has the description and repairs for the brakesystem. These parts include the park brake, servicebrake and master cylinder, the disassembly and assem-bly of the service brakes and the park brakes. The elec-trically released park brake is also described in this sec-tion. Checks and Adjustments are described at the end ofthis section.cal advantage for effective braking. The service brakemaster cylinder and separate reservoir are sealed. Thereservoir has a level sensor connected to a warning lightin the instrument panel, which displays when the brakefluid is low. The service brake is actuated by the largepedal located in the operator’s compartment. The pedalcan be operated with either the left or right foot. Thepark brake is set by a pedal operated by the operator’sleft foot. The park brake is released by operating the re-lease lever located on the left side of the instrument pan-el. Both a warning buzzer and indicator light are used toremind the operator to set and release the park brake.The lift truck may also be furnished with an optionalelectrically operated park brake. When furnished, thepark brake applies when the operator leaves the seat ofthe lift truck. The park brake mechanism is attached tothe park brake linkage at the front of the lift truck andreplaces the standard park brake linkage.DESCRIPTIONThe J30XMT, J35XMT, J40XMT J1.60XMT,J1.80XMT and J2.00XMT lift trucks feature dual hy-draulically operated service disc brakes and mechani-cally operated park disc brakes. Both brake systems op-erate independently of each other although they both usea single disc mounted on the bevel gear shaft of thetransaxle for braking. The location provides a mechani-REPAIRSSERVICE BRAKE PADS(See FIGURE 1 AND FIGURE 2)Removal4. Remove the pins and the brake pads.NOTE:The original brake pad installed in the carrierside of the service brake is affixed to the carrier side withhot glue. Use a screwdriver to pry the pad from the carri-er side. Clean the carrier side before installing a replace-ment pad.Installation1. Install the brake pads in both the carrier side and thecam side of the caliper.2. Install the pins to retain the pads.3. Install the spring clips to retain the pins.4. Install the disc brake shield.5. Remove the air from the brake system. SeeREMOVE AIR FROM BRAKE SYSTEM.6. Connect the battery. Remove the safety chain andlower the mast. Remove the blocks from the tires.1WARNINGTo access the brakes, the mast and carriage must beraised and a safety chain installed. Follow theinstructions in section PERIODIC MAINTE-NANCE, 8000 SRM 528 or 8000 SRM 584, SAFETYPROCEDURES WHEN WORKING NEAR THEMAST.1. Move the lift truck to a safe, level area. Block thetires. Raise the carriage high enough to chain thecarriage so that it does not move. Disconnect the battery.2. Remove the capscrews retaining the disc brakeshield and remove the disc brake shield.3. Remove the spring clips retaining the pins on bothends of the service brake caliper.1263451.2.3.4.5.6.7.RESERVOIRBRAKE SWITCHMASTER CYLINDERBRACKETPEDALSERVICE BRAKE CALIPERSPRING7FIGURE 1 – SERVICE BRAKE ARRANGEMENTSERVICE BRAKE CALIPERRemovaltires. Raise the carriage high enough to chain thecarriage so that it does not move. Disconnect the battery.2. Remove the capscrews and lockwashers retainingthe disc brake shield and remove the disc brake shield.3. Disconnect and cap the hydraulic brake lines to theservice brakes. Cap the ports of the service brake toprevent dirt from entering the system.4. Remove the three capscrews and lockwashersretaining the service brake bracket to the transaxle.Remove the bracket containing the service brakeassembly from the brake disc.5.WARNINGTo access the brakes, the mast and carriage must beraised and a safety chain installed. Follow theinstructions in section PERIODIC MAINTE-NANCE, 8000 SRM 528or8000 SRM 584, SAFETYPROCEDURES WHEN WORKING NEAR THEMAST.1. Move the lift truck to a safe, level area. Block the21.2.3.4.INSERTPISTONDUST COVERPISTON SEAL513421361295.6.7.8.109.10.11.12.13.11857BLEEDER SCREWRETAINER PINBUSHINGSPRING CLIPDISC PADCARRIERCAPSCREWWASHERLOCKNUTFIGURE 2 – SERVICE BRAKE CALIPERInstallation1. Align the service brake assembly with the brakedisc and align the service brake bracket with thetransaxle housing.2. Install the service brake housing to the transaxlehousing using the three capscrews and lockwashers.Tighten the capscrews to 41 NSm (30 lbf ft).3. Check to see that the service brake assembly slidesfreely within the mounting bracket. If the brake does notmove freely, loosen the two nuts that hold the brakeassembly together. Tighten the nuts to 19 NSm (14 lbf ft)and check again for free movement. The service brakemust be free to float.4. Remove the caps from the service brake assemblyand the hydraulic brake lines and connect the lines to thebrake assembly. It may be necessary to remove air fromthe system.5. Remove the air from the brake system.6. Install the disc brake shield between the transaxles,using the four capscrews and lockwashers.7. Remove the safety chain and lower the carriage tothe floor. Remove the blocks from the tires and connectthe battery. Check the level of brake fluid. Check theoperation of the service brake before returning the lifttruck to service.Disassembly1. After the service brakes have been removed fromthe lift truck, remove the two nuts retaining the brakecaliper halves together.2. Remove the clips retaining the brake discs to thebrake calipers and remove the discs. Separate the brakehalves, by removing the capscrews and spacers.3. Remove the dust cover, piston and piston seal fromthe caliper.WARNINGCleaning solvents can be flammable and toxic, andcan cause skin irritation. When using cleaning sol-vents, always follow the recommendations of themanufacturer. Wear eye protection.CAUTIONDO NOT use an oil solvent to clean the brake caliper.Use a solvent approved for cleaning of brake parts.Do not permit oil or grease in the brake fluid or onthe brake components or the brake pads.4. Clean and inspect the piston and the caliper bore forscores, erosion, or pitting. Replace the piston if any of3these conditions are noted. The caliper should not behoned. Replace the complete assembly if theseconditions are noted.5. Measure the brake disc pads. The minimummeasurement for the pads is*0.76 mm (0.03 in).Replace the pads if necessary.Assembly1. Lubricate a new piston seal with clean brake fluidand install the seal onto the piston. Assemble the pistoninto the brake caliper bore. Install a new dust cover.2. Install the capscrews, spacers and nut to hold thecaliper halves together. Do not tighten the capscrewsand nut completely until the brake assembly is installed.See INSTALLATION–SERVICE BRAKES.3. Align and install the pins and the brake discs in thebrake assembly. Install the spring clips to retain thebrake pads.halves together. Remove the caliper halves (carrier sideand cam side), and disc pads from the brake disc. Thepark brake assembly may also be removed from thetransaxle by removing the two capscrews andlockwashers retaining the bracket and brake assembly tothe transaxle.5. If the brake bracket and brake assembly have beenremoved as a unit from the transaxle, disassemble thebrake assembly by removing the two capscrews, spacersand nuts. Separate the caliper halves. Retain the spacersremoved from between the caliper halves for use atassembly.Installation1. Align the carrier and cam sides of the brake in thepark brake bracket. Align the spacers between bothsides. Install a spacer under the head of the capscrewsand install the capscrews through the caliper halves andthe spacer. Install another spacer on the opposite side ofthe capscrew and install the nut. Tighten the nut to 29NSm (21 lbf ft) torque, then turn the nut an additionalone half turn.2. Install the bracket and brake assembly on thetransaxle using the two capscrews and washers. Tightenthe capscrews to 41 NSm (30 lbf ft).3. Align the brake lever and the rod end. Install theclevis pin through the lever and rod end. Install a newcotter pin to retain the clevis pin.4. Check to make certain that the park brake assemblycan float within the brake bracket.5. Install the disc brake shield using the fourcapscrews removed at assembly.6. Remove the safety chain and lower the carriage tothe floor. Remove the blocks from the tires and connectthe battery. Check the operation of the park brake beforereturning the lift truck to service.Disassembly1. After the park calipers have been removed from thelift truck, remove the two nuts retaining the brakecaliper halves (carrier side and cam side) together.Remove the capscrews, bushings, spacers and both thedisc pads.PARK BRAKE CALIPER(See FIGURE 3)RemovalWARNINGTo access the brakes, the mast and carriage must beraised and a safety chain installed. Follow theinstructions in PERIODIC MAINTENANCE, 8000SRM 528 or 8000 SRM 584, SAFETY PROCE-DURES WHEN WORKING NEAR THE MAST.1. Park the lift truck in a level area, block the wheels.Disconnect the battery. Release the park brake. Raisethe carriage high enough to chain the carriage so that itdoes not move.2. Remove the capscrews retaining the disc brakeshield and remove the disc brake shield.3. Remove the cotter pin and the clevis pin retainingthe rod ends to the brake lever.4. The park brake caliper can be removed withoutremoving the park brake bracket assembly by removingthe two capscrews, spacers and nuts holding the two41.2.3.4.5.6.7.8.9.CARRIER SIDEDISC PAD15CAM SIDEDISC PADBACKUP PLATEPUSH PIN12SPRINGCOTTER PINNUT891013131412476113510.11.12.13.14.15.WASHERLEVERCAPSCREWBUSHINGNUTSPACERFIGURE 3 – PARKING BRAKE CALIPER2. Remove the cotter pin, nut, washer, push pin, springand backup plate from the cam side of the park brakecaliper.2. Install the park brake in the park brake bracket. SeeINSTALLATION–PARK BRAKES.MASTER CYLINDERRemovalWARNINGCleaning solvents can be flammable and toxic, andcan cause skin irritation. When using cleaning sol-vents, always follow the recommendations of themanufacturer. Wear eye protection.WARNINGTo access the brakes, the mast and carriage must beraised and a safety chain installed. Follow theinstructions in PERIODIC MAINTENANCE, 8000SRM 528 or 8000 SRM 584, SAFETY PROCE-DURES WHEN WORKING NEAR THE MAST.1. Move the lift truck to a safe, level area. Block thetires. Raise the carriage high enough to chain thecarriage so that it does not move. Disconnect the battery.2. Remove the floor plates.3. Loosen one of the hydraulic brake lines to theservice brakes and drain the brake fluid from thereservoir into a suitable container. Plug the brake lineand the fitting on the service brake.4. Remove and discard the cotter pin retaining themaster cylinder to the brake pedal. Remove the washerand clevis pin and remove the master cylinder from thepedal.5. Remove the capscrew and washers retaining themaster cylinder to the block.6. Remove the clamp retaining the hose to the mastercylinder from the reservoir and disconnect the hose.5CAUTIONDO NOT use an oil solvent to clean the brake caliper.Use a solvent approved for cleaning of brake parts.Do not permit oil or grease in the brake fluid or onthe brake components or the brake pads.3. Clean and inspect the bushings and spacers for wearor elongated holes. Inspect the spring for damage.Replace any damage parts if these conditions are noted.4. Measure the disc pads. The minimum thickness ofcam side park brake disc pad is 6.60 mm (0.26 in).Replace the disc pads if the cam side pad is less than thespecified thickness. The brake disc pads must bereplaced in pairs.Assembly1. Install the disc pad in the carrier side. Install thebackup plate and the disc pad in the cam side.

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