180094, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}INTRODUCTIONGENERALThis section has the description and the repair proce-dures for the brake assembly. Checks and adjustmentsfor the brake system are described at the end of this sec-tion.must be used to disengage the brake as shown inFIGURE 2.DESCRIPTION(See FIGURE 1. and FIGURE 2.)The brake assembly is part of the Master Drive Unit.The brake drum is connected to the motor shaft on theend of the traction motor with the commutator. Thebrake assembly is both a service brake and a parkingbrake. (See FIGURE 1.)The brake is a normally ”ON” type of mechanism. Tomove the lift truck, the operator must use the brakeswitch as a footrest. The brake switch electrically disen-gages the brake when the solenoid is energized. (SeeFIGURE 2.) When the operator does not use the brakeswitch as a footrest,the brake is engaged automatically.If it is necessary to move the lift truck without batterypower, the brake can be released manually. Early mod-els had a release lever as shown in FIGURE 1. andFIGURE 2.. Battery power will automatically reset thebrake to normal operation. On later model units a blockFIGURE 1. BRAKE ASSEMBLYREPAIRSREMOVAL AND DISASSEMBLY(See FIGURE 2.)WARNINGAlways disconnect the battery connector when doingmaintenance or making repairs.1. Turn the master drive unit to a position so that there iseasy access to the brake assembly.2. To replace the brake shoes, remove the small snapring (1) and pin (2) from each shoe. Replace the brakeshoes and install the pin and snap ring again. If the brakeassembly must be disassembled farther, do not replacethe brake shoes and continue with step 3.3. Remove the castle nut (4) from the brake drum (5).Remove the brake drum with a puller.4. Remove the snap rings (6), locknut (7) and clevis(10), and adjusting screws (13) from each brake arm.Remove the brake arms (12).5. Disconnect the wires from the terminal strip on thebrake mount. Make a note so that the wires will be con-nected correctly again.6. Remove the brake mount and solenoid assembly fromthe master drive unit by removing the six capscrews.7. Remove the solenoid. The solenoid is fastened to thebrake mount with two nuts.8. Remove the release lever from the brake mount.1ÅÅÅÅÅÅÅÅÅÅÅÅÅÅÅ35891620176131821413191110213590515129713812141.2.3.4.5.6.7.8.9.10.11.SNAP RINGPINBRAKE SHOESCASTLE NUTBRAKE DRUMSNAP RINGLOCKNUTLOCKING PLATEJAM NUTCLEVISCAM ROLLER12.13.14.15.16.17.18.19.20.21.BRAKE ARMSADJUSTING SCREWSSPRINGJAM NUTTERMINAL STRIPBRAKE MOUNTSOLENOIDSOLENOID CAMBUSHINGMANUAL RELEASE LEVER (EARLYPRODUCTION MODELS ONLY)3589FIGURE 2. BRAKE ASSEMBLY2Cleaning2. Fasten the solenoid to the brake mount with the twonuts.3. Fasten the brake mount to the master drive unit withthe six capscrews.4. Connect the wires to the correct terminals on the ter-minal strip.5. Install the clevis (10) on the brake arm. Install thebrake arms,bushings and snap rings (6). Install thespring and adjusting screws.6. Install the brake drum and woodruff key. Install thecastle nut and cotter pin.7. Fasten the brake shoes to the brake arms with the pins(2) and the snap rings (1).WARNINGBrake linings can contain dangerous fibers. Inhalingthe dust from these brake linings is a cancer or lungdisease hazard. Do not make dust! Do not cleanbrake parts with compressed air or by brushing. Usevacuum equipment approved for brake dust or fol-low the cleaning procedure in this section. When thebrake drums are removed, do not create dust.Do not sand, grind, chisel, hammer, or change liningsin any way that will make dust. Any changes to brakelinings must be done in a restricted area with specialventilation. Protective clothing and a respiratormust be used.1. Carefully remove the brake drum. Do not release dustfrom the brake linings into the air when the brake drumis removed.BRAKE SWITCH (See FIGURE 3.)The brake switch is a normally ”OFF” switch found onthe operator’s platform. The brake is released and thecontrol circuits are energized only when he operatorpushes on the switch plunger.WARNINGCleaning solvents can be flammable and toxic, andcan cause skin irritation. When using cleaning sol-vents, always follow the solvent manufacturer’s rec-ommended safety precautions.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 make brake lining dustwith the spray.3. When the brake lining dust is wet, clean the parts. Putany rags or towels in a plastic bag or an airtight containerwhile they are still wet. Put a “DANGEROUSFI-BERS”warning label on the plastic bag or airtight con-tainer4. Any cleaning rags that will be washed must becleaned so that fibers are not released into the air.132CAUTIONDo not use an oil solvent to clean the wheel cylinder.Use a solvent approved for cleaning of brake parts.Do not permit oil or grease in the brake fluid or onthe brake linings.41.2.3.4.PLUNGERPLUNGER BARSWITCH MOUNTING SCREWSWITCH HOUSING ASSEMBLY3920ASSEMBLY AND INSTALLATION1. Install the release lever on the brake mount.FIGURE 3. BRAKE SWITCH ASSEMBLY3CHECKS AND ADJUSTMENTS1WARNINGPut blocks under the wheels so that the lift truck can-not move when the parking brakes are released.Never operate a unit that has the brake released. Tagthe controller to indicate that the truck has nobrakes any time the brake is released or blocked.NOTE: Adjust each brake shoe for correct opera-tion.The brake shoes must be adjusted with the solenoid en-ergized and the brake released electrically.1. Adjust brake shoe clearance to 0.002 to 0.004 inches(0.05 to 0.10 mm) at all points along both shoe linings.Each shoe is adjusted by moving the nuts on the camroller clevis. Tighten the adjusting nuts.2. Deenergize the brake circuit. Check that the cam roll-ers do not touch the solenoid cam when the solenoid isdeenergized.3. (See FIGURE 4.) Use the adjustable screws to adjustthe brake force. Use a spring gauge to check the forceneeded to release the brake. The brake force must be aslisted in TABLE 1. Adjust if necessary. Tighten the jamnuts.TABLE 1. SPRING FORCE3MODELR25AR30CR30CAR30CH (Shoe Brake)N30–50 24VN30–50 36VN30–50 48VSpring ForceN121–143121–143187–210187–210116–139161–183192–215lbs27–3227–3242–4742–4726–3136–4143–481. 0.002” to 0.004” (0.050 to 0.10 mm)CLEARANCE BETWEEN BRAKESHOES AND DRUM2 .MEASURE SPRING FORCE3. BRAKE FORCE ADJUSTMENT4. MANUAL RELEASE LEVER5. ADJUST CAM ROLLER CLEVISUNTIL SHOE CONTACTS GAUGEFIGURE 4. BRAKE ADJUSTMENT4ÅÅÅÅÅÅÅÅ25435893TROUBLESHOOTINGPROBLEMBrake will not release.Discharged battery.Battery not connected.Brakes not adjusted correctly.Brake solenoid with defects.Foot switch with defects.Brake will not stop lift truck correctly.pyBrakes not adjusted correctly.Brake shoes worn.Oil or grease on brake shoes.Solenoid or cam mechanism with defects.CAUSE5

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