THE BRAKE SYSTEM H40-60XL $40-60XL HYSTERSAFETY PRECAUTIONS MAINTENANCE AND REPAIR When lifting parts or assemblies, make sure that all slings, chains or cables are correctly fastened and that the load being lifted is balanced. Make sure ‘that the crane, cables and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand. Use a lifting mechanism. ‘Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any ‘maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See “How To Put The Lift Truck On Blocks” in the OPERATING MANUAL or the PERIODIC MAINTENANCE section, Keep the unit and working area clean and in order. Use the correct tools for the job. Keep the tools clean and in good condition. Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. ‘Make sure that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when ‘making repairs or if the unit needs repairs. Make sure you follow the DANGER, WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels. Make sure that you follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area, Make sure the area has ventilation.CONTENTS INTRODUCTION GENERAL ..... DESCRIPTION AND OPERATION ... Service and Parking Brakes . REPAIRS .. REMOVAL AND DISASSEMBLY Service and Parking Brakes . Master Cylinder ........-.000c0eee0es : seve : CLEANING AND INSPECTION .......000cseeceeeeeesseeeeeteseeeeetseeees ASSEMBLY AND INSTALLATION Service and Parking Brakes . Master Cylinder .. CHECKS AND ADJUSTMENTS . ADJUST THE SERVICE BRAKES . ADJUST THE PARKING BRAKE Units with Monotrol Pedal. REMOVE THE AIR FROM THE BRAKE SYSTEM . ADJUST THE BRAKE PEDAL AND INCHING PEDAL . .. : CHECK AND ADJUST THE NEUTRAL START SWITCH (Monotrol Control Only) .. TROUBLESHOOTING ..... SPECIFICATIONS ... ‘This section is forthe following models: 'S2.00-3.00XL (S40-60XL) H12.00-3.00XL (H40-60XL) © HYSTER COMPANY 1996“THE QUALITY KEEPERS" HYSTER APPROVED PARTSINTRODUCTION GENERAL This section has a description and the service proce- dures for the brake system. The parts of the brake sys- tem include the master cylinder, the brake shoes, wheel cylinders, pedals and linkage, and the parking brake system, Troubleshooting is included at the end of this section, DESCRIPTION AND OPERATION ‘The master cylinder has a housing, a piston with two ring cups, a return spring and a check valve assembly. ‘The reservoir for the fluid is separate from the master cylinder. When the brake pedal or inching pedal is pushed, the push rod moves the piston assembly. The primary cup forces the brake fluid through the check valve to the wheel cylinders. The secondary cup keeps the fluid that is above the primary cup in the master cylinder. ‘When the brake pedal is released, the retum spring. pushes the piston assembly back against the retainer ‘washer. The return springs for the brake shoes force the fluid that is in the wheel cylinders back through the lines to the check valve. The pressure in the lines moves the check valve from its seat. The fluid flows around the check valve to the master cylinder bore. When the brake pedal is released quickly, the retum spring moves the piston faster than the brake fluid can flow around the check valve. To prevent cavitation, holes are drilled in the piston. Fluid from the inlet port flows through the holes. The fluid bends the lip of the primary cup and permits fluid to enter the pressure chamber. ‘The check valve assembly permits fluid from the pres- sure chamber to flow to the lines when the brake pedal is pushed. When the pressure in the pressure chamber is greater than pressure in the lines, the check valve will open, When the brake pedal is released, the pres- sure in the lines is greater than the pressure in the pres~ sure chamber. The check valve assembly then moves against the spring pressure to permit fluid to return to the pressure chamber. The check valve assembly re- tums to its seat when the pressure in the lines decreases to less than the spring pressure. This action keeps a low pressure in the wheel cylinders to hold the lips of the seals against the bores. This low pressure prevents leaks, but cannot apply the brake shoes. A very small hole is drilled between the inlet port and the pressure chamber. The hole is just below the prima- ry cup when the piston is against the stop washer. The hole is a compensator port to permit fluid to flow be- tween the reservoir and the pressure chamber. The fluid expands because of the heat from using the brakes. The additional volume of the expanded fluid flows through the compensator port when the pedal is fully released. Ifthe push rod is adjusted so that there is no clearance, the compensator port can be closed by the primary cup. This condition can cause the brakes to be applied without pushing the pedal. ‘A service brake assembly is installed at each end of the drive axle. The parts of the brake assembly are shown in FIGURE 2. When the brake pedal is pushed, fluid pressure from the master cylinder causes the pistons in the wheel cylinder to move out. The pistons cause the brake shoes to expand against the drum. ‘The parking brake system uses the service brake shoes. Additional linkage activates the parking brake system when the lever for the parking brake is pulled. When the lever for the parking brake is pulled, the cables ‘cause the cranks to rotate. This rotation causes the cable guide to pull on the cable that is connected to the levers for the brake shoes. The levers push the brake shoes against the brake drum, The design of the systempermits the tension of each cable to be the same when the lever is pulled. 1. WHEEL CYLINDER 2. RETURN SPRING 3. PIVOT PLATE 4. LINK 5. PIN . ACTUATOR FOR ADJUSTER WHEEL . ADJUSTER WHEEL . ADJUSTER NUT . CABLE . RETAINER, . LEVERS FOR PARKING BRAKE . LINING FOR BRAKE SHOE. . BRAKE SHOE, . ANCHOR (SPECIAL CAPSCREW) FIGURE 2. PARTS OF THE BRAKE ASSEMBLY |. PUSH ROD . RETAINER WASHER/SNAP RING The clearance between the brake shoes and the brake a Soe cUP drum is adjusted automatically. The adjuster linkage 5. PISTON turns the adjuster wheel to adjust the clearance. The . PRIMARY CUP primary (front) shoe and the adjuster links move with . RETAINER the drum during a stop when the lift truck is moving in TEER SURE CHANGER! the reverse direction. The linkage permits the adjuster . CHECK VALVE ASSEMBLY lever to rotate the adjuster wheel. The adjuster wheel . COMPENSATOR PORT can tum only when there is clearance between the lin- . FITTING ing and the brake drum, The adjuster wheel can also be . INLET PORT tumed manually. A hole in the drum is used to get ac- FIGURE 1. MASTER CYLINDER cess to the adjuster wheel.REPAIRS REMOVAL AND DISASSEMBLY Service and Parking Brakes (See FIGURE 3. and FIGURE 4.) A warNinc Brake linings contain dangerous fibers. Breathing ‘the dust from these brake linings can be a cancer or lung disease hazard. Do not create dust! Do not clean brake parts with compressed air or by brushing. Use ‘vacuum equipment approved for dangerous fibers or follow the cleaning procedure in this section, ‘When the brake drums are removed, do not create dust. Do not sand, grind, chisel, hammer or change linings in any way that will create dust. Any changes to brake linings must be done in a restricted area with special ventilation. Protective clothing and a respira- tor must be used. 1, Remove the capscrews that hold the axle shaft to the hub. Remove the axle shaft. 2. Start the engine and tilt the masts fully back. Put blocks under the masts. Tilt the masts forward until the wheels just touch the floor. Stop the engine. Put blocks under the lift truck frame. 3. Bend the lock plate and remove the nut that holds the axle bearing. Remove the washer and the bearing cone. 4, Put grease on the floor so that the wheel assembly will slide eesily from the axle tube. Pull the wheel as- sembly from the lift truck. 5. Ifthe wheel assembly cannot be removed easily, re~ move the wheel from the hub. Align the hole in the brake drum with the adjuster wheel. Pull the adjuster plate away from the adjuster wheel. Use a screwdriver to tum the adjuster wheel to loosen the brake shoes. ‘Tum the adjuster wheel upward. Remove the hub and drum assembly. Do not damage the seal when remov- ing the hub. Acaution ‘The return springs are not the same, Make sure that the return springs are installed in the same positions from which they were removed. See FIGURE 3. ‘6. Remove the return springs with spring pliers. 1. RETURN SPRING FIGURE 3. BRAKE ASSEMBLY AccauTion The adjuster screw assemblies are not the same. Make sure that each assembly has identification for installation on the correct side of the axle. 7. Remove the spring assemblies that hold the brake shoes to the back plate. Remove the brake shoes and adjuster assembly. 8, Remove the brake line from the wheel cylinder. Re- ‘move the capscrews that hold the back plate to the axle housing. 9, Remove the boots, pistons, cups and springs from the wheel cylinder. 10, Remove the snap rings from the parking brake le- vers. Remove the parking brake levers from the back plate.Master Cylinder (See FIGURE 1. and FIGURE 13.) 1. Remove the pin from the clevis for the push rod. Acaution Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface. 2. Disconnect the special capscrews from the fitting at the bottom of the master cylinder. a 1. SNAP RING 2. PIN 3. BACK PLATE 4. CABLE 5. CABLE GUIDE 6. SPECIAL CAPSCREW 7. CAPSCREWS 8. PARKING BRAKE LEVER 9. . WHEEL CYLINDER 15. SPECIAL CAPSCREW 10. PIVOT PIN 16. LINK: 11. BRAKE SHOE 17. LINK 12 PNoTPLATE {6c ReTANER SPRING AsseweLy 3 AMUSTER NUT 13, RETURN SPRING 19. BRAKE SHOE 23, ACTUATOR 14, RETURN SPRING 20. SPRING 3, Remove the hose from the nipple. Put a plug in the hose to prevent the reservoir from draining. 4, Remove the capscrews and nuts that hold the master cylinder to the bracket. Remove the master cylinder from the lift truck. ‘5. Remove the rubber dust shield and push rod. Put the bottom of the master cylinder in a container, Push on the piston with a screwdriver to remove the brake fluid. FIGURE 4. BRAKE SYSTEM PARTSA warninc ‘The piston has a compressed spring behind it. Care- fully remove the piston so that you can control the spring and prevent an injury. 6. Put the master cylinder in a vise with soft jaws. Push on the piston with a screwdriver to release the tension on the snap ring. Remove the snap ring, washer and piston. 7. Remove the spring and the check valve. CLEANING AND INSPECTION A caution ‘Do 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 on the brake linings. A warning Cleaning solvents can be flammable and toxic, and can 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 lin- ings into the air when the brake drum is removed. 2. Use a solvent approved for cleaning of brake parts to wet the brake lining dust. Follow the instructions and cautions of the manufacturer for the use of the solvent. If a solvent spray is used, spray at a distance so that the dust is not released into the air. 3. When the brake lining dust is wet, clean the parts. Put any rags or towels in a plastic bag or an airtight container while they are still wet. Put a “DANGER- OUS FIBERS” warning label on the plastic bag or air- tight container, 4, Any cleaning rags that will be washed must be cleaned so that fibers are not released into the air. A caution Do not permit oil or grease on the brake linings. Use a brake cleaning fluid as necessary to clean linings that will not be replaced. Inspection procedures: A warning Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. a. Clean all metal parts except the linings and the wheel cylinder with solvent. b. Check the bore of the wheel cylinder for holes or seratches. Replace the wheel cylinder if there is any damage. ¢. Check the bore of the master cylinder and the ‘matching surfaces of the piston. Replace a master cylinder that has been damaged. 4. Check the return springs for damage. Inspect the back plate for wear where the brake shoes touch the back plate. . Inspect the brake shoes for cracks or damage. If the linings or shoes are wom or damaged, replace the brake shoes. It is recommended that brake shoes be replaced in complete sets. £. Check the adjuster screw wheel for wear. Make sure the adjuster screw tums, Check for bent or broken adjuster links. g. Inspect the brake drums for cracks or damage. Use sandpaper on the surface for the brake shoes. 1h. Make sure that the levers and cranks for the park- ing brake move freely. NOTE: If the brake drums require grinding, do not agrind more than 1.5 mm (0,060 in) from the diameter. ‘The maximum inside diameter of the brake drum, in- cluding wear, is 262.7 mm (10.35 in). Ifthe brake drum is larger than this, replace the brake drum. ASSEMBLY AND INSTALLATION Service and Parking Brakes 1, Assemble the wheel cylinder according to FIGURE 5. Use only HYSTER Approved Parts.|. PORT FOR SPECIAL FITTING . INLET PORT |. BRAKE SHOE |. BOOT |. WHEEL CYLINDER . SPRING . CUP . PISTON ASSEMBLY FIGURE 5. WHEEL CYLINDER, 2. Install the wheel cylinder on the back plate. Make sure that the special fitting for removing the air is in the top hole. Apply adhesive-sealant (Hyster Part Number 264134) to the threads of the capscrews. Tighten the ‘two capscrews that are near the top of the wheel cylin der to 80 to 85 Nm (59 to 63 Ibf ft). Tighten the two larger capscrews to 80 to 102 Nm (59 to 75 Ibf ft). 3, Put the pins that hold the brake shoes through the back plate. See FIGURE 6. Install the shield and back plate on the axle housing. Apply adhesive-sealant (Hyster Part Number 264134) to the threads of the three special capscrews (FIGURE 4., Items 6 and 15). Install the two special capscrews (6) for the parking brake levers. See SPECIFICATIONS for the correct torque. Install all the other capscrews that hold the back plate to the axle hous- ing. The special capscrew that is the anchor pin (FIGURE 7.) has a different torque value. See SPECI- FICATIONS for the correct torque. 4, Install the parking brake levers and cable, Install the snap rings. Install the cable guide and snap ring on the crank for the parking brake. AcauTion ‘The upper link for the left brake assembly is not the same as the upper link for the right brake assembly. 6 Install the pivot plate so that the letter “L” is seen on tthe left brake assembly. Install the pivot plate on the right brake assembly so that the letter “R” is seen. FIGURE 6. INSTALL THE PINS 5. Install the pivot pin through the brake shoe that is, toward the rear ofthe lift truck. Install the links in the pivot plate. Install the pivot plate, links and cotter pin. 6. Lubricate the back plate with a small amount of white grease where the shoes touch. Install the brake shoes. Put a spring seat, spring and retainer on the pin. See FIGURE 8. Push on the retainer and rotate the re-tainer 90 degrees. Make sure that the retainer is in the correct position. Install the other spring assembly. FIGURE 8. INSTALL THE RETAINER SPRING ASSEMBLY 7. Put an anti-seize compound on the threads of the ad- Jjuster wheel. Install the adjuster wheel assembly be- tween the two brake shoes. Make sure that the adjuster wheel is toward the rear of the lift truck. NOTE: The adjuster screw wheels have left-hand and right-hand threads. Make sure that the movement of the automatic adjuster lever causes the adjuster screw wheel to expand the brake shoes. ‘Turn the adjuster wheel into the adjuster nut so that the adjuster assembly is in its shortest position. This action permits the brake drum to be easily installed over the ‘brake shoes. 8. Install the link in the adjuster wheel actuator. Put the adjuster wheel actuator in the hole in the brake shoe. Install the spring to the adjuster wheel actuator and the brake shoe. The spring must be installed in the position shown in FIGURE 9. Install the return springs for the brake shoes. Make sure the retum springs are installed in the correct positions, See FIGURE 9. A grey spring is installed on the front shoe on the right side of the lift truck. A gray spring is installed on the rear shoe on the left-hand brake assembly. 9. Make sure that the bottom edge of the adjuster wheel actuator (6) is just above the horizontal centerline of the adjuster wheel and nut (7). See FIGURE 9. Bend the lower link (4) to align the adjuster wheel actuator if necessary. 10. Clean the bearings and lubricate them with grease for wheel bearings. Install the bearings and seals in the hhub. Install the assembly on the axle housing. See FIGURE 10. and FIGURE 11. NOTE: To prevent damage to the inner oil seal when in- stalling the hub, the hub and drum assembly can be tem- porarily fastened to the wheel. Align the height of the axle housing with the bearings inthe hub. Put grease un- der the wheel and slide the wheel toward the axle hous- ing. Install the outer bearing and aut. Remove the wheel from the hub so that the clearance of the brake shoes can be adjusted. 11, Adjust the wheel bearings by tightening the nut to 205 Nm (150 Ibf ft) while rotating the hub. Loosen the nut until the hub turns freely. The torque must be less than 27 Nm (20 Ibf fi). Tighten the nut to 34 Nm (25 Ibf fi) or until the first alignment position after 34 Nm (25 Ibf ft). Bend the lock plate over the nut. 12, Adjust the clearance of the brake shoes. Put a screwdriver through the hole in the drum. Move the screwdriver so that the teeth of the adjuster whee! move downward. Tum the adjuster wheel until the brake drum will not rotate. Move the actuator away from the adjuster wheel, Tum the adjuster wheel up- ward 15 teeth to loosen the brake shoes. The brakes will adjust to the correct clearance when they are applied as the lift truck travels in the reverse direction. 7too large. A clearance that is too small can cause rap- 4 warnina id wear of the adjuster wheel. This condition can pre- ‘The brakes and the automatic adjusters cannot op- _yent automatic adjustment of the brakes. erate if the clearance between the shoes and drum is 1. SPRING FOR SECONDARY SHOE 2. SPRING FOR PRIMARY (FRONT) SHOE 3. UPPER LINK 4, LOWER LINK 5. GRAY 6. ADJUSTER WHEEL ACTUATOR 7. ADJUSTER WHEEL AND NUT RIGHT SIDE FIGURE 9. INSTALLATION OF THE SPRINGS13. Put sealant on the flange of the axle shaft. Install NOTE: Units from later production eee aos Eee the axle shaft and capscrews. Tighten the capscrews to 98 Nm (72 Ibf ft). 14, Install the cranks that actuate the brakes for park- ing. The correct position of the crank (1) when the parking brake lever is released is shown in FIGURE 12. Connect the cables to the cranks. 15, Remove the air from the brake hydraulic system, ‘See REMOVE THE AIR FROM THE BRAKE SYS- TEM in this section. ‘$2.00-3.00XL (S40-60XL) 4 Ly 3 40° to 60° in Y released position 4. OUTER SEAL SNe ces H2.00-3.00XL (H40-60xL) 3. BRAKE DRUM FIGURE 10. LOCATION OF ‘THE GREASE SEALS. ( yp Jet 2S 0° to 20° in released position 2. PIN 4, CABLE 3. CLEVIS 5. VERTICAL REFERENCE 1. CRANK FIGURE 12. ADJUST THE CRANKS FOR THE PARKING BRAKE 16. Install the wheel on the hub. Tighten the nuts: + $2.00-3,00XL ($40-60XL), 270 Nm (200 Ibf ft) FIGURE 11. INSTALL THE INNER. + H2.00-3.00XL (H40-60XL), 610 to 680 Nm CREE Sear (450 to 500 Ib ft)17. Start the engine and tilt the masts back to remove the blocks. Push on the brake pedal. The pedal must not touch the floor plate. Move the lift truck in the re- verse direction and push on the brake pedal to operate the adjusting mechanism. Master Cylinder (See FIGURE 1. and FIGURE 13.) 1. Lubricate the parts with clean brake fluid. Use only HYSTER Approved Parts. 2. Install the secondary cup in the piston with the lip away from the push rod, See FIGURE 13. 3. Install the primary cup and retainer on the piston. ‘The lip must be toward the spring. 4. Install the new check valve assembly in the bore, Put the spring and the piston assembly in the bore. Push on. the piston with a screwdriver to allow installation of the retainer washer and snap ring. Install the retainer washer and snap ring. 5. Install the push rod and dust boot. 6. Install the master cylinder in the lift truck. Connect the hose to the reservoir. Adjust the push rod so that the clearance between the piston and the push rod is 1 mm_ (0.04 in), See “Adjust the Brake Pedal and Inching 7. To remove the air from the master cylinder, fill the reservoir with clean brake fluid. Put a container under the master cylinder and slowly push the brake pedal. Slowly release the pedal. Repeat this procedure until brake fluid without bubbles flows from the outlet port. 8. Connect the fitting to the master cylinder. Remove any air in the system as described in CHECKS AND ADJUSTMENTS. SHIELD . SNAP RING. RETAINER WASHER SECONDARY CUP 5. PISTON . PRIMARY CUP ”, RETAINER . SPRING FIGURE 13. MASTER CYLINDER PARTS CHECKS AND ADJUSTMENTS, ADJUST THE SERVICE BRAKES. Put the lift truck on blocks so that the drive wheels can be removed. See the section 8000 SRM 259, PERI- ODIC MAINTENANCE, for the correct procedure. Remove the drive wheels. Use a screwdriver to adjust the clearance of the brake shoes. Put the screwdriver through the hole in the brake drum. Move the screw- 10 driver so that the teeth of the adjuster wheel move downward. Tum the adjuster wheel until the brake drum will not rotate. Move the actuator away from the teeth of the adjuster wheel. Tum the adjuster wheel up- ward 15 teeth to loosen the brake shoes. Install the drive wheels. Remove the lift truck from the blocks. Operate the lift truck in the forward and reversedirections. Apply the brake pedal to stop the lift truck 10 times in each direction. ADJUST THE PARKING BRAKE ‘Make sure that the service brakes are adjusted and that the operation of the automatic adjuster mechanism is correct. Test the operation of the parking brake. The brake must hold the lift truck and a capacity load on a 15% grade [a slope that increases 1.5 metres in 10 metres (1.5 ft increase in 10 ft)]. Turn the knob on the parking brake lever if a small adjustment is necessary. Adjust the cranks that actuate the brakes for parking if more adjustment is necessary. See FIGURE 12, Make sure that the hand lever is in the released position. Loosen the knob on the end of the hand lever. Loosen the bolt and nut for the crank. Move the crank toward the front of the truck to tighten the cable. Make sure that the shaft does not rotate when the crank moves. ‘Tighten the bolt for the crank, Make sure that the posi- tion of the crank is as shown in FIGURE 12. when the parking brake is released. EARLY PRODUCTION Units with Monotro! Pedal (See FIGURE 14.) Lift trucks with a Monotrol pedal have a switch (4) in the assembly for the parking brake lever. A link (3, ear- ly production) or cam (5, later production) operates the switch. The switch closes the circuit for starting the en- gine and opens the circuit for the Monotrol control when the parking brake is applied. Check or adjust the ‘operation of the switch according to one of the follow- ing procedures. Early Production: ‘a, Put the lift truck on blocks so that the drive tires do not touch the ground. See the section 8000 ‘SRM 259, PERIODIC MAINTENANCE, for the correct procedure. . Release the parking brake, The link (3) must not actuate the switch (4), Tum the ignition key to the START position. The engine must not start. Turn the ignition key to the OFF position. LATER PRODUCTION . LEVER, PARKING BRAKE . RELEASE LATCH | LINK (SWITCH ACTUATOR) |. NEUTRAL START SWITCH . CAM (SWITCH ACTUATOR) FIGURE 14. PARKING BRAKE LEVER FOR UNITS WITH MONOTROL PEDAL, ncc. Apply the parking brake. The link(3) must move upward far enough to actuate the switch (4), Turn the ignition key to the START position. The en- ‘gine must start. Release the parking brake. The circuit for the transmission must be energized (the drive wheels rotate). Tum the ignition key to the OFF position, 4d. Adjust the link by bending the link if the switch does not operate according to step b, and step c. ‘The link must actuate the switch when the park- ing brake is applied, Make sure thatthe circuit for the transmission is energized when the parking brake is released. Later Production: a, Put the lift truck on blocks so that the drive tires do not touch the ground. See the section 8000 ‘SRM 259, PERIODIC MAINTENANCE, for the correct procedure. Release the parking brake. The cam (5) must ac- tuate the switch (4). Tum the ignition key to the START position. The engine must not start. Tum the ignition key to the OFF position. Apply the parking brake. The cam must fully re- lease the lever on the switch, Tur the ignition key to the START position. The engine must start, but the circuit for the transmission must be ‘open (drive wheels do not rotate). Release the parking brake while the engine runs. The circuit for the transmission must be energized (the drive wheels rotate). 4. Apply the parking brake while the engine runs. Push the parking brake lever toward the released position without using the release latch (2). The parking brake must remain in the applied position and the transmission must remain in neutral. €. Inspect the switch for incorrect wiring if the switch does not operate according to steps b. and c. Replace the assembly that has the parking brake lever if it fails the check in step d. REMOVE THE AIR FROM THE BRAKE SYSTEM Before removing the air from the brake system, make sure the service brakes are adjusted. Fill the master cyl- 2 inder reservoir with brake fluid. Put one end of a rub- ber hose on the special fitting of the wheel cylinder. Put the other end of the hose into a clear container of brake fluid. Loosen the special fitting one tum, Slowly push the brake pedal and hold it at the end of its stroke. Close the special fitting. Repeat the procedure until there are no bubbles in the container. Check the level of the brake fluid in the reservoir for the master cylinder during the procedure. Keep the brake fluid at the cor- rect level. Repeat the procedure for the other wheel cylinder. If there is still air in the system, the air must bbe removed from the master cylinder. Slowly push on the brake pedal. Release the pedal slowly. Repeat this Procedure until there are no air bubbles entering the reservoir. ADJUST THE BRAKE PEDAL AND INCHING PEDAL (See FIGURE 15.) Always check and adjust the brake pedal and the inch- ing pedal if the control valve was removed for repairs. NOTE: Ifthe lift truck has been operated for more than 25 hours since the brake shoes were installed, and the operation of the brakes is normal, continue at Step 1. If the lift truck has new brake shoes, adjust the brake shoes, before you adjust the pedals. See ADJUST THE SER- VICE BRAKES in this section. 1. Adjust the pedal stops (5) so that the bottom of each pedal pad is at Dimension A from the floor plate. Tighten the jam nuts. Loosen the pedal synchronizer serew (7) as required to adjust the inching pedal (2). 2. Loosen the jam nut (11) on the push rod (12) for the master cylinder (13). Tum the push rod (12) clockwise so that it touches the piston of the master cylinder. Tum the push rod one-half tum counterclockwise to set the correct clearance between the push rod and the piston. ‘Tighten the jam nut. 3. Early Production Only (Note appearance of Item. 6, FIGURE 15.). Disconnect the ball joint (3) at the inching pedal. Loosen the jam nut on the inching spool (6). Tum the inching spool to adjust the length of the inching spring to dimension B. Do not tighten the jam nut on the inching spool.EARLY PRODUCTION See Figure 15, 2 of 2, for detail. |. BRAKE PEDAL . INCHING PEDAL |. BALL JOINT . LINKAGE ROD 5. PEDAL STOP . INCHING SPOOL ‘$2.00-3.00XL (S40-60XL) (See FIGURE 16. for this view of the H12,00-3.00XL [H40-60XL}.) A= °Yy '$2.00-3.00XL (S40-60XL) FIGURE 15. PEDAL ADJUSTMENT, 52.00-3.00XL (S40-60XL) AND H2.00-3.00XL (H40-60XL) (I of 2) ”. PEDAL SYNCHRONIZER SCREW CONTROL VALVE ‘TEST PORT TP-2 (FORWARD CLUTCH) |. BRAKE ACTUATOR PLATE H12.00-3.00XL (H40-60XL) B'$2.00-3.00XL ($40-60XL) H2.00-3.00XL (H40-60XL) 1. BRAKE PEDAL 8. CONTROL VALVE 2. INCHING PEDAL 9. TEST PORT TP-2 (FORWARD CLUTCH) 3. BALL JOINT 10. BRAKE ACTUATOR PLATE 4, LINKAGE ROD 11. JAM NUT 3. SETSCREW, PEDAL STOP 12. PUSH ROD. INCHING SPOOL 18. MASTER CYLINDER PEDAL SYNCHRONIZER SCREW — 14. JAM NUT. FIGURE 15. PEDAL ADJUSTMENT, S2.00-3.00XL (S40-60XL) AND H2.00-3.00XL (H40-60XL) (2 of 2) 5. 6 44, Early Production Only. Loosen the jam nut and tum the ball joint to adjust the length of the linkage rod (4). Adjust the length of the linkage rod so that it aligns with the hole in the inching pedal (2). Connect the link~ age rod to the inching pedal and tighten the jam nut for the ball joint when the adjustment is complete. 5, Start the engine and tilt the mast backward. Put blocks under the mast, then tilt the mast forward. Make sure that the drive wheels are raised from the floor. ‘Stop the engine, Put blocks in front of and behind the steering tires. 6. Install a gauge that can measure 2000 kPa (300 psi) in the test port TP-2 shown in FIGURE 15. Start the engine, release the parking brake, and shift the trans- ‘mission to the forward gear. Measure the pressure for the forward clutch. The correct pressure is 724 to 862 kPa (105 to 125 psi) at 2000 rpm (transmission oil tem- perature at 50°C [120°F}). 7. Early Production Only. Use a wrench on the wrench flats to tum the inching spool (6) for adjust- ‘ment. Tum the inching spool to decrease the length un- til the pressure for the forward clutch decreases to 620 kPa (90 psi) at 2000 rpm. Turn the inching spool clock- wise 1-1/2 rotations to increase the length. Tighten the jam nut on the inching spool. Check the pressure for the forward clutch again. The pressure will be 724 to ‘862 kPa (105 to 125 psi) at 2000 rpm if the adjustment is correct. 8, Later Production Only (Note appearance of Item 6, FIGURE 15.) Loosen the jam nuts (14) on the link- age rod (4). Tum the linkage rod (4) counterclockwise (in a top view) until pressure for the forward clutch de- creases to 620 kPa (90 psi) at 2000 rpm. Then tum the linkage rod 1-1/4 tums clockwise. Tighten the jam nuts (14). Check the pressure for the forward clutch again. The pressure will be 724 to 862 kPa (105 to 125 psi) at 2000 rpm if the adjustment is correct. 1. TENSION SPRING, EARLY MODELS 2. TORSION SPRING, LATER MODELS. H2.00-3.00XL (H40-60XL) '$2.00-3.00XL (S40-60XL) FIGURE 16. PEDAL ARRANGEMENTS 159. Check the overlap between the brake and the inching functions. Run the engine at 2000 rpm. Units from ear- Jy production have a tension spring (see FIGURE 16.). Push on the inching pedal with a force of 156 to 178 N (35 to 40 Ibf). Units from later production have a tor- sion spring. Push on the pedal with a force of 111 to 133 N (25 to 30 Ibf). The pressure for the forward clutch will decrease to 21 to 48 kPa (3 to 7 psi) if the adjustment is correct. The drive wheels will normally stop rotating when the pressure decreases to 21 to 48 KPa G3 to 7 psi). Use the pedal synchronizer screw (7) to adjust the overlap if necessary. Turn the synchronizer screw (7) a ‘maximum of one tum counterclockwise (view from front of truck) to increase overlap. Turn the screw (7) a ‘maximum of one tum clockwise to decrease overlap. Keep a minimum of 1/4 rotation of clearance between the head of the pedal synchronizer screw (7) and the brake actuator plate (10). This clearance makes sure that the clearance between the push rod and the master cylinder (adjustment in step 2, does not change. Do not set too much overlap. The clutches must be completely released when the brakes are fully applied with the See the note in CHECK AND ADJUST THE NEU- TRAL START SWITCH in this section before you re- ‘move the gauge or the blocks under the truck. ‘CHECK AND ADJUST THE NEUTRAL ‘START SWITCH (Monotrol Control Only) (See FIGURE 17.) NOTE: The adjustment of the brake shoes and the inch— brake overlap must be correct before the neutral start switch is adjusted. Step 2, can be used to adjust the neu- ‘al start switch ifthe lift truck remains as prepared for adjustment of inch-brake overlap. The procedure in ‘Step 3. is also acceptable. 1. Use the procedure in this step to check the adjust- ‘ment of the neutral start switch: a, Put the lift trick on blocks. See the section 8000 SRM 259, PERIODIC MAINTENANCE, for the correct procedure. b. Tum the ignition key to the OFF position. Re- lease the parking brake. Use the service brake pedal to apply the brakes. 16 TYPICAL DETAIL Position of Switch Lever: ‘A. Before contact with disc (3) B. At 12mm (0.47 in) stroke of inching spool (neutral start switch actuated) 1. SWITCH BRACKET 2. CAPSCREWS: 3. NEUTRAL START DISC 4, NEUTRAL START SWITCH 5. SWITCH LEVER 6. REVERSE SOLENOID 7. FORWARD SOLENOID FIGURE 17.ADJUSTMENT, NEUTRAL START ‘SWITCH (MONCTROL ONLY) ¢. Tum the ignition key to the START position. If the starter is energized, the neutral start switch has a fault or is not adjusted correctly. Turn the ig- nition key to the OFF position. Release the brake pedal. 4. Push the inching pedal fully down, Tum the igni- tion key to the START position. The starter will bbe energized if the operation and adjustment of the neutral start switch are correct,2. Lift Truck on Blocks a. Loosen the two capscrews that fasten the switch bracket to the transmission control valve. b. Start the engine. Put the transmission in the For- ward gear. Release the parking brake. c. Push the inching pedal until the gauge indicates a pressure of 0 to 48 kPa (0 t0 7 psi) at the forward clutch. Hold the pedal so that the pressure re- ‘mains in that range. 4. Adjust the switch bracket (1) so that the lever (5) for the switch is actuated by the outside diameter of the disc (3). See FIGURE 17. Make sure that the switch lever moves far enough (position B) to actuate the switch. e. Tighten the capscrews (2) to 19 Nm (14 Ibf ft). 3. Lift Truck Not On Blocks ‘a, Stop the engine and apply the parking brake. . Loosen the two capscrews that fasten the switch bracket to the transmission control valve. . Push the inching pedal down far enough to move the inching spool a minimum of 12 mm (0.5 in). Hold the inching pedal in this position. 4. Adjust the switch bracket (1) so that the lever (5) for the switch is actuated by the outside diameter of the disc (3), See FIGURE 17. Make sure that the switch lever moves far enough (position B) to actuate the switch. €. Tighten the capscrews (2) to 19 Nm (14 Ibf ft). aTROUBLESHOOTING PROBLEM CAUSE ‘The brakes do not operate equally. Ollor brake fluid Is on the linings. The linings are worn or hard. The wheel cylinders are damaged The brake lines have a restriction. The brake shoes or back plates are damaged ‘The drum is not round. ‘One brake coes not release. The shoes are adjusted too tight. ‘A brake shoe is damaged. ‘A return spring is damaged. The brake ines have a restriction. “The parking cable is damaged. ‘The wheel bearings are adjusted too tight. ‘The wheel cylinder is damaged. ‘The back plate is damaged. Both brakes do not release. ‘The parking brake is not released. ‘The pedal push rod clearance is not enough. ‘The master cylinder is damaged. ‘The shoes are adjusted too tight. ‘The seals are damaged because of oil in the brake fluid. ‘The pedal is hard to push. “There Is not enough clearance for the push rod. The linings are too hard. ‘Water or oil is on the linings ‘The master cylinder is damaged. ‘The wheel cylinders are damaged. ‘The pedal return spring is damaged. ‘The pedal does not have enough resistance. 18 Airis in the brake system. ‘The master cylinder mount is loose. ‘The brake shoes are damaged. A drum is cracked. ‘A back plate is damaged. ‘A wheel cylinder is damaged. The linings do not ft the drums.TROUBLESHOOTING PROBLEM CAUSE ‘The pedal travels to0 far. Air is in the brake system. The shoes are adjusted wrong. The linings are worn. ‘The clearance at the push rod is too much. ‘The pedal moves to the floor. Aris in the brake system. ‘The master cylinder is damaged. ‘The brake system has a leak. The brakes make too much noise. ‘il, water or brake fluid is on the linings. “The linings are worn. The drum is damaged. ‘A brake shoe is damaged. Dirtis on the linings. The brakes do not stop the truck. Oil, water or brake fluid is on the linings. The linings are worn ‘The wheel cylinders are damaged. The shoes are not adjusted correctly. The master cylinder is damaged. The parking brake will not hold ‘Oil, water or brake fluid is on the linings. The parking cables are not adjusted correctly. ‘A parking cable is damged. ‘The brake linings are worn. "The parking brake will not release. ‘The parking brake lever Is adjusted too tight. SPECIFICATIONS ITEM TORQUE '$2,00-3.00XL H2.00-3.00XL Capscrews, Brake Back Plate (S40-6OXL) (H40-60XL) Bottom four (or three) 245 Nm (180 Ibf ft) 205 Nm (151 lof ft) ‘Special (lever studs, two) 245 Nm (180 Ibf ft) 205 Nm (151 Ibf ft) ‘Special (spring anchor) 125 Nm (92 loft) 110 Nm (81 Ib ft) Capscrews, Wheel Cylinder Top two 80 to 85 Nm (59 to 63 Ibf ft) Bottom two 80 to 102 Nm (69 to 75 lof) Nuts, Drive Wheel 270.Nm (200 Ibf ft) 610 to 680 Nm (450 to 500 lof ft) Capscrews, Axle Shaft ‘90 Nm (66 Ibf ft) 98 Nm (72 Ibf ft) »HYSTER TECHNICAL PUBLICATIONS 1800 SRM 157 3/97 (8/90) (7/87) (2/85) (10/84) (7/81) ( Litho in U.S.A.