HMM180001 Brake System H1.5-1.8TX, H2.0TXS [B475]; H2.5-3.5TX [B466] Safety Precautions Maintenance and Repair When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure 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 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 clean and the working area clean and orderly. 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 all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), and Diesel fuel are flammable. Be sure to 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 is well ventilated. NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a condition that can cause immediate death or injury! CAUTION Indicates a condition that can cause property damage! 1
Disclaimer The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.
GENERAL This section has a description and the service procedures for the parts of the brake system. The brake system includes the following parts: master cylinder, brake shoes, wheel cylinders, and parking brake system. [1] Service Brakes A service brake assembly is installed on the mounts at each end of the drive axle. See Figure 1. The parts of the service brake assembly are shown in Figure 4 for H2.0-3.5TX [B466] lift trucks and Figure 6 for H1.5-1.8TX, H2.0TXS [B475]. When the brake pedal is pushed, fluid pressure from the master cylinder causes the pistons in the wheel cylinder to extend. The pistons expand the brake shoes against the drums. The clearance between the brake shoes and the brake drum is adjusted automatically. An adjuster linkage turns the adjuster wheel to adjust the clearance. When the lift truck moves in the REVERSE direction and the brakes are applied, the rear brake shoe and the adjuster links move with the drum. This linkage moves the adjuster lever to rotate the adjuster wheel. The adjuster wheel can turn only when there is clearance between the lining of the brake shoe and the brake drum. The adjuster wheel can also be turned with a tool. A slot in the back plate gives access to the adjuster wheel. [2] Master Cylinder The master cylinder is designed for a singlecircuit system. The master cylinder has a piston that operates in the bore of the master cylinder. See Figure 2. NOTE: The reservoir is located to the right of the park brake and is attached to the cowl. [3] Brake Position Sensor This sensor senses the park brake hand lever position. The sensor is located on the left hand side of the park brake handle. See Figure 1. 1. PARKING BRAKE LEVER 2. ADJUSTMENT KNOB 3. PARKING BRAKE CABLE 4. INCHING/BRAKE PEDAL 5. MASTER CYLINDER 6. BRAKE ASSEMBLY 7. PARK BRAKE SENSOR Figure 1. Brake System 12
1. YOKE 2. NUT 3. PUSH ROD 4. BOOT 5. SNAP RING 6. CYLINDER HOUSING 7. SEAL 8. FITTING 9. PISTON SEAL 10. PISTON 11. SPACER 12. PISTON CUP 13. RETAINER 14. SPRING 15. CHECK VALVE 16. VALVE SEAT 17. BLEEDER VALVE 18. CAP Figure 2. Master Cylinder [4] Parking Brake The 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, the cables and linkage expand the brake shoes against the drums. The design of the parking brake linkage adjusts each cable so that the tension is the same when the lever is moved to apply the parking brake. The park brake sensor is located on the left side of the park brake handle. 23
[1] Remove and Disassemble SERVICE BRAKES REPAIR WARNING Brake linings can contain dangerous fibers. Breathing the dust from these brake linings is 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 brake dust 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 respirator must be used. 1. Remove the capscrews that hold the axle shaft to the hub. Remove the axle shaft. 2. See the procedure How to Put Lift Truck on Blocks in the section Periodic Maintenance or the Operating Manual. Start the engine and tilt the mast fully backward. Put blocks under the mast. Tilt the mast forward until the wheels just touch the floor. Stop the engine. Put blocks under the frame of the lift truck. 3. Remove the set screw and remove the nut that holds the axle bearing. Remove the washer and the bearing cone. 1. WHEEL CYLINDER 2. RETURN SPRING 3. RETURN SPRING 4. ANCHOR 5. ANCHOR GUIDE 6. BACK PLATE 7. SECONDARY BRAKE SHOE 8. ADJUSTER WHEEL ACTUATOR 9. PIVOT PLATE 10. SPRING AND CABLE ASSEMBLY 11. ADJUSTER WHEEL 12. ADJUSTER ASSEMBLY 13. PRIMARY BRAKE SHOE 14. PARKING BRAKE LEVER 15. LINK, PARKING BRAKE 16. SPRING, PARKING BRAKE 17. RETAINER, AND SPRING WASHER 18. ADJUSTER ACTUATOR SPRING 19. SPRING Figure 3. Brake Assembly (Left-Hand Shown), H2.0-3.5TX [B466] 34
WARNING When the brake shoes are removed, do not create dust in the air. See the Clean procedure in this section. 4. Put grease on the floor so that the wheel assembly will slide easily from the axle tube. Pull the wheel assembly from the lift truck. If the wheel assembly cannot be removed easily, use a small screwdriver to push the adjuster actuator away from the adjuster wheel. Use a brake adjustment tool or a screwdriver to turn the adjuster wheel to loosen the brake shoes. Remove NOTE: Right-hand brake assembly shown. 1. WHEEL CYLINDER 2. RETURN SPRING 3. RETURN SPRING 4. ANCHOR 5. ANCHOR GUIDE 6. BACK PLATE 7. SECONDARY BRAKE SHOE 8. ADJUSTER WHEEL ACTUATOR 9. PIVOT PLATE 10. ADJUSTER ACTUATOR LINK 11. ADJUSTER WHEEL 12. ADJUSTER ASSEMBLY 13. PRIMARY BRAKE SHOE 14. PARKING BRAKE LEVER 15. PARKING BRAKE LINK 16. PARKING BRAKE SPRING 17. RETAINER, AND SPRING WASHER 18. ADJUSTER ACTUATOR SPRING 19. SPRING 20. RETAINING PIN 21. RETAINING WASHER 22. PARKING BRAKE CABLE Figure 4. Service Brake Parts, H2.0-3.5TX [B466] 45
the hub and drum assembly. Do not damage the grease seal when removing the hub. 5. Make a note of the arrangement of the parts. See Figure 3 and Figure 4 for H2.0-3.5TX [B466] lift trucks. See Figure 5 and Figure 6 for H1.5-1.8TX, H2.0TXS [B475] lift trucks. Remove the return springs with spring pliers. 6. Remove the retainers, springs, and anchor pins that hold the brake shoes to the back plate. 7. Disengage the link from the adjuster wheel actuator. Remove the link, washer, and pivot plate. Remove the anchor guide. 8. Move the brake shoes away from each other to disengage the brake shoes from the wheel cylinder. Disconnect the parking brake lever from the parking brake cable as the brake assembly is removed from the back plate. The parking brake lever has a hook that engages the parking brake cable. NOTE: The adjuster wheel for the left brake is not the same as the adjuster wheel for the right brake. The adjuster wheel for the left brake has left-hand threads. 9. Make a note of the arrangement of parts and disassemble the brake assembly. Remove the parking brake link and spring if they are still engaged with brake shoes. The parking brake link and spring will often fall from the brake assembly when the brake assembly is removed from the back plate. The adjuster wheel will also disengage from the brake shoes after the brake assembly is removed. 10. Remove the spring for the adjuster wheel actuator. Remove the adjuster wheel actuator from the brake shoe. 11. Use a screwdriver or small pry bar to move apart the ends of the retainer. Remove the spring washer and pivot pin to remove the parking brake lever from the brake shoe. 12. Disconnect the brake line from the wheel cylinder. Remove the capscrews that hold the wheel cylinder to the back plate and remove the wheel cylinder. 1. BACKING PLATE 2. RETAINING RING 3. LEVER PIN 4. GUIDE PLATE 5. WHEEL CYLINDER 6. PAWL LEVER STOPPER 7. SPRING (ANTI-RATTLE) 8. RETURN SPRING 9. SPRING (ACTUATOR) 10. ADJUSTER WHEEL ACTUATOR 11. SECONDARY BRAKE SHOE 12. ADJUSTER ASSEMBLY 13. ADJUSTER SPRING 14. PARK BRAKE LEVER 15. PRIMARY BRAKE SHOE 16. STRUT Figure 5. Brake Assembly (Left Hand Side), H1.5-1.8TX, H2.0TXS [B475] 56
1. BOLT 2. WHEEL CYLINDER 3. STRUT 4. SPRING 5. SECONDARY BRAKE SHOE 6. GUIDE PLATE 7. RETURN SPRING 8. PAWL LEVER STOPPER 9. SPRING (ACTUATOR) 10. WASHER 11. SPRING (SHOE HOLD DOWN) 12. WASHER 13. ADJUSTER WHEEL ACTUATOR 14. PARK BRAKE CABLE 15. ADJUSTER ASSEMBLY 16. RETAINING RING 17. SPRING (ADJUSTER) 18. PRIMARY BRAKE SHOE 19. PARK BRAKE LEVER 20. LEVER PIN 21. PLUG 22. BACKING PLATE 23. PIN Figure 6. Service Brake Parts, H1.5-1.8TX, H2.0TXS [B475] NOTE: For H2.0-3.5TX [B466] lift trucks, the back plate is not normally removed from the axle housing for brake repairs. Eight special capscrews are used to fasten the back plate to the axle mount, and the locking function of the capscrews is reduced if they are removed. The capscrews are tightened to 255 to 306 N m (2600 to 3120 kgf cm). NOTE: For H1.5-1.8TX, H2.0TXS [B475] lift trucks, the back plate is not normally removed from the axle housing for brake repairs. Six special capscrews are used to fasten the back plate to the axle mount, and the locking function of the capscrews is reduced if they are removed. The capscrews are tightened to 152 to 167 N m (1550 to 1700 kgf cm). 13. Remove the push rods, dust covers, pistons, cups, and spring from the wheel cylinder. See Figure 7. 67
1. PUSH ROD (2) 2. DUST COVER (2) 3. PISTON (2) 4. CUP (2) 5. SPRING 6. WHEEL CYLINDER BODY 7. INLET PORT 8. PRESSURE BLEEDER 9. DUST COVER Figure 7. Wheel Cylinder [2] Clean WARNING DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or brake linings. Use a solvent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid or on the brake linings. Oil and grease will cause damage and leaks in the seals of a brake system. The brakes will not operate correctly if oil, grease, or brake fluid is on the brake linings. Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the safety instructions of the solvent manufacturer. 1. Do not release brake lining dust from the brake linings 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 cloth or towels in a plastic bag or an airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on the plastic bag or airtight container. 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. 78
4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air. [3] Inspect 1. Inspect the bore of the wheel cylinder for holes or scratches. Replace the wheel cylinder assembly if there is any damage. 2. Inspect the return springs for wear and damage. Inspect the back plate for wear where the brake shoes touch the back plate. Remove any grooves or replace a worn or damaged back plate. WARNING The brake shoes on both wheels must be replaced if any shoe is damaged. The brake performance on both ends of an axle must be equal, or the lift truck can be difficult to steer when the brakes are applied. 3. Inspect the brake shoes for cracks or damage. If the linings or shoes are worn or damaged, replace the brake shoes. Maximum wear is to within 1 mm of contact with the rivets, or the metal shoe on bonded linings. Brake shoes must be replaced in complete sets. Inspect the brake drums for cracks or damage. Replace any damaged parts. 4. Inspect the brake drum for deep grooves or other damage. NOTE: On H2.0-3.5TX [B466] lift trucks, if grooves must be removed from the brake drums, do not grind more than 1.5 mm from the internal diameter of the brake drum. The maximum limit of the internal diameter of the brake drum is 312 mm. If the internal diameter is larger than the limit, replace the brake drum. NOTE: On H1.5-1.8TX, H2.0TXS [B475] lift trucks, if grooves must be removed from the brake drums, do not grind more than 1.5 mm from the internal diameter of the brake drum. The maximum limit of the internal diameter of the brake drum is 255.5 mm. If the internal diameter is larger than the limit, replace the brake drum. 5. The teeth of the adjuster wheel must not be worn. The adjuster wheel must turn freely. Check the adjuster links for damage. 6. Make sure the parking brake cables are in good condition. 7. Check the grease seals and the surfaces of the seals for wear or damage. [4] Assemble and Install 1. If the wheel cylinder was disassembled for repair, assemble the wheel cylinder. See Figure 7. Use only HYSTER APPROVED parts. 2. Install the wheel cylinder on the back plate and tighten the two capscrews to 18 to 26 N m (180 to 260 kgf cm) for H2.0-3.5TX [B466] and 15 to 23 N m (150 to 230 kgf cm) for H1.5-1.8TX, H2.0TXS [B475]. Connect the brake line to the wheel cylinder. 3. Install the parking brake lever. Use the spring washer, and retainer to fasten the parking brake lever to the brake shoe. Close the ends of the retainer to fasten the pivot pin in position. See Figure 4 for H2.0-3.5TX [B466] and Figure 6 for H1.5-1.8TX, H2.0TXS [B475] lift trucks. 4. Fasten the adjuster actuator spring to the lever and the brake shoe. 5. Put antiseize compound on the threads of the adjuster wheel. 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. 89
WARNING The threads of the adjuster wheel are not the same for each side. If the adjuster assemblies are installed on the wrong side, the brake shoe clearance will increase each time the brakes are applied. The adjuster wheel for the right brake has right-hand threads. The adjuster wheel for the left brake has left-hand threads. 6. Install the adjuster wheel between the two brake shoes. Make sure the adjuster wheel will be toward the rear of the lift truck. Move the brake shoes apart so that the adjuster wheel is held in position and the adjuster actuator spring is in tension. 7. Lubricate the back plate with a small amount of lithium grease where the brake shoes touch. Install the brake shoes on the anchor and engage the push rods of the wheel cylinder. Engage the parking brake lever in the slot in the parking brake cable as the brake shoes are installed on the back plate. 8. Put an anchor pin that holds the brake shoes through the back plate. Put a spring seat, spring, and retainer on the anchor pin. Push the retainer onto the anchor pin and rotate the retainer 90 degrees. Make sure the retainer is in the correct position. 9. Install the link, parking brake, and spring between the parking brake lever and the brake shoe. 10. Install the other spring retainer that holds the brake shoes. Make sure the parking brake link and the spring are correctly engaged after the spring retainers are installed. 11. Install the anchor guide on the anchor. Install the pivot plate on its anchor. 12. Lubricate the adjuster cable where it slides in the pivot plate groove. 13. Fasten the link to the adjuster wheel actuator and put the cable around the pivot plate. Raise the adjuster wheel actuator against the spring tension and connect the link to the anchor. CAUTION H2.0-3.5TX [B466]: Be sure to install the white return spring first and then the black return spring. See Figure 9. Improper assembly can result in brake failure and/or component damage. 1. RETURN SPRING 2. ANCHOR GUIDE 3. RETURN SPRING 4. SPRING AND CABLE ASSEMBLY 5. PIVOT PLATE Figure 8. Return Springs, H2.0-3.5TX [B466] 10 9
1. WHITE SPRING 2. BLACK SPRING Figure 9. Proper Installation of Return Springs, H2.0-3.5TX [B466] NOTE: The shape of the return springs permits them to be installed correctly in only one position. The arrangement of the return springs on the anchors is shown in Figure 8 and Figure 9. 14. H2.0-3.5TX [B466]: Using the correct tools, install the return springs as follows (see Figure 9): a. Install the white spring. b. Install the black spring. 15. H2.0-3.5TX [B466]: Verify that the return springs are properly installed as shown in Figure 9 1. RETURN SPRING 2. GUIDE PLATE 3. RETURN SPRING 4. SPRING ACTUATOR Figure 10. Return Springs, H1.5-1.8TX, H2.0TXS [B475] 10 11
1. INNER SEAL 2. OUTER SEAL 3. BRAKE DRUM 4. INNER BEARING 5. OUTER BEARING Figure 11. Grease Seals and Bearing Locations 16. H1.5-1.8TX, H2.0TXS [B475]: Use the correct tools to install the return springs. Install the return spring. Install the washer and the return spring. The shape of the return springs permits them to be installed correctly in only one position. The arrangement of the return springs on the anchors is shown in Figure 10. NOTE: Seal and bearings are to be installed flush with the hub. Seal is to be installed with no grease or oil on outside surface. 17. Clean the bearings and lubricate them Figure 12. Inner Grease Seal Installation with wheel bearing grease. Install the bearings and seals in the brake drum. Install the assembly on the axle housing. See Figure 11 and Figure 12. NOTE: To prevent damage to the inner oil seal when installing the hub, the hub and drum assembly can be temporarily fastened to the wheel. Align the height of the axle housing with hub bearings. Put grease under the wheel and slide the wheel toward the axle housing. Install the outer bearing and nut. 18. Adjust the hub bearings by tightening the nut until the hub cannot be rotated. Loosen the nut 30 to 60 degree and fix at hub rotating torque 3.0 to 3.4 N m (30 to 35 kgf cm). 19. Apply the loctite on the thread of the set screw and fasten to the thread where aligned to the V-groove on the washer. See Figure 13 12 11
CAUTION If there is too much clearance, the automatic adjusters will not operate. If the clearance is too small, the automatic adjuster cannot turn the adjuster wheel to increase the clearance, and the adjuster wheel will not turn until the brake shoes wear. If the adjuster wheel does not move for a long operating period, the adjuster link can wear a spot on the adjuster wheel so that it will not turn correctly. NOTE: If the brake shoes were not replaced, loosen the adjuster wheel approximately 20 teeth. 20. Adjust the clearance of the brake shoes. Put a brake adjustment tool or a screwdriver through the slot in the back plate. Use the tool to rotate the adjuster wheel. The actuator for the adjuster wheel will only permit rotation in one direction. Turn the adjuster wheel until the brake shoes have expanded against the brake drum and the hub will not turn. Use a small screwdriver to lift the actuator away from the adjuster wheel and turn the adjuster wheel approximately 20 teeth in the opposite direction. The brakes will adjust to the correct clearance when they are applied while the lift truck is traveling in the reverse direction. 21. Put liquid sealant, Hyster Part Number 0264159, on the flange of the axle shaft. Install the axle shaft and capscrews. Tighten the capscrews in cross pattern to a torque specified below for your lift truck. a. For H2.0-3.5TX [B466] lift trucks, tighten between 90 to 108 N m (920 to 1100 kgf cm). b. For H1.5-1.8TX, H2.0TXS [B475] lift trucks, tighten between 52 to 62 N m (530 to 630 kgf cm). See Figure 14. [5] Adjust 1. WASHER 2. BRAKE DRUM ASSEMBLY 3. WHEEL ADJUSTMENT NUT 4. SET SCREW Figure 13. Lock Plate Figure 14. Axle Shaft Tightening Sequence 1. Remove the air from the brake hydraulic system. See Brake System Air Removal. 2. Install the wheel on the hub. Tighten the wheel nuts to the torque specified below for your lift truck. a. For H2.0-3.5TX [B466] lift trucks, tighten between 196 to 216 N m (2000 to 2200 kgf cm) for 2-2.5 ton, 294 to 343 N m (3000 to 3500 kgf cm) for 3-3.5 ton. b. For H1.5-1.8TX, H2.0TXS [B475] lift trucks, tighten between 196 to 216 N m (2000 to 2200 kgf cm). 12 13
1. PARKING BRAKE LEVER 2. ADJUSTMENT KNOB 3. PARKING BRAKE CABLES 4. CONNECTING PINS 5. COTTER PINS 6. WASHER 7. SLIDER 8. CLAMP Figure 15. 3. Start the engine and tilt the mast backward to remove the blocks. Push on the brake pedal. The pedal must not touch the floor plate. Move the lift truck in REVERSE and push on the brake pedal to permit adjusting mechanism to operate. Repeat this operation several times. 4. The service brakes must be adjusted before the parking brake can be adjusted. See Figure 16 and the following paragraphs in this section for the correct adjustment of the parking brake. 13 14
[1] Remove and Disassemble PARKING BRAKE REPAIR If the lever assembly for the parking brake must be removed from the cowl, use the following procedure (see Figure 16): 1. Use blocks next to the wheels to make sure the lift truck cannot move. Release the parking brake lever. 2. Remove the two capscrews that fasten the parking brake to the cowl. Remove the parking brake lever assembly. 3. Turn the adjuster knob counterclockwise until the brake cables are loosened. Remove the cotter pins, the washers and the connecting pins and the cables from the slider. 4. Loosen the nuts that fasten the threaded ends of the brake cables to the parking brake lever assembly. 5. The service brake assembly must be removed before the parking brake cable can be removed from the back plate of the service brake. A snap ring holds the sheath of the parking brake cable in the back plate of the service brake. Remove the snap ring and remove the parking brake cable from the back plate. [2] Assemble and Install 1. Loosen the two capscrews on the parking lever assembly and install the bracket to the parking lever assembly by using the capscrews loosened. 2. Make sure the parking brake lever is in the released position. Turn the adjustement knob counterclockwise until the slider is adjusted to the bottom of the adjustment slot. 3. Adjust the nuts on the ends of the cable assemblies so that the threads of the cable sheaths extend to 11 mm above the support plate in the lever assembly. 4. Install the cable ends to the slider with connecting pins, cotter pins and washers. Tighten the upper nut to hold the sheath of the parking brake cables to the parking brake lever with the support plate. 5. Install the parking brake lever to the cowl and tighten two capscrews. [3] Adjust Make sure the service brakes are adjusted and the operation of the automatic adjuster mechanism is correct before the parking brake is adjusted. 1. Turn the adjustment knob to raise the slider and tighten the parking brake cables. Turn the adjustment knob until the parking brakes are fully applied with 167 N (15 kgf) of the lever effort at the top of the lever when the lever is used to apply the parking brake. 2. Test the operation of the parking brake. The lift truck with a capacity load must not move when the parking brake is applied on a 15 percent grade [a slope that increases 1.5 m in 10 m]. [4] Inspection Inspect each part by the following procedure. If there are any damages, replace the new parts. 1. Inspect the pin (30) for wear and damage. 2. Inspect the O-ring (3) for wear and damage. Replace if the o-ring is worn or damaged and 14 15
does not hold the adjustment knob in position. 3. Inspect any link (13), plate (40) (41) and pins (10) (39) for damage. 4. Inspect the threads on the inner collar (6) and outer collar (5) for damage. 5. Make sure the parking cables are in good condition. 1. GRIP 2. RELEASE BUTTON 3. O-RING 4. PLATE 5. ADJUSTMENT KNOB 6. INNER COLLAR 7. LEVER 8. HOOK 9. SPRING 10. PIN 11. PIN 12. RETAINING RING 13. LINK 14. SPACER 15. SWITCH 16. CAPSCREW 17. GUIDE PLATE 18. GUIDE PLATE 19. BRACKET 20. CAPSCREW 21. CAPSCREW 22. RETAINING RING 23. CAPSCREW 24. PUSH NUT 25. CAPSCREW 26. SPACER 27. RUBBER 28. SPACER 29. NUT 30. PIN 31. NUT 32. SLIDER 33. PIN 34. PUSH NUT 35. PIN 36. WASHER 37. NUT 38. CAPSCREW 39. SPACER 40. PLATE 41. PLATE 42. COTTER PIN Figure 16. Parking Brake Lever Adjustment (Left Hand Side Shown) 15 16
MASTER CYLINDER REPAIR [1] Remove 1. Remove the floor plate, and kick plate, from the lift truck for access to the master cylinder. 2. Remove the brake hydraulic line from the master cylinder. See Figure 17. 3. Disconnect the brake fluid supply hose from the master cylinder. Plug hose to prevent reservoir from draining. 4. Remove the brake fluid reservoir and supply hose from the lift truck. 5. Remove the cotter pin and rod end pin that is attached to the brake linkage lever arm. 6. Remove capscrews that hold master cylinder to bracket assembly. 1. RESERVOIR 2. CAPSCREWS 3. BRAKE FLUID SUPPLY HOSE 4. CAPSCREWS 5. MASTER CYLINDER 6. BRAKE HOSE 7. PUSH ROD 8. NUT 9. YOKE 10. ROD END PIN 11. COTTER PIN 12. STOP LAMP SWITCH 13. BRACKET 14. CAPSCREWS Figure 17. Master Cylinder and Reservoir Assembly [2] Disassemble CAUTION When the piston is removed or installed, make sure the cylinder bore and piston are not scratched or damaged. 1. Remove yoke, push rod, nut, boot, fitting, seal and bleeder valve. See Figure 18. 16 17
1. YOKE 2. NUT 3. PUSH ROD 4. BOOT 5. SNAP RING 6. CYLINDER HOUSING 7. SEAL 8. FITTING 9. PISTON SEAL 10. PISTON 11. SPACER 12. PISTON CUP 13. RETAINER 14. SPRING 15. CHECK VALVE 16. VALVE SEAT 17. BLEEDER VALVE 18. CAP Figure 18. Master Cylinder 2. Remove snap ring, piston seal, and piston. 3. Remove spacer, piston cup, retainer, spring, check valve, and valve seat. NOTE: Install new seals when the master cylinder is disassembled for repair. 17 18
[3] Clean and Inspect CAUTION DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or brake linings. Use a solvent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid or on the linings. Inspect the bore of the master cylinder for holes or scratches. Replace the master cylinder assembly, if there is damage. [4] Assemble 1. Install valve seat, check valve, spring, retainer, piston cup, and spacer. 2. Install the piston, piston seal, and snap ring. 3. Install bleeder valve seal, fitting, boot, nut, push rod, and yoke. [5] Install and Adjust 1. Install brake fluid reservoir, supply hose and master cylinder on lift truck as an assembly. See Figure 17. 2. Install brake hydraulic line on master cylinder. 3. Orient master cylinder side of brake hose assembly. 4. Tighten fitting nuts at each end of brake pipe and hose assembly to 13 to 18 N m (130 to 185 kgf cm). 5. Apply a layer of multipurpose grease to the rod end pin and, with twisting motion, insert through yoke and the inching/brake pedal. Install cotter pin into the rod end pin. 6. Adjust free pedal per the following procedure: a. Loosen nut and screw it away from yoke. b. Turn push rod counterclockwise, as viewed from top, until push rod can be moved from side to side. c. Turn push rod clockwise until it can no longer be moved from side to side. d. Turn push rod counterclockwise 1/3 to 2/3 turns. e. Tighten nut to lock the push rod and the yoke. f. Verify free pedal is 3 to 5 mm. See Figure 19. 7. Flush with brake fluid and air bleed system. See Brake System Air Removal. 8. Adjust fluid level until level is within 2.5 mm of MAX line. 9. Verify all connections are leak-free. 10. Check adjustment of brake pedal as described in Brake Pedal Adjustment. 11. Install floor plate, and kick plate, on lift truck. 18 19
SERVICE BRAKES ADJUSTMENT The following procedure is for newly installed brake shoes. If the lift truck has been operated for more than 25 hours and has correct pedal height, the brakes normally will not need adjustment. 1. See the procedure How to Put Lift Truck on Blocks in the Periodic Maintenance section for your lift truck or the Operating Manual for your lift truck. Put the lift truck on blocks so that the drive wheels can be removed. Remove the drive wheels. 2. Use an adjuster tool to rotate the adjuster wheel so that the teeth of the wheel move downward. This adjustment expands the brake shoes. Adjust the brake shoes so that the brake drum will not rotate. NOTE: If the brake shoes were not replaced, loosen the adjuster wheel approximately 20 teeth. 3. Push the automatic adjuster lever away from the adjuster wheel with a small screwdriver. Use the adjuster tool to loosen the adjuster wheel approximately 20 teeth (new brake shoes). 4. Install the drive wheels. Remove the lift truck from the blocks. Operate the lift truck in the FORWARD and REVERSE directions. Stop the lift truck 10 times in each direction. This procedure causes the brake shoes to wear a small amount and fit the brake drum better. 19 20
BRAKE SYSTEM AIR REMOVAL There are two commonly used methods to remove air from the brake system. The preferred method is using a pressure bleed system. The other method is by applying pressure using the brake pedal. [1] Using Pressure Bleed System NOTE: Adjust the service brakes before the air is removed from the brake system. 1. Fill the brake fluid reservoir with brake fluid. 2. Place one end of a rubber hose on the bleeder screw of each wheel cylinder. Place the other end of each hose into a clear container of brake fluid. 3. Connect a pressure bleeder to the brake fluid reservoir. 4. Loosen the bleeder screws at the wheel cylinders one turn. NOTE: While applying air pressure to the pressure bleeder, check the level of the brake fluid in the reservoir for the master cylinder. Make sure to obtain the brake fluid at the correct level to avoid forcing more air into the brake system. 5. Apply 34.5 kpa (0.4kgf/cm 2 ) of air pressure to the pressure bleeder, forcing fluid through the lines until all air is removed from the system. Close the bleeder screws. 6. Check the level of the brake fluid in the reservoir for the master cylinder. Fill the brake fluid reservoir to the correct level. [2] Using Brake Pedal Pressure Perform the following procedure to remove used brake fluid from the remainder of the brake system. 1. Ensure that the master cylinder reservoir is filled with brake fluid and the appropriate free play exists between the push rod and the piston. 2. Put one end of a rubber hose on the bleeder valve of the master cylinder. Put the other end of the hose into a empty container. 3. Loosen the bleeder valve at the master cylinder one turn so that the used brake fluid can be removed from the brake system and close the bleeder valve. 4. Slowly push the brake pedal and hold it at the end of its stroke. Loosen the bleeder valve so that the air in the master cylinder can be removed with the fluid. Close the bleeder valve when the fluid flow stops. Release the brake pedal. NOTE: The new brake fluid will be easily recognized, as the color will be more clear than the used fluid which will be darker. 5. Repeat Step 4 until there is new brake fluid in the container and no air exists in the fluid coming out of master cylinder. 6. Repeat Step 1 through Step 5 for the wheel cylinder. 7. Check the level of the brake fluid in the reservoir for the master cylinder during the procedure. Make sure to keep the brake fluid at the correct level. 8. Repeat the procedure for the other wheel cylinder. 20 21
BRAKE PEDAL ADJUSTMENT, 1-PEDAL OPTION Check and adjust the inching/brake pedal by the following procedure if the control valve on the transmission, the master cylinder, the service brakes and the pedal linkage are repaired and reinstalled. See Figure 19. 1. Adjust the pedal height to 169 to 174 mm from the top surface of the floor plate (160 to 165 mm from the top of the floor mat) by the capscrew (3). 2. Adjust the inching/brake pedal stroke for actuating the bell crank (4) (overlap stroke of inching and brake) to 17 to 21 mm by the stop lamp switch (5). 3. Adjust the free play on the pedal for actuating the master cylinder (6). See INSTALL AND ADJUST of MASTER CYLINDER REPAIR. 4. Adjust the free play on the pedal for actuating the inching cable (7) to 2.5 to 7.5 mm by the adjustment nut on the inching cable (8). Ensure the bell crank on the inching valve (9) does not push the spool (10) when the pedal (2) in released. 1. BRACKET 2. INCHING/BRAKE PEDAL 3. CAPSCREW 4. BELL CRANK 5. STOP LAMP SWITCH 6. MASTER CYLINDER 7. INCHING CABLE 8. ADJUSTMENT NUTS 9. BELL CRANK 10. SPOOL Figure 19. 21 22
See Figure 20. BRAKE PEDAL ADJUSTMENT, 2-PEDAL OPTION 1. Adjust the inching pedal height to 160 to 165 mm from the top surface of the floor plate (151 to 156 mm from the top of the floor mat) by the capscrew (3). 2. Adjust the inching pedal stroke for actuating the brake pedal (4) (overlap stroke of inching and brake) to 19 to 25 mm by the stop lamp switch (5). 3. Ensure the brake pedal height is 160 to 165 mm from the top surface of the floor plate (151 to 156 mm from the top of the floor mat). Repeat Step 1 through Step 3 if the measurement is out of the range. 4. Adjust the free play on the brake pedal for actuating the master cylinder (6). See INSTALL AND ADJUST of MASTER CYLINDER REPAIR. 5. Adjust the free play on the inching pedal for actuating the inching cable (7) to 2.5 to 7.5 mm by the adjustment nut on the inching cable (8). Ensure the bell crank on the inching valve (9) does not push the spool (10) when the inching pedal (2) is released. 1. BRACKET 2. INCHING PEDAL 3. CAPSCREW 4. BARKE PEDAL 5. STOP LAMP SWITCH 6. MASTER CYLINDER 7. INCHING CABLE 8. ADJUSTMENT NUT 9. BELL CRANK 10. SPOOL Figure 20. 22 23
TORQUE SPECIFICATIONS Back Plate to Axle Mount Capscrews H2.0-3.5TX [B466] 255 to 306 N m (2600 to 3120 kg cm) H1.5-1.8TX, H2.0TXS [B475] 152 to 167 N m (1550 to 1700 kg cm) Wheel Cylinder Capscrews H2.0-3.5TX [B466] 18 to 26 N m (133 to 195 kg cm) H1.5-1.8TX, H2.0TXS [B475] 15 to 23 N m (150 to 230 kg cm) Axle Shaft Capscrews H2.0-3.5TX [B466] 90 to 108 N m (920 to 1100 kg cm) H1.5-1.8TX, H2.0TXS [B475] 52 to 62 N m (530 to 630 kg cm) Wheel Nuts H3.0-3.5TX [B466] 294 to 343 N m (3000 to 3500 kg cm) H1.5-1.8TX, H2.0TXS [B475] and H2.0-2.5TX [B466] 196 to 216 N m (2000 to 2200 kg cm) 23 24