SERVICE REPAIR H80FT H90FT H100FT H110FT H120FT [P005]
1800 SRM 1247
General
General DRY BRAKE SYSTEM
WET BRAKE SYSTEM
NOTE: The dry brake system is used only on lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005).
NOTE: The wet brake system is used on all lift truck models covered in this SRM. The wet brake system in this section includes the following parts: master cylinder and parking brake system. See Figure 2 and Figure 3.
This section has service procedures for the dry brake system. The dry brake system includes the following parts: master cylinder and parking brake system (see Figure 1) and brake shoes and wheel cylinders (see Figure 4).
NOTE: LIFT TRUCK MODEL S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) SHOWN. 1. 2. 3. 4. 5.
1. 2. 3. 4. 5. 6. 7.
PARK BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB PARK BRAKE CABLES INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER BRAKE ASSEMBLY BRAKE POSITION SENSOR (RIGHT-HAND SIDE) Figure 1. Dry Brake System
6. 7. 8. 9. 10. 11.
PARK BRAKE HANDLE ASSEMBLY INCH/BRAKE PEDAL BOOSTER ASSEMBLY PARK BRAKE LEVERS PLANETARY CARRIER HOUSING (LEFT-HAND SIDE SHOWN) WET DISC BRAKE HOUSING PARK BRAKE CABLES ADJUSTMENT KNOB BRAKE POSITION SENSOR (LEFT-HAND SIDE SHOWN) MASTER CYLINDER CYLINDER BLOCK
Figure 2. Wet Brake System for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
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Service Brakes Repair (Dry Brake)
1800 SRM 1247
The wet disc brakes are a component of the wet brake drive axle. The brake discs are located inside the planetary carrier housing at each end of the drive axle. See Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1246 for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1318 for lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) or Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1344 for lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) for the removal, assembly and installation procedures.
NOTE: LIFT TRUCK MODEL S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) SHOWN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
PARK BRAKE HANDLE ASSEMBLY INCH/BRAKE PEDAL BOOSTER ASSEMBLY ADJUSTMENT KNOB PLANETARY CARRIER HOUSING (LEFT-HAND SIDE SHOWN) WET DISC BRAKE HOUSING PARK BRAKE CABLES BRAKE POSITION SENSOR MASTER CYLINDER CYLINDER BLOCK PARK BRAKE LEVERS
Figure 3. Wet Brake System for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
Service Brakes Repair (Dry Brake) NOTE: The procedures in this section apply on to lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
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(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) equipped with the dry brake system.
1800 SRM 1247
REMOVE AND DISASSEMBLE 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. See the procedure How to Put Lift Truck on Blocks in the section Periodic Maintenance 8000 SRM 1248 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. 2. Remove the capscrews that hold the axle shaft to the hub. Remove the axle shaft.
Service Brakes Repair (Dry Brake) 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 the hub and drum assembly. Do not damage the grease seal when removing the hub. NOTE: During disassembly, note the arrangement of parts to aid in re-assemble of the brake system. 5. Remove the primary, secondary return springs and tension spring with spring pliers and remove the anchor pin from the primary brake shoe. See Figure 4. 6. Remove the pressure springs that hold the brake shoes to the backing plate. 7. Disconnect the parking brake cable from park brake lever. See Figure 4.
WARNING When the brake shoes are removed, do not create dust in the air. See the Clean procedure in this section. 8. Remove brake shoes. 9. Remove the auto adjuster assembly from the backing plate. See Figure 5.
3. Bend the lock plate tab and remove the nut, lockplate, washer and bearing cone.
10. Disconnect the brake line from the wheel cylinder. Remove wheel cylinder from backing plate. See Figure 5.
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
11. If damaged, remove the backing plate from the axle housing. Discard the eight mounting lock bolts.
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Service Brakes Repair (Dry Brake)
1. 2. 3. 4. 5. 6. 7. 8.
RETAINER SECONDARY RETURN SPRING SECONDARY BRAKE SHOE PRESSURE SPRING AUTO ADJUSTER LINK ADJUSTER WHEEL AUTO ADJUSTMENT ASSEMBLY PARKING BRAKE CABLE
1800 SRM 1247
9. 10. 11. 12. 13. 14. 15. 16.
TENSION SPRING PRIMARY BRAKE SHOE PARK BRAKE LEVER STRUT PRIMARY RETURN SPRING ANCHOR PIN BACKING PLATE WHEEL CYLINDER
Figure 4. Brake Assembly (Left-Hand Shown)
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1800 SRM 1247
Service Brakes Repair (Dry Brake) damage and leaks in the seals of a brake system. Small amounts of water in the brake system can cause reduced braking if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water. DO NOT use unfiltered shop air to blow out brake components. 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.
CAUTION Do not permit brake cleaning fluid to contact the master cylinder or wheel cylinder. Brake cleaning fluid will cause damage and leaks in seals of the brake system. 1. Do not release brake lining dust from the brake linings into the air when the brake drum is removed.
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. 1. 2. 3. 4.
WHEEL CYLINDER CAPSCREWS AUTO ADJUSTER CAPSCREW ADJUSTER WHEEL ACCESS PLUGS BRAKE LINE
Figure 5. Auto Adjuster and Wheel Cylinder Mount Location
CLEAN WARNING DO NOT use an oil solvent to clean the brake linings, use a solvent approved for cleaning of brake parts. Do not permit oil or grease on the brake linings, the brakes will not operate correctly if oil, grease, or brake cleaning fluid is on the brake linings. Oil and grease will cause
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. 4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air.
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Service Brakes Repair (Dry Brake)
INSPECT WARNING Small amounts of water in the brake system can cause reduced braking if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water. DO NOT use unfiltered shop air to blow out brake components. 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.
CAUTION Do not permit brake cleaning fluid to contact the master cylinder or wheel cylinder. Brake cleaning fluid will cause damage and leaks in seals of the brake system. 1. Inspect the bore of the wheel cylinder for holes or scratches. Replace the wheel cylinder assembly if there is any damage. 2. Inspect wheel cylinder parts for dirt or water. Clean any dirt or water present in the wheel cylinder parts using a lint free cloth. 3. Inspect the primary, secondary and tension 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. 4. Inspect the park brake lever and strut. If damaged, replace primary and secondary brake shoe assembly.
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.
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1800 SRM 1247 5. 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 (0.039 in.) 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. 6. Inspect the brake drum for deep grooves or other damage. NOTE: If grooves must be removed from the brake drums, do not grind more than 1.5 mm (0.060 in.) from the internal diameter of the brake drum. The maximum limit of the internal diameter of the brake drum is 317.5 mm (12.4 in.). If the internal diameter is larger than the limit, replace the brake drum. 7. The teeth of the adjuster wheels must not be worn. The adjuster wheel must turn freely. Check the adjuster links for damage. See Figure 4 and Figure 5. Replace the auto adjuster assembly if there is any damage. 8. Make sure the parking brake cables are in good condition. Replace parking brake cables if worn or damaged. 9. Check the grease seals and the surfaces of the seals for wear or damage. Replace damaged seals.
ASSEMBLE AND INSTALL 1. If removed, install backing plate using eight new lock bolts to the axle housing using tightening sequence, see Figure 6. Tighten bolts to 340 to 375 N•m (251 to 277 lbf ft). NOTE: Replace wheel cylinder if there is any damage or it is not working properly. 2. Install the wheel cylinder on the backing plate and tighten capscrews to 20 to 25 N•m (15 to 19 lbf ft). Connect the brake line to the wheel cylinder. See Figure 5.
1800 SRM 1247
Service Brakes Repair (Dry Brake)
NOTE: Replace auto adjuster assembly if there is any damage or it is not working properly.
7. Install pressure springs to hold the brake shoes to the backing plate.
3. Install the auto adjuster assembly on the backing plate between the two brake shoes and tighten capscrew to 120 to 140 N•m (89 to 103 lbf ft). See Figure 4 and Figure 5.
8. Install the primary and secondary return springs, and tension spring to the brake shoe. See Figure 4.
4. Lubricate the backing plate with small amount of lithium grease where the brake shoes touch.
9. Coat threads of the adjuster wheels with antiseize compound. Turn the adjuster wheels so that the adjuster assembly is in its shortest position. This action permits the brake drum to be easily installed over the brake shoes. 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. 10. Clean the bearings and lubricate them with wheel bearing grease. Install the bearings and seals in the wheel hub. Install the assembly on the axle housing. See Figure 7 and Figure 8. 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.
Figure 6. Backing Plate to Axle Housing Tightening sequence NOTE: The park brake lever and strut are a component of the primary brake shoe. If damaged, replace primary and secondary brake shoe assembly. 5. Install the primary and secondary brake shoes on the push rod of wheel cylinder and auto adjuster link. See Figure 4.
11. Install the washer, lock plate and wheel adjustment nut. See Figure 9. To align the bearing rollers, tighten the wheel adjustment nut to 28 to 32 N•m (21 to 24 lbf ft) and rotate the hub 2 revolutions in both directions. To seat the wheel bearings, tighten the wheel adjustment nut to 400 to 480 N•m (295 to 354 lbf ft). Back off the wheel adjustment nut to zero end play. Preload the wheel bearings by tightening the wheel adjustment nut to 28 to 32 N•m (21 to 24 lbf ft). Rotate the hub 3 complete revolutions in both directions. Verify the wheel adjustment nut torque is 28 to 32 N•m (21 to 24 lbf ft) and that the torque stabilizes at that specification.
6. Connect the parking brake cable to park brake lever.
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Service Brakes Repair (Dry Brake)
1. INNER SEAL 2. OUTER SEAL 3. BRAKE DRUM
1800 SRM 1247
4. INNER BEARING 5. OUTER BEARING Figure 7. Grease Seals and Bearing Locations
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
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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 two adjuster wheels equally, approximately 20 teeth.
1800 SRM 1247
Service Brakes Repair (Dry Brake) 13. 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.
Figure 8. Inner Grease Seal Installation
1. ADJUSTER LEVER 2. ADJUSTER WHEEL 3. ADJUSTER LINK Figure 10. Auto Adjuster Assembly
1. 2. 3. 4. 5.
AXLE SHAFT WHEEL ADJUSTMENT NUT LOCK PLATE WASHER HUB
14. Coat the flange of the axle shaft with liquid sealant, Hyster Part Number 264159. Install the axle shaft and capscrews. Tighten the capscrews in the sequence shown in Figure 11 to 90 to 99 N•m (66 to 73 lbf ft).
Figure 9. Wheel Adjustment 12. To manually adjust the brakes, it is necessary to turn the adjuster wheels. See Figure 4. Remove the two access plugs in the adjustment slots located on the back side of the backing plate. Place an adjuster tool and screwdriver through the slot in the backing plate. See Figure 5. Push the adjuster lever away from the adjuster wheel, in the direction indicated in Figure 10 and turn the adjuster wheel until the brake shoe just touches the brake drum. Use the adjuster tool to loosen the adjuster wheel approximately 20 teeth. Adjust the brake shoe for the other adjuster wheel using the same method. See Figure 10. Make sure to install the access plugs after the adjustment is complete. See Figure 5.
Figure 11. Axle Shaft Tightening Sequence
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Parking Brake Repair
1800 SRM 1247
ADJUST
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.
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 610 to 680 N•m (450 to 502 lbf ft). 3. Start the engine and tilt the mast backward to remove the blocks. Push on the brake pedal. The
4. The service brakes must be adjusted before the parking brake can be adjusted. See Figure 13 and the following paragraphs in this section for the correct adjustment of the parking brake.
Parking Brake Repair REMOVE AND DISASSEMBLE NOTE: For removal and disassembly procedures for a dry brake system use Step 1 through Step 5. For the wet brake system use Step 1 through Step 4 and Step 6. If the handle assembly for the parking brake must be removed from the cowl, use the following procedure. For dry brake system see Figure 13 and for wet brake system see Figure 14 and Figure 15. 1. Block the front and rear side of the wheels to make sure the lift truck cannot move. Release the parking brake handle assembly. 2. Remove the four capscrews that fasten the bracket for the parking brake to the cowl. Remove the bracket and parking brake handle assembly. 3. Loosen the jam nuts that fasten the threaded ends of the parking brake cables to the parking brake handle assembly. 4. Turn the adjustment knob counterclockwise until the parking brake cables are loosened. Disconnect the cables from the equalizer links. 5. The service brake assembly must be removed before the parking brake cable can be removed from the back plate of the service brake. See Figure 12. 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. See Figure 12.
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1. 2. 3. 4. 5.
PARKING BRAKE CABLE SHEATH SNAP RING SERVICE BRAKE ASSEMBLY BACK PLATE
Figure 12. Parking Brake Cable Removal for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Dry Brake System 6. The cotter pin, clevis pin, and cable clamps must be removed from the parking brake levers before the parking brake cables can be removed. See Figure 14 and Figure 15.
1800 SRM 1247
Parking Brake Repair
Figure 13. Parking Brake Lever Adjustment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Dry Brake System 11
Parking Brake Repair
1800 SRM 1247 Legend for Figure 13
A. RIGHT HAND SIDE
B. LEFT HAND SIDE
1. 2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12. 13. 14.
PARKING BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB PARKING BRAKE CABLES INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER BRAKE ASSEMBLY BRAKE POSITION SENSOR
ADJUSTMENT SLOT (UNDERNEATH SPRING) EQUALIZER LINK NUT CAPSCREW PARKING BRAKE BRACKET JAM NUTS PARKING BRAKE CABLE BRACKET
Legend for Figure 14 A. 1. 2. 3. 4. 5. 6. 7.
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005)
PARKING BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB EQUALIZER LINKS PARKING BRAKE CABLES NUT CAPSCREW BRAKE POSITION SENSOR (RIGHT SIDE SHOWN) 8. ADJUSTMENT SLOT (UNDERNEATH SPRING)
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B. S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) 9. 10. 11. 12. 13. 14. 15. 16. 17.
INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER CLEVIS PIN COTTER PIN PARKING BRAKE LEVER CABLE CLAMPS PARKING BRAKE BRACKET JAM NUTS PARKING BRAKE CABLE BRACKET
1800 SRM 1247
Parking Brake Repair
Figure 14. Parking Brake Lever Adjustment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Wet Brake System 13
Parking Brake Repair
1800 SRM 1247
Figure 15. Parking Brake Lever Adjustment for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) (Wet Brake System)
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1800 SRM 1247
Parking Brake Repair Legend for Figure 15
A. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
B. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
1. 2. 3. 4. 5. 6. 7. 8.
9. 10. 11. 12. 13. 14. 15.
PARKING BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB EQUALIZER LINKS PARKING BRAKE CABLES NUT CAPSCREW BRAKE POSITION SENSOR ADJUSTMENT SLOT (UNDERNEATH SPRING)
ASSEMBLE AND INSTALL NOTE: For assemble and install procedures for a dry brake system use Step 1, Step 3, Step 4, Step 6 and Step 7. For the wet brake system use Step 2, Step 3, and Step 5 through Step 7. If the lever assembly for the parking brake was removed from the cowl, use the following procedure for installation:
INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER CLEVIS PIN COTTER PIN PARKING BRAKE LEVER CABLE CLAMPS/MOUNTING BRACKET JAM NUTS in the parking brake handle assembly and not pulling on the equalizer links with the parking brake handle assembly in the released position. See Figure 14 and Figure 15.
6. Install the round ends of the parking brake cables in their slots in the equalizer link. Tighten the upper jam nuts to hold the sheaths of the parking brake cables in the parking brake cable bracket.
1. The parking brake cables must be installed in the back plate before the service brake is installed. See Figure 12. A snap ring holds the sheath of the parking brake cable in the back plate of the service brake. Install the parking brake cable in the back plate and install the snap ring that holds the sheath of the parking brake cable in the back plate. See Figure 12.
7. Use the four capscrews, washers, and nuts and fasten the bracket to the inside of the cowl. Tighten park brake cable clamps on frame and axle.
2. The parking brake cables must be installed on the parking brake levers located on the wet brake drive axle and the cables loosely clamped to the frame and axle in the correct position before connecting cables to the equalizer links located on the parking brake handle assembly. See Figure 14 and Figure 15.
Make sure the service brakes are adjusted and the operation of the automatic adjuster mechanism is correct before the parking brake cables are adjusted.
3. Make sure the parking brake handle is in the released position. Turn the adjustment knob until the equalizer link is adjusted to the bottom of the adjustment slot. For Dry Brake system, see Figure 13. For Wet Brake system, see Figure 14 and Figure 15. 4. Adjust the jam nuts on the ends of the cable assemblies so that the threads of the cable sheaths extend 23 to 26 mm (0.90 to 1.02 in.) above their support plate in the lever assembly. See Figure 13. 5. Adjust the jam nuts on the ends of the parking cables so that the threads of the cable are level
ADJUST Dry Brake System
Wet Brake System Make sure the park brake levers are adjusted before the parking brake cables are adjusted. See Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1246 for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1318 for lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) or Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1344 for lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) for park brake lever adjustment procedures.
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Master Cylinder Repair
1800 SRM 1247
Lift Trucks With a MONOTROLÂŽ Pedal or Forward Reverse Lever The switch energizes the seat warning circuit when hand lever is released. This switch puts the transmission in NEUTRAL by de-energizing the direction solenoid. There is also a switch on the left-hand side of bracket. This switch prevents engine from starting unless parking brake is applied.
CAUTION On lift trucks equipped with the wet brake system, check the dash display to verify the transmission oil is at operating temperature, 49 to 66 C (120 to 150 F) before adjusting the parking brake adjustment knob. 1. To adjust the parking brake, turn the adjustment knob to raise the equalized link and tighten the parking brake cables shown in Figure 13, Figure 14 and Figure 15. Do not tighten the adjustment so that the brake is applied when the lever is released. The lever for the parking brake has a lock. Use your thumb or finger to release the lock on the lever when the parking brake is released.
NOTE: Before doing Step 2 and Step 3, make sure the parking brake is correctly adjusted. The parking brake is correctly adjusted when it takes 125 N (28 lbf) force (6 clicks) to fully apply the parking brake for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and 200 N (45 lbf) force (6 clicks) to fully apply the parking brake for lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006). 2. For new brakes, test the operation of the parking brake. The lift truck, with a capacity load, must not move when parking brake is applied on a 7.5 percent grade [a slope that increases .75 m in 10 m (9 in. in 10 ft)]. 3. For burnished brakes, test the operation of the parking brake. The lift truck, with a capacity load, must not move when parking brake is applied on a 15 percent grade [a slope that increases 1.5 m in 10 m (1.5 ft in 10 ft)].
Master Cylinder Repair REMOVE NOTE: The removal procedure in this section is the same for both dry and wet brake systems. 1. Remove the floor plate, kick plate, and seal plate from the lift truck for access to the master cylinder and booster assembly. 2. Remove master cylinder hoses and brake pressure transducer: a. For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, S100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), remove and tag the brake
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booster supply and return hoses from the master cylinder and booster assembly. Plug hoses to prevent hoses from draining. Disconnect the connector at the brake pressure transducer, and remove brake pressure transducer. See Figure 16. b. For lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024), remove and tag the accumulator to booster hose, the booster and accumulator supply hose, the brake hose, and booster return hose. Plug hoses to prevent hoses from draining. Disconnect the connector at the brake pressure transducer, and remove brake pressure transducer. See Figure 17.
1800 SRM 1247
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
CAPSCREW BRAKE OIL RESERVOIR CLAMP UPPER BRAKE OIL SUPPLY HOSE CYLINDRICAL BLOCK MOUNT LOWER BRAKE OIL SUPPLY HOSE INSERT FITTING FOR BOOSTER RETURN HOSE BRAKE HOSE
Master Cylinder Repair
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
BRAKE PRESSURE TRANSDUCER BOOSTER SUPPLY HOSE BOOSTER ASSEMBLY MOUNTING BOLT MANIFOLD MOUNT BRACKET COTTER PIN ROD END PIN MASTER CYLINDER NIPPLE
Figure 16. Master Cylinder and Reservoir Assembly, Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
17
Master Cylinder Repair
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
BOOSTER MASTER CYLINDER BOOSTER RETURN HOSE MANIFOLD BOOSTER AND ACCUMULATOR SUPPLY HOSE ACCUMULATOR TO BOOSTER HOSE ELBOW FITTING ACCUMULATOR MOUNTING CLAMP/BRACKET BRAKE HOSE BRAKE PRESSURE TRANSDUCER
Figure 17. Accumulator and Boosted Master Cylinder, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) c. For lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006), remove and tag the accumulator to booster line, the booster and accumulator supply hose and the brake hose. Plug hoses to prevent hoses from draining. Disconnect the connector at the brake pressure transducer, and remove brake pressure transducer. See Figure 18.
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1800 SRM 1247
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
BOOSTER BOOSTER RETURN HOSE MANIFOLD MASTER CYLINDER ACCUMULATOR TO BOOSTER LINE BOOSTER AND ACCUMULATOR SUPPLY HOSE TEE FITTING MOUNTING CLAMP/BRACKET ACCUMULATOR BRAKE HOSE BRAKE PRESSURE TRANSDUCER
Figure 18. Accumulator and Boosted Master Cylinder, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
1800 SRM 1247 3. Disconnect and cap the lower brake oil supply hose from nipple at the master cylinder. See Figure 16. 4. Remove the cotter pin and rod end pin from the clevis that is attached to the brake linkage lever arm. 5. Remove capscrews and nuts that hold master cylinder and booster assembly to bracket assembly.
DISASSEMBLE CAUTION When the piston is removed or installed, make sure the cylinder bore and piston are not scratched or damaged. 1. Place master cylinder and booster assembly into a soft jawed vise. 2. Remove three mounting capscrews and master cylinder from booster. See Figure 19.
WARNING Piston is under extreme pressure. Use care when removing snap ring to avoid possible injury. 3. Remove the snap ring holding the piston. 4. Remove Piston.
Master Cylinder Repair 7. Remove the washer between the pressure seal and the piston. 8. Remove and discard the retaining seal from the piston. Note the position of the seal.
CLEAN AND INSPECT WARNING Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water, therefore, DO NOT use unfiltered shop air to blow out components.
CAUTION DO NOT permit brake cleaning fluid to contact master cylinder. Brake cleaning fluid will cause damage and leaks in seals of the brake system. Inspect the bore of the master cylinder for holes and scratches. Replace the master cylinder and booster assembly if there is damage. See Figure 19. Inspect master cylinder parts for dirt or water. Clean any dirt or water present in master cylinder parts using a clean lint free cloth.
5. Remove the spring and retainer from the bore. 6. Remove and discard the pressure seal from the spring end of the piston.
19
Master Cylinder Repair
1. 2. 3. 4. 5.
1800 SRM 1247
BOOSTER ASSEMBLY HOUSING (MASTER CYLINDER) SNAP RING PISTON RETAINING SEAL
6. 7. 8. 9. 10.
PRESSURE SEAL WASHER RETAINER SPRING CAPSCREW
Figure 19. Master Cylinder and Booster
ASSEMBLE NOTE: Install new seals when the master cylinder is being assembled. 1. Install the new retaining seal on the piston, as noted during removal. 2. Install the washer between the pressure seal and the piston.
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3. Install the new pressure seal and retainer over the spring end of the plunger. 4. Install the spring and piston into the bore of the master cylinder. 5. Install the snap ring holding the piston. 6. Install the master cylinder on the booster assembly with three capscrews and tighten to 49 to 59 N•m (36 to 43 lbf ft).
1800 SRM 1247
INSTALL AND ADJUST WARNING Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water, therefore, DO NOT use unfiltered shop air to blow out components. NOTE: The install and adjust procedure is the same for both dry and wet brake systems.
Master Cylinder Repair 5. Install the brake pressure transducer into master cylinder and tighten to 23 to 28 N•m (16.9 to 20.6 lbf ft). See Figure 16, Figure 17, or Figure 18. 6. Orient master cylinder side of brake supply and return lines parallel with brake pressure transducer. 7. Tighten fitting nuts at each end of brake hose assembly to 13 to 18 N•m (84 to 117 lbf in). 8. Apply a layer of multipurpose grease to the rod end pin and, with twisting motion, insert through clevis and the inching/brake pedal. Install cotter pin into the rod end pin. 9. Adjust free pedal per the following procedure:
NOTE: The master cylinder uses Dexron III brake oil. For the correct amount oil used see the Maintenance Schedule. 1. Using capscrews and nuts, install the master cylinder and brake booster assembly on the bracket assembly. See Figure 16. 2. Attach the clevis to the bracket using the rod end pin and cotter pin. 3. Uncap and install the lower brake oil supply hose onto the nipple at the master cylinder. 4. Connect hoses to master cylinder booster assembly: a. For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, S100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), connect the brake booster supply and return hoses to the master cylinder and booster assembly. See Figure 16. b. For lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024), connect the accumulator to booster hose, the booster and accumulator supply hose, the brake hose, and booster return hose. See Figure 17. c. For lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006), connect the accumulator to booster line, the booster and accumulator supply hose and the brake hose. See Figure 18.
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 1.5 to 1.75 turns. e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft). f.
Verify free pedal is 10 to 12 mm (0.39 to 0.47 in.). See Figure 26.
10. Flush with Dexron III brake oil from a sealed container, and air bleed system. See Brake System Air Removal. 11. Adjust oil level until level is within 2.5 mm (0.098 in.) of MAX line or 5 to 7.5 mm (0.19 to 0.29 in.) above large rib on reservoir if MAX line is not present. 12. Verify all connections are leak-free. 13. Install floor plate, kick plate, and seal plate on lift truck. 14. Check adjustment of brake pedal as described in Brake Pedal Adjustment.
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Accumulator
1800 SRM 1247
Accumulator The accumulator is used on the S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) lift trucks only.
4. Remove the cap from the accumulator. See Figure 20. 5. Connect a 0 to 34 bar (0 to 500 psi) gauging assembly to the accumulator check valve. See Figure 20. 6. Apply brake pedal ten times until the pressure stabilizes and observe the gauge reading. This reading in pressure represents the precharge of the accumulator. 7. Recharge with nitrogen gas to the required precharge pressure of 4 ±0.35 bar (58 ±5 psi). 8. Disconnect gauging assembly and install cap.
REMOVE WARNING The accumulator has a pressure charge and can cause an injury if the pressure is released too fast. Follow the manufacturer’s instructions during removal and installation. 1. 2. 3. 4.
CAP O-RING CHECK VALVE ACCUMULATOR Figure 20. Accumulator
PRECHARGE CHECK NOTE: During service, the precharge pressure will decrease as a result of the natural diffusion of nitrogen gas. Therefore, the precharge pressure must be checked every 12 months and recharged if required. NOTE: For checking of the precharge value, proceed as follows: 1. Lower the forks completely. 2. Switch the engine OFF. 3. For lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024), remove the floor mats, floor plates and raise the hood for access to the accumulator. For lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) remove the floor mats and floor plates for access to the accumulator.
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Before disconnecting any hydraulic lines, release pressure from hydraulic circuit as follows: • Shut OFF the engine and completely lower the forks. Install blocks at the wheels to prevent the lift truck from moving. • Operate the lift/lower lever and the brake pedals until the hydraulic pressure is released. 1. Perform the following step that applies to your lift truck. a. For S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) lift trucks, release pressure from the accumulator by slowly disconnecting the elbow fitting on the accumulator from the hose between the accumulator and booster. See Figure 21. b. For H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) lift trucks, to release system pressure, slowly disconnect the line between the booster and accumulator from the tee fitting on the accumulator. Slowly disconnect the hose between the manifold on the drive axle and accumulator from the tee fitting on the accumulator. See Figure 22.
1800 SRM 1247
1. 2. 3. 4. 5. 6. 7. 8. 9.
BOOSTER MASTER CYLINDER BOOSTER RETURN HOSE MANIFOLD BOOSTER AND ACCUMULATOR SUPPLY HOSE ACCUMULATOR TO BOOSTER HOSE ELBOW FITTING ACCUMULATOR MOUNTING CLAMP/BRACKET
Figure 21. Accumulator and Boosted Master Cylinder, S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) 2. Place caps on all disconnected lines and hoses. 3. Loosen the nut on the accumulator mounting clamp/bracket and remove accumulator. See Figure 23. 4. If necessary, remove the elbow or tee fitting from the accumulator. See Figure 23.
Accumulator
1. 2. 3. 4. 5. 6. 7. 8. 9.
BOOSTER BOOSTER RETURN HOSE MANIFOLD MASTER CYLINDER ACCUMULATOR TO BOOSTER LINE BOOSTER AND ACCUMULATOR SUPPLY HOSE TEE FITTING MOUNTING CLAMP/BRACKET ACCUMULATOR
Figure 22. Accumulator and Boosted Master Cylinder, H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
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Accumulator
1800 SRM 1247
A. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
B. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
1. ACCUMULATOR 2. ELBOW FITTING 3. CLAMP/BRACKET
4. NUT 5. TEE FITTING Figure 23. Accumulator and Mounting Clamp/Bracket
INSTALL 1. If removed, install the elbow or tee fitting to accumulator. See Figure 23. 2. Place the accumulator in position in the mounting clamp/bracket and tighten nut to 17 N•m (13 lbf ft). 3. Perform the following step that applies to your lift truck. a. For S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) lift trucks, connect the hose between the booster and accumulator to the elbow fitting on the accumulator. See Figure 21.
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b. For H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) lift trucks, connect the line between the booster and accumulator to the tee fitting on the accumulator. Connect the hose between the manifold on the drive axle and accumulator to the tee fitting on the accumulator. See Figure 22. 4. For lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024), install the floor mats, floor plates and close the hood. For lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) install the floor mats and floor plates. 5. Operate the system and check for leaks.
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