Hyster A177 (H2.00XL Europe) Forklift Service Repair Manual

SERVICE REPAIR H2.00XL H2.50XL H3.00XL Europe [A177]

LIFT TRUCK WEIGHTS* Unit

Kilograms

Pounds

H2.00XL (H40XL)

3515

7750

H2.50XL (H50XL)

3855

8500

H3.00 (H60XL)

4315

9510

*Lift trucks equipped with overhead guard, mast, carriage, load backrest extension, forks, gasoline engine and operator.

H2,00–2.50XL (H40–50XL) with 3760 mm (148 in) two–stage mast.

H3.00XL (H60XL) with 3600 mm (142 in) two–stage mast.

ENGINE SPECIFICATIONS Engine

Mazda M4–121G (A177, B177, C177)*

GM 4–181 (C177)*

Isuzu C240 (A177, B177, C177)*

Isuzu 4JB1 (C177)*

No. of Cylinders Firing Order Bore and Stroke

4 1–3–4–2 82 mm x 94 mm (3.23 in x3.70 in) 1985 cm3 (121.1 in3) 8.0:1 (A177) 8.6:1 (B177, C177) 1075 kPa (156 psi) @ 200 rom

4 1–3–4–2 102 mm x 91 mm (4.00 in x 3.60 in) 2966 cm3 (181 in3) 8.0:1

4 1–3–4–2 86 mm x 102 mm (3.39 in x 4.02 in) 2369 cm3 (144.5 in3) 20.0:1

4 1–3–4–2 93 mm x 102 mm (3.67 in x 4.02 in) 2771 cm3 (169 in3) 18.2:1

758 kPa (110 psi) @ 200 rpm

3040 kPa (441 psi) @ 200 rpm

3040 kPa (441 psi) @ 200 rpm

Displacement Compression Ratio Compression Pressure Oil Pressure Ignition Timing Valve Clearance (Inlet and Exhaust) Idle Speed Governor Speed @ No Load Stall Speed** Gasoline LPG Thermostat Range Cooling System Pressure Fuel Injector Pressure Fuel Injection Timing

450 kPa (65 psi) 138 kPa (20 psi) 390 kPa (57 psi) 294 kPa (43 psi) minimum @3000 rpm minimum @1200 rpm minimum @1000 rpm minimum @2000 rpm Not Applicable Not Applicable 13° BTDC @625 rpm 0° BTDC @500 rpm 0.3 mm (0.012 in) Hot 600 to 650 rpm 3000 to 3100 rpm

One turn down from zero clearance 560 to 600 rpm 2700 to 2800 rpm

0.45 mm (0.018 in) Cold 600 to 650 rpm 3000 to 3100 rpm

0.40 mm (0.016 in) Cold 750 to 800 rpm 2250 to 2350 rpm

2000 to 2100 rpm 1950 to 2050 rpm

2150 to 2250 rpm 2100 to 2200 rpm

2050 to 2150 rpm (Diesel)

1955–2055 rpm (Diesel)

75 to 78°C (167 to 172°F) 103 kPa (15 psi)

82°C (180°F) 88 kPa (13 psi)

75 to 78°C (167 to 172°F) 103 kPa (15 psi)

75 to 78°C (167 to 172°F) 103 kPa (15 psi)

Not Applicable

Not Applicable

1195 MPa (1706 psi)

1814 MPa (2630 psi)

Not Applicable

Not Applicable

14° BTDC Static

16° BTDC Static

*Lift truck serial number code **Engines with 50 hours or more of operation ♦With initial timing connector disconnected

1

ENGINE ELECTRICAL SPECIFICATIONS Item

Mazda M4–121G (A177, B177, C177)*

GM 4–181 (C177)*

Isuzu C240 (A177, B177, C177)*

Isuzu 4JB1 (C177)*

All Models

12 volt Negative Ground 35 amps (A177) or 56 amps (B/C177) @3000 rpm 0.4 to 0.5 mm (0.016 to 0.020 in) NGK BP–2E or ND W9EPR 0.7 to 0.8 mm (0.028 to 0.032 in)

12 volt Negative Ground 56 amps @2750 rpm

12 volt Negative Ground 56 amps @3000 rpm

12 volt Negative Ground 56 amps @2350 rpm

Electronic ignition system AC R46TS or Champion RBL 17Y 1.1 mm (0.045 in)

Not Applicable

Not Applicable

Not Applicable

Not Applicable

Not Applicable

Not Applicable

Alternator Output (hot) Distributor Points A177 Only Spark Plug Type Gap

*Lift truck serial number code

HYDRAULIC SPECIFICATIONS Item Pump Type

Specification Gear Pump with Flow Control Valve

Main Flow (to Lift, Tilt, and Attachments) A177** @ 2000 rpm with no load

32.9 litres per minute (8.7 gallons per minute)

B177** @ 2000 rpm with no load

35.2 litres per minute (9.3 gallons per minute)

C177** @ 2000 rpm with no load, Mazda or Isuzu Engines

44.7 litres per minute (14.3 gallons per minute)

GM 4–181 Engine

54.1 litres per minute (14.3 gallons per minute)

**Lift truck serial number code

Controlled Flow (to Steering, all units)

6.4 litres/minute (1.7 gallons per minute)

Relief Pressure, Lift System Control valve with three spools and one relief valve

19.3 to 20.0 MPa (2800 to 2900 psi) at full flow (Check at inlet line to control valve port.)

Control valves with four spools and two relief valves: Primary relief valve

19.3 to 20.0 MPa (2800 to 2900 psi) at full flow (Check at inlet line to control valve port with lift spool in full Lift position.)

Secondary relief valve

15.2 to 15.9 MPa (2200 to 2300 psi) at full flow (Check at inlet line to control valve port with tilt spool in full Tilt position.)

Relief Pressure, Steering System, all units

10.3 to 11.0 MPa (1435 to 1552 psi) @ 1000 rpm

Capacity, Hydraulic System

35.0 litre (9.2 gallons)

Capacity, Hydraulic Tank

31.8 litre (8.4 gallons)

Hydraulic System Hydraulic oil temperature at 55 to 65°C (130 to 150°F).

Hydraulic oil with different viscosity will change “flow” values.

2

CAPACITIES Item

Quantity

Engine Oil, Mazda M4–121G

5.2 litre (5.5 qt)

Engine Oil, GM 4–181

4.3 litre (4.5 qt)

Engine Oil, Isuzu C240

5.2 litre (5.5 qt)

Engine Oil, Isuzu 4JB1

6.5 litre (6.9 qt)

Cooling System, Mazda M4–121G

11.1 litre (11.7 qt)

Cooling System, GM 4–181

11.0 litre (11.6 qt)

Cooling System, Isuzu C240

11.4 litre (12.0 qt)

Cooling System, Isuzu 4JB1

11.0 litre (11.6 qt)

Transmission

9.0 litre (9.5 qt)

Differential

7.6 litre (8.0 qt)

Fuel Tank

43.5 litre (11.5 gallons)

Brake Fluid

0.2 litre (0.5 pint)

LIFT TRUCK TRAVEL SPEEDS Unit

Forward

Reverse

H2.00XL (H40XL)

19.5 km/hr (12.1 mph)

19.5 km/hr (12.1 mph)

H2.50XL (H50XL)

19.5 km/hr (12.1 mph)

19.5 km/hr (12.1 mph)

H3.00 (H60XL)

21.4 km/hr (13.3 mph)

21.4 km/hr (13.3 mph)

TIRE SPECIFICATIONS Steering Tires

6.00 x 9, 10 ply

Steering Tires

7.00 x 12, 12 ply

Drive Tires

29 x 8 – 15, 12 ply

Drive Tires

28 x 9 – 15, 12 ply

All Tire Pressures are 860 kPa (125 psi)

3

MAST SPEEDS (Early A177* Units) *Lift truck serial number code

STANDARD MAST Unit

Lifting NO LOAD

Lowering

RATED LOAD

NO LOAD

RATED LOAD

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

H2.00–2.50XL (H40–50XL)

0.50

98

0.46

90

0.55

109

0.55

109

H3.00XL (H60XL)

0.42

82

0.38

74

0.47

92

0.47

92

VISTA TWO–STAGE MAST H2.00–2.50XL (H40–50XL)

0.47

93

0.43

85

0.55

109

0.58

115

H3.00XL (H60XL)

0.37

82

0.34

74

0.47

92

0.47

92

VISTA THREE–STAGE MAST H2.00–2.50XL (H40–50XL)

0.47

92

0.43

84

0.52

102

0.52

102

H3.00XL (H60XL)

0.40

78

0.35

69

0.44

86

0.44

86

MAST SPEEDS (Later A177* Units) *Lift truck serial number code

VISTA FREE–LIFT MAST Unit

Lifting NO LOAD

Lowering

RATED LOAD

NO LOAD

RATED LOAD

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

H2.00–2.50XL (H40–50XL)

0.40

79

0.37

74

0.41

81

0.49

96

H3.00XL (H60XL)

0.40

79

0.35

69

0.41

81

0.48

94

VISTA TWO–STAGE MAST H2.00–2.50XL (H40–50XL)

0.42

83

0.37

74

0.45

89

0.46

91

H3.00XL (H60XL)

0.42

83

0.35

69

0.45

89

0.49

96

VISTA THREE–STAGE MAST

4

H2.00–2.50XL (H40–50XL)

0.40

79

0.37

74

0.43

85

0.45

89

H3.00XL (H60XL)

0.40

79

0.35

69

0.43

85

0.46

91

MAST SPEEDS (B177* and C177* with Mazda M4–121G or Isuzu 240 Engines) *Lift truck serial number code

VISTA FREE–LIFT MAST Unit

Lifting NO LOAD

Lowering

RATED LOAD

NO LOAD

RATED LOAD

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

H2.00–2.50XL (H40–50XL)

0.45

98

0.41

81

0.39

77

0.49

96

H3.00XL (H60XL)

0.42

82

0.38

74

0.47

92

0.47

92

VISTA TWO–STAGE MAST H2.00–2.50XL (H40–50XL)

0.47

93

0.43

85

0.42

83

0.47

92

H3.00XL (H60XL)

0.47

93

0.40

79

0.42

83

0.52

102

VISTA THREE–STAGE MAST H2.00–2.50XL (H40–50XL)

0.45

89

0.41

81

0.41

81

0.46

91

H3.00XL (H60XL)

0.45

89

0.38

75

0.41

81

0.49

96

MAST SPEEDS (C177* with GM 4–181 or Isuzu 4JB1 Engines) *Lift truck serial number code

VISTA FREE–LIFT MAST Unit

Lifting NO LOAD

Lowering

RATED LOAD

NO LOAD

RATED LOAD

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

H2.00–2.50XL (H40–50XL)

0.51

100

0.48

94

0.41

81

0.49

96

H3.00XL (H60XL)

0.51

100

0.48

94

0.41

81

0.48

94

VISTA TWO–STAGE MAST H2.00–2.50XL (H40–50XL)

0.53

104

0.50

98

0.45

89

0.46

91

H3.00XL (H60XL)

0.53

104

0.50

98

0.45

89

0.49

96

VISTA THREE–STAGE MAST H2.00–2.50XL (H40–50XL)

0.51

100

0.48

94

0.43

85

0.45

89

H3.00XL (H60XL)

0.51

100

0.48

94

0.43

85

0.46

91

5

TRANSMISSION PRESSURES PORT 1 Pressure Transmission Pump kPa (psi)

965 to 1170 (140 to 170)

PORT 2 Forward Clutch

PORT 3 Reverse Clutch

PORT 4 Torque Converter

724 to 860 724 to 860 724 to 860 (105 to 125) (105 to 125) (105 to 125)

NOTES: For HYSTER transmissions only.

All pressures are measured at 2000 rpm with oil temperature at 50°C (130°F).

The difference in the Forward and Reverse clutch pressures must not be more than 70 kPa (10 psi).

PORT 5 Lubrication Pressure

PORT 6 Modulator Pressure

105 to 175 (15 to 25)

Pressure Variation

4

2

TEST PORT 1 – PRESSURE FROM TRANSMISSION PUMP TEST PORT 2 – PRESSURE TO FORWARD CLUTCH TEST PORT 3 – PRESSURE TO REVERSE CLUTCH TEST PORT 4 – OIL PRESSURE TO TORQUE CONVERTER TEST PORT 5 – OIL PRESSURE FROM OIL COOLER TEST PORT 6 – MODULATOR PRESSURE

11166

*On some T43 transmissions and on T42 transmissions before serial number T42M 3040 (and one unit T42M 3068) test ports 3 and 5 are reversed.

1

5* 6

3*

TRANSMISSION PRESSURES Pressure

PORT 1 Main Regulator

PORT 2 Torque Converter

PORT 3 Oil Cooler In

PORT 4 Forward Clutch

PORT 5 Reverse Clutch

kPa (psi)

985 to 1103 (140 to 160)

758 to 896 (110 to 130)

345 to 383 (50 to 70)

655 to 793 (95 to 115)

655 to 793 (95 to 115)

NOTES: For early (horizontal oil filter) transmissions only.

All pressures are measured at 2000 rpm with oil temperature at 50°C (130°F).

TEST PORT 1 – MAIN REGULATOR TEST PORT 2 – TORQUE CONVERTER REGULATOR TEST PORT 3 – OIL COOLER TEST PORT 4 – FORWARD CLUTCH PRESSURE TEST PORT 5 – REVERSE CLUTCH PRESSURE 6. TORQUE CONVERTER REGULATOR

3

4

2

6

1

6

5

TORQUE SPECIFICATIONS Item ENGINE (MAZDA M4–121G)

Specification See the torque specifications in the Service Manual section for this engine.

Motor mount to engine (upper capscrews are Grade 5)

56 N.m (41 lbf ft)

Motor mount to engine (lower capscrews are Grade 8)

81 N.m (60 lbf ft)

Motor mount bolts

53 N.m (39 lbf ft)

ENGINE (GM 4–181)

Motor mount bolts ENGINE (ISUZU C240)

See the torque specifications in the Service Manual section for this engine .

53 N.m (39 lbf ft) See the torque specifications in the Service Manual section for this engine.

Motor mount to engine (short capscrews)

55 N.m (40 lbf ft)

Motor mount to engine (long capscrews)

40 N.m (30 lbf ft)

Motor mount bolts

53 N.m (39 lbf ft)

ENGINE (ISUZU 4JB1)

See the torque specifications in the Service Manual section for this engine.

Motor mount to engine

55 N.m (40 lbf ft)

Motor mount bolts

178 N.m (130 lbf ft)

TRANSMISSION

See the torque specifications in the Service Manual section for the transmission.

Drive plate to torque converter

45 N.m (33 lbf ft)

Torque converter housing to engine

38 N.m (28 lbf ft)

Torque converter housing to transmission 3/ inch capscrews 8 7/ inch capscrews 16

37 to 43 N.m (27 to 32 lbf ft) 57 to 68 N.m (42 to 50 lbf ft)

Differential housing to transmission

38 N.m (28 lbf ft)

HYDRAULIC PUMP Acorn nut for adjustment screw

28 to 31 N.m (20 to 23 lbf ft)

Plug for relief valve

34 to 39 N.m (25 to 29 lbf ft)

Plug for regulator valve

59 to 69 N.m (43 to 51 lbf ft)

Capscrews for pump body

46 to 49 N.m (34 to 36 lbf ft)

HYDRAULIC CONTROL VALVE Through bolts, 5/16 inch

19 N.m (14 lbf ft)

Through bolts, 3/8 inch

45 N.m (33 lbf ft) 7

TORQUE SPECIFICATIONS Item

Specification

BRAKES

See the torque specifications in the Service Manual section for the brakes.

DRIVE AXLE

See the torque specifications in the Service Manual section for the drive axle.

STEERING AXLE

See the torque specifications in the Service Manual section for the steering axle.

Rod end capscrews, Tilt cylinders

77 N.m (57 lbf ft)

Mast, bolts for hanger caps

165 N.m (122 lbf ft)

Counterweight capscrews

320 N.m (235 lbf ft)

8

INTRODUCTION GENERAL This section has a description and the service procedures for the brake system. The parts of the brake system 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 return 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 return 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 pressure 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 pressure in the lines is greater than the pressure in the pressure chamber. The check valve assembly then moves against the spring pressure to permit fluid to return to the pressure chamber. The check valve assembly returns 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 primary cup when the piston is against the stop washer. The hole is a compensator port to permit fluid to flow between 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. If the 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

1

permits the tension of each cable to be the same when the lever is pulled.

9524

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

9671

1. PUSH ROD 2. RETAINER WASHER/SNAP RING 3. SECONDARY CUP 4. BODY 5. PISTON 6. PRIMARY CUP 7. RETAINER 8. SPRING 9. PRESSURE CHAMBER 10. CHECK VALVE ASSEMBLY 11. COMPENSATOR PORT 12. FITTING 13. INLET PORT

FIGURE 1. MASTER CYLINDER 2

WHEEL CYLINDER RETURN SPRING PIVOT PLATE LINK 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

The clearance between the brake shoes and the brake drum is adjusted automatically. The adjuster linkage turns the adjuster wheel to adjust the clearance. The primary (front) shoe and the adjuster links move with the drum during a stop when the lift truck is moving in the reverse direction. The linkage permits the adjuster lever to rotate the adjuster wheel. The adjuster wheel can turn only when there is clearance between the lining and the brake drum. The adjuster wheel can also be turned manually. A hole in the drum is used to get access to the adjuster wheel.

REPAIRS REMOVAL AND DISASSEMBLY Service and Parking Brakes (See FIGURE 3. and FIGURE 4.)

WARNING 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.

CAUTION 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 1

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.

9520

1. Remove the capscrews that hold the axle shaft to the hub. Remove the axle shaft.

1. RETURN SPRING

FIGURE 3. BRAKE ASSEMBLY 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 easily from the axle tube. Pull the wheel assembly from the lift truck.

5. If the wheel assembly cannot be removed easily, remove 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 turn the adjuster wheel to loosen the brake shoes.

Turn the adjuster wheel upward. Remove the hub and drum assembly. Do not damage the seal when removing the hub.

CAUTION 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. Remove 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 levers. Remove the parking brake levers from the back plate.

3

Master Cylinder (See FIGURE 1. and FIGURE 13.)

3. Remove the hose from the nipple. Put a plug in the hose to prevent the reservoir from draining.

1. Remove the pin from the clevis for the push rod.

CAUTION 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.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

SNAP RING PIN BACK PLATE CABLE CABLE GUIDE SPECIAL CAPSCREW CAPSCREWS PARKING BRAKE LEVER WHEEL CYLINDER PIVOT PIN BRAKE SHOE PIVOT PLATE RETURN SPRING RETURN SPRING

15.

16.

17.

18.

19.

20.

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.

SPECIAL CAPSCREW LINK LINK RETAINER SPRING ASSEMBLY BRAKE SHOE SPRING

FIGURE 4. BRAKE SYSTEM PARTS

4

21. ADJUSTER NUT 22. ADJUSTER WHEEL 23. ACTUATOR

WARNING The piston has a compressed spring behind it. Carefully remove the piston so that you can control the spring and prevent an injury.

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:

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 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.

WARNING 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 rags 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 rags that will be washed must be cleaned so that fibers are not released into the air.

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 scratches. Replace the wheel cylinder if there is any damage. c. Check the bore of the master cylinder and the matching surfaces of the piston. Replace a master cylinder that has been damaged. d. Check the return springs for damage. Inspect the back plate for wear where the brake shoes touch the back plate. e. Inspect the brake shoes for cracks or damage. If the linings or shoes are worn or damaged, replace the brake shoes. It is recommended that brake shoes be replaced in complete sets. f. Check the adjuster screw wheel for wear. Make sure the adjuster screw turns. 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. h. Make sure that the levers and cranks for the parking brake move freely.

NOTE: If the brake drums require grinding, do not grind more than 1.5 mm (0.060 in) from the diameter.

The maximum inside diameter of the brake drum, including wear, is 262.7 mm (10.35 in). If the 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.

5

1.

2.

3.

4.

5.

6.

7.

8.

PORT FOR SPECIAL FITTING INLET PORT BRAKE SHOE BOOT WHEEL CYLINDER SPRING CUP PISTON ASSEMBLY

1025

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 cylinder to 80 to 85 Nm (59 to 63 lbf ft). Tighten the two larger capscrews to 80 to 102 Nm (59 to 75 lbf 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 housing. The special capscrew that is the anchor pin (FIGURE 7.) has a different torque value. See SPECIFICATIONS 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.

CAUTION 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 the left brake assembly. Install the pivot plate on the right brake assembly so that the letter “R” is seen.

9517

FIGURE 6. INSTALL THE PINS 5. Install the pivot pin through the brake shoe that is toward the rear of the 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.

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 return 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.

9516

FIGURE 7. INSTALL THE ANCHOR PIN

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 hub. Install the assembly on the axle housing. See FIGURE 10. and FIGURE 11.

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 the bearings in the hub. Put grease under the wheel and slide the wheel toward the axle housing. Install the outer bearing and nut. Remove the wheel from the hub so that the clearance of the brake shoes can be adjusted.

9521

FIGURE 8. INSTALL THE RETAINER SPRING ASSEMBLY 7. Put an anti–seize compound on the threads of the adjuster wheel. Install the adjuster wheel assembly between 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

11. Adjust the wheel bearings by tightening the nut to 205 Nm (150 lbf ft) while rotating the hub. Loosen the nut until the hub turns freely. The torque must be less than 27 Nm (20 lbf ft). Tighten the nut to 34 Nm (25 lbf ft) or until the first alignment position after 34 Nm (25 lbf 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 wheel move downward. Turn the adjuster wheel until the brake drum will not rotate. Move the actuator away from the adjuster wheel. Turn the adjuster wheel upward 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

WARNING The brakes and the automatic adjusters cannot operate if the clearance between the shoes and drum is

FRONT

too large. A clearance that is too small can cause rapid wear of the adjuster wheel. This condition can prevent automatic adjustment of the brakes.

LEFT SIDE

6

7

1.

2.

3.

4.

5.

6.

7.

SPRING FOR SECONDARY SHOE SPRING FOR PRIMARY (FRONT) SHOE UPPER LINK LOWER LINK GRAY ADJUSTER WHEEL ACTUATOR ADJUSTER WHEEL AND NUT

RIGHT SIDE

9524

FIGURE 9. INSTALLATION OF THE SPRINGS 8

FRONT

13. Put sealant on the flange of the axle shaft. Install the axle shaft and capscrews. Tighten the capscrews to 98 Nm (72 lbf ft).

NOTE: Units from later production have a one–piece hub and brake drum.

14. Install the cranks that actuate the brakes for parking. 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 SYSTEM in this section.

S2.00–3.00XL (S40–60XL)

40° to 60° in released position H2.00–3.00XL (H40–60XL)

9519

1. OUTER SEAL 2. INNER SEAL 3. BRAKE DRUM

FIGURE 10. LOCATION OF THE GREASE SEALS

12607

1. CRANK 2. PIN 3. CLEVIS

0° to 20° in released position 4. CABLE 5. VERTICAL REFERENCE

FIGURE 12. ADJUST THE CRANKS FOR THE PARKING BRAKE 16. Install the wheel on the hub. Tighten the nuts: 9518

FIGURE 11. INSTALL THE INNER GREASE SEAL

S2.00–3.00XL (S40–60XL), 270 Nm (200 lbf ft)

H2.00–3.00XL (H40–60XL), 610 to 680 Nm (450 to 500 lbf ft)

9

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 reverse 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 Pedal�, step 2.

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.

1.

2.

3.

4.

5.

6.

7.

8.

9.

SHIELD SNAP RING RETAINER WASHER SECONDARY CUP PISTON PRIMARY CUP RETAINER SPRING CHECK VALVE ASSEMBLY

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, PERIODIC 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 screw10

driver so that the teeth of the adjuster wheel move downward. Turn the adjuster wheel until the brake drum will not rotate. Move the actuator away from the teeth of the adjuster wheel. Turn the adjuster wheel upward 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.

Units with Monotrol Pedal (See FIGURE 14.)

ADJUST THE PARKING BRAKE

Lift trucks with a Monotrol pedal have a switch (4) in the assembly for the parking brake lever. A link (3, early production) or cam (5, later production) operates the switch. The switch closes the circuit for starting the engine 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 following procedures.

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 position of the crank is as shown in FIGURE 12. when the parking brake is released.

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. b. Release the parking brake. The link (3) must not actuate the switch (4). Turn the ignition key to the START position. The engine must not start. Turn the ignition key to the OFF position.

EARLY PRODUCTION

LATER PRODUCTION

1.

2.

3.

4.

5.

LEVER, PARKING BRAKE RELEASE LATCH LINK (SWITCH ACTUATOR) NEUTRAL START SWITCH CAM (SWITCH ACTUATOR)

12663

FIGURE 14. PARKING BRAKE LEVER FOR UNITS WITH MONOTROL PEDAL

11

c. 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 engine must start. Release the parking brake. The circuit for the transmission must be energized (the drive wheels rotate). Turn the ignition key to the OFF position. d. 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 parking brake is applied. Make sure that the 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. b. Release the parking brake. The cam (5) must actuate the switch (4). Turn the ignition key to the START position. The engine must not start. Turn the ignition key to the OFF position. c. Apply the parking brake. The cam must fully release the lever on the switch. Turn 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). d. 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. e. 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 cyl12

inder reservoir with brake fluid. Put one end of a rubber 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 turn. 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 correct level. Repeat the procedure for the other wheel cylinder. If there is still air in the system, the air must be 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 inching pedal if the control valve was removed for repairs.

NOTE: If the 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 SERVICE 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 screw (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). Turn the push rod (12) clockwise so that it touches the piston of the master cylinder. Turn the push rod one–half turn 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). Turn the inching spool to adjust the length of the inching spring to dimension B. Do not tighten the jam nut on the inching spool.

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