SERVICE REPAIR J40XM J50XM J60XM J65XM [A216]
INTRODUCTION GENERAL This section has the description and repair procedures for the steering axle. See the following sections for additional information on the parts of the steering system: THE STEERING CONTROL UNIT and HYDRAULIC SYSTEM.
DESCRIPTION (See FIGURE 1.) The steering axle assembly includes an axle frame, steering cylinder and two spindle and hub assemblies. The steering axle is connected to the frame with center pivot mounts. The center pivot mounts on the axle frame are fastened to the lift truck frame with rubber mounts. The steering axle can make an articulated motion and give the lift truck a smoother travel over rough surfaces. The end caps of the steering cylinder are also the mounts for the cylinder and are held to the shell by the mount capscrews. O–rings, seals, and wipers in the end caps are used to keep the oil inside of the steering cylinder. 1. SPINDLE AND HUB ASSEMBLY 2. AXLE FRAME 3. BRACKET
The ends of the piston rod extend from both ends of the cylinder. A single piston and the seal are at the center of the rod. Oil pressure on one side of the piston moves the piston in the bore. When the piston moves in the bore, it pushes an equal amount of oil from the opposite end of the cylinder. This oil returns to the steering control unit. When the piston reaches the end of the stroke, a relief valve controls the oil pressure so that the components are not damaged. Tie rods connect the spindle arms to the cylinder. Each spindle turns on two tapered roller bearings. The spindle and bearings are held in the axle frame by a kingpin. The preload on the bearings is controlled by a threaded nut on the bottom of the king pin. The wheel or hub rotates on two tapered roller bearings and is held on the spindle by a castle nut. The preload on the bearings in the hub is adjusted by the castle nut. A grease seal in the inner hub and a hub cap protect the bearings from dirt and water. A wear sleeve in the inner hub protects the hub from wear by the seal.
4. RUBBER MOUNT 5. STEERING CYLINDER 6. NUT AND BOLT
4
2
6
5 3 1
4 3
12768
FIGURE 1. STEERING AXLE 1
REPAIRS WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: drive axle, battery or counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: 1. If the mast and drive axle are removed, put blocks under the counterweight so that the lift truck can not fall backward. 2. If the battery (electric lift trucks) or counterweight is removed, put blocks under the mast so that the lift truck can not fall forward. Put the lift truck on blocks on a solid, even and level surface. Make sure the blocks of stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies.
STEERING AXLE ASSEMBLY NOTE: The steering axle assembly without the wheels weighs approximately 115 kg (250 lb)
Removal (See FIGURE 1.)
holds the weight of the axle assembly. Remove the four capscrews and nuts that fasten the two brackets under the rubber mounts. Remove the brackets and slowly lower the axle assembly onto the wheels. Carefully roll the axle assembly from under the lift truck.
Installation (See FIGURE 1.) 1. Install the rubber mounts on the axle as follows:. a. E1.25–1.75XL (E25–35XL), J2.00–3.00XL (J40–60XL), H/J2.00–3.20XM (H/J40–65XM): Make sure the PART NO. on the mounts is right side up and facing away from the axle frame. b. J1.25–1.75XL (Europe only): Make sure the PART NO. on the mounts is upside down and facing away from the axle frame. 2. Apply a lubricant that is approved for use with rubber to the rubber mount. The lubricant is used where the rubber mount fits into the frame brackets. 3. Use a floor jack or another lift truck to put the steering axle into the position in the frame. Make sure the rubber mounts fit inside the frame brackets for the mounts. 4. Install the bottom brackets. Tighten the four bracket capscrews and nuts to 88 N.m (65 lbf ft). 5. Remove the plugs and caps and connect the hydraulic lines to the steering cylinder.
The steering axle can be removed without removing the counterweight. If necessary, remove the counterweight as described in the FRAME.
6. Operate the steering system to remove the air from the system. Turn the steering wheel several times from one stop to the other stop. Check for hydraulic leaks.
1. Make sure the wheels are set for straight travel. Put the lift truck on blocks so that the steering axle can be removed. The top of the axle frame must have clearance under the counterweight so that the steering axle can be removed.
WHEELS AND HUBS
2. Disconnect the hydraulic lines at the steering cylinder. Install caps on the cylinder and put plugs in the hydraulic lines. The caps will prevent the spindles from turning when the axle is removed from under the lift truck.
Completely deflate the tires before removing them from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode causing serious injury or death.
3. Slide a floor jack or the forks of another lift truck under the steering axle. Raise the lifting device until it 2
Removal and Disassembly (See FIGURE 2.)
WARNING
Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire.
H2.00–3.20XM (H40–65XM) SHOWN, OTHERS SIMILAR
21 22
1 23 20
16
18 26*
25*
19
17
27*
5 3
19
18 18
6
2 18
17 14
17
16 17
10
16
24
15
7
10
8
4 9
3
12 9
4
10
11 11
28 29
14
28
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
AXLE FRAME WASHER BOLT BELLEVILLE WASHER RUBBER MOUNT BRACKET NUT STEERING CYLINDER PIN SNAP RING BUSHING
4 4
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
TIE ROD GREASE FITTING CASTLE NUT SLEEVE SEAL BEARING CONE BEARING CUP SPINDLE SPACER O–RING
10
13 22. KING PIN 23. GROOVE PIN 24. WEAR SLEEVE 25. HUB* 26. STUD* 27. WHEEL NUT* 28. COTTER PIN 29. GREASE CAP * PNEUMATIC TIRES ONLY
FIGURE 2. STEERING AXLE 1. Put the axle on blocks so that the tires are raised from the floor. Remove the grease cap. Remove the cotter pin and the castle nut. Remove the outer bearing cone. Slide the wheel from the spindle. Remove the inner bearing cone and the seal from the spindle.
vents, always follow the solvent manufacturer’s recommended safety procedures.
2. If the wheel bearings must be replaced, use a brass drift to remove the bearing cups and the wear sleeve.
Assembly And Installation (See FIGURE 2.)
3. Repeat the procedure for the other wheel.
Cleaning
WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning sol-
Clean all parts with solvent. Make sure the bearings are clean.
1. If the wheel bearings must be replaced, use a press to install the new bearing cups in the wheel or hub. Install a new wear sleeve in the wheel or hub. Install the grease seal on the spindle. Lubricate the bearing cones with grease. Make sure the bearings are filled with grease. Install the bearing cone on the spindle. 3
the axle. Use a driver to remove the bearings and seals from the spindle.
CAUTION Do not damage the seals during installation. 2. Carefully slide the wheel or hub onto the spindle. Install the outer bearing cone. 3. Install the castle nut. Tighten the castle nut to 200 N.m (150 lbf ft) while the wheel is rotated. Loosen the nut to less than 27 N.m (20 lbf ft). Tighten the nut to 34 N.m (25 lbf ft). If the cotter pin can not be installed with the nut tightened to 34 N.m (25 lbf ft), tighten the castle nut until the cotter pin can be installed. Install the cotter pin. 4. Repeat the procedure for the other wheel. 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
O–RING KING PIN GROOVE PIN SPACER SEAL BEARING CONE BEARING CUP SPINDLE SEAL WEAR SLEEVE CASTLE NUT COTTER PIN GREASE CAP SLEEVE 6
3
2 4
Installation (See FIGURE 2., FIGURE 3.) 1. Use new bearings and seals. Apply grease to the bearings and king pin as they are installed in the axle. Install the bearings in the spindle. Install the seals in the correct position. Align the spindle in the axle and install the king pin. Make sure a new O–ring is installed at the top of the king pin. Install the sleeve on the bottom of the king pin. Install the castle nut and tighten it to 90 N.m (66 lbf ft). Loosen the castle nut to less than 34 N.m (25 lbf ft). Tighten the nut to 34 N.m (25 lbf ft). If the cotter pin can not be installed with the nut tightened to 34 N.m (25 lbf ft), tighten the castle nut until the cotter pin can be installed. Install the cotter pin. 2. Connect the tie rods. Make sure the belleville washers are installed on both sides of the bushings.
5 6
3. Install the wheels or hubs. See the section WHEELS AND HUBS for the proper installation procedure. On the H/J2.00–3.20XM (H/J40–65XM), tighten the wheel nuts to 237 to 305 N.m (175 to 225 lbf ft). On the J1.25–1.75XL (J25–35XL) and the J2.00–3.00XL (J40–60XL), tighten the wheel nuts to 155 N.m (115 lbf ft).
7 8 9
10
7 7
STEERING CYLINDER
11
7 6 5 6 12 13
14 12 11
FIGURE 3. SPINDLE ASSEMBLY
SPINDLES, BEARINGS AND TIE RODS Removal (See FIGURE 3.) Remove the wheel or hub from the steering axle spindle. Remove the pin to disconnect the tie rod from the spindle. Remove the cotter pin and the castle nut from the bottom of the king pin. Use a driver to remove the king pin. Remove the sleeve and then the spindle from 4
NOTE: Dirt and corrosion can make the spacer difficult to remove from the steering axle frame. A machined space is made in the top of the spacer so that the spacer can be removed with a bearing puller.
Removal And Disassembly (See FIGURE 4.) NOTE: The end caps of the steering cylinder are held in the shell by the cylinder mount capscrews. To prevent oil leaks at the caps, hold the caps on the shell during removal. 1. Disconnect the hydraulic lines at the steering cylinder. Install caps in the fittings on the cylinders and put caps on the hydraulic lines. 2. Remove the snap rings from the pins in the tie rods. Remove the pins. 3. Remove the capscrews or nuts and bolts that fasten the cylinder to the axle frame. Hold the end caps on the shell and remove the steering cylinder.
4. Hold the end of the steering cylinder over a drain pan. Remove the cap for the hydraulic fitting from each end cap. Push the rod toward the end of the shell that is over the drain pan. Oil will drain from the cylinder. Repeat the procedure for the other end.
Inspect the piston rod for grooves or damage. Remove small scratches with fine emery cloth. Inspect the cylinder bore for damage. Inspect the mounts for cracks.
5. Carefully slide one end cap from the shell. Carefully pull the cylinder rod and piston from the shell. Keep the cylinder rod aligned in the center of the shell during removal so that the parts are not damaged. Remove the end cap from the rod. Remove the other end cap from the shell. Remove all seals, wipers, and O–rings.
1. Put the seals and wipers in warm hydraulic oil. Install the quadrant ring and piston seal as shown in FIGURE 4.
Cleaning and Inspection
Assembly and Installation (See FIGURE 4.)
CAUTION Do not damage the O–rings, seals or wipers during installation. 2. Lubricate the O–rings, seals, and wipers with O–ring lubricant and install them in the end caps. Install one end cap on the cylinder rod.
WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. Clean all parts in solvent.
3. Carefully slide the cylinder rod and piston into the shell. Keep the cylinder rod aligned in the center of the shell during installation so that the parts are not damaged. Carefully slide the end cap into the shell. Carefully install the other end cap on the rod and shell. Put caps on the hydraulic fittings of the end caps.
1 7
2
9 5
4
8
3
6 5
3 2
8 3 1
2
4 5
6
4
9 7
1. 2. 3. 4.
ROD WIPER END CAP O–RING
5. 6. 7. 8. 9.
BACK–UP RING SHELL PISTON SEAL ROD SEAL QUADRANT RING
3 8 5
FIGURE 4. STEERING CYLINDER 5
4. Hold the end caps and install the cylinder on the axle frame using the capscrews or nuts and capscrews. On the H/J2.00–3.20XM (H/J40–65XM), tighten the capscrews to 225 N.m (165 lbf ft). On the E/J1.25–1.75XL (E25–35XL) and the J2.00–3.00XL (J40–60XL), tighten the capscrews and nuts to 165 N.m (122 lbf ft). NOTE: On J2.00–3.00XL (J40–60XL) units the nuts are against the end caps.
5. Install the tie rods between the cylinder and the spindles. Make sure the belleville washers are on each side of the bushings in the tie rods. Install the pins and snap rings. 6. Remove the caps and connect the hydraulic lines to the steering cylinder. Operate the steering system to remove the air from the cylinder and the hydraulic system. Turn the steering wheel several times from one stop to the other.
TORQUE SPECIFICATIONS
6
Steer Axle Mount Bracket Hardware
88 N.m (65 lbf ft)
Wheel/Hub Nut Initial Torque Final Torque
200 N.m (150 lbf ft) 34 N.m (25 lbf ft)
King Pin Nut Initial Torque Final Torque
90 N.m (66 lbf ft) 34 N.m (25 lbf ft)
Wheel Nuts H/J2.00–3.20XM (H/J40–65XM) J1.25–1.75XL (J25–35XL) J2.00–3.00XL (J40–60XL)
237 to 305 N.m (175 to 225 lbf ft) 155 N.m (115 lbf ft) 155 N.m (115 lbf ft)
Steer Cylinder Mount Hardware H/J2.00–3.20XM (H/J40–65XM) E/J1.25–1.75XL (E/J25–35XL) J2.00–3.00XL (J40–60XL)
225 N.m (165 lbf ft) 165 N.m (122 lbf ft) 165 N.m (122 lbf ft)
TROUBLESHOOTING PROBLEM
POSSIBLE CAUSE
There is no action when the steering wheel is turned.
There is no oil or not enough oil in the hydraulic tank.
Fill the tank to the correct level.
The lines are loose at the control unit or manifold block.
Tighten fittings.
The sleeve and spool in the control unit will not move.
Repair steering control unit.
Steering cylinder leaks.
Repair steering cylinder.
Spacer for center pin is not installed.
Assemble steering control unit correctly.
The oil level is low. There is no oil in the tank.
Fill the tank to the correct level.
The lines to the control unit are damaged.
Repair oil lines.
The sleeve and spool in the control unit are worn.
Repair steering control unit.
The parts of the metering section are worn.
Repair steering control unit.
The check valve in the control unit does not open.
Clean or repair steering control unit.
The check valve or relief valve in the manifold block is damaged or is not adjusted correctly.
Clean or replace manifold block.
The lift truck steers slowly. The steering wheel is hard to turn.
PROCEDURE OR ACTION
Priority valve is not operating correctly. Clean or repair priority valve. Steering relief pressure is too low.
Adjust relief pressure.
Engine idle speed is too low.
Adjust idle speed to specifications.
The steering wheel turns the tires in the wrong direction.
The lines at the control unit are not correctly connected.
Connect lines correctly.
The tires continue to turn after the steering wheel stops.
The neutral position springs are broken.
Repair steering control unit.
The sleeve or spool has damage.
Repair steering control unit.
Steering wheel kicks back in both directions.
Center shaft is not correctly aligned with metering section.
Correctly assemble steering control unit.
7
INTRODUCTION 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 the parking brake system. A troubleshooting section is included at the end of this section.
DESCRIPTION AND OPERATION Service Brakes (See FIGURE 8.) A service brake assembly is installed on the mounts at each end of the drive axle. The parts of the service brake assembly are shown in FIGURE 2. and FIGURE 3. When the brake pedal is pushed, fluid pressure from the master cylinder causes the pistons in the wheel cylinders 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 hole in the brake drum gives access to the adjuster wheel.
Master Cylinder (See FIGURE 1.) The master cylinder is designed for a dual circuit system. The master cylinder has two separate pistons that
operate in the single bore of the master cylinder. The reservoir for the fluid is pressed into the two ports on top of the master cylinder and held in position by seals. When the brake pedal is pushed, the push rod moves the piston assemblies. The operation of the master cylinder is described in FIGURE 1. If a failure occurs in one of the dual circuits, the other circuit will apply one of the service brakes. This failure will cause the brake pedal to travel farther when the brakes are applied, but the service brakes on one drive wheel will operate. This failure of one of the brake circuits can cause the lift truck to turn toward the drive wheel with the good brake when the brakes are applied. The operator must control the direction of the lift truck with the steering when the brakes are applied during this condition. The reservoir is equipped with an indicator for low fluid level. A float in the reservoir moves up and down with the fluid level. When the fluid level is low, a magnet on the float activates a switch in the bottom of the reservoir. This switch energizes a warning light on the instrument cluster.
Parking Brake (See FIGURE 9.) The parking brake system uses the service brake shoes. Additional linkage activates the parking brake system. When the pedal 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 pedal is moved to apply parking brake.
1
BRAKE “OFF”
7
6
When the brakes are “OFF,” the hydraulic fluid can move freely between the dual circuit system and the separate chambers of the fluid reservoir. 9
BRAKE “RELEASED” When the brake pedal is released, the return springs cause the pistons to retract faster than the fluid. This action causes a vacuum between the fluid in chambers A and C. The vacuum causes the seals (2) to change shape. When the seals change shape, they permit the fluid in chambers B and D to flow through the holes in the pistons and past the seals into chambers A and C. The supply holes in the cylinder body supplies fluid as the flow moves from the one chamber to the other chamber. The fluid returns to the reservoir through the bypass holes when the pistons are fully retracted.
8 9 8
2
A
2
1
B
3
4
5
C
D
FLUID WITH NO PRESSURE FLUID UNDER PRESSURE
1. 2. 3. 4. 5.
SECONDARY SPRING SEAL SECONDARY PISTON PRIMARY SPRING PRIMARY PISTON
6. 7. 8. 9.
PRIMARY FLUID CHAMBER SECONDARY FLUID CHAMBER BYPASS HOLES SUPPLY HOLES
BRAKE “APPLIED” When the brake pedal is pressed, the primary piston moves in the cylinder bore. This movement creates hydraulic pressure that combines with the force of the primary spring. These combined forces overcome the secondary spring force and move the secondary piston in the bore with the primary piston. The first movement of both pistons pushes the seals (2) past the bypass holes in the chambers A and C. This action applies pressure to the fluid in those chambers and causes fluid to flow to the chambers of the two separate systems. The fluid in chambers B and D is not effected by movement of the pistons. This fluid can move freely between the piston chambers and the chambers of the fluid reservoir, before and during brake application.
A
B
C
D 12595
FIGURE 1. OPERATION OF MASTER CYLINDER 2
SERVICE BRAKES
3. Remove the capscrews that hold the axle shaft to the hub. Remove the axle shaft.
Removal And Disassembly
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 A LIFT TRUCK ON BLOCKS” in the PERIODIC MAINTENANCE section of the service manual or the OPERATING MANUAL. Tilt the mast fully backward. Put blocks under the mast. Tilt the mast forward until the wheels just touch the floor. Stop the motor. Put blocks under the frame of the lift truck. 2. If tilt does not function use a hydraulic jack, crane or another lift truck to lift the drive wheels until they just touch the floor. Put blocks under the frame of the lift truck.
1
4. Release the parking brake. Bend the lock plate and remove the nut that holds the axle bearing. Remove the washer and the bearing cone. 5. 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, remove the wheel and 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. Install the wheel and then remove the hub and drum assembly. Do not damage the grease seal when removing the hub.
DANGER When the brake shoes are removed do not create dust in the air. See the cleaning procedure in this section. 6. See FIGURE 2. Remove the return springs (2 and 14) with spring pliers. NOTE: The return springs (2 and 14) are not the same part number. Make sure the springs are installed in the same positions from which they were removed.
14
LEFT SIDE SHOWN
2 12 3 12
5 11
4
11 13
13
10 10 9
6 8
9524
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
WHEEL CYLINDER RETURN SPRING, MAROON PIVOT PLATE LINK ANCHOR ADJUSTER WHEEL ACTUATOR ADJUSTER WHEEL ADJUSTER NUT CABLE, PARKING BRAKE RETAINER LEVER, PARKING BRAKE BRAKE SHOE PIN, HOLD DOWN RETURN SPRING, GREY
7
FIGURE 2. BRAKE ASSEMBLY (LEFT BRAKE ASSEMBLY SHOWN) 3
7. Remove the retainers, springs, and retainer pins that hold the brake shoes to the back plate. See FIGURE 3. Remove the brake shoes and adjuster assembly.
10. Remove the snap rings from the parking brake levers. Remove the parking brake levers from the back plate.
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 right brake has left–hand threads.
NOTE: 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 five capscrews with 5/8 inch thread are tightened to 245 N.m (180 lbf ft). The capscrew with 1/2 inch thread is tightened to 125 N.m (92 lbf ft).
8. Remove the brake line from the wheel cylinder. Remove the wheel cylinder. 9. Remove the dust covers, pistons, cups, and springs from the wheel cylinder. See FIGURE 4.
DO NOT BEND OR PUT STRESS ON THE UPPER LINK (17) BY FORCING THE HOOK END ON OR AROUND THE POST ON THE SPECIAL CAPSCREW (15).
11
14 17*
12
LEFT SIDE SHOWN 9
10
8 2 16
15
20
7
6 23 1 18
8 19
1 5
22
21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
3
SNAP RING RETURN SPRING, MAROON BACK PLATE CABLE CABLE GUIDE SPECIAL CAPSCREW CAPSCREWS LEVER, PARKING BRAKE WHEEL CYLINDER PIVOT PIN BRAKE SHOE, REAR PIVOT PLATE HOLD–DOWN PIN (2) RETURN SPRING, GREY SPECIAL CAPSCREW
4
13
24 25 16. 17. 18. 19. 20. 21.
ADJUSTER LINK ADJUSTER LINK* RETAINER SPRING ASSEMBLY BRAKE SHOE, FRONT SPRING ADJUSTER NUT
FIGURE 3. PARTS OF THE SERVICE BRAKE 4
1
22. ADJUSTER WHEEL 23. ADJUSTER WHEEL ACTUATOR 24. CABLE RETAINER 25. CRANK
3
4
6 7 8
5 1. 2. 3. 4. 5. 6. 7. 8.
PORT FOR SPECIAL FITTING INLET PORT BRAKE SHOE DUST COVER WHEEL CYLINDER SPRING CUP PISTON ASSEMBLY
1 2 4
FIGURE 4. WHEEL CYLINDER
Cleaning
WARNING DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or the 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, do not create brake lining dust with the spray. 3. When the brake lining dust is wet, clean the parts. Put any cloth or towels in a plastic bag or an airtight con-
tainer while they are still wet. Put an “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.
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 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 or 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. 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 (0.025 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. 5
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. 4. 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 262 mm (10.22 in). 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 for the seals for wear or damage.
Assembly And Installation (See FIGURE 4) 1. Assemble the wheel cylinder. See FIGURE 4. Use only HYSTER APPROVED parts. 2. Install the wheel cylinder (9) on the back plate (3). Make sure the special fitting for removing the air is in the top hole. Put Loctite 271 on the threads of the capscrews (7). Tighten the two capscrews with the 7/16 inch thread to 78 to 91 N.m (58 to 67 lbf ft). Tighten the two capscrews with the 1/2 inch thread to 91 to 102 N.m (67 to 75 lbf ft). 3. Put the retainer pins (13) that hold the brake shoes through the back plate. Install the back plate on the axle housing. 4. See FIGURE 3. Tighten the two special capscrews (6) for the parking brake levers (8) to 245 N.m (180 lbf ft). Tighten the capscrews that hold the back plate to the axle
6
housing to 245 N.m (180 lbf ft). Install the washer and the special capscrew (15) that is the anchor for the return springs. This capscrew (15) must be tightened to 125 N.m (92 lbf ft). Make sure the washer is installed so that the capscrew (15) does not loosen during operation. 5. Install the parking brake levers (8) and cable (4). Install the snap rings (1). Install the cable guide (5) and snap ring on the crank (25) for the parking brake. 6. Install the pivot pin (10) through the brake shoe that is toward the rear of the lift truck. Install the links (16 and 17) in the pivot plate (12). Install the pivot plate (12), links, and cotter pin. NOTE: The upper link for the left brake assembly is not the same as the upper link for the right brake assembly. Install the pivot plate (12) so that the letter “L” is seen on the left brake assembly. Install the pivot plate (12) on the right brake assembly so that the letter “R” is seen. 7. Lubricate the back plate with a small amount of grease where the shoes touch. Install the brake shoes. Install the retainer spring assembly (18). Put a spring seat, spring, and retainer on the pin. Push the retainer on to the pin and rotate the retainer 90 degrees to lock the pin into the retainer. Install the other spring assembly. 8. Put an anti–seize compound on the threads of the adjuster wheel (22). Install the adjuster wheel assembly between the two brake shoes. Make sure the adjuster wheel is toward the rear of the lift truck.
WARNING The threads of the adjuster wheel are not the same for each brake assembly. If the adjuster wheel assemblies are installed on the wrong brake, the brake shoe clearance will increase each time the brakes are applied. The adjuster wheel for the right brake has left–hand threads. The adjuster wheel for the left brake has right–hand threads. 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.
9. Install the link in the adjuster wheel actuator (23). Put the adjuster wheel actuator in the hole in the brake shoe. Fasten the spring (20) to the adjuster wheel actuator and the brake shoe. The spring must be installed in the position shown in FIGURE 5. Install the return springs for the brake shoes . Make sure the return springs (2 and 14) are installed in the correct positions. See FIGURE 5. A gray spring is always installed on the right brake shoe. 10. Make sure the bottom edge of the adjuster wheel actuator is just above the center of the teeth of the adjuster wheel. Bend the lower link (16) to align the adjuster wheel actuator. 11. Clean the hub bearings and lubricate them with wheel bearing grease. Install the hub bearings and seals in the hub. Install the brake drum and hub on the axle housing. See FIGURE 6. and FIGURE 7. 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. Remove the wheel from the hub so that the clearance of the brake shoes can be adjusted. 12. Adjust the hub bearings by tightening the nut to 205 N.m (150 lbf ft) while rotating the hub. Loosen the nut until the hub turns freely. The torque must be less than 27 N.m (20 lbf ft). Tighten the nut to 34 N.m (25 lbf ft) or until the first alignment position after 34 N.m (25 lbf ft). Bend the lock plate over the nut. 13. Adjust the clearance of the brake shoes. Put a brake adjustment tool or a screwdriver through the hole in the drum. Turn the adjuster wheel so that the teeth of the adjuster wheel nearest the back plate move upward. Turn the adjuster wheel until the hub will not turn. Pull the ac-
tuator away from the adjuster wheel and turn the adjuster wheel approximately 15 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. NOTE: If the brake shoes were not replaced, loosen the adjuster wheel approximately 25 teeth.
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. 14. Put sealant on the flange of the axle shaft. Install the axle shaft and capscrews. Tighten the capscrews to 98 N.m (72 lbf ft).
Adjustments 1. Remove the air from the brake hydraulic system. See the procedure “Remove The Air From The Brake System�, under CHECKS AND ADJUSTMENTS. 2. Install the wheel on the hub. Tighten the nuts to 237 to 305 N.m (175 to 225 lbf ft). 3. Tilt the mast backward or lift the truck 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 9. and the following paragraphs in this section for the correct adjustment of the parking brake.
7
FRONT LEFT SIDE
3
1
2
2
3
1 4
FRONT RIGHT SIDE
1
3
2
1 3
2 4
1. 2. 3. 4.
SPRING FOR (LEFT) SHOE (MAROON) SPRING FOR (RIGHT) SHOE (GRAY) ADJUSTER LINK, UPPER ADJUSTER LINK, LOWER
FIGURE 5. INSTALLATION OF THE SPRINGS
8
9524
2. Turn the adjustment knob (5) so that the link (17) is at the bottom of the adjustment slot (18).
3
3. Remove the cotter pin (22) and pin (23) to disconnect the parking brake cable from the brake assembly.
2 1
4. Remove the cotter pin and anchor pin (8) that connect the link (4) to the parking brake assembly (3). 5. Remove the nuts (10) and washers that hold the parking brake assembly to the bracket (16). Remove the capscrews (9) and spacers (12). 6. Remove the cotter pin, washer, and anchor pin (13) from the link (17).
Assembly And Installation (See FIGURE 9.) 12879
1. OUTER SEAL 2. INNER SEAL
3. BRAKE DRUM
FIGURE 6. LOCATION OF THE GREASE SEALS
If the lever assembly for the parking brake was removed from the frame, use the following procedure for installation: 1. Make sure the parking brake lever is in the released position. Turn the adjustment knob (5) until the link (17) is adjusted to the bottom of the adjustment slot (18). 2. Install the ends of the cables into the compensator (15). Install the anchor pin (13), washer, and cotter pin into the parking brake assembly. Make sure the anchor pin is through the link and compensator. 3. Install the mounting bolts (9) through the cable clamps (11) and spacers (12). Mount the assembly to the bracket (16).
9518
FIGURE 7. INSTALLATION OF THE INNER GREASE SEAL
4. Before tightening the the mounting capscrews (9), push down the parking brake assembly to make sure it is in contact with the frame bracket (19).
If the lever assembly for the parking brake must be removed from the frame, use the following procedure (See FIGURE 9.):
5. The following procedure must be used to connect the link (4) to the parking brake assembly (3) and the brake pedal assembly (6): put the parking brake lever (3) in the applied position. Install the anchor pin (8) in the hole in the link (4) that will adjust the bottom side of the parking brake pedal to 28 mm (1.1 in) above the frame. See FIGURE 9. Install the cotter pins. Install the return spring (25) in an empty hole in the link (4).
1. Use blocks next to the wheels to make sure the lift truck can not move. Release the parking brake.
6. With the brake in the applied position, adjust and tighten the nuts (14) on the end of the cable (20) to
PARKING BRAKE Removal And Disassembly (See FIGURE 9.)
9
remove all the free–play from the release handle (7).
ment knob until the parking brakes are fully applied when the pedal is used to apply the parking brake.
7. With the parking brake applied, adjust the switch (24) so that the lever on the switch moves 1 to 3 mm (.04 to .12 in) beyond the operating point.
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% grade, [a slope that increases 1.5 metres in 10 metres (1.5 ft in 10 ft)].
Adjust The Parking Brake (See FIGURE 9.) Make sure that 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 (5) to raise the link (17) and tighten the parking brake cables (2). Turn the adjust-
10
3. With the parking brake applied, adjust the nuts (14) to remove any free play from the release handle (7). 4. Check the operation of the switches on the parking brake as described in CHECKS AND ADJUSTMENTS.
2
3
95 mm (3.7 in)
1
5 6
4 7
9 9
8
12836
1. 2. 3. 4. 5.
CAPSCREW BRAKE PEDAL FLOORPLATE LOCKNUT PUSH ROD
6. 7. 8. 9.
LOCKNUT MASTER CYLINDER BRAKE ASSEMBLY BRAKE LINES
FIGURE 8. SERVICE BRAKE
11
5 12838
8
7 17
13
15
6, RELEASED POSITION
20
6, APPLIED POSITION 14 18
12
28 mm (1.1 in) 3
19 16
11
24 4
9
5 1 25
3
9
9
9
2
10 11 12 21
12837
1. 2. 3. 4. 5. 6. 7.
22 23 BRAKE ASSEMBLY BRAKE CABLES PARKING BRAKE ASSEMBLY LINK ADJUSTMENT KNOB PARKING BRAKE PEDAL RELEASE HANDLE
8. 9. 10. 11. 12. 13. 14. 15. 16.
ANCHOR PIN MOUNTING CAPSCREW NUT CLAMP SPACER ANCHOR PIN NUT COMPENSATOR BRACKET, FRAME
FIGURE 9. PARKING BRAKE 12
17. 18. 19. 20. 21. 22. 23. 24. 25.
LINK ADJUSTMENT SLOT FRAME BRACKET CABLE CRANK COTTER KEY PIN SWITCH RETURN SPRING
MASTER CYLINDER
vent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid or on the linings.
Removal (See FIGURE 10.) 1. Remove the floor plates from the lift truck for access to the master cylinder.
Inspect the bore of the master cylinder for holes or scratches. Replace the master cylinder assembly if there is damage.
2. Loosen and remove the two brake hydraulic lines from the master cylinder. Disconnect the wire at the switch on the reservoir.
Repair 3. Remove the cotter pin, washer, and pin from the push rod end that is attached to the brake linkage lever arm. See the repair procedures for the master cylinder in FIGURE 11.
4. Remove the capscrews, washers, and nuts that hold the master cylinder to the bracket assembly and remove the master cylinder from the lift truck.
Installation (See FIGURE 10.)
Cleaning And Inspection
Use the reverse order of Removal to install the master cylinder. Check the adjustment of the brake pedal as described in CHECKS AND ADJUSTMENTS.
CAUTION DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or the brake linings. Use a sol-
1. CAP 2. RESERVOIR 3. SEAL 1
19
4. 5. 6. 7. 8.
RETURN SPRING BODY PIN SEAL SECONDARY PISTON
18 20
2
13
21 3 4
5
7
6
SEAL SPRING PRIMARY PISTON WASHER RETAINER RING DUST COVER ROD LOCK NUT CLEVIS PRIMARY FLUID CHAMBER SECONDARY FLUID CHAMBER 20. FLOAT 21. SWITCH (FLUID LEVEL)
15
7
7 8
9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
10
11 9
12
14
16
17 12595
FIGURE 10. MASTER CYLINDER
13
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