Hyster A216 (J3.00XM Europe) Forklift Service Repair Manual

General

Thissectionhasadescriptionandtheserviceproceduresforthepartsofthebrakesystem.Thebrakesystem includesthefollowingparts:mastercylinder,brakeshoes,wheelcylinders,andparkingbrakesystem.Atroubleshootingsectionisincludedattheendofthissection.

DescriptionandOperation SERVICEBRAKES

Aservicebrakeassemblyisinstalledonthemounts ateachendofthedriveaxle.Thepartsoftheservice brakeassemblyareshowninFigure3andFigure4. Whenthebrakepedalispushed,fluidpressurefrom themastercylindercausesthepistonsinthewheel cylinderstoextend.Thepistonsexpandthebrake shoesagainstthedrums.SeeFigure9.

Theclearancebetweenthebrakeshoesandthebrake drumisadjustedautomatically.Anadjusterlinkageturnstheadjusterwheeltoadjusttheclearance. WhenthelifttruckmovesintheREVERSEdirection andthebrakesareapplied,therearbrakeshoeand theadjusterlinksmovewiththedrum.Thislinkage movestheadjusterlevertorotatetheadjusterwheel. Theadjusterwheelcanturnonlywhenthereisclearancebetweentheliningofthebrakeshoeandthe brakedrum.Theadjusterwheelcanalsobeturned withatool.Aholeinthebrakedrumgivesaccessto theadjusterwheel.

MASTERCYLINDER

Themastercylinderisdesignedforadualcircuitsystem.Themastercylinderhastwoseparatepistons thatoperateinthesingleboreofthemastercylinder.Thereservoirforthefluidispressedintothe twoportsontopofthemastercylinderandheldin positionbyseals.Whenthebrakepedalispushed, thepushrodmovesthepistonassemblies.Theoperationofthemastercylinderisasfollows:

Whenthebrakesare OFF ,thehydraulicfluidcan movefreelybetweenthedualcircuitsystemandthe separatechambersofthefluidreservoir.SeeFigure1.

Whenthebrakepedalisreleased,thereturnsprings causethepistonstoretractfasterthanthefluid.This actioncausesavacuumbetweenthefluidinchambers A and C.Thevacuumcausesthesealstochange shape.Whenthesealschangeshape,theypermit thefluidinchambers B and D toflowthroughthe holesinthepistonsandpastthesealsintochambers

A and C.Thesupplyholesinthecylinderbodysuppliesfluidastheflowmovesfromtheonechamberto theotherchamber.Thefluidreturnstothereservoir throughthebypassholeswhenthepistonsarefully retracted.

Whenthebrakepedalispressed,theprimarypistonmovesinthecylinderbore.Thismovementcreateshydraulicpressurethatcombineswiththeforce oftheprimaryspring.Thesecombinedforcesovercomethesecondaryspringforceandmovethesecondarypistonintheborewiththeprimarypiston. Thefirstmovementofbothpistonspushestheseals pastthebypassholesinthechambers A and C.This actionappliespressuretothefluidinthosechambersandcausesfluidtoflowtothechambersofthe twoseparatesystems.Thefluidinchambers B and D isnotaffectedbymovementofthepistons.This fluidcanmovefreelybetweenthepistonchambers andthechambersofthefluidreservoir,beforeand duringbrakeapplication.SeeFigure2.

Ifafailureoccursinoneofthedualcircuits,theother circuitwillapplyoneoftheservicebrakes.Thisfailurewillcausethebrakepedaltotravelfartherwhen thebrakesareapplied,buttheservicebrakesonone drivewheelwilloperate.Thisfailureofoneofthe brakecircuitscancausethelifttrucktoturntoward thedrivewheelwiththegoodbrakewhenthebrakes areapplied.Theoperatormustcontrolthedirection ofthelifttruckwiththesteeringwhenthebrakes areappliedduringthiscondition.

Thereservoirisequippedwithanindicatorforlow fluidlevel.Afloatinthereservoirmovesupand downwiththefluidlevel.Whenthefluidlevelislow, amagnetonthefloatactivatesaswitchinthebottomofthereservoir.Thisswitchenergizesawarning lightontheinstrumentcluster.

PARKINGBRAKE

Theparkingbrakesystemusestheservicebrake shoes.Additionallinkageactivatestheparking brakesystem.Whenthepedalismovedtoapply theparkingbrake,thecablesandlinkageexpand

thebrakeshoesagainstthedrums.Thedesignof theparkingbrakelinkageadjustseachcablesothat

thetensionisthesamewhenthepedalismovedto applyparkingbrake.SeeFigure10.

Figure1.MasterCylinderBrakeOFFandBrakeRELEASED

Figure2.MasterCylinderBrakeAPPLIED

ServiceBrakeRepairs

REMOVEANDDISASSEMBLE

WARNING

Brakeliningscancontaindangerousfibers. Breathingthedustfromthesebrakelinings isacancerorlungdiseasehazard.Donot createdust!Donotcleanbrakepartswith compressedairorbybrushing.Usevacuum equipmentapprovedforbrakedustorfollow theCleanprocedureinthissection.Whenthe brakedrumsareremoved,donotcreatedust.

Donotsand,grind,chisel,hammer,orchange liningsinanywaythatwillcreatedust.Any changestobrakeliningsmustbedoneinarestrictedareawithspecialventilation.Protectiveclothingandarespiratormustbeused.

1. SeetheprocedureHowToPutaLiftTruckon Blocksinthe PeriodicMaintenance section oftheservicemanualorthe OperatingManual.Tiltmastfullybackward.Putblocksunder mast.Tiltmastforwarduntilwheelsjusttouch thefloor.Stopmotor.Putblocksunderframeof lifttruck.

2. Iftiltdoesnotfunction,useahydraulicjack, crane,oranotherlifttrucktoliftdrivewheels untiltheyjusttouchthefloor.Putblocksunder frameoflifttruck.

3. Removecapscrewsthatholdaxleshafttohub. Removeaxleshaft.

4. Releaseparkingbrake.Bendlockplateand removenutthatholdsaxlebearing.Remove washerandbearingcone.

5. Putgreaseonfloorsowheelassemblywillslide easilyfromaxletube.Pullwheelassembly fromlifttruck.Ifwheelassemblycannotbe removedeasily,removewheelanduseasmall screwdrivertopushadjusteractuatorawayfrom adjusterwheel.Useabrakeadjustmenttoolor

ascrewdrivertoturnadjusterwheeltoloosen brakeshoes.Installwheelandthenremovehub anddrumassembly.Donotdamagegreaseseal whenremovinghub.

WARNING

Whenthebrakeshoesareremoved,donotcreatedustintheair.SeetheCleanprocedurein thissection.

6. Removereturnspringswithspringpliers.See Figure3.

NOTE: Thereturnspringsarenotthesamepart number.Makesurespringsareinstalledinsame positionsfromwhichtheywereremoved.

7. Removeretainers,springs,andretainerpins thatholdbrakeshoestobackplate.SeeFigure4. Removebrakeshoesandadjusterassembly.

NOTE: Theadjusterwheelfortheleftbrakeisnot thesameastheadjusterwheelfortherightbrake. Theadjusterwheelfortherightbrakehasleft-hand threads.

8. Removebrakelinefromwheelcylinder.Remove wheelcylinder.

9. Removedustcovers,pistons,cups,andsprings fromwheelcylinder.SeeFigure5.

NOTE: Thebackplateisnotnormallyremovedfrom theaxlehousingforbrakerepairs.Sixspecialcapscrewsareusedtofastenthebackplatetotheaxle mountandthelockingfunctionofthecapscrewsisreducediftheyareremoved.Thefivecapscrewswith 5/8inchthreadaretightenedto245N•m(181lbfft). Thecapscrewwith1/2inchthreadistightenedto 125N•m(92lbfft).

10. Removesnapringsfromparkingbrakelevers. Removeparkingbrakeleversfrombackplate.

CLEAN WARNING

Donotuseanoilsolventtocleanthemaster cylinder,wheelcylinder,orthebrakelinings. Useasolventapprovedforcleaningofbrake parts.Donotpermitoilorgreaseinthebrake fluidoronthebrakelinings.Oilandgrease willcausedamageandleaksinthesealsof abrakesystem.Thebrakeswillnotoperate correctlyifoil,grease,orbrakefluidisonthe brakelinings.

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing

cleaningsolvents,alwaysfollowthesafety instructionsofthesolventmanufacturer.

1. Donotreleasebrakeliningdustfrombrakeliningsintoairwhenbrakedrumisremoved.

2. Useasolventapprovedforcleaningofbrake partstowetbrakeliningdust.Followinstructionsandcautionsofmanufacturerforuseof solvent.Ifasolventsprayisused,donotcreate brakeliningdustwithspray.

CAUTION

Donotpermitoilorgreaseonthebrakelinings. Useabrakecleaningfluidasnecessarytoclean liningsthatwillnotbereplaced.

3. Whenthebrakeliningdustiswet,cleanparts. Putanyclothortowelsinaplasticbagoran airtightcontainerwhiletheyarestillwet.Put aDANGEROUSFIBERSwarninglabelonthe plasticbagorairtightcontainer.

4. Anycleaningclothsthatwillbewashedmustbe cleanedsofibersarenotreleasedintotheair.

INSPECT

1. Inspectboreofwheelcylinderforholesor scratches.Replacewheelcylinderassemblyif thereisanydamage.

2. Inspectreturnspringsforwearordamage.Inspectbackplateforwearwherebrakeshoes touchbackplate.Removeanygroovesorreplace awornordamagedbackplate.

WARNING

Thebrakeshoesonbothwheelsmustbereplacedifanyshoeisdamaged.Thebrakeperformanceonbothendsofanaxlemustbeequal orthelifttruckcanbedifficulttosteerwhen thebrakesareapplied.

3. Inspectbrakeshoesforcracksordamage.If liningsorshoesarewornordamaged,replace brakeshoes.Maximumwearistowithin1mm (0.04in.)ofcontactwithrivetsormetalshoeon bondedlinings.Brakeshoesmustbereplacedin completesets.Inspectbrakedrumsforcracksor damage.Replaceanydamagedparts.

Figure3.BrakeAssembly(LeftBrakeAssembly

*DONOTBENDORPUTSTRESSONTHEUPPERLINKBYFORCINGTHEHOOKENDONORAROUNDTHE POSTONTHESPECIALCAPSCREW.

Figure4.ServiceBrakeParts

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NOTE: Ifgroovesmustberemovedfromthebrake drums,donotgrindmorethan1.5mm(0.060in.) fromtheinternaldiameterofthebrakedrum.The maximumlimitoftheinternaldiameterofthebrake drumis262mm(10.32in.).Iftheinternaldiameter islargerthanthelimit,replacebrakedrum.

4. Inspectbrakedrumfordeepgroovesorother damage.

5. Theteethoftheadjusterwheelmustnotbeworn. Theadjusterwheelmustturnfreely.Checkadjusterlinksfordamage.

6. Makesureparkingbrakecablesareingoodcondition.

7. Checkgreasesealsandsurfacesofsealsforwear ordamage.

ASSEMBLEANDINSTALL

1. Assemblewheelcylinder.SeeFigure5.Useonly HYSTERAPPROVEDparts.

2. Installwheelcylinderonbackplate.Makesure specialfittingforremovingairisintophole.Put Loctite® 271onthreadsofcapscrews.Tighten twocapscrewswith7/16inchthreadto78to 91N•m(58to67lbfft).Tightentwocapscrews with1/2inchthreadto91to102N•m(67to 75lbfft).

3. Putretainerpinsthatholdbrakeshoesthrough backplate.Installbackplateonaxlehousing.

4. Tightentwospecialcapscrewsforparkingbrake leversto245N•m(181lbfft).SeeFigure4. Tightencapscrewsthatholdbackplatetoaxle housingto245N•m(181lbfft).Installwasher andspecialcapscrewthatistheanchorforthe returnsprings.Thiscapscrewmustbetightened to125N•m(92lbfft).Makesurewasherisinstalledsocapscrewdoesnotloosenduringoperation.

5. Installparkingbrakeleversandcable.Install snaprings.Installcableguideandsnapringon crankforparkingbrake.

6. Installpivotpinthroughbrakeshoethatistowardrearoflifttruck.Installlinksinpivotplate. Installpivotplate,links,andcotterpin.

NOTE: Theupperlinkfortheleftbrakeassemblyis notthesameastheupperlinkfortherightbrake assembly.InstallpivotplatesotheletterLisseenon theleftbrakeassembly.Installpivotplateonright brakeassemblysotheletterRisseen.

7. Lubricatebackplatewithasmallamountof greasewheretheshoestouch.Installbrake shoes.Installretainerspringassembly.Puta springseat,spring,andretaineronpin.Push retainerontopinandrotateretainer90degrees tolockpinintoretainer.Installotherspring assembly.

WARNING

Thethreadsoftheadjusterwheelarenotthe sameforeachbrakeassembly.Iftheadjuster wheelassembliesareinstalledonthewrong brake,thebrakeshoeclearancewillincrease eachtimethebrakesareapplied.Theadjuster wheelfortherightbrakehasleft-handthreads. Theadjusterwheelfortheleftbrakehasrighthandthreads.

8. Putanantiseizecompoundonthreadsofadjuster wheel.Installadjusterwheelassemblybetween twobrakeshoes.Makesureadjusterwheelis towardrearoflifttruck.

Turnadjusterwheelintoadjusternutsoadjuster assemblyisinitsshortestposition.Thisaction permitsbrakedrumtobeeasilyinstalledover brakeshoes.

9. Installlinkinadjusterwheelactuator.Put adjusterwheelactuatorintheholeinbrake shoe.Fastenspringtoadjusterwheelactuator andbrakeshoe.Thespringmustbeinstalled inthepositionshowninFigure6.Installreturnspringsforbrakeshoes.Makesurereturn springsareinstalledincorrectpositions.See Figure6.Agrayspringisalwaysinstalledon rightbrakeshoe.

10. Makesurebottomedgeofadjusterwheelactuatorisjustabovecenterofteethofadjusterwheel. Bendlowerlinktoalignadjusterwheelactuator.

NOTE: Topreventdamagetotheinneroilsealwhen installingthehub,thehubanddrumassemblycan betemporarilyfastenedtothewheel.Alignthe heightoftheaxlehousingwithhubbearings.Put greaseunderwheelandslidewheeltowardaxle housing.Installouterbearingandnut.Remove wheelfromhubsotheclearanceofthebrakeshoes canbeadjusted.

11. Cleanhubbearingsandlubricatethemwith wheelbearinggrease.Installhubbearingsand sealsinhub.Installbrakedrumandhubonaxle housing.SeeFigure7andFigure8.

12. Adjusthubbearingsbytighteningnutto 205N•m(151lbfft)whilerotatinghub.Loosen nutuntilhubturnsfreely.Thetorquemust belessthan27N•m(20lbfft).Tightennut to34N•m(25lbfft)oruntilfirstalignment positionafter34N•m(25lbfft).Bendlockplate overnut.

CAUTION

Ifthereistoomuchclearance,theautomatic adjusterswillnotoperate.Iftheclearanceis toosmall,theautomaticadjustercannotturn theadjusterwheeltoincreasetheclearance andtheadjusterwheelwillnotturnuntil thebrakeshoeswear.Iftheadjusterwheel doesnotmoveforalongoperatingperiod,the adjusterlinkcanwearaspotontheadjuster wheelsothatitwillnotturncorrectly.

NOTE: Ifthebrakeshoeswerenotreplaced,loosen adjusterwheelapproximately25teeth.

13. Adjusttheclearanceofthebrakeshoes.Puta brakeadjustmenttoolorascrewdriverthrough holeindrum.Turnadjusterwheelsoteethof adjusterwheelnearestbackplatemoveupward. Turnadjusterwheeluntilhubwillnotturn.Pull actuatorawayfromadjusterwheelandturnadjusterwheelapproximately15teethinopposite direction.Thebrakeswilladjusttocorrectclearancewhentheyareappliedwhilelifttruckis travelingin REVERSE direction.

14. Putsealantonflangeofaxleshaft.Install axleshaftandcapscrews.Tightencapscrewsto 98N•m(72lbfft).

A. LEFTSIDE

1.SPRINGFOR(LEFT)SHOE(MAROON)

2.SPRINGFOR(RIGHT)SHOE(GRAY)

B. RIGHTSIDE

3.UPPERADJUSTERLINK

4.LOWERADJUSTERLINK

Figure6.SpringsInstallation

ADJUST

1. Removeairfrombrakehydraulicsystem.Seethe procedureBrakeSystemAirRemoval.

2. Installwheelonhub.Tightennutsto237to 305N•m(175to225lbfft).

3. Tiltmastbackwardorliftthetrucktoremove blocks.Pushonbrakepedal.Thepedalmustnot touchfloorplate.MovelifttruckinREVERSE andpushonbrakepedaltopermitadjusting mechanismtooperate.Repeatthisoperation severaltimes.

4. Theservicebrakesmustbeadjustedbeforethe parkingbrakecanbeadjusted.SeeFigure9and Figure10andthefollowingparagraphsinthis sectionforthecorrectadjustmentoftheparking brake.

1.OUTERSEAL 2.INNERSEAL

3.BRAKEDRUM

Figure7.GreaseSealsLocation

Figure8.InnerGreaseSealInstallation

1.CAPSCREW

2.BRAKEPEDAL

3.FLOORPLATE

4.LOCKNUT

5.PUSHROD

6.LOCKNUT

7.MASTERCYLINDER

8.BRAKEASSEMBLY

9.BRAKELINES

Figure9.ServiceBrake

ParkingBrakeRepair

REMOVEANDDISASSEMBLE

Iftheleverassemblyfortheparkingbrakemustbe removedfromtheframe,usethefollowingprocedure (seeFigure10):

1. Useblocksnexttothewheelstomakesurethe lifttruckcannotmove.Releasetheparking brake.

2. Turntheadjustmentknobsothatthelinkisat thebottomoftheadjustmentslot.

3. Removethecotterpinandpintodisconnectthe parkingbrakecablefromthebrakeassembly.

4. Removethecotterpinandanchorpinthatconnectthelinktotheparkingbrakeassembly.

5. Removethenutsandwashersthatholdtheparkingbrakeassemblytothebracket.Removethe capscrewsandspacers.

6. Removethecotterpin,washer,andanchorpin fromthelink.

ASSEMBLEANDINSTALL

Iftheleverassemblyfortheparkingbrakewasremovedfromtheframe,usethefollowingprocedure forinstallation:

1. Makesuretheparkingbrakeleverisinthereleasedposition.Turntheadjustmentknobuntil thelinkisadjustedtothebottomoftheadjustmentslot.

2. Installtheendsofthecablesintothecompensator.Installtheanchorpin,washer,andcotter pinintotheparkingbrakeassembly.Makesure theanchorpinisthroughthelinkandcompensator.

3. Installthemountingboltsthroughthecable clampsandspacers.Mounttheassemblytothe bracket.

4. Beforetighteningthemountingcapscrews,push downtheparkingbrakeassemblytomakesure itisincontactwiththeframebracket.

5. Thefollowingproceduremustbeusedtoconnect thelinktotheparkingbrakeassemblyandthe brakepedalassembly:puttheparkingbrake leverintheappliedposition.Installtheanchor pinintheholeinthelinkthatwilladjustthe bottomsideoftheparkingbrakepedalto28mm (1.1in.)abovetheframe.SeeFigure10.Install thecotterpins.Installthereturnspringinan emptyholeinthelink.

6. Withthebrakeintheappliedposition,adjust andtightenthenutsontheendofthecableto removeallthefreeplayfromthereleasehandle.

7. Withtheparkingbrakeapplied,adjustthe switchsothattheleverontheswitchmoves1 to3mm(0.04to0.12in.)beyondtheoperating point.

ADJUST

Makesurethattheservicebrakesareadjustedand theoperationoftheautomaticadjustermechanism iscorrectbeforetheparkingbrakeisadjusted.See Figure10.

1. Turntheadjustmentknobtoraisethelinkand tightentheparkingbrakecables.Turntheadjustmentknobuntiltheparkingbrakesarefully appliedwhenthepedalisusedtoapplytheparkingbrake.

2. Testtheoperationoftheparkingbrake.Thelift truckwithacapacityloadmustnotmovewhen theparkingbrakeisappliedona15%grade,[a slopethatincreases1.5min10m(1.5ftin10ft)].

3. Withtheparkingbrakeapplied,adjustthenuts toremoveanyfreeplayfromthereleasehandle.

4. ChecktheoperationoftheswitchesontheparkingbrakeasdescribedinParkingBrakeNotAppliedSwitchTest.

Figure10.ParkingBrake