Hyster A454 (W25XTC) Forklift Service Repair Manual by u1yiuef6

SERVICE REPAIR W20XTC W25XTC W30XTC W40XTC [A454]

General

Thissectionhasthedescriptionandrepairproceduresforthebrakes.Checksandadjustmentsforthebrake assemblyaredescribedattheendofthissection.Atroubleshootingchartisalsoattheendofthissection.

Description

Amechanically-operatedshoebrakewithabrake drumfastenedtothebevelgearshaftoftheMDU isusedonallunits.Anelectricalcutoutswitch operatedbythelinkageinterruptsthepowertothe drivemotorwhenthebrakeisapplied.Thebrake andcutoutswitch,whenproperlyadjusted,operate simultaneously.

W/B60-80XT

Aspringappliesthebrakewhenthesteeringhandle isintheverticalpositionorparalleltothefloor.See Figure1.Thesteeringhandlehasacamthatmovesa camfollowerattachedtoabellcrank.Thebellcrank isattachedthroughlinkagetoabrakereleasearm thatwillapplyorreleasethebrakewhenthesteering handleismoved.Movementofthebrakereleasearm compressesthespringtoreleasethebrake.

1800SRM535 Description

Figure1.BrakeOperation

W20-40XTA,W20-40XTC,W20-30XTR, W60-80XT

Aspringappliesthebrakewhenthesteeringhandleisintheverticalpositionorparalleltothefloor. Thesteeringhandlehasacamthatmovesaroller attachedtoabrakereleasearm.Movementofthe brakereleasearmcompressesthespringtorelease thebrake.

C60-80XT,CA60-80XT/XT2,T5XT

Thebrakeassemblyisoperatedbyhandleversthat arepartofthesteeringhandle.Thehandleversare attachedtolinkagethatapplythebrakes.Squeezingthebrakeleverswillcompressthespringsand applythebrakes.Whenthehandlesarereleased, thespringswillreleasethebrakes.Theseunitsalso haveaparkingbrake.Theparkingbrakeisnotautomaticallyapplied.Theparkingbrakemustbeset manuallywhentheoperatorleavesthetruck.

Repairs-General

WARNING

Donotoperatealifttruckthatneedsrepairs.If arepairisnecessary,putaDONOTOPERATE tagonthecontrolhandle.Removethekeyfrom thekeyswitch.

WARNING

Beforeperformingrepairsoradjustmentson thebrakesystem,blocksmustbeplacedunder eachsideoftheframetoraisethedrivetireoff theground.Theblocksmustpreventthelift truckfromfallingandcausingpersonalinjury orpropertydamage.SeethePeriodicMaintenancesectionforyourtruck.RefertoHowto PutLiftTruckonBlocks.

WARNING

Alwaysdisconnectandseparatethebattery connectorsotheconnectoriscompletelyfree beforeperforminganyserviceorrepairs.If theconnectorisnotcompletelyfree,itcan reconnect.TagtheconnectorDONOTCONNECT.

WARNING

Thecapacitorinthetractionmotorcontroller canholdanelectricalchargeafterthebattery isdisconnected.Topreventelectricalshock

andpersonalinjury,dischargethecapacitor beforeinspectingorrepairinganycomponent. Wearsafetyglasses.Makecertainthebattery hasbeendisconnected.Dischargethecapacitorsinthecontrollerbyconnectingaload (suchasa contactorcoilorahorn)acrossthe controller’sB+andB terminals.DONOTuse ascrewdrivertodischargethetractionmotor controller.

WARNING

Becarefulwhenremovingorinstallingsnap rings.Thesesnapringscancomelooseduringremovalorinstallationwithenoughforce tocauseapersonalinjury.Alwaysusethecorrectsnapringpliersandweareyeandfaceprotectionduringremovalandinstallation.

Somepartsofthesteeringcontrolhandlemustbe disconnectedtodisassemblethebrakes.Forremoval andinstallationofthesteeringcontrolhandlesee section SteeringMechanism 1600SRM534.

Separatepartsofthebrakesystemcanberemoved withoutdisassemblingthecompletebrakesystem. Thisprocedurehasstepstoreplacethebrakeshoe assembliesortodisassemblethecompletebrakesystem.Readtheprocedureanddoonlythestepsnecessarytomaketherequiredrepairstotheunitbeing workedon.

BrakeShoeRemoval

W/B60-80XT,W20-40XTA,W20-40XTC, W20-30XTR

SeeFigure2fortheB60-80XTandFigure3for theW20-40XTA,W20-40XTC,W20-30XTR,and W60-80XT.

BrakeShoeRemoval 1800SRM535

1. Raisethedrivewheeloffthefloor.Blockthelift truck.Seethe PeriodicMaintenance section foryourtruck.See8000SRM281or8000SRM 652.Referto WARNINGS inRepairs-General.

2. Disconnectthebatteryconnector.

3. Removethedriveunitcompartmenthoodtoaccessthebrakes.

4. Dischargethetractionmotorcontrollercapacitor.Referto WARNINGS inRepairs-General.

5. Removethegreasefittingsfromthebrakeshoe pivotpins.

6. Disassemblethesnapringsandpivotpinlink fromthebrakepivotpins.Referto WARNINGS inRepairs-General.

7. Loosenthenutsthatapplytensiontothespring toreleasethebrakeshoesfromthedrum.

8. Thebrakeshoeandliningassemblycannowbe removedbyslidingtheassemblyoffthebrake drumandpivotpinsandoutoftheslotinthe brakereleasearm.

9. Ifthebrakeshoeandliningassemblyrequire furtherdisassembly,removethetwonutsfrom thespringretainerbolt.Disassemblethespring seats,spring,andspringretainerbolt.Notethat thespringretainerboltheadhasaslottedhead tokeeptheboltfromturning.

10. Loosenthesetscrewsandremovetheadjusting screwsfromthebrakeshoeandliningassembly. Disassemblethesetscrewsfromthebrakeshoes andremovethesetscrewseats.

1800SRM535 BrakeShoeRemoval

1.NUT 2.SPRINGSEAT 3.SPRING 4.BRAKESHOEW/LINING 5.PIVOTPIN 6.LINK 7.SNAPRING 8.LUBEFITTING 9.SETSCREW 10.SETSCREWSEAT 11.ADJUSTINGSCREW 12.BRAKERELEASEARM 13.LUBEFITTING 14.THREADEDROD

Figure2.BrakeShoeAssembly(B60-80XT)

C60-80XT

SeeFigure4.

1. Raisethedrivewheeloffthefloor.Blockthelift truck.Seethesection PeriodicMaintenance 8000SRM281.Referto WARNINGS inRepairs -General.

2. Disconnectthebatteryconnector.

3. Removethedriveunitcompartmenthoodtoaccessthebrakes.

4. Dischargethetractionmotorcontrollercapacitor.Referto WARNINGS inRepairs-General.

5. Removethegreasefittingsfromthebrakeshoe pivotpins.

BrakeShoeRemoval 1800SRM535 1.NUT 2.THREADEDROD 3.SPRINGSEAT 4.SPRING 5.BRAKESHOEW/LINING 6.PIVOTPIN 7.LINK 8.RETAININGRING 9.LUBEFITTING 10.SETSCREWSEAT 11.SETSCREW 12.STUD 13.BRAKECAM 14.ROLLERW/BUSHING 15.NUT 16.ADJUSTINGSCREW 17.BRAKERELEASEARM 18.LUBEFITTING 19.NUT 20.SWITCHACTUATOR 21.SWITCH 22.MOUNTINGBRACKET 23.CAPSCREW 24.CAPSCREW 25.LOCKWASHER 26.SPACER

Figure3.BrakeShoeAssembly(W20-40XTA,W20-40XTC,W20-30XTR,W60-80XT)

6. Disassemblethesnapringsfromthebrakepivot pins.Removethecotterpinandflatwasher retainingthearmcamweldmenttothesupport weldment.Removethecapscrewandlockwasher supportingthecenteringshafttothesupport weldment.Removethesupportweldment. Checkthebushinginthesupportweldmentfor elongationordamage.Replacethebushingif necessary.Referto WARNINGS inRepairsGeneral.

SeeFigure5.

1. Removethetwojamnutsfromthebottomofthe brakeshaft.Loosenthehexnutonthetopofthe brakeshaft.Loosenthesetscrewsretainingthe adjustingscrews.Loosentheadjustingscrews. Removethebrakeshaftoutofthearmcamweldment,brakeshoes,andcenteringshaft.Support thespringswhenremovingthebrakeshaft.

1800SRM535 BrakeShoeRemoval 1.ARMCAMWELDMENT 2.COTTERPIN 3.FLATWASHER 4.NUT 5.LOCKWASHER 6.ADJUSTINGNUT 7.LUBEFITTING 8.SNAPRING 9.CAPSCREW 10.LOCKWASHER 11.SUPPORTWELDMENT 12.BUSHING 13.CENTERINGSHAFT 14.NUT 15.NUT 16.BRAKESHAFT 17.ADJUSTINGSCREW-UPPER 18.SPRING 19.ADJUSTINGSCREW-LOWER 20.SETSCREWSEAT 21.SETSCREW 22.BRAKESHOEW/LINING

Figure4.BrakeShoeAssembly(C60-80XT) CA/C60-80XT/XT2,T5XT

BrakeShoeInstallation

W/B60-80XT,W20-40XTA,W20-40XTC, W20-30XTR

SeeFigure2fortheB60-80XTandFigure3for theW20-40XTA,W20-40XTC,W20-30XTR,and W60-80XT.

1. Assemblethesetscrewseatandsetscrewinthe brakeshoeandliningassembly.Donottighten thesetscrewcompletely.Installtheadjusting screwsintothebrakeshoe.RefertoBrake Adjustment,W/B60-80XTbeforetighteningthe setscrews.

2. Insertthespringretainerboltthroughthebrake shoesandadjustingscrews.Installthespring seats,spring,andnutsontheretainerbolt.

3. Positionthebrakeshoeandliningassemblies onthepivotpinsandbetweenthebrakerelease arm.

4. Installthepivotpinlinkonthepivotpinsand installthesnaprings.Referto WARNINGS in Repairs-General.Assemblethegreasefittings intothepivotpins.Greasethepivotpins.

BrakeShoeInstallation 1800SRM535 1.ARMCAMWELDMENT 2.COTTERPIN 3.FLATWASHER 4.NUT 5.LOCKWASHER 6.ADJUSTINGNUT 7.LUBEFITTING 8.SNAPRING 9.CAPSCREW 10.LOCKWASHER 11.SUPPORTWELDMENT 12.BUSHING 13.CENTERINGSHAFT 14.NUT 15.NUT 16.BRAKESHAFT 17.UPPERADJUSTINGSCREW 18.SPRING 19.LOWERADJUSTINGSCREW 20.SETSCREWSEAT 21.SETSCREW 22.BRAKESHOEW/LINING 23.PIVOTPIN

Figure5.BrakeShoeAssembly(CA60-80XT/XT2,T5XT)

5. Adjustthenutsonthespringretainerboltuntil thespringiscompressedto100mm(3.94in.) for6000-lblifttrucksand97mm(3.81in.)for 8000-lblifttrucks.

6. Adjustthebrakes.RefertoBrakeAdjustment.

7. Installthedriveunitcompartmenthood.

8. Lowerthelifttrucksothedrivewheelisonthe floor.Connectthebattery.Testtheoperationof thelifttruckbeforereturningtoservice.

C60-80XT2,CA60-80XT,T5XT

SeeFigure4andFigure5.

1. Assemblethesetscrewseatandsetscrewinthe brakeshoeandliningassembly.Donottighten thesetscrewcompletely.Installtheadjusting screwsintothebrakeshoe.RefertoBrakeAdjustment,C60-80XT,CA60-80XT/XT2,T5XTbeforetighteningthesetscrews.

2. Installthecenteringshaftinthedriveunithousingandinstallthenuttoretaintheshaft.Make certainthattheholeinthecenteringshaftis alignedwiththebrakeshoesbeforetightening thenut.

3. Positionthebrakeshoeandliningassemblieson thepivotpins.

W/B60-80XT

SeeFigure6.

4. Positionthespringsinthebrakeshoesandcenteringshaft.Installthebrakeshaftthroughthe centeringshaft,brakeshoes,andsprings.Install thetwojamnutsonthebottomofthebrakeshaft. Snugtheadjustingnutonthetopofthebrake shafttocontacttheslotinthearmcamweldment.RefertoBrakeAdjustmentbeforetighteningtheadjustingnut,retainingnut,andlockwasher.

5. Installthebushinginthesupportweldment.Positionthesupportweldmentonthepivotpins andarmcamweldment.Installthesnapringson thepivotpins.Referto WARNINGS inRepairs -General.Assemblethegreasefittingsintothe pivotpins.Greasethepivotpins.

6. Installthecapscrewandwashertoretainthe supportweldmenttothecenteringshaft.Install thewasherandanewcotterpintoattachthearm camweldmenttothesupportbracket.

7. Adjustthebrakes.RefertoBrakeAdjustment.

8. Installthedriveunitcompartmenthood.

9. Lowerthelifttruckortractorsothedrivewheel isonthefloor.Connectthebatteryandtestthe operationofthelifttruckbrakespriortoreturningthelifttrucktoservice.

BrakeLinkageRemoval

6. Straightenandremovethecotterpinretaining thebellcranktothecontrolhandlepivot.Remove theclevispinandthebellcrank.

1. Raisethedrivewheeloffthefloor.Blockthe lifttruck.Seesection PeriodicMaintenance 8000SRM281.Referto WARNINGS inRepairs -General.

2. Disconnectthebatteryconnector.

3. Removethedriveunitcompartmenthoodtoaccessthebrakes.

4. Dischargethetractionmotorcontrollercapacitor.Referto WARNINGS inRepairs-General.

5. Straightenandremovethecotterpinsretaining boththeupperandlowerclevispins.Removethe clevispinsfromtheyokeends.

7. Removetheyokeends,jamnuts,andswitch platefromtheconnectingrod.

8. Removetheretainingringfromthebrakerelease arm.Ifnecessary,useadrifttoremovethearm fromtheMDUhousing.Referto WARNINGS in Repairs-General.

9. Taganddisconnectthewirestothebrakeswitch. Removethenutretainingtheswitchtothedrive unithousingandremovetheswitch.

10. Removethecapscrews,locknuts,wireclamp, andbracketfromthedriveunithousing.

1800SRM535 BrakeLinkageRemoval

BrakeLinkageRemoval 1800SRM535 1.COTTER PIN 2.PIN 3.BELLCRANK 4.CAMFOLLOWER 5.LOCKNUT 6.YOKEPIN 7.YOKERHTHREAD 8.JAMNUT 9.THREADEDROD 10.SWITCHPLATE 11.CAPSCREW 12.LOCKNUT 13.NUT 14.BRACKET 15.WIREHARNESS 16.SWITCH 17.CAPSCREW 18.LOCKWASHER 19.WASHER 20.CLAMP 21.CLAMP 22.WASHER 23.LOCKWASHER 24.CAPSCREW 25.SUPPORT 26.LOCKWASHER 27.CAPSCREW 28.E-RING

Figure6.BrakeLinkage(W/B60-80XT)

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C60-80XT

SeeFigure7.

1. Raisethedrivewheeloffthefloor.Blockthelift truck.Seethesection PeriodicMaintenance 8000SRM281.Referto WARNINGS inRepairs -General.

2. Disconnectthebatteryconnector.

3. Removethedriveunitcompartmenthoodtoaccessthebrakes.

4. Dischargethetractionmotorcontrollercapacitor.Referto WARNINGS inRepairs-General.

5. Removethetwocapscrewsandlockwashersretainingthefrontcoverandthetwocapscrewsretainingthecoverplate.Removethefrontcover andthecoverplate.

NOTE: Beforedisassemblinganyofthebrakelinkage,marktheyokes,brakerods,andnutssothatthe lengthofthelinkageisnotchanged.Ifcomponents onthethreadedrodsarebeingremoved,measurethe rodsandrecordtheirdimensionsfortheproperalignmentatassembly.

6. Removethecotterpin(28)retainingtheclevis pintothearmcamweldment(53).Removethe clevispin.Removethecotterpin(48)retaining thelowerbrakerod(47)tothebellcrank(46). Removethewashers(49)andthelowerbrakerod (47)fromthebellcrank(46).

7. Removethecotterpinretainingtheclevispinto theupperthreadedbrakerod(34)andthebellcrank(46).Removetheclevispin.

8. Removethesnaprings(45)retainingthebellcrank(46)tothedisc.Referto WARNINGS in Repairs-General.Removethepin(44)andbellcrank(46)fromthedisc(50).

9. Removethecotterpinsretainingtheclevispins (28)tothearmandcam(36)andthebrakerod (34).Removetheclevispins(28)andthebrake rod(34).

10. Removethesnaprings(24)retainingthepin(23) andcam(22)tothesteerhandle(25).Referto WARNINGS inRepairs-General.Removethe pinandthecam.

11. Removetherollpins(13)retainingtheplate weldments(12)tothehandles(15and16).Removethehandlesandbushings(14).

12. Removethesprings(11)fromtherodweldments (10)andthemountingbracketsinthesteerhandle(25).RemovetheE-rings(9)retainingtherod weldments(10)totheplateweldments(12)and thepin(17)tothecam(22).Removetheplate weldments(12),cam(22),pin(17),andtherod weldments(10)fromthesteerhandle.

13. Removethesnaprings(38)fromtheparking brakepin(37).Removethepinandparking brakearmandcam(36).Removethecotterpin retainingtheeyebolt(35),nut(30),andyoke (29)fromthearmandcam.

14. Identifythewirestothebrakeswitch(33).Removethebrakeswitchwires.Removetheupper nutandremovetheswitchfromthetower.

1800SRM535 BrakeLinkageRemoval

BrakeLinkageRemoval 1800SRM535

Figure7.BrakeLinkage(CA60-80XT)

SeeFigure8.

1. Raisethedrivewheeloffthefloor.Blockthelift truckseethesection PeriodicMaintenance 8000SRM281.Referto WARNINGS inRepairs -General.

2. Disconnectthebatteryconnector.

3. Removethedriveunitcompartmenthoodtoaccessthebrakes.

4. Dischargethetractionmotorcontrollercapacitor.Referto WARNINGS inRepairs-General.

5. Removethetwocapscrewsandlockwashersretainingcovers(14and15).Removethecapscrew (12)andlockwasher(13).Removeknob(10)and nut(11).Removecovers(14and15).

6. Removethecotterpins(40)retainingthecenteringshafttotheyokearm(38).Removethecenteringshaft.Removethewashers(39).Disconnectthecableendfromtheyokeend(38).

7. Removethecotterpin(27)retainingthepin(28) tothebrakearm(20)androdend(29).Disconnectthecablefromtherodend.

8. Removethepin(21)retainingthebrakehandles (19and22).Removethebrakearmsandhandles.

9. RemovetheE-rings(17)fromthepin(18).Refer to WARNINGS inRepairs-General.Remove thepin(18)fromthearm(16).Removearm.

1800SRM535 BrakeLinkageRemoval

1.CONTROLHEAD 2.COVERPLATE 3.BACKCOVER 4.CAPSCREW 5.LOCKWASHER 6.NUT 7.FRONTCOVER 8.KNOB 9.E-RING 10.RODWELDMENT 11.SPRING 12.PLATEWELDMENT 13.ROLLPIN 14.BUSHING 15.HANDLE 16.16.HANDLE 17.PIN 18.CAPSCREW 19.PIVOT 20.LOCKWASHER 21.LOCKNUT 22.CAM 23.PIN 24.SNAPRING 25.STEERHANDLE 26.KNOB 27.NUT 28.PINW/COTTERPIN 29.YOKE 30.NUT 31.JAMNUT 32.SWITCHPLATE 33.SWITCH 34.BRAKEROD 35.EYEBOLT 36.ARMANDCAM 37.PIN 38.SNAPRING 39.WIREHARNESS 40.TOWER 41.NUT 42.LOCKWASHER 43.CAPSCREW 44.PIN 45.SNAPRING 46.BELLCRANK 47.BRAKEROD 48.COTTERPIN 49.FLATWASHER 50.DISC 51.CAPSCREW 52.LOCKWASHER 53.ARMCAMWELDMENT

LegendforFigure7

CA60-80XT/XT2,T5XT

Figure8.BrakeLinkage(C60-80XT2,T5XT)

BrakeLinkageRemoval 1800SRM535

LegendforFigure8

BrakeLinkageandCableInstallation

W/B60-80XT

SeeFigure6.

1. Installthebellcrankonthecontrolhandlepivot withtheclevispinandanewcotterpin.

2. Assembletheswitchactuatorplate,jamnuts, andyokeendstotheconnectingrod.Thecorrect lengthoftherodassemblymustbedetermined priortoconnectingtherodtotheupperbellcrank andthebrakereleasecam.Makecertainthat thecamfolloweristouchingthecamonthecontrolhandle.Placea0.38to0.76mm(0.015to 0.030in.)shimbetweenthebrakereleasecam andtheupperadjustingnut.Itmaybenecessary toadjustthenut.Loosenthesetscrewtomake anyadjustment.Keeptheshimbetweenthenut andbrakereleasearm.Adjustthebrakeconnectingrodtothelengthrequiredtoenablethe upperandlowerclevispinstobeinstalledinthe brakereleasecamandtheupperbellcrank.Installtheclevispinsandnewcotterpins.Tighten thesetscrewandremovetheshim.

3. Installthesameshimonthelowersideofthe brakereleasecam.Loosenthesetscrewandadjusttheloweradjustingnuttoobtainthesame clearance.Tightenthesetscrewwhenaclearanceof0.38to0.76mm(0.015to0.030in.)is obtained.

4. Adjustthebrakes.RefertoBrakeAdjustment, W/B60-80XT.

5. Installthedriveunitcompartmenthood.

6. Lowerthelifttrucksothedrivewheelisonthe floor.Connectthebatteryandtesttheoperation ofthelifttruckpriortoreturningthelifttruckto service.

C60-80XT

SeeFigure7.

1. Installthebrakeswitch(33)inthetower(40)and installtheuppernuttoretaintheswitchtothe housing.Installthewirestotheswitch.

2. Assembletheeyebolt(35),nut(30),andyoke(29) totheparkingbrakeandcam(36).Installthe clevispin(28)andanewcotterpin.Alignthe pivotpin(37)andthearmandcaminthetower. Installthesnaprings(38)toretainthepivotpin. Referto WARNINGS inRepairs-General.

3. Assembletherodweldments(10)totheplate weldments(12)usingtheE-rings(9).

4. Installthebushings(14)inthesteerhandle(25). Installthehandles(15and16)intothebushings. Aligntheholesinthehandlesandplateweldments(12)andinstalltherollpins(13).

5. Installthepivotpin(23)forthebellcrank(22)in onesideofthetower.Positionthebellcrankon thepivotpin.Installthesnaprings(24)toretain thebellcrank.Completeinstallingthepivotpin inthetowerandinstalltheoutersnapringsto retainthepivotpin.

1800SRM535BrakeLinkageandCableInstallation

1.STEERHEAD 2.CAPSCREW 3.WASHER 4.WASHER 5.STEERARM 6.CAPSCREW 7.CAPSCREW 8.LOCKWASHER 9.NUT 10.KNOB 11.NUT 12.CAPSCREW 13.LOCKWASHER 14.COVER 15.COVER 16.ARM 17.E-RING 18.PIN 19.LHBRAKEHANDLE 20.BRAKEARM 21.PIN 22.RHBRAKEHANDLE 23.TENNERMANNUT 24.STEERCOLUMN 25.BUSHING 26.BUSHING 27.COTTERPIN 28.PIN 29.RODEND 30.CABLE 31.SETSCREW 32.SETSCREW 33.SETSCREW 34.STEERDISC 35.PIVOTSHAFT 36.LOCKWASHER 37.CAPSCREW 38.YOKEEND 39.WASHER 40.PIN 41.BRACKET-CABLE MOUNTING 42.CAPSCREW 43.LOCKWASHER 44.BALLHANDLE 45.JAMNUT 46.PIPEFITTING 47.SPRING 48.WASHER 49.PIN 50.LOCKINGPIN