Hyster K005 (H70XM) Forklift Service Repair Manual

General

Thissectionhasadescriptionandtherepairproceduresforthepartsofthehydraulicbrakesystem.These partsincludethebrakebooster,mastercylinder,andbrakeshoeassemblies.

DescriptionandOperation

Thebrakepedalisconnectedtothepushrodforthe brakebooster.Thebrakeboosterhelpsincreasethe forceonthemastercylinderbyusingvacuumfrom theengine.Thepistoninthemastercylinderforces oiltothewheelcylinderstoapplythebrakes.(The systemallowsbrakingwithoutvacuumfromtheengine.)

thepistonpushesfluidthroughthecheckvalve.A returnspringpushesthepistonbacktothestop platewhenthepedalisreleased.Fluidcanflow throughpassagesinthepistonandpasttheprimarycupasthepistonreturns.Fluidflowsacross thepistontopreventavacuumwhilefluidreturns throughthecheckvalve.Whenthepistonpasses thecompensatorport,excessfluidfromthesystem canreturntothereservoir.Thecheckvalvekeepsa verysmallamountofpressureinthebrakesystem. Thereservoirforbrakefluidhasasendingunitfor alowfluidlevelwarninglight.

SERVICEBRAKEASSEMBLY

Aservicebrakeassemblyisinstalledateachendof thehousingforthedriveaxle.Eachservicebrakeassemblyhasasingle-wheelcylinderatthetopofeach backplate.Thesupportplatehasananchorforeach shoe.Whenthewheelcylinderisactuatedbyfluid pressurefromthemastercylinder,theshoesexpand againstthedrum.Theprimaryshoestartstoturn withthedrum.Thisactionpushesthesecondary shoetightagainstthedrumandtheanchor.When thelifttruckistravelinginreverse,theprimaryshoe ispushedagainsttheanchorandthedrumbythe secondaryshoe.

BRAKEBOOSTERANDMASTER

CYLINDER

Thebrakeboosterandmastercylinderareassembledasaunit.Thebrakeboosterhasadiaphragm thatisactuatedbyenginevacuum.SeeFigure1. Thediaphragm,alongwiththeoperator’seffort, pushesonthepistoninthemastercylinder.Hydraulicpressureactuatesthewheelcylindersas

Theautomaticadjustinglinkageturnstheadjuster screwwheeltoadjusttheclearancebetweenthe brakeshoesandthebrakedrum.Thesecondary shoeandthelinksmovewiththedrumduringa stopwhenthetruckistravelinginreverse.The linkspermittheadjusterspringlevertorotatethe adjusterscrewwheel.Theadjusterscrewwheelonly canturnwhenthereisclearancebetweenthelining andthebrakedrum.Theadjusterscrewwheelcan beturnedmanuallythroughaslotinthebackplate.

Figure1.BrakeBoosterandMasterCylinder

PARKINGBRAKE

Theparkingbrakeusestheservicebrakeshoes. Additionallinkagepushestheshoesapartwhen thehandleverpullsthecables.Aswitchonthe right-handsideofthemountingbracketisactuated bythehandlever.Onallunits,theswitchenergizestheseatwarningcircuitwhenthehandlever

isreleased.OnunitswithaMONOTROL® pedal, thisswitchputsthetransmissionin NEUTRAL by de-energizingthedirectionsolenoids.Onunitswith aMONOTROLpedal,thereisalsoaswitchonthe left-handsideofthebracket.Thisswitchprevents theenginefromstartingunlesstheparkingbrakeis applied.

BrakeShoeAssembliesRepair

REMOVEANDDISASSEMBLE

WARNING

Brakeliningscancontaindangerousfibers. Breathingthedustfromthesebrakelinings isacancerorlungdiseasehazard.Donot createdust!Donotcleanbrakepartswith compressedairorbybrushing.Usevacuum equipmentapprovedforbrakedustorfollow thecleaningprocedureinthissection.When thebrakedrumsareremoved,donotcreate dust.

Donotsand,grind,chisel,hammer,orchange liningsinanywaythatwillcreatedust.Any changestoliningsmustbedoneinarestricted areawithspecialventilation.Protectiveclothingandarespiratormustbeused.

1. Tiltthemastback,andputblocksunderthe outermastweldment.Tiltthemastforwardto raisethetiresfromthefloor.

WARNING

Completelyremovetheairfromthetiresbeforeremovingthemfromthelifttruck.Air pressureinthetirescancausethetireand wheelpartstoexplode,causingseriousinjury ordeath.

2. Makesurethatyouremovealltheairpressure fromthetiresbeforeyouremovethewheels fromthehub.Removethewheelnuts;then removethewheels.Putcapscrews(16mm)in thethreadedholestopushthebrakedrumsfrom thehubs.SeeFigure2andFigure3.

3. Removethecapscrewsthattheholdtheaxle shafttothehub.Removetheaxleshaft.

4. Removethelocknut,lockplate,andbearingadjustmentnutfromtheaxlehousing.Removethe outerbearingcone.Removethehubfromthe axlehousing.Removetheinnersealsandbearingconefromthehub.

WARNING

Whenthebrakeshoesareremoved,donotcreatedustintheair.Seethecleaningprocedures inthissection.

5. Turntheadjusterscrewtoloosenthebrake shoes.Disconnectthelinkagefortheautomatic adjuster.

6. Usespringplierstoremovetheshoereturn springs.

7. Removetheholddownsprings.

CAUTION

Theadjusterscrewassembliesarenotthe same.Makesurethateachassemblyhasidentificationforinstallationonthecorrectsideof theaxle.

8. Removethebrakeshoesfromthewheelcylinder rods.Removetheadjusterscrewspring.Remove theadjusterscrewassembly.

9. Removetheparkingbrakecablefromthelever. Removetheleverfromthebrakeshoe.

10. Disconnectandputacaponthelinetothewheel cylinder.Removethebackplateandshield.Removethecapscrewsthatholdthewheelcylinder tothebackplate.Removethecableclampand pullthecablethroughthebackplate.

CLEAN

2. Useasolventapprovedforcleaningofbrake partstowetthebrakeliningdust.Followthe instructionsandcautionsofthemanufacturer fortheuseofthesolvent.Ifasolventsprayis used,donotcreatedustwiththespray.

Figure2.ServiceBrakesH3.50-4.00XMS(H70-90XM)

1. Donotreleasebrakeliningdustfromthebrake liningsintotheairwhenthebrakedrumisremoved.

CAUTION

Donotuseanoilsolventtocleanthewheel cylinder.Useasolventapprovedforcleaning ofbrakeparts.Donotpermitoilorgreasein thebrakefluidoronthebrakelinings.

3. Whenthedustiswet,cleantheparts.Putany clothortowelsinaplasticbagoranairtightcontainerwhiletheyarestillwet.PutaDANGEROUSFIBERSwarninglabelontheplasticbagor airtightcontainer.

NOTE: LEFT-HANDSIDESHOWN.

Figure3.ServiceBrakesH4.00XM-5.50XM(H100-120XM)

4. Anycleaningclothsthatwillbewashedmustbe cleanedsothatfibersarenotreleasedintothe air.

INSPECT

WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowtherecommendationsofthemanufacturer.

1. Cleanallmetalpartsexcepttheliningsandthe wheelcylinderwithsolvent.

2. Checktheboreofthewheelcylinderforholesor scratches.Replacethewheelcylinderifthereis anydamage.

3. Checkthereturnspringsfordamage.Inspectthe backplateforwearwherethebrakeshoestouch thebackplate.

4. Inspectthebrakeshoesforcracksordamage.If theliningsorshoesarewornordamaged,replace thebrakeshoes.Itisrecommendedthatbrake shoesbereplacedincompletesets.

5. Checktheadjusterscrewwheelforwear.Make suretheadjusterscrewturns.Checkforbentor brokenadjusterlinks.

WARNING

Thebrakeshoesonbothwheelsmustbereplacedifanyshoeisdamaged.Thebrakeperformanceonbothendsofanaxlemustbeequal orthelifttruckcanbedifficulttosteerwhen thebrakesareapplied.

NOTE: Ifthebrakedrumsrequiregrinding,donot grindmorethan1.5mm(0.060in.)fromthediameter.Themaximuminsidediameterofthebrake drum,includingwear,is319.5mm(12.58in.).If thebrakedrumislargerthanthis,replacethebrake drum.

6. Inspectthebrakedrumsforcracksordamage. Usesandpapertocleanthesurfaceforthebrake shoes.

ASSEMBLEANDINSTALL

1. Installthewheelcylinderonthebackplate.Push theparkingcablethroughthebackplateandfastentheclamp.SeeFigure2andFigure3.

2. Useasealant(HysterPartNo.264159)between thebackplateandtheaxlehanger.Installthe shieldandbackplate.Usingthesequenceshown inFigure4,tightenthecapscrewsto340to 375N•m(250to275lbfft).

Figure4.BackplateInstallation

3. Connectthebrakelinetothefittingonthewheel cylinder.

4. Installthelinkpivotontherearshoe.Install theparkingbrakeleveronthefrontshoe.Install theanchorpinsinthesupportflangesothatthey engagethebrakeshoes.

5. Lubricatethebackplatewithasmallamountof greasewherethebrakeshoestouch.Installthe brakeshoesontheanchorandengagethepush rodsofthewheelcylinder.Engagetheparking brakeleverintheslotintheparkingbrakecable asthebrakeshoesareinstalledonthebackplate.

6. Putananchorpinthatholdsthebrakeshoes throughthebackplate.Putaspringseat,spring, andretainerontheanchorpin.Pushtheretainer ontotheanchorpinandrotatetheretainer90 degrees.Makesuretheretainerisinthecorrect position.Installanotherretainerspringassembly.

7. Installthelink,parkingbrake,andspringbetweentheparkingbrakeleverandthebrake shoe.

8.H4.00XM-5.50XM(H100-120XM):Usingthe correcttools,installthereturnsprings.

9.H3.50-4.00XMS(H70-90XM):Installtheanchor guideontheanchor.Installthepivotplateonits anchor.

10.H3.50-4.00XMS(H70-90XM):Lubricatethe adjustercablewhereitslidesinthepivotplate groove.

11.H3.50-4.00XMS(H70-90XM):Fastenthelinkto theadjusterwheelactuatorandputthecable aroundthepivotplate.Raisetheadjusterwheel actuatoragainstthespringtensionandconnect thelinktotheanchor.

CAUTION

Besuretoinstallthewhitereturnspringfirst andthentheblackreturnspring.SeeFigure5. Improperassemblycanresultinbrakefailure and/orcomponentdamage.

12.H3.50-4.00XMS(H70-90XM):Usingthecorrect tools,installthereturnspringsasfollows:

a. Installthewhitespring.

b. Installtheblackspring.

13.H3.50-4.00XMS(H70-90XM):Verifythatthereturnspringsareproperlyinstalledasshownin Figure5.

14. Connectthecablefortheparkingbraketothe lever.

Figure5.ProperInstallationofReturnSprings

LegendforFigure5

NOTE: H3.50-4.00XMS(H70-90XM)RETURNSPRINGSSHOWN.

1.WHITESPRING

WARNING

Thethreadsoftheadjusterwheelarenotthe sameforeachside.Iftheadjusterassemblies areinstalledonthewrongside,thebrakeshoe clearancewillincreaseeachtimethebrakes areapplied.Theadjusterwheelfortheright brakehasright-handthreads.Theadjuster wheelfortheleftbrakehasleft-handthreads.

15. Lubricatetheadjusterscrewwithantiseizecompound.Turntheadjusterscrewinsothatthe brakeshoesretract.Installtheadjusterbetween theshoes.Aligntheadjusterscrewwheelwith theslotinthebackplate.Installtheadjuster springwiththelonghooktowardtheadjuster screwwheel.

CAUTION

Donotdamagethesealswhenyouinstallthe hubassembly.

17. Usenewoilseals.Installtheinnerseal,thebearingcups,andtheoutersealinthehub.Install theinnerbearingconeonthespindle.Lubricate theinnerbearingwithgrease.SeeFigure6.

18. Installthehubonthespindle.SeeFigure6.Lubricatetheouterbearingconewith80W-90oilfor gears.Installtheouterbearingconeandtheadjustmentnut.Tightentheadjustmentnutto200 to225N•m(148to166lbfft)whileyourotatethe hub.Loosenthenutuntilthehubrotatesfreely withNOendplay.Thetorquemustbelessthan 27N•m(20lbfft).Tightenthenutto34N•m (25lbfft)ortothefirstalignmentpositionafter 34N•m(25lbfft).Installthelockwashertohold thenut.Installthelocknutandtightenitto135 to150N•m(100to111lbfft).

19. Installthebrakedrumandadjustthebrake shoesasdescribedinBrakeShoesAdjustment.

2.BLACKSPRING

20. Applysealant(HysterPartNumber264159)to theflangeoftheaxleshaft.Installtheaxleshaft. Tightenthecapscrewsto225to250N•m(166to 184lbfft).SeeFigure7.

CAUTION

Whenthewheelshavebeeninstalled,check allwheelnutsafter2to5hoursofoperation. Tightenthenutstothecorrecttorque.When thenutsstaytightafteran8-hourcheck,the intervalforcheckingcanbeextendedto500 hours.

21. Installthewheel.Tightenthewheelnutsto610 to680N•m(450to500lbfft)onallunits.

16.H4.00XM-5.50XM(H100-120XM):Installthe adjusterspringleverandthetwolinks.

Figure6.BrakeandHubAssembly

22. Removetheairfromthebrakesystemandadjust thebrakes.SeeBrakeShoesAdjustmentinthis section.

BrakeBoosterandMasterCylinderRepair REMOVE

1. Disconnectthepushrodfromthebrakepedal. SeeFigure8.Disconnectthebrakelineatthe mastercylinder.Covertheendofthebrakeline. Disconnectthewiresatthereservoir.

2. Removethenutsthatholdthebrakeboosterto themount.

3. Removethebrakeboosterandmastercylinder.

DISASSEMBLE

NOTE: Donotdisassemblethebrakebooster.Repair partsarenotavailable.

1. Removethenutsthatholdthemastercylinderto thebrakebooster.SeeFigure9.

WARNING

Thereisacompressedspringbehindthepiston.Becarefulwhenremovingthesnapring andpiston.

2. Removethesnapringfromtheendofthemaster cylinder.Carefullyremovethepistonandspring fromthebore.

3. Removesealsfromthepiston.

CLEANANDINSPECT CAUTION

DONOTuseanoilsolventtocleanthemaster cylinder.Useasolventapprovedforcleaning ofbrakeparts.

Inspecttheboreofthemastercylinderforholesor scratches.Replacethemastercylinderassemblyif thereisdamage.

ASSEMBLE

NOTE: Lubricatethepartsofthemastercylinder withcleanbrakefluid.

1. Installthesealsonthepiston.Installtheseat, checkvalve,andspringinthebore.Installthe springandpiston.Installthesnapringinthe bore.SeeFigure9.

2. InstalltheO-ringandmastercylinderonthe brakebooster.

Figure7.AxleShaftTighteningSequence

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Figure8.BrakeSystemArrangement

INSTALL

1. Putthemastercylinderinpositiononthebrake boosterandinstallthenutsforthemastercylinder.Installthebrakeboosteronthemount.Installthenutsforthebrakebooster.Connectthe pushrodtothebrakepedal.SeeFigure8.

2. Connectthebrakelineatthemastercylinder. Connectthewiresatthereservoir.Fillthereservoirandremovetheairfromthebrakesystemas describedinBrakeSystemAirRemovalinthis section.

3. AdjustthebrakelinkageasdescribedinBrake PedalAdjustment.

Figure9.BrakeBoosterandMasterCylinder

BRAKEBOOSTERFILTER,REPLACE

1. Removethetwoclampsholdingtheoldfilter tothebrakevacuumlines.Removethebrake boosterfilter.SeeFigure9.

REMOVEANDDISASSEMBLE

2. Installnewfilterontobrakevacuumlines.Installthetwoclampstoholdbrakeboosterfilter ontobrakevacuumlines.

ParkingBrakeRepair

ASSEMBLEANDINSTALL

Iftheleverassemblyfortheparkingbrakemustbe removedfromthecowl,usethefollowingprocedure (seeFigure10):

1. Useblocksnexttothetirestomakesurethelift truckcannotmove.Releasetheparkingbrake lever.

2. Removethefournuts,bolts,andwashersthat fastenthebracketfortheparkingbraketothe cowl.Disconnectthewiresattheswitches.Removethebracketandbrakeleverassembly.

3. Loosenthejamnutsthatfastenthethreaded endsofthebrakecablestothebrakeleverassembly.

4. Turntheadjusterknobcounterclockwiseuntil thebrakecablesareloosened.Disconnectthecablesfromthelink.

5. Theservicebrakeassemblymustberemovedbeforetheparkingbrakecablecanberemovedfrom thebackplateoftheservicebrake.Asnapring holdsthesheathoftheparkingbrakecablein thebackplateoftheservicebrake.Removethe snapringandremovetheparkingbrakecable fromthebackplate.

OntheH3.50-4.00XMS(H70-90XM)units,theparkingbrakecablesmustbeinstalledinthebackplate beforetheservicebrakeisinstalled.Asnapring holdsthesheathoftheparkingbrakecableinthe backplateoftheservicebrake.Installtheparking brakecableinthebackplateandinstallthesnapring thatholdsthesheathoftheparkingbrakecablein thebackplate.

Iftheleverassemblyfortheparkingbrakewasremovedfromthecowl,usethefollowingprocedurefor installation(seeFigure10):

1. Makesuretheparkingbrakeleverisinthereleasedposition.Turntheadjustmentknobuntil thelinkisadjustedtothebottomoftheadjustmentslot.

2. Adjustthejamnutsontheendsofthecableassembliessothatthethreadsofthecablesheaths extend6mm(0.25in.)abovetheirsupportplate intheleverassembly.

3. Installtheroundendsoftheparkingbrakecablesintheirslotsinthelink.Tightentheupper jamnutstoholdthesheathsoftheparkingbrake cablesintheirsupport.

4. Usethefourcapscrews,washers,andnutsand fastenthebrackettotheinsideofthecowl.

BrakeSystemAirRemoval

Theairmustberemovedfromthebrakefluid.Fill thereservoirforthemastercylinderwithbrakefluid. Alwaysremovetheairfromthemastercylinderfirst, thenthewheelcylinders.Putoneendofarubber hoseonthespecialfittingatthemastercylinderor thewheelcylinders.Puttheotherendofthehoseina

containerwithbrakefluid.Loosenthespecialfitting. Pushslowlyonthebrakepedal.Closethespecial fitting.Repeattheprocedureuntilnoairbubbles areseeninthecontainer.Checkthefluidlevelin thereservoir.Keepthereservoirfullofbrakefluid duringtheseprocedures.

BrakePedalAdjustment

NOTE: Theadjustmentforthebrake/inchingpedalisinthesection Single-SpeedPowershiftTransmission, TroubleshootingandRepair 1300SRM752or Two-SpeedPowershiftTransmission, Troubleshooting andRepairs 1300SRM728.

ParkingBrakeAdjustment

Makesurethattheservicebrakesareadjustedand theoperationoftheautomaticadjustermechanism iscorrectbeforetheparkingbrakeisadjusted.

1. Turntheadjustmentknobtoraisethelinkand tightentheparkingbrakecables.Turntheadjustmentknobuntiltheparkingbrakesarefully appliedwhentheleverisusedtoapplytheparkingbrake.SeeFigure10.

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

3. Checktheoperationoftheswitchesontheparkingbrake.

Figure10.ParkingBrakeLeverAdjustment

ParkingBrakeNotAppliedSwitchTest

TheParkingBrakeNotAppliedswitchislocatedintheoperatorseat.Thisswitchactuatesanaudiblebuzzer ontheinstrumentcluster.Whentheoperatorleavestheseatformorethantwosecondswithoutapplyingthe parkingbrake,thebuzzerwillbeoncontinuouslyfor10seconds.Thebuzzeroperateswhetherthekeyswitch is ON or OFF

ParkingBrakeSwitchTest(MONOTROL® PedalOnly)

Whentheparkingbrakeassemblyandcableshave beenadjusted,theparkingbrakeswitchesmustbe testedforcorrectoperation.

WARNING

Ifthebrakeswitchesarenotadjustedcorrectly,theenginecanbestartedwiththe parkingbrakereleased.Thepurposeofthe left-handswitch(MONOTROLonly)istopreventthestartermotorfrombeingenergized whentheparkingbrakeisnotapplied.The right-handswitchde-energizesthedirection solenoidstoputthetransmissioninNeutral (MONOTROLonly)whentheparkingbrakeis applied.

1. Putthelifttruckonblockssothatthedrive wheelsdonottouchthegroundoranyother object.Putblocksatbothsidesofthesteering tirestopreventmovementofthelifttruck.

2. Releasetheparkingbrake.Theright-hand,twocircuitmicroswitchclosestheelectriccircuitfor theMONOTROLpedal(energizesthesolenoids forthepowershifttransmission).Theleft-hand switchde-energizesthestartingcircuit.

3. Turntheignitionswitchtothe START position. Iftheparkingbrakeswitchoperatescorrectly,

thestarterwillnotenergize.Turntheignition switchtothe OFF position.

4. Applytheparkingbrakewiththeparkingbrake lever.Theright-hand,two-circuitmicroswitch openstheMONOTROLcircuit(de-energizethe solenoidsforthetransmission).Thestartingcircuitisenergizedbytheignitionswitchthrough theleft-handswitch.

5. Turntheignitionswitchtothe START position. Thestarteroperateswhentheparkingbrake switchoperatescorrectly.Turntheignition switchtothe OFF position.

6. Checkthewiresfortheparkingbrakeswitchesif theconditionsfromtheresultsofStep2through Step5arenotcorrect.

7. Applytheparkingbrakeandstarttheengine. Pushtheparkingbrakelevertowardthereleasedposition,butdonotpushtherelease button.TheparkingbrakewillstayintheON positionandlocked.Thetransmissionmustbe inNEUTRALanytimetheparkingbrakelever isapplied.Iftheresultsofthetestarenotcorrect,checkforwearanddamage.Makerepairs asnecessaryandrepeatStep1throughStep7.