Академический Документы
Профессиональный Документы
Культура Документы
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Brake System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Service Brakes ............................................................................................................................................... 1
Master Cylinder............................................................................................................................................. 2
Parking Brake................................................................................................................................................ 3
Service Brakes Repair ....................................................................................................................................... 3
Remove and Disassemble .............................................................................................................................. 3
Clean .............................................................................................................................................................. 7
Inspect ............................................................................................................................................................ 7
Assemble and Install ..................................................................................................................................... 7
Adjust ............................................................................................................................................................. 10
Parking Brake Repair........................................................................................................................................ 12
Remove and Disassemble .............................................................................................................................. 12
Assemble and Install ..................................................................................................................................... 12
Adjust ............................................................................................................................................................. 13
Master Cylinder Repair ..................................................................................................................................... 17
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 18
Clean and Inspect .......................................................................................................................................... 20
Assemble ........................................................................................................................................................ 20
Install ............................................................................................................................................................. 23
Seat Brake Assembly ......................................................................................................................................... 23
Seat Brake, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
N30XMH, and N30XMH 2 (A210, C210), V30ZMD (D210).......................................................................... 23
Brake Switch, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
N30XMH, and N30XMH 2 (A210, C210), V30ZMD (D210).......................................................................... 23
Electric Seat Brake, Adjust for Lift Truck Model E2.00-3.20XM (E45-65Z) (F108/G108), V30ZMD
(D210/E210) ................................................................................................................................................... 24
Electric Seat Brake Adjustment With Handle For Lift truck Models E2.00-3.20XM (E45-65Z)
(G108), V30ZMD (E210) ................................................................................................................................ 26
Remove....................................................................................................................................................... 26
Clean .......................................................................................................................................................... 26
Inspect........................................................................................................................................................ 26
Install ......................................................................................................................................................... 28
Adjustments ................................................................................................................................................... 28
Solenoid Adjustment ................................................................................................................................. 28
Traction cutoff Switch Adjustment........................................................................................................... 28
Cable Adjustment...................................................................................................................................... 30
Service Brakes Adjustment ............................................................................................................................... 32
Brake Pedal Adjustment ................................................................................................................................... 32
Master Cylinder Adjustment............................................................................................................................. 32
Brake System Air Removal ............................................................................................................................... 32
Parking Brake Not Applied Switch Test........................................................................................................... 33
Torque Specifications ......................................................................................................................................... 33
Troubleshooting.................................................................................................................................................. 33
ii
1800 SRM 574 Description and Operation
General
This section has a description and the service pro- brake shoes, wheel cylinders, parking brake system,
cedures for the parts of the brake system. The brake and seat brake system. A troubleshooting section is
system includes the following parts: master cylinder, included at the end of this section.
1. BRAKE PEDAL
2. MASTER CYLINDER
3. BRAKE ASSEMBLY
4. BRAKE FLUID RESERVOIR
1
Description and Operation 1800 SRM 574
MASTER CYLINDER A and C. The supply holes in the cylinder body supply
fluid as the flow moves from one chamber to the other
The master cylinder is designed for a dual circuit sys- chamber. The fluid returns to the reservoir through
tem. The master cylinder has two separate pistons the bypass holes when the pistons are fully retracted.
that operate in the single bore of the master cylin- See Figure 2.
der. The reservoir for the fluid is pressed into the
two ports on top of the master cylinder and held in When the brake pedal is pressed, the primary pis-
position by seals. When the brake pedal is pushed, ton moves in the cylinder bore. This movement cre-
the push rod moves the piston assemblies. The oper- ates hydraulic pressure that combines with the force
ation of the master cylinder is as follows: of the primary spring. These combined forces over-
come the secondary spring force and move the sec-
When the brakes are OFF, the hydraulic fluid can ondary piston in the bore with the primary piston.
move freely between the dual circuit system and the The first movement of both pistons pushes the seals
separate chambers of the fluid reservoir. See Fig- past the bypass holes in the chambers A and C. This
ure 2. action applies pressure to the fluid in those cham-
bers and causes fluid to flow to the chambers of the
When the brake pedal is released, the return springs
two separate systems. The fluid in chambers B and
cause the pistons to retract faster than the fluid. This
D is not affected by movement of the pistons. This
action causes a vacuum between the fluid in cham-
fluid can move freely between the piston chambers
bers A and C. The vacuum causes the seals to change
and the chambers of the fluid reservoir before and
shape. When the seals change shape, they permit
during brake application. See Figure 3.
the fluid in chambers B and D to flow through the
holes in the pistons and past the seals into chambers
2
1800 SRM 574 Service Brakes Repair
If a failure occurs in one of the dual circuits, the other a magnet on the float activates a switch in the bot-
circuit will apply one of the service brakes. This fail- tom of the reservoir. This switch energizes a warning
ure will cause the brake pedal to travel farther when light in the instrument cluster.
the brakes are applied, but the service brakes on one
drive wheel will operate. This failure of one of the PARKING BRAKE
brake circuits can cause the lift truck to turn toward
the drive wheel with the good brake when the brakes The parking brake system uses the service brake
are applied. The operator must control the direction shoes. Additional linkage activates the parking
of the lift truck with the steering when the brakes brake system. When the lever is moved to apply
are applied during this condition. the parking brake, the cables and linkage expand
the brake shoes against the drums. The design of
The reservoir is equipped with an indicator for low the parking brake linkage adjusts each cable so the
fluid level. A float in the reservoir moves up and tension is the same when the lever is moved to apply
down with the fluid level. When the fluid level is low, the parking brake.
3
Service Brakes Repair 1800 SRM 574
NOTE: On N30XMH, N30XMH 2 (C210) and lift truck. If wheel assembly cannot be removed
V30ZMD (D210/E210) lift trucks, the tilt func- easily, use a small screwdriver to push adjuster
tion is not installed. actuator away from adjuster wheel. Use a brake
adjustment tool or a screwdriver to turn adjuster
2. If tilt does not function, use a hydraulic jack, wheel to loosen brake shoes. Remove hub and
crane, or another lift truck to lift drive wheels drum assembly. Do not damage grease seal when
until they just touch the floor. Put blocks under removing hub.
frame of lift truck.
4
1800 SRM 574 Service Brakes Repair
7. Remove retainers, springs, and anchor pins that 9. Move brake shoes away from each other to dis-
hold brake shoes to back plate. engage brake shoes from wheel cylinder. Dis-
connect parking brake lever from parking brake
8. Disengage cable from adjuster wheel actuator. cable as brake assembly is removed from back
Remove cable, washer, and cable guide. Remove plate. The parking brake lever has a hook that
anchor guide. engages parking brake cable.
5
Service Brakes Repair 1800 SRM 574
NOTE: The adjuster wheel for the left brake is not 12. Use a screwdriver or small pry bar to move apart
the same as the adjuster wheel for the right brake. the ends of the retainer. Remove spring washer
The adjuster wheel for the right brake has left-hand and pivot pin to remove parking brake lever from
threads. brake shoe.
10. Make a note of the arrangement of parts and 13. Disconnect brake line from wheel cylinder. Re-
disassemble brake assembly. Remove parking move capscrews that hold wheel cylinder to back
brake link and spring if they are still engaged plate and remove wheel cylinder.
with brake shoes. The parking brake link and
spring will often fall from the brake assembly 14. Remove push rods, dust covers, pistons, cups,
when the brake assembly is removed from the and spring from wheel cylinder. See Figure 6.
back plate. The adjuster wheel will also disen-
NOTE: The back plate is not normally removed from
gage from the brake shoes after the brake assem-
the axle housing for brake repairs. Eight special cap-
bly is removed.
screws are used to fasten the back plate to the axle
11. Remove spring for adjuster wheel actuator. Re- mount and the locking function of the capscrews is
move adjuster wheel actuator from brake shoe. reduced if they are removed. These capscrews are
Loosen nut and remove anchor and spacer from tightened to 255 N•m (188 lbf ft).
brake shoe.
6
1800 SRM 574 Service Brakes Repair
CLEAN
WARNING
The brake shoes on both wheels must be re-
WARNING
placed if any shoe is damaged. The brake per-
DO NOT use an oil solvent to clean the mas- formance on both ends of an axle must be equal
ter cylinder, wheel cylinder, or the brake lin- or the lift truck can be difficult to steer when
ings. Use a solvent approved for cleaning of the brakes are applied.
brake parts. Do not permit oil or grease in the
brake fluid or on the brake linings. Oil and 3. Inspect brake shoes for cracks or damage. If
grease will cause damage and leaks in the seals linings or shoes are worn or damaged, replace
of a brake system. The brakes will not operate brake shoes. Maximum wear is to within 1 mm
correctly if oil, grease, or brake fluid is on the (0.025 in.) of contact with rivets or metal shoe on
brake linings. bonded linings. Brake shoes must be replaced in
complete sets. Inspect brake drums for cracks or
Cleaning solvents can be flammable and toxic damage. Replace any damaged parts.
and can cause skin irritation. When using
cleaning solvents, always follow the safety NOTE: If grooves must be removed from the brake
instructions of the solvent manufacturer. drums, do not grind more than 1.5 mm (0.060 in.)
from the internal diameter of the brake drum. The
1. Do not release brake lining dust from brake lin- maximum limit of the internal diameter of the brake
ings into air when brake drum is removed. drum is 311.7 mm (12.27 in.). If the internal diame-
2. Use a solvent approved for cleaning of brake ter is larger than the limit, replace brake drum.
parts to wet brake lining dust. Follow instruc- 4. Inspect brake drum for deep grooves or other
tions and cautions of manufacturer for use of damage.
solvent. If a solvent spray is used, do not create
brake lining dust with spray. 5. The teeth of the adjuster wheel must not be worn.
The adjuster wheel must turn freely. Check ad-
3. When brake lining dust is wet, clean parts. Put juster links for damage.
any cloth or towels in a plastic bag or an airtight
container while they are still wet. Put a DAN- 6. Make sure parking brake cables are in good con-
GEROUS FIBERS warning label on plastic bag dition.
or airtight container.
7. Check grease seals and surfaces of seals for wear
or damage.
CAUTION
Do not permit oil or grease on the brake linings. ASSEMBLE AND INSTALL
Use a brake cleaning fluid as necessary to clean
linings that will not be replaced. 1. If wheel cylinder was disassembled for repair, as-
semble wheel cylinder. See Figure 6. Use only
4. Any cleaning cloths that will be washed must be HYSTER APPROVED parts.
cleaned so that fibers are not released into the
air. 2. Install wheel cylinder on back plate and tighten
two capscrews to 18 to 27 N•m (13 to 20 lbf ft).
INSPECT Connect brake line to wheel cylinder.
1. Inspect bore of wheel cylinder for holes or 3. Install parking brake lever. See Figure 5. Use
scratches. Replace wheel cylinder assembly if pivot pin, spring washer, and retainer to fasten
there is any damage. parking brake lever to brake shoe. Close the ends
of the retainer to fasten the pivot pin in position.
2. Inspect return springs for wear or damage. In-
spect back plate for wear where brake shoes 4. Install anchor and spacer in brake shoe. Install
touch back plate. Replace a worn or damaged adjuster wheel actuator in brake shoe.
back plate.
5. Fasten adjuster actuator spring to adjuster
wheel actuator and brake shoe.
7
Service Brakes Repair 1800 SRM 574
6. Put an antiseize compound on threads of adjuster 9. Put an anchor pin that holds brake shoes through
wheel. Turn adjuster wheel into adjuster nut so back plate. Put a spring seat, spring, and re-
adjuster assembly is in its shortest position. This tainer on anchor pin. Push retainer on to anchor
action permits brake drum to be easily installed pin and rotate retainer 90 degrees. Make sure
over the brake shoes. retainer is in correct position. Install another re-
tainer spring assembly.
WARNING 10. Install link, parking brake, and spring between
The threads of the adjuster wheel are not the parking brake lever and brake shoe.
same for each side. The adjuster wheel for the
right brake has left-hand threads. The adjuster 11. Install other spring retainers that hold brake
wheel for the left brake has right-hand threads. shoes. Make sure parking brake link and spring
are correctly engaged after spring retainers are
If the adjuster assemblies are installed on installed.
the wrong side, the brake shoe clearance will
increase when the brakes are applied. This 12. Install anchor guide on anchor. Install cable
would result in a loss of braking ability. guide on its anchor.
7. Install adjuster wheel between two brake shoes. 13. Fasten cable to adjuster wheel actuator and put
Make sure adjuster wheel will be toward rear of cable around cable guide. Raise adjuster wheel
lift truck. Move brake shoes apart so adjuster actuator against spring tension and connect ca-
wheel is held in position and adjuster actuator ble to anchor.
spring is in tension.
14. Use the correct tools to install the return springs.
8. Lubricate back plate with a small amount of Install return spring. Install washer and return
grease where brake shoes touch. Install brake spring. The shape of the return springs permits
shoes on anchor and engage push rods of wheel them to be installed correctly in only one posi-
cylinder. Engage parking brake lever in slot in tion. The arrangement of the return springs on
parking brake cable as brake shoes are installed the anchors is shown in Figure 7.
on back plate.
8
1800 SRM 574 Service Brakes Repair
15. Make sure bottom edge of adjuster wheel actua- alignment position at or above 3 N•m (25 lbf in),
tor is just above center of teeth of adjuster wheel. bend lock plate over nut.
Check for correct installation if alignment is not
correct.
1. OUTER SEAL
2. INNER SEAL
3. BRAKE DRUM
9
Service Brakes Repair 1800 SRM 574
10
1800 SRM 574 Service Brakes Repair
11
Parking Brake Repair 1800 SRM 574
12
1800 SRM 574 Parking Brake Repair
ADJUST
Make sure that the service brakes are adjusted and
the operation of the automatic adjuster mechanism
is correct before the parking brake is adjusted. See
Figure 13.
13
Parking Brake Repair 1800 SRM 574
Figure 13. Parking Brake Assembly For Lift Trucks Built Before March 7, 2000
14
1800 SRM 574 Parking Brake Repair
15
Parking Brake Repair 1800 SRM 574
Figure 14. Parking Brake Assembly For Lift Trucks Built After March 7, 2000
16
1800 SRM 574 Master Cylinder Repair
17
Master Cylinder Repair 1800 SRM 574
DISASSEMBLE
The disassembly procedures for the master cylinder are in the following steps:
STEP 1.
Remove the fluid reservoir. Apply force in the direc-
tion of the arrow and pull the reservoir from the mas-
ter cylinder.
STEP 2.
Be careful to not scratch the surfaces. Use a tool
(screwdriver with a flat tip) that has a smooth and
rounded end to remove the reservoir seals.
STEP 3.
Push the primary piston into the bore as shown in the
illustration. Remove the pin at the secondary piston
through the port for the secondary reservoir.
18
1800 SRM 574 Master Cylinder Repair
STEP 4.
Remove the clevis and nut from the push rod. Re-
move the dust cover.
WARNING
Keep control of the pistons as they are removed so that the return springs do not suddenly release
the pistons from the bore with enough force to cause an injury.
CAUTION
When the piston is removed, make sure the cylinder bore or piston is not scratched or damaged.
STEP 5.
Remove the snap ring and the primary piston assem-
bly.
CAUTION
During disassembly of the primary and secondary piston assemblies, make sure not to scratch or
damage the cylinder bore when the spring is removed.
STEP 6.
Hit the cylinder lightly on a soft or wooden surface
and remove the secondary piston assembly. Lubri-
cate the cylinder bore with clean brake fluid to help
removal.
19
Master Cylinder Repair 1800 SRM 574
NOTE: Install a new seal when the master cylinder is disassembled for repair.
STEP 7.
Remove the seal from the piston with a smooth and
rounded tool.
CLEAN AND INSPECT parts. Do not permit oil or grease in the brake
fluid or on the linings.
CAUTION Inspect the bore of the master cylinder for holes or
DO NOT use an oil solvent to clean the master scratches. Replace the master cylinder assembly if
cylinder, wheel cylinder, or the brake linings. there is damage.
Use a solvent approved for cleaning of brake
ASSEMBLE
The assembly procedures for the master cylinder are in the following steps:
NOTE: Install a new seal when the master cylinder is assembled for repair.
STEP 1.
Install the seal into the piston.
20
1800 SRM 574 Master Cylinder Repair
CAUTION
During assembly of the primary and secondary piston assemblies, make sure not to scratch or dam-
age the cylinder bore when the spring is removed.
STEP 2.
During installation of the secondary piston, insert
the piston assembly into the cylinder until the seal
is at the center of the bore opening. Be careful to not
cause a restriction of the seal during installation. To
make sure the seal enters the bore correctly, carefully
rotate and tilt the piston until the seal is installed
in the bore. Slowly push the piston assembly into
the bore in one continuous motion after the seal fully
enters the bore.
CAUTION
When the piston is installed, make sure the cylinder bore or piston is not scratched or damaged.
STEP 3.
Install the snap ring and primary piston assembly.
STEP 4.
Install the clevis and nut from the push rod. Install
the dust cover. Be sure to install the dust cover lip
into the recess in the bore of the cylinder.
21
Master Cylinder Repair 1800 SRM 574
STEP 5.
Install the primary piston into the bore as shown in
the illustration. Install the pin at the secondary pis-
ton through the port for the secondary reservoir.
STEP 6.
Put new seals in clean brake fluid, then install the
seals in the body of the master cylinder.
STEP 7.
Install the reservoir by pushing and turning the
reservoir in the direction shown by the arrow. Make
sure brake fluid does not leak from the reservoir
seals. If there is any leakage, replace the seals.
22
1800 SRM 574 Seat Brake Assembly
23
Seat Brake Assembly 1800 SRM 574
Figure 16. Seat Brake Assembly, Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
N30XMH, and N30XMH 2 (A210, C210), V30ZMD (D210)
ELECTRIC SEAT BRAKE, ADJUST FOR plunger face and the lip of the solenoid housing.
LIFT TRUCK MODEL E2.00-3.20XM See Figure 17.
(E45-65Z) (F108/G108), V30ZMD 2. Turn the lift truck power ON and release the
(D210/E210) brake.
NOTE: The spring must be fully set before any ad- 3. Rotate the brake drum. If brake drum turns
justments can be done. freely, go to Step 7.
1. Turn the plunger counterclockwise to pull it out 4. If the brake drum does not turn freely, turn the
and clockwise to push it in, so that there is a truck power OFF and turn the solenoid plunger
10 mm (0.40 in.) distance between the solenoid counterclockwise.
24
1800 SRM 574 Seat Brake Assembly
Figure 17. Electric Seat Brake Adjustment for Lift Truck Model E2.00-3.20XM (E45-65Z)
(F108/G108), V30ZMD (D210/E210)
25
Seat Brake Assembly 1800 SRM 574
ELECTRIC SEAT BRAKE ADJUSTMENT 1. Do not release brake lining dust from the brake
WITH HANDLE FOR LIFT TRUCK MODELS linings into the air when brake drum is removed.
E2.00-3.20XM (E45-65Z) (G108), V30ZMD 2. Use a solvent approved for cleaning of brake
(E210) parts to wet the brake lining dust. Follow the
instructions and cautions of the manufacturer
NOTE: Remove the battery from the lift truck before for the use of the solvents. If a solvent spray is
removing the seat brake. See the Operating Man- used, do not create brake lining dust with the
ual or the section Periodic Maintenance 8000 spray.
SRM 1060 for the procedures.
3. When the brake lining dust is wet, clean the
Remove parts. Put any cloth or towels in a plastic bag
or an airtight container while they are still wet.
1. Loosen brake drum capscrew. Pull manual re-
Put DANGEROUS FIBERS warning labels on
lease lever up to release the compression spring.
the plastic bag or airtight container.
Remove capscrew, washer, and lockwasher from
brake drum. Remove brake drum from brake as-
sembly. Remove spacer from motor shaft. CAUTION
Do not permit oil or grease on the brake linings.
2. Put manual release lever down. Disconnect Use a brake cleaning fluid as necessary to clean
guide pipe and brake cable. Disconnect electri- brake linings that will be installed again.
cal connections. See Figure 18.
4. Any cleaning cloths that will be washed must be
3. Loosen the compression spring. Remove pin se- cleaned so that the fibers are not released into
curing clevis and stud to brake assembly. Re- the air.
move brake assembly from traction motor.
26
1800 SRM 574 Seat Brake Assembly
Figure 18. Seat Brake Assembly With Handle for Lift Truck Models E2.00-3.20XM (E45-65Z) (G108),
V30ZMD (D210/E210)
27
Seat Brake Assembly 1800 SRM 574
28
1800 SRM 574 Seat Brake Assembly
29
Seat Brake Assembly 1800 SRM 574
NOTE: The Solenoid and Traction Cutoff Switch ad- 3. Pull the handle back into the UP position, and
justment must be completed before adjusting the re- check for drag by rotating the brake drum by
lease cable. hand.
NOTE: When handle is in the UP position, brake is 4. If the brake drags while the handle is in the
released. When handle is in the DOWN position, UP position, lower the handle, loosen the wire
brake is applied. stop, pull cable through, and retighten the wire
stop. Repeat Step 3 and Step 4 until the brake
NOTE: The solenoid must NOT be energized when no longer drags. Lower the handle to the DOWN
performing this procedure. position.
NOTE: When the handle is in the UP position, the air 5. Adjust handle by tightening nut to 0.85 N•m (7.5
gap between the leaf and the switch housing must be lbf in) so that the washers clamp onto the handle
0.5 mm (0.019 in.) minimum. but allows handle to pivot easily.
1. With brake fully assembled, and the handle in
the UP position. Pull the cable tight through the
wire stop. Insert excess cable into the handle.
See Figure 20.
30
1800 SRM 574 Seat Brake Assembly
Figure 20. Seat Brake Adjustment With Handle for Lift Truck Models E2.00-3.20XM (E45-65Z)
(G108), V30ZMD (D210/E210)
31
Brake System Air Removal 1800 SRM 574
1. If the lift truck must be put on blocks for mainte- NOTE: If the brake shoes were not replaced, loosen
nance or repair, see How to Put Lift Truck on adjuster wheel approximately 15 teeth.
Blocks in the Operating Manual or Periodic
Maintenance of your vehicle. Put lift truck on 4. Install drive wheels. Remove lift truck from
blocks so drive wheels can be removed. Remove blocks. Operate lift truck in FORWARD and
the drive wheels. REVERSE directions. Stop lift truck 10 times
in each direction. This procedure causes the
2. Use an adjuster tool to rotate adjuster wheel so brake shoes to wear a small amount and fit the
teeth of wheel move downward. This adjustment brake drum better.
expands brake shoes. Adjust brake shoes so
brake drum will not rotate.
1. Fill the master cylinder reservoir with brake 5. Check the level of the brake fluid in the reser-
fluid. voir for the master cylinder during the procedure.
Make sure to keep the brake fluid at the correct
2. Put one end of a rubber hose on the special fitting level.
of the wheel cylinder. Put the other end of the
hose into a clear container of brake fluid. 6. Repeat the procedure for the other wheel cylin-
der. If there is still air in the system, the air
3. Loosen the special fitting at the wheel cylinder must be removed from the master cylinder. Push
one turn so that the air can be removed from the on the brake pedal with a steady stroke. Release
brake system. Slowly push the brake pedal and the pedal slowly. Repeat this procedure until no
hold it at the end of its stroke. Close the special air bubbles enter the reservoir.
fitting.
32
1800 SRM 574 Troubleshooting
Torque Specifications
Back Plate to Axle Mount Capscrews Axle Shaft Capscrews
225 N•m (166 lbf ft) 90 N•m (66 lbf ft)
Troubleshooting
The brakes do not correctly Air in the brake system. Repair system to prevent air enter-
stop the lift truck. ing. Remove air from system.
The brake shoes are worn or dam- Install new brake shoes.
aged.
The brake linings do not fit the brake Install correct linings.
drums.
33
Troubleshooting 1800 SRM 574
One brake does not release. A brake shoe is damaged. Install new parts.
The brakes make too much Dirt, oil, water, or brake fluid is on Clean or install new linings.
noise. the linings.
The brakes do not operate Oil or brake fluid is on the linings. Repair leak. Clean or install new lin-
equally. ings.
The brake linings are not correctly Install brake linings correctly.
installed.
The brake drums are not round. Check to make sure there is adequate
material to allow for machining. Ma-
chine brake drums to make them
round or install new drums.
The shoes are adjusted too tight. Adjust brakes. Check self-adjusters.
34
1800 SRM 574 Troubleshooting
Both brakes do not release. The parking brake is not released. Release parking brake.
The parking brake cables need ad- Adjust or install new cables.
justment.
There is not enough clearance at the Adjust clearance between push rod
end of the push rod in the master and piston.
cylinder.
The brake pedal travels too Air in the brake system. Remove air from system. Check for
far. leaks.
Brake fluid level low. The brake sys- Fill brake fluid reservoir to correct
tem has a leak. level. Repair leak. Remove air from
system.
The brake shoes are not adjusted cor- Check operation of self-adjusters.
rectly. Adjust brakes.
One of the dual brake circuits is not Repair or install new parts.
operating.
There is too much clearance at the Adjust clearance between push rod
end of the push rod in the master and piston.
cylinder.
The master cylinder is worn or dam- Repair or install new master cylin-
aged. der. Remove air from system.
35
Troubleshooting 1800 SRM 574
The parking brake will not Parking brake not adjusted correctly. Use adjustment knob on parking
hold the lift truck. brake lever to adjust holding force.
See adjustment procedure for correct
specifications.
The parking brake cables need ad- Install new parts. Lubricate and ad-
justment, lubrication, or have dam- just cables.
age.
The parking brake will not The parking brake lever is adjusted Adjust parking brake. See adjust-
release. too tight. ment procedure for correct specifica-
tions.
The parking brake cables need ad- Install new parts. Lubricate and ad-
justment, lubrication, or have dam- just cables.
age.
The seat brake will not hold Seat brake not adjusted properly. See adjustment procedure for correct
the lift truck. specifications.
The seat brake will not re- Seat brake not adjusted properly. See adjustment procedure for correct
lease. specifications.
The seat brake linkage needs adjust- Install new parts. Lubricate and ad-
ment, lubrication, or has damage. just linkage.
36
TECHNICAL PUBLICATIONS