BRAKE SYSTEM

J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];

J2.00-3.20XM (J40-65Z) [A416]

PART NO. 897653 1800 SRM 566

Brake System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Service Brakes ............................................................................................................................................... 1
Master Cylinder............................................................................................................................................. 1
Parking Brake................................................................................................................................................ 1
Service Brake Repairs ....................................................................................................................................... 3
Remove and Disassemble .............................................................................................................................. 3
Clean .............................................................................................................................................................. 4
Inspect ............................................................................................................................................................ 4
Assemble and Install ..................................................................................................................................... 6
Adjust ............................................................................................................................................................. 9
Parking Brake Repair........................................................................................................................................ 11
Remove and Disassemble .............................................................................................................................. 11
Assemble and Install ..................................................................................................................................... 11
Adjust ............................................................................................................................................................. 11
Master Cylinder Repair ..................................................................................................................................... 13
Remove ........................................................................................................................................................... 13
Clean and Inspect .......................................................................................................................................... 14
Repair ............................................................................................................................................................. 14
Install ............................................................................................................................................................. 16
Service Brakes Adjustment ............................................................................................................................... 17
Brake Pedal Adjustment ................................................................................................................................... 17
Master Cylinder Adjustment............................................................................................................................. 17
Brake System Air Removal ............................................................................................................................... 17
Parking Brake Not Applied Switch Test........................................................................................................... 18
Torque Specifications ......................................................................................................................................... 18
Troubleshooting.................................................................................................................................................. 18

This section is for the following models:

J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];

J2.00-3.20XM (J40-65Z) [A416]

©2005 HYSTER COMPANY i

1800 SRM 566
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 parking brake system. A trou-
bleshooting section is included at the end of this section.
Description and Operation
SERVICE BRAKES
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 3 and Figure 4.
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. See Figure 9.
The clearance between the brake shoes and the brake
drum is adjusted automatically. An adjuster link-
age 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 clear-
ance 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
The master cylinder is designed for a dual circuit sys-
tem. The master cylinder has two separate pistons
that operate in the single bore of the master cylin-
der. 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 oper-
ation of the master cylinder is as follows:
When the brakes are OFF, the hydraulic fluid can
move freely between the dual circuit system and the
separate chambers of the fluid reservoir. See Fig-
ure 1.
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 cham-
bers A and C. The vacuum causes the seals 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
Description and Operation
A and C. The supply holes in the cylinder body sup-
plies 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.
When the brake pedal is pressed, the primary pis-
ton moves in the cylinder bore. This movement cre-
ates hydraulic pressure that combines with the force
of the primary spring. These combined forces over-
come the secondary spring force and move the sec-
ondary piston in the bore with the primary piston.
The first movement of both pistons pushes the seals
past the bypass holes in the chambers A and C. This
action applies pressure to the fluid in those cham-
bers and causes fluid to flow to the chambers of the
two separate systems. The fluid in chambers B and
D is not affected 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. See Figure 2.
If a failure occurs in one of the dual circuits, the other
circuit will apply one of the service brakes. This fail-
ure 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 bot-
tom of the reservoir. This switch energizes a warning
light on the instrument cluster.
PARKING BRAKE
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
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Description and Operation 1800 SRM 566

the brake shoes against the drums. The design of the tension is the same when the pedal is moved to
the parking brake linkage adjusts each cable so that apply parking brake. See Figure 10.

1. SECONDARY SPRING 6. PRIMARY FLUID CHAMBER

2. SEAL 7. SECONDARY FLUID CHAMBER
3. SECONDARY PISTON 8. BYPASS HOLES
4. PRIMARY SPRING 9. SUPPLY HOLES
5. PRIMARY PISTON

Figure 1. Master Cylinder Brake OFF and Brake RELEASED

Figure 2. Master Cylinder Brake APPLIED

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1800 SRM 566
Service Brake Repairs
REMOVE AND DISASSEMBLE
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 Clean 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 re-
stricted area with special ventilation. Protec-
tive 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 Man-
ual. Tilt mast fully backward. Put blocks under
mast. Tilt mast forward until wheels just touch
the floor. Stop motor. Put blocks under frame of
lift truck.
2. If tilt does not function, use a hydraulic jack,
crane, or another lift truck to lift drive wheels
until they just touch the floor. Put blocks under
frame of lift truck.
3. Remove capscrews that hold axle shaft to hub.
Remove axle shaft.
4. Release parking brake. Bend lock plate and
remove nut that holds axle bearing. Remove
washer and bearing cone.
5. Put grease on floor so wheel assembly will slide
easily from axle tube. Pull wheel assembly
from lift truck. If wheel assembly cannot be
removed easily, remove wheel and use a small
screwdriver to push adjuster actuator away from
adjuster wheel. Use a brake adjustment tool or
Service Brake Repairs
a screwdriver to turn adjuster wheel to loosen
brake shoes. Install wheel and then remove hub
and drum assembly. Do not damage grease seal
when removing hub.
WARNING
When the brake shoes are removed, do not cre-
ate dust in the air. See the Clean procedure in
this section.
6. Remove return springs with spring pliers. See
Figure 3.
NOTE: The return springs are not the same part
number. Make sure springs are installed in same
positions from which they were removed.
7. Remove retainers, springs, and retainer pins
that hold brake shoes to back plate. See Figure 4.
Remove brake shoes and adjuster assembly.
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.
8. Remove brake line from wheel cylinder. Remove
wheel cylinder.
9. Remove dust covers, pistons, cups, and springs
from wheel cylinder. See Figure 5.
NOTE: The back plate is not normally removed from
the axle housing for brake repairs. Six special cap-
screws are used to fasten the back plate to the axle
mount and the locking function of the capscrews is re-
duced if they are removed. The five capscrews with
5/8 inch thread are tightened to 245 N•m (181 lbf ft).
The capscrew with 1/2 inch thread is tightened to
125 N•m (92 lbf ft).
10. Remove snap rings from parking brake levers.
Remove parking brake levers from back plate.
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Service Brake Repairs 1800 SRM 566

cleaning solvents, always follow the safety

instructions of the solvent manufacturer.

1. Do not release brake lining dust from brake lin-

ings into air when brake drum is removed.

2. Use a solvent approved for cleaning of brake

parts to wet brake lining dust. Follow instruc-
tions and cautions of manufacturer for use of
solvent. If a solvent spray is used, do not create
brake lining dust with spray.

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.

3. When the brake lining dust is wet, clean parts.

Put any cloth or towels in a plastic bag or an
airtight container while they are still wet. Put
NOTE: LEFT SIDE SHOWN. a DANGEROUS FIBERS warning label on the
plastic bag or airtight container.
1. WHEEL CYLINDER
2. MAROON RETURN SPRING 4. Any cleaning cloths that will be washed must be
3. PIVOT PLATE cleaned so fibers are not released into the air.
4. LINK
5. ANCHOR
6. ADJUSTER WHEEL ACTUATOR INSPECT
7. ADJUSTER WHEEL
8. ADJUSTER NUT 1. Inspect bore of wheel cylinder for holes or
9. PARKING BRAKE CABLE scratches. Replace wheel cylinder assembly if
10. RETAINER there is any damage.
11. PARKING BRAKE LEVER
12. BRAKE SHOE 2. Inspect return springs for wear or damage. In-
13. HOLD DOWN PIN
14. GREY RETURN SPRING spect back plate for wear where brake shoes
touch back plate. Remove any grooves or replace
Figure 3. Brake Assembly (Left Brake Assembly a worn or damaged back plate.
Shown)
WARNING
CLEAN
The brake shoes on both wheels must be re-
placed if any shoe is damaged. The brake per-
WARNING formance on both ends of an axle must be equal
Do not use an oil solvent to clean the master or the lift truck can be difficult to steer when
cylinder, wheel cylinder, or the brake linings. the brakes are applied.
Use a solvent approved for cleaning of brake
parts. Do not permit oil or grease in the brake 3. Inspect brake shoes for cracks or damage. If
fluid or on the brake linings. Oil and grease linings or shoes are worn or damaged, replace
will cause damage and leaks in the seals of brake shoes. Maximum wear is to within 1 mm
a brake system. The brakes will not operate (0.04 in.) of contact with rivets or metal shoe on
correctly if oil, grease, or brake fluid is on the bonded linings. Brake shoes must be replaced in
brake linings. complete sets. Inspect brake drums for cracks or
damage. Replace any damaged parts.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using

4
1800 SRM 566 Service Brake Repairs

NOTE: LEFT SIDE SHOWN.

1. SNAP RING 11. REAR BRAKE SHOE 20. SPRING
2. MAROON RETURN SPRING 12. PIVOT PLATE 21. ADJUSTER NUT
3. BACK PLATE 13. HOLD DOWN PIN (2) 22. ADJUSTER WHEEL
4. CABLE 14. GREY RETURN SPRING 23. ADJUSTER WHEEL
5. CABLE GUIDE 15. SPECIAL CAPSCREW ACTUATOR
6. SPECIAL CAPSCREW 16. ADJUSTER LINK 24. CABLE RETAINER
7. CAPSCREWS 17. ADJUSTER LINK* 25. CRANK
8. PARKING BRAKE LEVER 18. RETAINER SPRING
9. WHEEL CYLINDER ASSEMBLY
10. PIVOT PIN 19. FRONT BRAKE SHOE

*DO NOT BEND OR PUT STRESS ON THE UPPER LINK BY FORCING THE HOOK END ON OR AROUND THE
POST ON THE SPECIAL CAPSCREW.

Figure 4. Service Brake Parts

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Service Brake Repairs 1800 SRM 566

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 (10.32 in.). If the internal diameter
is larger than the limit, replace brake drum.
4. Inspect brake drum for deep grooves or other
damage.
5. The teeth of the adjuster wheel must not be worn.
The adjuster wheel must turn freely. Check ad-
juster links for damage.
6. Make sure parking brake cables are in good con-
dition.
7. Check grease seals and surfaces of seals for wear
or damage.
ASSEMBLE AND INSTALL
1. Assemble wheel cylinder. See Figure 5. Use only
HYSTER APPROVED parts.
2. Install wheel cylinder on back plate. Make sure
special fitting for removing air is in top hole. Put
Loctite® 271 on threads of capscrews. Tighten
two capscrews with 7/16 inch thread to 78 to
91 N•m (58 to 67 lbf ft). Tighten two capscrews
with 1/2 inch thread to 91 to 102 N•m (67 to
75 lbf ft).
3. Put retainer pins that hold brake shoes through
back plate. Install back plate on axle housing.
4. Tighten two special capscrews for parking brake
levers to 245 N•m (181 lbf ft). See Figure 4.
Tighten capscrews that hold back plate to axle
housing to 245 N•m (181 lbf ft). Install washer
and special capscrew that is the anchor for the
return springs. This capscrew must be tightened
to 125 N•m (92 lbf ft). Make sure washer is in-
stalled so capscrew does not loosen during oper-
ation.
5. Install parking brake levers and cable. Install
snap rings. Install cable guide and snap ring on
crank for parking brake.

1. PORT FOR SPECIAL FITTING 5. WHEEL CYLINDER

2. INLET PORT 6. SPRING
3. BRAKE SHOE 7. CUP
4. DUST COVER 8. PISTON ASSEMBLY

Figure 5. Wheel Cylinder

6
1800 SRM 566
6. Install pivot pin through brake shoe that is to-
ward rear of lift truck. Install links in pivot plate.
Install pivot plate, 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 pivot plate so the letter L is seen on
the left brake assembly. Install pivot plate on right
brake assembly so the letter R is seen.
7. Lubricate back plate with a small amount of
grease where the shoes touch. Install brake
shoes. Install retainer spring assembly. Put a
spring seat, spring, and retainer on pin. Push
retainer onto pin and rotate retainer 90 degrees
to lock pin into retainer. Install other spring
assembly.
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.
8. Put an antiseize compound on threads of adjuster
wheel. Install adjuster wheel assembly between
two brake shoes. Make sure adjuster wheel is
toward rear of lift truck.
Turn adjuster wheel into adjuster nut so adjuster
assembly is in its shortest position. This action
permits brake drum to be easily installed over
brake shoes.
9. Install link in adjuster wheel actuator. Put
adjuster wheel actuator in the hole in brake
shoe. Fasten spring to adjuster wheel actuator
and brake shoe. The spring must be installed
in the position shown in Figure 6. Install re-
turn springs for brake shoes. Make sure return
springs are installed in correct positions. See
Figure 6. A gray spring is always installed on
right brake shoe.
10. Make sure bottom edge of adjuster wheel actua-
tor is just above center of teeth of adjuster wheel.
Bend lower link to align adjuster wheel actuator.
Service Brake Repairs
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 wheel and slide wheel toward axle
housing. Install outer bearing and nut. Remove
wheel from hub so the clearance of the brake shoes
can be adjusted.
11. Clean hub bearings and lubricate them with
wheel bearing grease. Install hub bearings and
seals in hub. Install brake drum and hub on axle
housing. See Figure 7 and Figure 8.
12. Adjust hub bearings by tightening nut to
205 N•m (151 lbf ft) while rotating hub. Loosen
nut until hub turns freely. The torque must
be less than 27 N•m (20 lbf ft). Tighten nut
to 34 N•m (25 lbf ft) or until first alignment
position after 34 N•m (25 lbf ft). Bend lock plate
over nut.
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.
NOTE: If the brake shoes were not replaced, loosen
adjuster wheel approximately 25 teeth.
13. Adjust the clearance of the brake shoes. Put a
brake adjustment tool or a screwdriver through
hole in drum. Turn adjuster wheel so teeth of
adjuster wheel nearest back plate move upward.
Turn adjuster wheel until hub will not turn. Pull
actuator away from adjuster wheel and turn ad-
juster wheel approximately 15 teeth in opposite
direction. The brakes will adjust to correct clear-
ance when they are applied while lift truck is
traveling in REVERSE direction.
14. Put sealant on flange of axle shaft. Install
axle shaft and capscrews. Tighten capscrews to
98 N•m (72 lbf ft).
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Service Brake Repairs 1800 SRM 566

A. LEFT SIDE B. RIGHT SIDE

1. SPRING FOR (LEFT) SHOE (MAROON) 3. UPPER ADJUSTER LINK
2. SPRING FOR (RIGHT) SHOE (GRAY) 4. LOWER ADJUSTER LINK

Figure 6. Springs Installation

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1800 SRM 566 Service Brake Repairs

ADJUST
1. Remove air from brake hydraulic system. See the
procedure Brake System Air Removal.

2. Install wheel on hub. Tighten nuts to 237 to

305 N•m (175 to 225 lbf ft).

3. Tilt mast backward or lift the truck to remove

blocks. Push on brake pedal. The pedal must not
touch floor plate. Move lift truck in REVERSE
and push on 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
Figure 10 and the following paragraphs in this
section for the correct adjustment of the parking
brake.

1. OUTER SEAL 3. BRAKE DRUM

2. INNER SEAL

Figure 7. Grease Seals Location

Figure 8. Inner Grease Seal Installation

9
Service Brake Repairs 1800 SRM 566

1. CAPSCREW 6. LOCK NUT

2. BRAKE PEDAL 7. MASTER CYLINDER
3. FLOOR PLATE 8. BRAKE ASSEMBLY
4. LOCK NUT 9. BRAKE LINES
5. PUSH ROD

Figure 9. Service Brake

10
1800 SRM 566
Parking Brake Repair
REMOVE AND DISASSEMBLE
If the lever assembly for the parking brake must be
removed from the frame, use the following procedure
(see Figure 10):
1. Use blocks next to the wheels to make sure the
lift truck cannot move. Release the parking
brake.
2. Turn the adjustment knob so that the link is at
the bottom of the adjustment slot.
3. Remove the cotter pin and pin to disconnect the
parking brake cable from the brake assembly.
4. Remove the cotter pin and anchor pin that con-
nect the link to the parking brake assembly.
5. Remove the nuts and washers that hold the park-
ing brake assembly to the bracket. Remove the
capscrews and spacers.
6. Remove the cotter pin, washer, and anchor pin
from the link.
ASSEMBLE AND INSTALL
If the lever assembly for the parking brake was re-
moved from the frame, use the following procedure
for installation:
1. Make sure the parking brake lever is in the re-
leased position. Turn the adjustment knob until
the link is adjusted to the bottom of the adjust-
ment slot.
2. Install the ends of the cables into the compen-
sator. Install the anchor pin, washer, and cotter
pin into the parking brake assembly. Make sure
the anchor pin is through the link and compen-
sator.
3. Install the mounting bolts through the cable
clamps and spacers. Mount the assembly to the
bracket.
4. Before tightening the mounting capscrews, push
down the parking brake assembly to make sure
it is in contact with the frame bracket.
Parking Brake Repair
5. The following procedure must be used to connect
the link to the parking brake assembly and the
brake pedal assembly: put the parking brake
lever in the applied position. Install the anchor
pin in the hole in the link that will adjust the
bottom side of the parking brake pedal to 28 mm
(1.1 in.) above the frame. See Figure 10. Install
the cotter pins. Install the return spring in an
empty hole in the link.
6. With the brake in the applied position, adjust
and tighten the nuts on the end of the cable to
remove all the free play from the release handle.
7. With the parking brake applied, adjust the
switch so that the lever on the switch moves 1
to 3 mm (0.04 to 0.12 in.) beyond the operating
point.
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 10.
1. Turn the adjustment knob to raise the link and
tighten the parking brake cables. Turn the ad-
justment knob until the parking brakes are fully
applied when the pedal is used to apply the park-
ing brake.
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 m in 10 m (1.5 ft in 10 ft)].
3. With the parking brake applied, adjust the nuts
to remove any free play from the release handle.
4. Check the operation of the switches on the park-
ing brake as described in Parking Brake Not Ap-
plied Switch Test.
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Parking Brake Repair 1800 SRM 566

Figure 10. Parking Brake

12
1800 SRM 566 Master Cylinder Repair

Legend for Figure 10

1. BRAKE ASSEMBLY 8. ANCHOR PIN 17. LINK
2. BRAKE CABLES 9. MOUNTING CAPSCREW 18. ADJUSTMENT SLOT
3. PARKING BRAKE ASSEMBLY 10. NUT 19. FRAME BRACKET
4. LINK 11. CLAMP 20. CABLE
5. ADJUSTMENT KNOB 12. SPACER 21. CRANK
6. PARKING BRAKE PEDAL 13. ANCHOR PIN 22. COTTER KEY
6A. RELEASED POSITION 14. NUT 23. PIN
6B. APPLIED POSITION 15. COMPENSATOR 24. SWITCH
7. RELEASE HANDLE 16. FRAME BRACKET 25. RETURN SPRING

Master Cylinder Repair

REMOVE
1. Remove floor plates from lift truck for access to
master cylinder. See Figure 11.
2. Loosen and remove two brake hydraulic lines
from master cylinder. Disconnect wire at switch
on reservoir.
3. Remove cotter pin, washer, and pin from push
rod end that is attached to brake linkage lever
arm.
4. Remove capscrews, washers, and nuts that hold
master cylinder to bracket assembly and remove
master cylinder from lift truck.

1. CAP 12. WASHER

2. RESERVOIR 13. RETAINER RING
3. SEAL 14. DUST COVER
4. RETURN SPRING 15. ROD
5. BODY 16. LOCK NUT
6. PIN 17. CLEVIS
7. SEAL 18. PRIMARY FLUID CHAMBER
8. SECONDARY PISTON 19. SECONDARY FLUID CHAMBER
9. SEAL 20. FLOAT
10. SPRING 21. SWITCH (FLUID LEVEL)
11. PRIMARY PISTON

Figure 11. Master Cylinder

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Master Cylinder Repair 1800 SRM 566

CLEAN AND INSPECT
CAUTION
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 linings.
Inspect bore of master cylinder for holes or scratches.
Replace master cylinder assembly if there is damage.

REPAIR
Repair master cylinder as follows:

STEP 1.
Remove fluid reservoir. Apply force in direction of ar-
row and pull reservoir from master cylinder. Install
reservoir by pushing and turning reservoir in oppo-
site direction. Make sure brake fluid does not leak
from reservoir seals. If there is any leakage, replace
seals.

STEP 2.
Be careful to not scratch the surfaces. Use a tool
(screwdriver with flat tip) that has a smooth and
rounded end to remove reservoir seals. Always in-
stall new seals. Put new seals in clean brake fluid;
then, install seals in body of master cylinder.

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1800 SRM 566 Master Cylinder Repair

STEP 3.
Push primary piston into bore as shown in the illus-
tration. Remove pin at secondary piston through port
for secondary reservoir. Use the same method to in-
stall pin during assembly.

STEP 4.
Remove clevis and nut from push rod. Remove dust
cover. Be sure to put lip of dust cover into recess in
bore of cylinder during assembly.

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 or installed, make sure the cylinder bore or piston is not scratched or
damaged.

STEP 5.
Remove snap ring and primary piston assembly.

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Master Cylinder Repair 1800 SRM 566

CAUTION
During disassembly and assembly of the primary and secondary pistons assembly, make sure not
to scratch or damage the cylinder bore when the spring is removed.

STEP 6.
Hit cylinder lightly on a soft or wooden surface and
remove secondary piston assembly. Lubricate cylin-
der bore with clean brake fluid to help removal.

STEP 7.
During installation of secondary piston, insert piston
assembly into cylinder until seal is at center of bore
opening. Be careful to not cause a restriction of seal
during installation. To make sure seal enters bore
correctly, carefully rotate and tilt piston until seal is
installed in bore. Slowly push piston assembly into
bore in one continuous motion after seal fully enters
bore.

NOTE: Install new seal when master cylinder is dis-

assembled for repair.

STEP 8.
Remove seal from piston with a smooth and rounded
tool.

INSTALL
Use the reverse order of Remove to install the mas-
ter cylinder. Check adjustment of brake pedal as de-
scribed in Brake Pedal Adjustment. See Figure 11.

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1800 SRM 566 Brake System Air Removal

Service Brakes Adjustment

The following procedure is for newly installed brake 3. Push automatic adjuster lever away from ad-
shoes. If the lift truck has been operated for more juster wheel with a small screwdriver. Use
than 25 hours and has correct pedal height, the adjuster tool to loosen adjuster wheel approxi-
brakes normally will not need adjustment. mately 15 teeth (new brake shoes).

1. See the procedure How To Put Lift Truck On
Blocks in the Periodic Maintenance section of
the service manual or the Operating Manual.
Put lift truck on blocks so drive wheels can be re-
moved. Remove drive wheels.
2. Use an adjuster tool to rotate adjuster wheel so
teeth of wheel move downward. This adjustment
expands the brake shoes. Adjust brake shoes so
brake drum will not rotate.
NOTE: If the brake shoes were not replaced, loosen
adjuster wheel approximately 15 teeth.
4. Install drive wheels. Remove lift truck from
blocks. Operate lift truck in FORWARD and
REVERSE directions. Stop lift truck 10 times
in each direction. This procedure causes brake
shoes to wear a small amount and fit the brake
drum better.

Brake Pedal Adjustment

Adjust pedal height to 95 mm (3.7 in.) by turning capscrew at rear of pedal assembly. This measurement is
made with the pedal pad mounted on the pedal. Make sure lock nut is tight. See Figure 9.

Master Cylinder Adjustment

Loosen lock nut on push rod. Turn push rod until will create the proper clearance, which will allow the
all of the clearance is removed between push rod and piston in the master cylinder to fully return when the
master cylinder. Turn push rod 1/8 of a turn counter- brake pedal is released. Make sure lock nut is tight.
clockwise (viewed from the rear of the fork lift). This See Figure 9.

Brake System Air Removal

Adjust the service brakes before the air is removed 4. Repeat the procedure in Step 1 through Step 3
from the brake system. until there are no air bubbles in the container.

1. Fill the master cylinder reservoir with brake
fluid.
2. Put one end of a rubber hose on the special fitting
of the wheel cylinder. Put the other end of the
hose into a clear container of brake fluid.
3. Loosen the special fitting at the wheel cylinder
one turn so that the air can be removed from the
brake system. Slowly push the brake pedal and
hold it at the end of its stroke. Close the special
fitting.
5. Check the level of the brake fluid in the reser-
voir for the master cylinder during the procedure.
Make sure to keep the brake fluid at the correct
level.
6. Repeat the procedure for the other wheel cylin-
der. If there is still air in the system, the air
must be removed from the master cylinder. Push
on the brake pedal with a steady stroke. Release
the pedal slowly. Repeat this procedure until no
air bubbles enter the reservoir.

17
Troubleshooting 1800 SRM 566

Parking Brake Not Applied Switch Test

The "Parking Brake Not Applied" system is actuated
by a combination of two switches, one attached to the
parking brake mechanism and the other is the seat
switch. These switches actuate an audible buzzer
on the instrument cluster. When the operator leaves
the seat for more than two seconds without applying
the parking brake, the buzzer will be on continuously
for 10 seconds. The buzzer operates whether the key
switch is ON or OFF.

Torque Specifications
Back Plate to Axle Mount Capscrews Wheel Nuts
5/8 in. Capscrews 245 N•m (181 lbf ft) 237 to 305 N•m (175 to 225 lbf ft)
1/2 in. Capscrews 125 N•m (92 lbf ft)
Hub Nut
Wheel Cylinder Capscrews Inital: 205 N•m (151 lbf ft)
7/16 in. Capscrews 78 to 91 N•m (58 to 67 lbf ft) Final: 34 N•m (25 lbf ft)
1/2 in. Capscrews 91 to 102 N•m (67 to 75 lbf ft)

Axle Shaft Capscrews

98 N•m (72 lbf ft)

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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 mount for the master cylinder is Tighten fasteners.

loose.

The brake shoes are worn or dam- Install new brake shoes.
aged.

The linings are too hard. Install new, correct lining.

A brake drum is cracked. Install new part.

A backplate is damaged. Install new part.

A wheel cylinder is leaking or does Repair or install new parts. Remove

not operate correctly. air from system.

The brake linings do not fit the brake Install correct linings. Machine
drums. brake drums.

The master cylinder is damaged. Install new master cylinder. Remove

air from system.

Water or oil is on the brake linings. Clean or install new linings.

18
1800 SRM 566 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

One brake does not release. A brake shoe is damaged. Install new parts.

A return spring is wrong. Install new, correct spring.

The brake lines have a restriction. Remove restriction or install new

lines. Remove air from system.

A parking brake cable is damaged or Adjust cable or install new parts.

needs adjustment.

The wheel cylinder is damaged. Repair or install new parts. Remove

air from system.

The backplate is worn or damaged. Repair or 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 brake linings are worn. Install new linings.

The brake drum is damaged. Repair or install new brake drum.

A brake shoe is worn or damaged. Install new brake shoe(s).

The brakes do not operate Oil or brake fluid is on the linings. Repair leak. Clean or install new lin-
equally. ings.

The linings are worn or hard. Install new linings.

A wheel cylinder is leaking. Repair or install new parts. Remove

air from system.

The brake linings are not correctly Install brake linings correctly.
installed.

The backplate or brake shoes are Repair or install new parts.

damaged.

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.

19
Troubleshooting 1800 SRM 566

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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 the clearance between push
end of the push rod in the master rod and piston.
cylinder.

The master cylinder is damaged. Install new master cylinder. Remove

air from system.

The brake shoes are adjusted too Check operation of self-adjusters.

tight. Adjust brakes.

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.

The brake linings are worn. Install new linings.

One of the dual brake circuits is not Repair or install new parts.
operating.

There is too much clearance at the Adjust the clearance between push
end of the push rod in the master rod and piston.
cylinder.

The master cylinder is worn or dam- Repair or install new master cylin-
aged. der. Remove air from system.

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.

Oil, water, or brake fluid is on the lin- Clean or install new linings.
ings.

The parking brake cables need ad- Install new parts. Lubricate and ad-
justment, lubrication, or have dam- just cables.
age.

20
1800 SRM 566 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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.

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