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1. SERVICE REPAIR
H40XL H50XL H60XL [B177]

2. 1
INTRODUCTION
GENERAL
This section has a description and the service
procedures for the brake system. The brake system
includes the following parts: master cylinder, master
cylinder with brake booster [only available lift truck
models H2.00–3.00XL (H40–60XL)], brake shoes,
wheel cylinders, a single inching/brake pedal and
linkage, and the parking brake system.
Two sizes of service brakes are used on the H3.00XL
(H60XL) lift trucks: a 260 mm (10.25 in) or a 310 mm
(12.20 in). New drive wheels and tires are required for
the larger diameter service brake. Both sizes of service
brakes are described in this section. A troubleshooting
section is included at the end of this section.
SERVICE BRAKES AND PARKING BRAKE
DESCRIPTION AND OPERATION
Service Brakes
A service brake assembly is installed on the brackets at
each end of the drive axle. The parts of the service brake
assembly for the 260 mm (10.25 in) brake are shown in
FIGURE 2. The parts of the service brake assembly for
the 310 mm (12.20 in) brake are shown in FIGURE 13.
When the brake pedal is pushed, fluid pressure from the
master cylinder causes the pistons in the wheel cylinder
to extend. The pistons expand the brake shoes against
the drum.
The clearance between the brake shoes and the brake
drum is adjusted automatically. An adjuster linkage
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 ad-
juster lever to rotate the adjuster wheel. The adjuster
wheel can turn only when there is clearance between the
lining of the brake shoe and the brake drum. The ad-
juster wheel can also be turned with a tool. A hole in the
drum is used for access to the adjuster wheel in the 260
mm (10.25 in) brake. A slot in the back plate gives ac-
cess to the adjuster wheel in the 310 mm (12.20 in)
brake.
FIGURE 1. BRAKE SYSTEM
1. LEVER, PARKING BRAKE
2. PEDAL, SERVICE BRAKE
3. BRAKE ROD
4. BRAKE BOOSTER *
5. MASTER CYLINDER
6. BRAKE LINE, RH
7. BRAKE LINE, LH
8. CABLE, LH
9. CABLE, RH
10. BRAKE ASSEMBLY
11. DRIVE WHEEL
12604
*AVAILABLE ONLY ON MODELS
H2.00–3.00XL (H40–60XL)

3. 2
Parking Brake
The parking brake system uses the service brake shoes.
Additional linkage activates the parking brake system.
When the lever is moved to apply the parking brake, the
cables and linkage expand the brake shoes against the
drum. The design of the parking brake linkage adjusts
each cable so that the tension is the same when the lever
is moved to apply parking brake.
REMOVAL AND DISASSEMBLY OF THE
260 mm (10.25 in) SERVICE BRAKES
WARNING
Brake linings can contain dangerous fibers. Breath-
ing 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 asbestos dust or
follow the cleaning 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 restricted area with
special ventilation. Protective clothing and a
respirator must be used.
1. See the procedure “HOW TO PUT A LIFT TRUCK
ON BLOCKS” in the MAINTENANCE section or the
OPERATING MANUAL. Start the engine and tilt the
mast fully backward. Put blocks under the mast. Tilt the
mast forward until the wheels just touch the floor. Stop
the engine. Put blocks under the frame of the lift truck.
2. Remove the capscrews that hold the axle shaft to the
hub. Remove the axle shaft.
3. Bend the lock plate and remove the nut that holds the
axle bearing. Remove the washer and the bearing cone.
4. Put grease on the floor so that the wheel assembly will
slide easily from the axle tube. Pull the wheel assembly
from the lift truck.
WARNING
When the brake shoes are removed do not create
dust in the air. See the cleaning procedure in this sec-
tion.
5. If the wheel assembly cannot be removed easily, re-
movethewheelfromthehub.Aligntheholeinthebrake
drum with the adjuster wheel. Pull the adjuster actuator
away from the adjuster wheel. Use an adjuster tool or a
screwdriver to turn the adjuster wheel to loosen the
brake shoes. Remove the hub and drum assembly. Do
not damage the seal when removing the hub.
6. See FIGURE 2. Remove the return springs (2) (15)
with spring pliers.
NOTE: The return springs (2) (15) are not the same part
number. Make sure the springs are installed in the same
positions from which they were removed.
7. Remove the retainers, springs and retainer pins that
hold the brake shoes to the back plate. See FIGURE 4.
Remove the 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 ad-
juster wheel for the right brake has left–hand threads.
8. The back plate must be removed from the axle hous-
ing for access to the capscrews for the wheel cylinder.
Remove the brake line from the wheel cylinder. Remove
the capscrews that hold the back plate to the axle hous-
ing.
9. Remove the dust covers, pistons, cups and springs
from the wheel cylinder. See FIGURE 3.
10. Remove the snap rings from the brake levers. Re-
move the parking brake levers from the back plate.

4. 3
FIGURE 2. THE 260 mm (10.25 in) BRAKE ASSEMBLY
1. WHEEL CYLINDER
2. RETURN SPRING, LEFT
3. PIVOT PLATE
4. LINK
5. RETAINER PIN
6. ACTUATOR FOR ADJUSTER
WHEEL
7. ADJUSTER WHEEL
8. ADJUSTER NUT
9. CABLE
10. SPRING RETAINER
(SPRING NOT SHOWN)
11. LEVERS FOR
PARKING BRAKE
12. LINING FOR BRAKE SHOE
13. BRAKE SHOE
14. ANCHOR
15. RETURN SPRING, RIGHT
16. BACK PLATE
9524
1
2
3
15
13
12
4
5
6
7
8
9
10
11
14
16
FIGURE 3. WHEEL CYLINDER
1. PORT FOR SPECIAL
FITTING
2. INLET PORT
3. BRAKE SHOE
4. DUST COVER
5. WHEEL CYLINDER
6. SPRING
7. CUP
8. PISTON ASSEMBLY
1025

5. 4
FIGURE 4. PARTS FOR THE 260 mm (10.25 in) BRAKE SYSTEM
5138
1. SNAP RING
2. ANCHOR PIN
3. BACK PLATE
4. CABLE
5. CABLE GUIDE
6. SPECIAL CAPSCREW
7. CAPSCREWS
8. PARKING BRAKE LEVER
9. WHEEL CYLINDER
10. PIVOT PIN
11. BRAKE SHOE
12. PIVOT PLATE
13. RETURN SPRING (GRAY)
14. RETURN SPRING
15. SPECIAL CAPSCREW
(SPRING ANCHOR) AND WASHER
16. LINK
17. LINK
18. RETAINER SPRING ASSEMBLY
19. BRAKE SHOE
20. SPRING
24
21. ADJUSTER NUT
22. ADJUSTER WHEEL
23. ACTUATOR, ADJUSTER WHEEL
24. CRANK, PARKING BRAKE
4
Parking Brake
If the lever assembly for the parking brake must be re-
moved from the cowl, use the following procedure (see
FIGURE 11.):
a. Use blocks next to the wheels to make sure the lift
truck can not move. Release the parking brake le-
ver.
b. Remove the four capscrews that fasten the brack-
etfortheparkingbrakelevertothecowl.Remove
the bracket and lever assembly.
c. Loosen the jam nuts that fasten the threaded ends
of the parking brake cables to the bracket assem-
bly.
d. Turntheadjusterknobcounterclockwiseuntilthe
brake cables are loosened. Disconnect the park-
ing brake cables from the link.

6. 5
CLEANING
WARNING
DO NOT use an oil solvent to clean the master cylin-
der, wheel cylinder, or the brake linings. Use a sol-
vent approved for cleaning of brake parts. Do not
permit oil or grease in the brake fluid or on the brake
linings. Oil and grease will cause damage and leaks
in the seals of a brake system. The brakes will not op-
erate correctly if oil, grease, or brake fluid is on the
brake linings.
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the safety instructions of the sol-
vent manufacturer.
1.Donotreleasebrakeliningdustfromthebrakelinings
into the air when the brake drum is removed.
2. Use a solvent approved for cleaning of brake parts to
wet the brake lining dust. Follow the instructions and
cautions of the manufacturer for the use of the solvent. If
a solvent spray is used, do not create brake lining dust
with the spray.
3. When the brake lining dust is wet, clean the parts. Put
any cloth or towels in a plastic bag or an airtight con-
tainer while they are still wet. Put an “ASBESTOS”
warning label on the plastic bag or airtight container.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the air.
CAUTION
Do not permit oil or grease on the brake linings be-
cause the brakes will not operate correctly. Use a
brake cleaning fluid as necessary to clean brake lin-
ings that will be installed again.
INSPECTION
1. Inspect the bore of the wheel cylinder for holes or
scratches. Replace the wheel cylinder assembly if there
is any damage.
2. Inspect the return springs for defects. Inspect the back
plate for wear where the brake shoes touch the back
plate. remove any grooves worn into the back plate.
3. Inspect the brake shoes for cracks or damage. If the
linings or shoes are worn or damaged, replace the brake
shoes. Maximum wear is to within 1 mm (0.039 in) of
contact with the rivets, or the metal shoe on bonded lin-
ings. Brake shoes must be replaced in complete sets. In-
spect the brake drums for cracks or damage. Replace
any damaged parts.
WARNING
The brake shoes on both wheels must be replaced if
any shoe is damaged. The brake performance on
both ends of an axle must be equal or the lift truck
can be difficult to steer when the brakes are applied.
4.Inspectthebrakedrumfordeepgroovesorotherdam-
age.
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 262.7
mm (10.35 in). If the internal diameter is larger than the
limit, replace the brake drum.
5. The teeth of the adjuster wheel must not be worn. The
adjuster wheel must turn freely. Check the adjuster links
for damage.
6. Make sure the parking brake levers and crank move
freely.
7. Check the grease seals and the surfaces for the seals
for wear or damage.
ASSEMBLY AND INSTALLATION OF THE
260 mm (10.25 in) SERVICE BRAKES
1. Assemble the wheel cylinder. See FIGURE 3. Use
only HYSTER APPROVED parts.
2.Installthewheelcylinderonthebackplate.Makesure
the special fitting for removing the air is in the top hole.
Put LoctiteR 271 on the threads of the capscrews.
Tighten the two capscrews that are near the top of the
wheel cylinder to 78 to 85 N.m (58 to 66 lbf ft). Tighten
the two larger capscrews to 80 to 102 N.m (67 to 75 lbf
ft).

7. 6
3. See FIGURE 5. Put the retainer pins that hold the
brake shoes through the back plate. Install the shield and
back plate on the axle housing.
FIGURE 5. INSTALL THE RETAINER PINS
9517
4. See FIGURE 4. and FIGURE 6. Tighten the two spe-
cial capscrews (6) for the parking brake levers (8) to 244
N.m (180 lbf ft). Tighten the capscrews that hold the
back plate to the axle housing to 245 N.m (180 lbf ft).
Install the washer and the special capscrew (15) that is
the anchor for the return springs. This capscrew (15)
must be tightened to 125 N.m (92 lbf ft). Make sure the
washer is installed so that the capscrew (15) does not
loosen during operation.
FIGURE 6. INSTALL THE ANCHOR PINS
9516
5. Install the parking brake levers (8) and cable (4). In-
stall the snap rings. Install the cable guide (5) and snap
ring on the crank (24) for the parking brake.
6. Install the pivot pin (10) through the brake shoe that is
toward the rear of the lift truck. Install the links (16) (17)
in the pivot plate. Install the pivot plate (12), 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 the pivot plate (12) so that the letter “L” is seen on
the left brake assembly. Install the pivot plate (12) on the
right brake assembly so that the letter “R” is seen.
FIGURE 7. INSTALL THE RETAINER SPRING
ASSEMBLY
9521
7. Lubricate the back plate with a small amount of
greasewheretheshoestouch.Installthebrakeshoes.In-
stall the retainer spring assembly. See FIGURE 7. Put a
spring seat, spring and retainer on the pin. Push the re-
tainer on to the pin and rotate the retainer 90 degrees to
lock the pin into the retainer. Install the other spring as-
sembly.
8. Put an anti–seize compound on the threads of the ad-
juster wheel. Install the adjuster wheel assembly be-
tweenthetwobrakeshoes.Makesuretheadjusterwheel
is toward the rear of the lift truck.
WARNING
The threads of the adjuster wheel are not the same
for each brake assembly. If the adjuster wheel as-
semblies 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.
Turn the adjuster wheel into the adjuster nut so that the
adjuster assembly is in its shortest position. This action
permits the brake drum to be easily installed over the
brake shoes.

8. 7
FIGURE 8. INSTALLATION OF THE SPRINGS [260 mm (10.25 in) SERVICE BRAKES]
FRONT
LEFT SIDE
RIGHT SIDE
FRONT
9524
1. SPRING FOR (LEFT) SHOE
2. SPRING FOR (RIGHT) SHOE (GRAY)
3. ADJUSTER LINK, UPPER
4. ADJUSTER LINK, LOWER
9. Install the link in the adjuster wheel actuator. Put the
adjuster wheel actuator in the hole in the brake shoe.
Fasten the spring to the adjuster wheel actuator and the
brake shoe. The spring must be installed in the position
shown in FIGURE 8. Install the return springs for the
brakeshoes.Makesurethereturnspringsareinstalledin
the correct positions. See FIGURE 8. A gray spring is
always installed on the right brake shoe.
10. Make sure the bottom edge of the adjuster wheel ac-
tuator is just above the center of the teeth of the adjuster
wheel. Bend the lower link to align the adjuster wheel
actuator.

9. 8
11. Clean the hub bearings and lubricate them with
wheel bearing grease. Install the hub bearings and seals
in the hub. Install the brake drum and hub on the axle
housing. See FIGURE 9. and FIGURE 10.
FIGURE 9. INSTALLATION OF THE INNER
GREASE SEAL
9518
FIGURE 10. LOCATION OF THE GREASE
SEALS
1. OUTER SEAL
2. INNER SEAL
3. BRAKE DRUM
9519
1
2
3
NOTE: To prevent damage to the inner oil seal when in-
stalling the hub, the hub and drum assembly can be tem-
porarily fastened to the wheel. Align the height of the
axle housing with hub bearings. Put grease under the
wheel and slide the wheel toward the axle housing. In-
stall the outer bearing and nut. Remove the wheel from
the hub so that the clearance of the brake shoes can be
adjusted.
12. Adjust the hub bearings by tightening the nut to 205
N.m (150 lbf ft) while rotating the hub. Loosen the nut
until the hub turns freely. The torque must be less than
27 N.m (20 lbf ft). Tighten the nut to 34 N.m (25 lbf ft) or
until the first alignment position after 34 N.m (25 lbf ft).
Bend the lock plate over the nut.
13. Adjust the clearance of the brake shoes. Put a brake
adjustment tool or a screwdriver through the hole in the
drum. Turn the adjuster wheel so that the teeth of the ad-
juster wheel nearest the back plate move upward. Turn
the adjuster wheel until the hub will not turn. Pull the ac-
tuator away from the adjuster wheel and turn the ad-
juster wheel approximately 15 teeth in the opposite di-
rection. The brakes will adjust to the correct clearance
when they are applied while the lift truck is traveling in
the REVERSE direction.
NOTE: If the brake shoes were not replaced, loosen the
adjuster wheel approximately 25 teeth.
CAUTION
If there is too much clearance, the automatic adjust-
ers will not operate. If the clearance is too small, the
automatic adjustercannotturntheadjusterwheelto
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
adjusterlinkcanwearaspotontheadjusterwheelso
that it will not turn correctly.
14. Put sealant on the flange of the axle shaft. Install the
axle shaft and capscrews. Tighten the capscrews to 98
N.m (72 lbf ft).
Adjustments
1. Remove the air from the brake hydraulic system. See
the procedure “Remove The Air From The Brake Sys-
tem”, under CHECKS AND ADJUSTMENTS.
2. Install the wheel on the hub. Tighten the wheel nuts
610 to 650 N.m (450 to 477 lbf ft).
3. Start the engine and tilt the mast backward to remove
the blocks. Push on the brake pedal. The pedal must not
touch the floor plate. Move the lift truck in REVERSE
and push on the brake pedal to permit the adjuster
mechanism to operate.
4. The service brakes must be adjusted before the park-
ing brake can be adjusted. See FIGURE 12. and the fol-

10. 9
lowing paragraphs in this section for the correct adjust-
ment of the parking brake.
Parking Brake Installation (See FIGURE 11.)
If the lever assembly for the parking brake was removed
from the cowl, use the following procedure for installa-
tion:
a. Make sure the parking brake lever is in the re-
leased position.
b. Adjust the cable assemblies so that the threads of
the cable ends extend above their support to the
dimension indicated at dimension “S” or “H” in
FIGURE 12.
c. Turn the adjustment knob until the link (4) is ad-
justed to the bottom of the adjustment slot (13).
d. Install the round ends of the two brake cables (5
and 6) into the link (4) inside of the lever assem-
bly. Tighten the jam nuts (14) on the threaded
ends of the brake cables as shown in FIGURE 11.
e. Use the four capscrews, washers and nuts (12)
and fasten the lever assembly to the inside of the
cowl (17).
d. Before the cable assemblies are connected to the
crank on the back plate of the service brake, pull
on the crank to remove any clearance from the in-
ternal cable and cable guide inside of the brake.
Models S2.00–3.00 (S40–60XL). Check that the
crank (8) is between 40 and 60_ from vertical to-
ward the rear of the lift truck.
Models H2.00–3.00 (H40–60XL). Check that
the crank (8) is between vertical and 20_ from
vertical toward the rear of the lift truck.
If the crank is not in this position, remove the
crank from the shaft, move it to the correct posi-
tion on the shaft.
e. Connect the cable assemblies to the crank. Adjust
the cables at the clevis to remove the looseness
from the cables when the parking brake is re-
leased.
FIGURE 11. LEVER ASSEMBLY AND CABLES
FOR THE PARKING BRAKE
1. LEVER
2. SWITCH
3. ADJUSTER KNOB
4. LINK
5. CABLE, RH
6. CABLE, LH
7. COWL
8. BRACKET
9. COTTER PIN
12607
10. PIN
11. SLIDE BLOCK
12. CAPSCREW, NUT,
WASHER
13. ADJUSTMENT SLOT
14. JAM NUTS
2
6
8
Adjust The Parking Brake For Lift Trucks
With 260 mm (10.25 in) Service Brakes
(See FIGURE 12.)
Make sure that the service brakes are adjusted and the
operation of the automatic adjuster mechanism is cor-
rect. Test the operation of the parking brake. The lift
truck with a capacity load must not move when the park-
ing brake is applied on a 15% grade, [a slope that in-
creases 1.5 metres in 10 metres (1.5 ft in 10 ft)].
1. Make sure the parking brake lever is in the released
position.
2. Adjust the cable assemblies so that the threads of the
cable ends have the dimension indicated at dimension
“S” or “H” in FIGURE 12.
3. Turn the adjustment knob (3) until the link is adjusted
to the bottom of the adjustment slot.

11. 10
4. Before the cable assemblies are connected to the lever
on the back plate of the service brake, operate the crank
with your hand to remove any clearance in the internal
cable and cable guide inside the brake.
Models S2.00–3.00 (S40–60XL). Check that the crank
(7) is between 40 and 60degrees from vertical toward the
rear of the lift truck.
Models H2.00–3.00 (H40–60XL). Check that the
crank(7)isbetweenverticaland20degrees fromvertical
toward the rear of the lift truck.
If the crank is not in this position, remove the crank from
the shaft, move it to the correct position on the shaft.
5. Connect the cable assemblies to the crank. Adjust the
cables at the clevis (9) to remove the looseness from the
cables when the parking brake is released.
6. Turn the adjustment knob (3) to raise the link and
tighten the parking brake cables. Turn the adjustment
knob until the parking brakes are fully applied when the
lever (1) is used to apply the parking brake.
FIGURE 12. LEVER ADJUSTMENT OF PARKING BRAKE
DIMENSION “H”
13 mm (0.51 in)
DIMENSION “S”
21 mm (0.80 in)
S2.00–3.00XL (S40–60XL) 1. LEVER
2. SWITCH
3. ADJUSTMENT KNOB
4. ADJUSTMENT SLOT
5. LINK
6. VERTICAL REFERENCE
7. CRANK
8. PIN
9. CLEVIS
10. CABLE
11. THREADED END
12. RELEASE BUTTON
12607
H2.00–3.00XL (H40–60XL)
0–20° IN “RELEASED” POSITION
40–60° IN “RELEASED” POSITION

12. 11
REMOVAL AND DISASSEMBLY OF THE
310 mm (12.20 in) SERVICE BRAKES
WARNING
Brake linings can contain dangerous fibers. Breath-
ing 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 fol-
low the cleaning 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 restricted area with
special ventilation. Protective clothing and a
respirator must be used.
1. Remove the capscrews that hold the axle shaft to the
hub. Remove the axle shaft.
2. See the procedure “HOW TO PUT A LIFT TRUCK
ON BLOCKS” in the MAINTENANCE section or the
OPERATING MANUAL. Start the engine and tilt the
mast fully backward. Put blocks under the mast. Tilt the
mast forward until the wheels just touch the floor. Stop
the engine. Put blocks under the frame of the lift truck.
3. Bend the lock plate and remove the nut that holds the
axle bearing. Remove the washer and the bearing cone.
4. Put grease on the floor so that the wheel assembly will
slide easily from the axle tube. Pull the wheel assembly
from the lift truck.
WARNING
When the brake shoes are removed do not create
dust in the air. See the cleaning procedure in this sec-
tion.
5. If the wheel assembly cannot be removed easily, use a
small screwdriver to lift the adjuster actuator away from
the adjuster wheel. Use a brake adjustment tool or a
screwdriver to turn the adjuster wheel to loosen the
brake shoes. Remove the hub and drum assembly. Do
not damage the grease seal when removing the hub.
6. Make a note of the arrangement of the parts. See
FIGURE 13. and FIGURE 14. Remove the return
springs (2) (3) with spring pliers.
FIGURE 13. THE 310 mm (12.20 in) BRAKE ASSEMBLY (LEFT BRAKE ASSEMBLY SHOWN)
1
2
3
4
6
7
15
8
8
9
10
12
11
14
16
17
19
1. WHEEL CYLINDER
2. RETURN SPRING
3. RETURN SPRING
4. ANCHOR
5. ANCHOR GUIDE
6. BACK PLATE
7. BRAKE SHOE
8. RETAINER SPRING
ASSEMBLY (4)
9. PIVOT PLATE
10. LINK
11. ACTUATOR,
ADJUSTER WHEEL
12. ADJUSTER WHEEL
13. PARKING BRAKE CABLE
14. SPRING,
ADJUSTER ACTUATOR
15. BRAKE SHOE
16. LINK, PARKING BRAKE
17. SPRING,
PARKING BRAKE LINK
18. PARKING BRAKE LEVER
19. PIVOT PIN, RETAINER,
AND SPRING WASHER
5
13
18

13. 12
FIGURE 14. PARTS FOR THE 310 mm (12.20 in) SERVICE BRAKE
1. WHEEL CYLINDER
2. RETURN SPRING
3. RETURN SPRING
4. ANCHOR
5. ANCHOR GUIDE
6. BACK PLATE
7. BRAKE SHOE
8. RETAINER SPRING
ASSEMBLY (4)
9. PIVOT PLATE
10. LINK
1
2
11
10
9
14
16
8
3
12
7
19
19
18
4
22
6
13
15
17
20
21
23
5
11. ACTUATOR,
ADJUSTER WHEEL
12. ADJUSTER WHEEL
13. PARKING BRAKE CABLE
14. SPRING,
ADJUSTER ACTUATOR
15. BRAKE SHOE
16. LINK, PARKING BRAKE
17. SPRING,
PARKING BRAKE LINK
18. PARKING BRAKE LEVER.
19. PIVOT PIN, RETAINER,
AND SPRING WASHER
20. WASHER
21. RETAINER
22. ANCHOR
23. SPACER
7. Remove the retainers, springs and anchor pins that
hold the brake shoes to the back plate.
8. Disengage the link (10) from the adjuster wheel ac-
tuator (11). Remove the link (10), washer (20), and the
pivot plate (9). Remove the anchor guide (5).
9. Move the brake shoes away from each other to disen-
gage the brake shoes from the wheel cylinder. Discon-
nect the parking brake lever (18) from the parking brake
cable (13) as the brake assembly is removed from the
back plate. The parking brake lever has a hook that en-
gages the parking brake cable.
10. Make a note of the arrangement of parts and disas-
semble the brake assembly. Remove the parking brake
link (16) and spring (17) if they are still engaged with
brake shoes. The parking brake link and spring will of-
ten fall from the brake assembly when the brake assem-
bly is removed from the back plate. The adjuster wheel
(12) will also disengage from the brake shoes after the
brake assembly is removed.
NOTE: The adjuster wheel for the left brake is not the
same as the adjuster wheel for the right brake. The ad-
juster wheel for the right brake has left–hand threads.

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15. 13
1. PUSH ROD (2)
2. DUST COVER (2)
3. PISTON (2)
4. CUP (2)
5. SPRING
6. BODY, WHEEL CYLINDER
7. INLET PORT
8. SPECIAL FITTING
9. DUST COVER
1
1
2
2
3
3
4
4
5
6
7
8
9
FIGURE 15. WHEEL CYLINDER
11. Remove the spring (14) for the actuator, adjuster
wheel (11). Remove the actuator, adjuster wheel (11)
from the brake shoe. Loosen the nut and remove the an-
chor (22) and spacer (23) from the brake shoe.
12. Use a screwdriver or small prybar to move apart the
ends of the retainer (19). Remove the spring washer (19)
andpivotpin(19)toremovetheparkingbrakelever(18)
from the brake shoe (15).
13. Disconnect the brake line from the wheel cylinder
(1). Remove the capscrews that hold the wheel cylinder
to the back plate and remove the wheel cylinder.
15. See FIGURE 15. Remove the push rods, dust cov-
ers, pistons, cups, and spring from the wheel cylinder.
NOTE: The back plate is not normally removed from
the axle housing for brake repairs. Eight special
capscrews are used to fasten the back plate to the axle
housing and the locking function of the capscrews is re-
duced if they are removed. These capscrews are tight-
ened to 255 N.m (188 lbf ft).
Parking Brake
If the lever assembly for the parking brake must be re-
moved from the cowl, use the following procedure (see
FIGURE 19.):
a. Use blocks next to the wheels to make sure the lift
truck can not move. Release the parking brake le-
ver.
b. Remove the four capscrews that fasten the brack-
et for the parking brake to the cowl. Remove the
bracket and brake lever assembly.
c. Loosen the jam nuts that fasten the threaded ends
of the brake cables to the brake lever assembly.
d. Turntheadjusterknobcounterclockwiseuntilthe
brake cables are loosened. Disconnect the cables
from the link.
e. The service brake assembly must be removed be-
fore the parking brake cable can be removed from
the back plate of the service brake. A snap ring
holds the sheath of the parking brake cable in the
back plate of the service brake. Remove the snap
ring and remove the parking brake cable from the
back plate.

16. 14
CLEANING
WARNING
DO NOT use an oil solvent to clean the master cylin-
der, wheel cylinder, or the brake linings. Use a sol-
vent approved for cleaning of brake parts. Do not
permit oil or grease in the brake fluid or on the brake
linings. Oil and grease will cause damage and leaks
in the seals of a brake system. The brakes will not op-
erate correctly if oil, grease, or brake fluid is on the
brake linings.
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the safety instructions of the sol-
vent manufacturer.
1.Donotreleasebrakeliningdustfromthebrakelinings
into the air when the brake drum is removed.
2. Use a solvent approved for cleaning of brake parts to
wet the brake lining dust. Follow the instructions and
cautions of the manufacturer for the use of the solvent. If
a solvent spray is used, do not create brake lining dust
with the spray.
3. When the brake lining dust is wet, clean the parts. Put
any cloth or towels in a plastic bag or an airtight con-
tainer while they are still wet. Put an “DANGEROUS
FIBERS” warning label on the plastic bag or airtight
container.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the air.
CAUTION
Donotpermitoilorgreaseonthebrakelinings.Usea
brakecleaningfluidasnecessarytocleanliningsthat
will not be replaced.
INSPECTION
1. Inspect the bore of the wheel cylinder for holes or
scratches. Replace the wheel cylinder assembly if there
is any damage.
2. Inspect the return springs for defects. Inspect the back
plate for wear where the brake shoes touch the back
plate. Remove any grooves or replace a worn or dam-
aged back plate.
3. Inspect the brake shoes for cracks or damage. If the
linings or shoes are worn or damaged, replace the brake
shoes. Maximum wear is to within 1 mm (0.025 in) of
contact with the rivets, or the metal shoe on bonded lin-
ings. Brake shoes must be replaced in complete sets. In-
spect the brake drums for cracks or damage. Replace
any damaged parts.
WARNING
The brake shoes on both wheels must be replaced if
any shoe is damaged. The brake performance on
both ends of an axle must be equal or the lift truck
can be difficult to steer when the brakes are applied.
4.Inspectthebrakedrumfordeepgroovesorotherdam-
age.
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 311.7
mm (12.27 in). If the internal diameter is larger than the
limit, replace the brake drum.
5. The teeth of the adjuster wheel must not be worn. The
adjuster wheel must turn freely. Check the adjuster links
for damage.
6. Make sure the parking brake cables are in good condi-
tion.
7. Check the grease seals and the surfaces for the seals
for wear or damage.
ASSEMBLY AND INSTALLATION OF THE
310 mm (12.20 in) SERVICE BRAKES
1. If the wheel cylinder was disassembled for repair, as-
semble the wheel cylinder. See FIGURE 15. Use only
HYSTER APPROVED parts.
2. Install the wheel cylinder on the back plate and tight-
en the two capscrews. Connect the brake line to the
wheel cylinder.
3. See FIGURE 14. Install the parking brake lever (18).
Usethepivotpin,springwasher,andretainer(19)tofas-
ten the parking brake lever to the brake shoe (15). Close
the ends of the retainer to fasten the pivot pin in position.
4. Install the anchor (22) and the spacer (23) in the brake
shoe (7). Install the actuator, adjuster wheel (11) in the
brake shoe (7).

17. 15
1. LINK, ADJUSTER ACTUATOR
2. RETURN SPRING
3. RETURN SPRING
4. ANCHOR
1
4
3 2
FIGURE 16. INSTALLATION OF THE RETURN SPRINGS [310 mm (12.20 in) SERVICE BRAKES]
5. Fasten the spring, adjuster actuator (14) to the actua-
tor, adjuster wheel (11) and the brake shoe (15).
6. Put an anti–seize compound on the threads of the ad-
juster wheel. Turn the adjuster wheel into the adjuster
nut so that the adjuster assembly is in its shortest posi-
tion. This action permits the brake drum to be easily in-
stalled over the brake shoes.
7. Install the adjuster wheel (12) between the two brake
shoes. Make sure the adjuster wheel will be toward the
rear of the lift truck. Move the brake shoes apart so that
the adjuster wheel is held in position and the spring, ad-
juster actuator is in tension.
WARNING
The threads of the adjuster wheel are not the same
for each side. If the adjuster assemblies are installed
on the wrong side, the brake shoe clearance will in-
crease each time the brakes are applied. The ad-
juster wheel for the right brake has left–hand
threads. The adjuster wheel for the left brake has
right–hand threads.
8. Lubricate the back plate with a small amount of
grease where the brake shoes touch. Install the brake
shoes on the anchor (4) and engage the push rods of the
wheel cylinder. Engage the the parking brake lever (18)
in the slot in the parking brake cable as the brake shoes
are installed on the back plate.
9. Put an anchor pin that holds the brake shoes through
the back plate. Put a spring seat, spring and retainer (8)
on the anchor pin. Push the retainer on to the anchor pin
androtatetheretainer90degrees.Makesuretheretainer
is in the correct position. Install another retainer spring
assembly.
10. Install the link, parking brake (16) and the spring
(17) between the parking brake lever (18) and the brake
shoe (7).
11. Install the other spring retainers (8) that hold the
brake shoes. Make sure the parking brake (16) and the
spring (17) are correctly engaged after the spring retain-
ers are installed.
12. Install the anchor guide (5) on the anchor (4). Install
the pivot plate (9) on its anchor (22).
13. Fasten the link (10) to the actuator, adjuster wheel
(11) and put the cable around the pivot plate (9). Raise
the actuator, adjuster wheel (11) against the spring ten-
sion and connect the link (10) to the anchor (4).
14. Use the correct tools to install the return springs. In-
stall the return spring (3). Install the washer (20) and the
return spring (2). The shape of the return springs permits
them to be installed correctly in only one position. The
arrangement of the return springs on the anchors is
shown in FIGURE 16.
15. Make sure the bottom edge of the actuator, adjuster
wheel is just above the center of the teeth of the adjuster
wheel. Check for correct installation if the alignment is
not correct.
16. Clean the hub bearings and lubricate them with
wheel bearing grease. Install the hub bearings and seals
in the hub. Install the assembly on the axle housing. See
FIGURE 17. and FIGURE 18.

18. 16
FIGURE 17. LOCATION OF THE GREASE
SEALS [310 mm (12.20 in) SERVICE BRAKES]
1. OUTER SEAL
2. INNER SEAL
3. BRAKE DRUM
3
1
2
FIGURE 18. INSTALLATION OF THE INNER
GREASE SEAL
9518
NOTE: To prevent damage to the inner oil seal when in-
stalling the hub, the hub and drum assembly can be tem-
porarily fastened to the wheel. Align the height of the
axle housing with hub bearings. Put grease under the
wheel and slide the wheel toward the axle housing. In-
stall the outer bearing and nut.
17. Adjust the hub bearings by tightening the nut to 205
N.m (150 lbf ft) while rotating the hub. Loosen the nut
until the hub turns freely. The torque must be less than
27 N.m (20 lbf ft). Tighten the nut to 34 N.m (25 lbf ft) or
until the first alignment position after 34 N.m (25 lbf ft).
Bend the lock plate over the nut.
18. Adjust the clearance of the brake shoes. Put a brake
adjustment tool or a screwdriver through the slot in the
back plate. Use the tool to rotate the adjuster wheel. The
actuator for the adjuster wheel will only permit rotation
in one direction. Turn the adjuster wheel until the brake
shoeshaveexpandedagainstthebrakedrumandthehub
will not turn. Use a small screwdriver to lift the actuator
away from the adjuster wheel and turn the adjuster
wheel approximately 15 teeth in the opposite direction.
The brakes will adjust to the correct clearance when
they are applied while the lift truck is traveling in the
REVERSE direction.
NOTE: If the brake shoes were not replaced, loosen the
adjuster wheel approximately 25 teeth.
CAUTION
If there is too much clearance, the automatic adjust-
ers will not operate. If the clearance is too small, the
automatic adjustercannotturntheadjusterwheelto
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
adjusterlinkcanwearaspotontheadjusterwheelso
that it will not turn correctly.
19. Put liquid sealant on the flange of the axle shaft. In-
stall the axle shaft and capscrews. Tighten the
capscrews to 98 N.m (72 lbf ft).
Adjustments
1. Remove the air from the brake hydraulic system. See
the procedure “Remove The Air From The Brake Sys-
tem”, under CHECKS AND ADJUSTMENTS.
2. Install the wheel on the hub. Tighten the nuts to 610 to
650 N.m (450 to 477 lbf ft).
3. Start the engine and tilt the mast backward to remove
the blocks. Push on the brake pedal. The pedal must not
touch the floor plate. Move the lift truck in REVERSE
and push on the brake pedal to permit adjusting mecha-
nism to operate.
4. The service brakes must be adjusted before the park-
ing brake can be adjusted. See FIGURE 19. and the fol-
lowing paragraphs in this section for the correct adjust-
ment of the parking brake.