Hyster a216 (j40 xm) forklift service repair manual

SERVICE REPAIR
J40XM J50XM J60XM J65XM [A216]

1
INTRODUCTION
GENERAL
This section has the description and repair procedures
for the steering axle. See the following sections for addi-
tional information on the parts of the steering system:
THE STEERING CONTROL UNIT and HYDRAU-
LIC SYSTEM.
DESCRIPTION (See FIGURE 1.)
The steering axle assembly includes an axle frame,
steering cylinder and two spindle and hub assemblies.
The steering axle is connected to the frame with center
pivot mounts. The center pivot mounts on the axle frame
are fastened to the lift truck frame with rubber mounts.
The steering axle can make an articulated motion and
give the lift truck a smoother travel over rough surfaces.
The end caps of the steering cylinder are also the mounts
for the cylinder and are held to the shell by the mount
capscrews. O–rings, seals, and wipers in the end caps
are used to keep the oil inside of the steering cylinder.
The ends of the piston rod extend from both ends of the
cylinder. A single piston and the seal are at the center of
the rod. Oil pressure on one side of the piston moves the
piston in the bore. When the piston moves in the bore, it
pushes an equal amount of oil from the opposite end of
the cylinder. This oil returns to the steering control unit.
When the piston reaches the end of the stroke, a relief
valve controls the oil pressure so that the components
are not damaged. Tie rods connect the spindle arms to
the cylinder.
Each spindle turns on two tapered roller bearings. The
spindle and bearings are held in the axle frame by a king-
pin. The preload on the bearings is controlled by a
threaded nut on the bottom of the king pin.
The wheel or hub rotates on two tapered roller bearings
and is held on the spindle by a castle nut. The preload on
the bearings in the hub is adjusted by the castle nut. A
grease seal in the inner hub and a hub cap protect the
bearings from dirt and water. A wear sleeve in the inner
hub protects the hub from wear by the seal.
FIGURE 1. STEERING AXLE
4. RUBBER MOUNT
5. STEERING CYLINDER
6. NUT AND BOLT 4
3
2
6
5
3
4
1
1. SPINDLE AND
HUB ASSEMBLY
2. AXLE FRAME
3. BRACKET
12768

2
REPAIRS
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some types of
maintenance and repair. The removal of the follow-
ing assemblies will cause large changes in the center
of gravity: drive axle, battery or counterweight.
When the lift truck is put on blocks, put additional
blocks in the following positions:
1. If the mast and drive axle are removed, put blocks
under the counterweight so that the lift truck can not
fall backward.
2. If the battery (electric lift trucks) or counter-
weight is removed, put blocks under the mast so that
the lift truck can not fall forward.
Put the lift truck on blocks on a solid, even and level
surface. Make sure the blocks of stands have enough
capacity to hold the lift truck. Use additional blocks
next to the tires as necessary to prevent movement of
the lift truck. Make sure the lifting devices used dur-
ing repairs can lift the weight of the parts and assem-
blies.
STEERING AXLE ASSEMBLY
NOTE: The steering axle assembly without the wheels
weighs approximately 115 kg (250 lb)
Removal (See FIGURE 1.)
The steering axle can be removed without removing the
counterweight. If necessary, remove the counterweight
as described in the FRAME.
1. Make sure the wheels are set for straight travel. Put
the lift truck on blocks so that the steering axle can be
removed. The top of the axle frame must have clearance
under the counterweight so that the steering axle can be
removed.
2. Disconnect the hydraulic lines at the steering cylin-
der. Install caps on the cylinder and put plugs in the hy-
draulic lines. The caps will prevent the spindles from
turning when the axle is removed from under the lift
truck.
3. Slide a floor jack or the forks of another lift truck un-
der the steering axle. Raise the lifting device until it
holds the weight of the axle assembly. Remove the four
capscrews and nuts that fasten the two brackets under
the rubber mounts. Remove the brackets and slowly
lower the axle assembly onto the wheels. Carefully roll
the axle assembly from under the lift truck.
Installation (See FIGURE 1.)
1. Install the rubber mounts on the axle as follows:.
a. E1.25–1.75XL (E25–35XL), J2.00–3.00XL
(J40–60XL), H/J2.00–3.20XM (H/J40–65XM):
Make sure the PART NO. on the mounts is right side
up and facing away from the axle frame.
b. J1.25–1.75XL (Europe only): Make sure the
PART NO. on the mounts is upside down and facing
away from the axle frame.
2. Apply a lubricant that is approved for use with rubber
to the rubber mount. The lubricant is used where the rub-
ber mount fits into the frame brackets.
3. Use a floor jack or another lift truck to put the steering
axle into the position in the frame. Make sure the rubber
mounts fit inside the frame brackets for the mounts.
4. Install the bottom brackets. Tighten the four bracket
capscrews and nuts to 88 N.m (65 lbf ft).
5. Remove the plugs and caps and connect the hydraulic
lines to the steering cylinder.
6. Operate the steering system to remove the air from the
system. Turn the steering wheel several times from one
stop to the other stop. Check for hydraulic leaks.
WHEELS AND HUBS
Removal and Disassembly
(See FIGURE 2.)
WARNING
Completely deflate the tires before removing them
from the lift truck. Air pressure in the tires can cause
the tire and rim parts to explode causing serious in-
jury or death.
Never loosen the nuts that hold the inner and outer
wheel halves together when there is air pressure in
the tire.

3
FIGURE 2. STEERING AXLE
1
2
5
6
8
9
10 13
21
22
23
29
1. AXLE FRAME
2. WASHER
3. BOLT
4. BELLEVILLE WASHER
5. RUBBER MOUNT
6. BRACKET
7. NUT
8. STEERING CYLINDER
9. PIN
10. SNAP RING
11. BUSHING
22. KING PIN
23. GROOVE PIN
24. WEAR SLEEVE
25. HUB*
26. STUD*
27. WHEEL NUT*
28. COTTER PIN
29. GREASE CAP
* PNEUMATIC TIRES ONLY
12. TIE ROD
13. GREASE FITTING
14. CASTLE NUT
15. SLEEVE
16. SEAL
17. BEARING CONE
18. BEARING CUP
19. SPINDLE
20. SPACER
21. O–RING
3
3
10
11
9
4
7
16
14
28
18
17
16
15
14
28
4
4
4
20
11
10 10
16
24
17
18
17
18
19
19
12
17
18
H2.00–3.20XM (H40–65XM) SHOWN, OTHERS SIMILAR
25*
26*
27*
1. Put the axle on blocks so that the tires are raised from
the floor. Remove the grease cap. Remove the cotter pin
and the castle nut. Remove the outer bearing cone. Slide
the wheel from the spindle. Remove the inner bearing
cone and the seal from the spindle.
2. If the wheel bearings must be replaced, use a brass
drift to remove the bearing cups and the wear sleeve.
3. Repeat the procedure for the other wheel.
Cleaning
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the solvent manufacturer’s rec-
ommended safety procedures.
Clean all parts with solvent. Make sure the bearings are
clean.
Assembly And Installation
(See FIGURE 2.)
1. If the wheel bearings must be replaced, use a press to
install the new bearing cups in the wheel or hub. Install a
new wear sleeve in the wheel or hub. Install the grease
seal on the spindle. Lubricate the bearing cones with
grease. Make sure the bearings are filled with grease.
Install the bearing cone on the spindle.

4
CAUTION
Do not damage the seals during installation.
2. Carefully slide the wheel or hub onto the spindle.
Install the outer bearing cone.
3. Install the castle nut. Tighten the castle nut to 200 N.m
(150 lbf ft) while the wheel is rotated. Loosen the nut to
less than 27 N.m (20 lbf ft). Tighten the nut to 34 N.m
(25 lbf ft). If the cotter pin can not be installed with the
nut tightened to 34 N.m (25 lbf ft), tighten the castle nut
until the cotter pin can be installed. Install the cotter pin.
4. Repeat the procedure for the other wheel.
1. O–RING
2. KING PIN
3. GROOVE PIN
4. SPACER
5. SEAL
6. BEARING CONE
7. BEARING CUP
8. SPINDLE
9. SEAL
10. WEAR SLEEVE
11. CASTLE NUT
12. COTTER PIN
13. GREASE CAP
14. SLEEVE
1
2
3
4
5
6
7
8
9
10
11
12
13
6
7
6
7
6
7
12
11
14
5
FIGURE 3. SPINDLE ASSEMBLY
SPINDLES, BEARINGS AND TIE RODS
Remove the wheel or hub from the steering axle spindle.
Remove the pin to disconnect the tie rod from the
spindle. Remove the cotter pin and the castle nut from
the bottom of the king pin. Use a driver to remove the
king pin. Remove the sleeve and then the spindle from
the axle. Use a driver to remove the bearings and seals
from the spindle.
NOTE: Dirt and corrosion can make the spacer difficult
to remove from the steering axle frame. A machined
space is made in the top of the spacer so that the spacer
can be removed with a bearing puller.
Installation (See FIGURE 2., FIGURE 3.)
1. Use new bearings and seals. Apply grease to the bear-
ings and king pin as they are installed in the axle. Install
the bearings in the spindle. Install the seals in the correct
position. Align the spindle in the axle and install the
king pin. Make sure a new O–ring is installed at the top
of the king pin. Install the sleeve on the bottom of the
king pin. Install the castle nut and tighten it to 90 N.m
(66 lbf ft). Loosen the castle nut to less than 34 N.m (25
lbf ft). Tighten the nut to 34 N.m (25 lbf ft). If the cotter
pin can not be installed with the nut tightened to 34 N.m
(25 lbf ft), tighten the castle nut until the cotter pin can
be installed. Install the cotter pin.
2. Connect the tie rods. Make sure the belleville washers
are installed on both sides of the bushings.
3. Install the wheels or hubs. See the section WHEELS
AND HUBS for the proper installation procedure. On
the H/J2.00–3.20XM (H/J40–65XM), tighten the wheel
nuts to 237 to 305 N.m (175 to 225 lbf ft). On the
J1.25–1.75XL (J25–35XL) and the J2.00–3.00XL
(J40–60XL), tighten the wheel nuts to 155 N.m (115 lbf
ft).
STEERING CYLINDER
Removal And Disassembly
(See FIGURE 4.)
NOTE: The end caps of the steering cylinder are held in
the shell by the cylinder mount capscrews. To prevent
oil leaks at the caps, hold the caps on the shell during re-
moval.
1. Disconnect the hydraulic lines at the steering cylin-
der. Install caps in the fittings on the cylinders and put
caps on the hydraulic lines.
2. Remove the snap rings from the pins in the tie rods.
Remove the pins.
3. Remove the capscrews or nuts and bolts that fasten the
cylinder to the axle frame. Hold the end caps on the shell
and remove the steering cylinder.

5
4. Hold the end of the steering cylinder over a drain pan.
Remove the cap for the hydraulic fitting from each end
cap. Push the rod toward the end of the shell that is over
the drain pan. Oil will drain from the cylinder. Repeat
the procedure for the other end.
5. Carefully slide one end cap from the shell. Carefully
pull the cylinder rod and piston from the shell. Keep the
cylinder rod aligned in the center of the shell during re-
moval so that the parts are not damaged. Remove the
end cap from the rod. Remove the other end cap from the
shell. Remove all seals, wipers, and O–rings.
Cleaning and Inspection
WARNING
Cleaning solvents can be flammable and toxic and
vents, always follow the solvent manufacturer’s rec-
ommended safety procedures.
Clean all parts in solvent.
Inspect the piston rod for grooves or damage. Remove
small scratches with fine emery cloth. Inspect the cylin-
der bore for damage. Inspect the mounts for cracks.
Assembly and Installation
(See FIGURE 4.)
1. Put the seals and wipers in warm hydraulic oil. Install
the quadrant ring and piston seal as shown in
FIGURE 4.
CAUTION
Do not damage the O–rings, seals or wipers during
installation.
2. Lubricate the O–rings, seals, and wipers with O–ring
lubricant and install them in the end caps. Install one end
cap on the cylinder rod.
3. Carefully slide the cylinder rod and piston into the
shell. Keep the cylinder rod aligned in the center of the
shell during installation so that the parts are not dam-
aged. Carefully slide the end cap into the shell. Careful-
ly install the other end cap on the rod and shell. Put caps
on the hydraulic fittings of the end caps.
1 2
3 4 5
6 7 8
5 9 3
5. BACK–UP RING
6. SHELL
7. PISTON SEAL
8. ROD SEAL
9. QUADRANT RING
1. ROD
2. WIPER
3. END CAP
4. O–RING
1
2
3
4
6
7
5
3
4
5
8
8
2
FIGURE 4. STEERING CYLINDER
9

6
4. Hold the end caps and install the cylinder on the axle
frame using the capscrews or nuts and capscrews. On
the H/J2.00–3.20XM (H/J40–65XM), tighten the caps-
crews to 225 N.m (165 lbf ft). On the E/J1.25–1.75XL
(E25–35XL) and the J2.00–3.00XL (J40–60XL), tight-
en the capscrews and nuts to 165 N.m (122 lbf ft).
NOTE: On J2.00–3.00XL (J40–60XL) units the nuts
are against the end caps.
5. Install the tie rods between the cylinder and the
spindles. Make sure the belleville washers are on each
side of the bushings in the tie rods. Install the pins and
snap rings.
6. Remove the caps and connect the hydraulic lines to
the steering cylinder. Operate the steering system to re-
move the air from the cylinder and the hydraulic system.
Turn the steering wheel several times from one stop to
the other.
TORQUE SPECIFICATIONS
Steer Axle Mount Bracket Hardware
Wheel/Hub Nut
Initial Torque
Final Torque
King Pin Nut
Initial Torque
Final Torque
Wheel Nuts
H/J2.00–3.20XM (H/J40–65XM)
J1.25–1.75XL (J25–35XL)
J2.00–3.00XL (J40–60XL)
Steer Cylinder Mount Hardware
H/J2.00–3.20XM (H/J40–65XM)
E/J1.25–1.75XL (E/J25–35XL)
J2.00–3.00XL (J40–60XL)
88 N.m (65 lbf ft)
200 N.m (150 lbf ft)
34 N.m (25 lbf ft)
90 N.m (66 lbf ft)
34 N.m (25 lbf ft)
237 to 305 N.m (175 to 225 lbf ft)
155 N.m (115 lbf ft)
155 N.m (115 lbf ft)
225 N.m (165 lbf ft)
165 N.m (122 lbf ft)
165 N.m (122 lbf ft)

7
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
There is no action when the
steering wheel is turned.
There is no oil or not enough oil in the
hydraulic tank.
The lines are loose at the control unit
or manifold block.
The sleeve and spool in the control
unit will not move.
Steering cylinder leaks.
Spacer for center pin is not installed.
Fill the tank to the correct level.
Tighten fittings.
Repair steering control unit.
Repair steering cylinder.
Assemble steering control unit correct-
ly.
The lift truck steers slowly.
The steering wheel is hard to
turn.
The oil level is low. There is no oil in
the tank.
The lines to the control unit are dam-
aged.
The sleeve and spool in the control
unit are worn.
The parts of the metering section are
worn.
The check valve in the control unit
does not open.
The check valve or relief valve in the
manifold block is damaged or is
not adjusted correctly.
Priority valve is not operating correctly.
Steering relief pressure is too low.
Engine idle speed is too low.
Fill the tank to the correct level.
Repair oil lines.
Clean or repair steering control unit.
Clean or replace manifold block.
Clean or repair priority valve.
Adjust relief pressure.
Adjust idle speed to specifications.
The steering wheel turns the
tires in the wrong direction.
The lines at the control unit are not
correctly connected.
Connect lines correctly.
The tires continue to turn
after the steering wheel
stops.
The neutral position springs are bro-
ken.
The sleeve or spool has damage.
Steering wheel kicks back in
both directions.
Center shaft is not correctly aligned
with metering section.
Correctly assemble steering control
unit.

1
INTRODUCTION
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 the parking brake
system. A troubleshooting section is included at the end
of this section.
DESCRIPTION AND OPERATION
Service Brakes (See FIGURE 8.)
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 2. and FIGURE 3.
When the brake pedal is pushed, fluid pressure from the
mastercylindercausesthepistonsinthewheelcylinders
to extend. The pistons expand the brake shoes against
the drums.
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
brake drum gives access to the adjuster wheel.
Master Cylinder (See FIGURE 1.)
The master cylinder is designed for a dual circuit sys-
tem. The master cylinder has two separate pistons that
operateinthesingleboreofthemastercylinder.Theres-
ervoir 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 operation of the master cylinder is de-
scribed in FIGURE 1.
If a failure occurs in one of the dual circuits, the other
circuit will apply one of the service brakes. This failure
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 cir-
cuits 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 bottom of the reservoir.
This switch energizes a warning light on the instrument
cluster.
Parking Brake (See FIGURE 9.)
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 the brake shoes against the
drums. The design of the parking brake linkage adjusts
each cable so that the tension is the same when the pedal
is moved to apply parking brake.

2
FIGURE 1. OPERATION OF MASTER CYLINDER
When the brakes are “OFF,” the hydraulic fluid
can move freely between the dual circuit system
and the separate chambers of the fluid reservoir.
When the brake pedal is pressed, the primary
piston moves in the cylinder bore. This move-
ment creates hydraulic pressure that combines
with the force of the primary spring. These com-
bined forces overcome the secondary spring
force and move the secondary piston in the
bore with the primary piston. The first move-
ment of both pistons pushes the seals (2) past
the bypass holes in the chambers A and C.
This action applies pressure to the fluid in those
chambers and causes fluid to flow to the cham-
bers of the two separate systems. The fluid in
chambers B and D is not effected by movement
of the pistons. This fluid can move freely be-
tween the piston chambers and the chambers
of the fluid reservoir, before and during brake
application.
When the brake pedal is released, the re-
turn springs cause the pistons to retract
faster than the fluid. This action causes a
vacuum between the fluid in chambers A
and C. The vacuum causes the seals (2)
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
A and C. The supply holes in the cylinder
body supplies fluid as the flow moves
from the one chamber to the other cham-
ber. The fluid returns to the reservoir
through the bypass holes when the pis-
tons are fully retracted.
BRAKE “OFF”
BRAKE “APPLIED”
BRAKE “RELEASED”
1. SECONDARY SPRING
2. SEAL
3. SECONDARY PISTON
4. PRIMARY SPRING
5. PRIMARY PISTON
FLUID UNDER PRESSURE
FLUID WITH NO PRESSURE
A B C D
1
2
3 4
5
6
7
A B C D
6. PRIMARY FLUID CHAMBER
7. SECONDARY FLUID CHAMBER
8. BYPASS HOLES
9. SUPPLY HOLES
9
8
8
9
2
12595

3
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. See the procedure “HOW TO PUT A LIFT TRUCK
ON BLOCKS” in the PERIODIC MAINTENANCE
section of the service manual or the OPERATING
MANUAL. Tilt the mast fully backward. Put blocks un-
der the mast. Tilt the mast forward until the wheels just
touch the floor. Stop the motor. Put blocks under the
frame of the lift truck.
2. If tilt does not function use a hydraulic jack, crane or
another lift truck to lift the drive wheels until they just
touch the floor. Put blocks under the frame of the lift
truck.
3. Remove the capscrews that hold the axle shaft to the
hub. Remove the axle shaft.
4. Release the parking brake. Bend the lock plate and re-
move the nut that holds the axle bearing. Remove the
washer and the bearing cone.
5. 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. If the wheel assembly cannot be re-
moved easily, remove the wheel and use a small screw-
driver to push the adjuster actuator away from the ad-
juster wheel. Use a brake adjustment tool or a screw-
driver to turn the adjuster wheel to loosen the brake
shoes. Install the wheel and then remove the hub and
drum assembly. Do not damage the grease seal when re-
moving the hub.
DANGER
When the brake shoes are removed do not create
dust in the air. See the cleaning procedure in this sec-
tion.
6. See FIGURE 2. Remove the return springs (2 and 14)
with spring pliers.
NOTE: The return springs (2 and 14) are not the same
part number. Make sure the springs are installed in the
same positions from which they were removed.
FIGURE 2. BRAKE ASSEMBLY (LEFT BRAKE ASSEMBLY SHOWN)
1
3
4
6
7
8
9
12
11
1. WHEEL CYLINDER
2. RETURN SPRING, MAROON
3. PIVOT PLATE
4. LINK
5. ANCHOR
6. ADJUSTER WHEEL ACTUATOR
7. ADJUSTER WHEEL
8. ADJUSTER NUT
9. CABLE, PARKING BRAKE
10. RETAINER
11. LEVER, PARKING BRAKE
12. BRAKE SHOE
13. PIN, HOLD DOWN
14. RETURN SPRING, GREY
5
2
13
13
10
10
11
12
9524
LEFT SIDE SHOWN
14

4
7. Remove the retainers, springs, and retainer pins that
hold the brake shoes to the back plate. See FIGURE 3.
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. Remove the brake line from the wheel cylinder. Re-
move the wheel cylinder.
9. Remove the dust covers, pistons, cups, and springs
from the wheel cylinder. See FIGURE 4.
10. Remove the snap rings from the parking brake lev-
ers. Remove the parking brake levers from the back
plate.
NOTE: The back plate is not normally removed from
the axle housing for brake repairs. Six special capscrews
are used to fasten the back plate to the axle mount and
the locking function of the capscrews is reduced if they
areremoved.Thefivecapscrewswith 5/8 inch thread are
tightened to 245 N.m (180 lbf ft). The capscrew with 1/2
inch thread is tightened to 125 N.m (92 lbf ft).
FIGURE 3. PARTS OF THE SERVICE BRAKE
1. SNAP RING
2. RETURN SPRING, MAROON
3. BACK PLATE
4. CABLE
5. CABLE GUIDE
6. SPECIAL CAPSCREW
7. CAPSCREWS
8. LEVER, PARKING BRAKE
9. WHEEL CYLINDER
10. PIVOT PIN
11. BRAKE SHOE, REAR
12. PIVOT PLATE
13. HOLD–DOWN PIN (2)
14. RETURN SPRING, GREY
15. SPECIAL CAPSCREW
16. ADJUSTER LINK
17. ADJUSTER LINK*
18. RETAINER SPRING ASSEMBLY
19. BRAKE SHOE, FRONT
20. SPRING
21. ADJUSTER NUT
22. ADJUSTER WHEEL
23. ADJUSTER WHEEL
ACTUATOR
24. CABLE RETAINER
25. CRANK
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
20
21
22
23
24
1
1
1
8
17*
LEFT SIDE SHOWN
DO NOT BEND OR PUT STRESS ON THE
UPPER LINK (17) BY FORCING THE HOOK
END ON OR AROUND THE POST ON THE
SPECIAL CAPSCREW (15).
25

5
FIGURE 4. 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
1
2
3
4
6
7
8
4
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.
Cleaning solvents can be flammable and toxic, and
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 wear or damage. Inspect
the back plate for wear where the brake shoes touch the
back plate. Remove any grooves or replace a worn or
damaged 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.

6
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
mm (10.22 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.
(See FIGURE 4)
1. Assemble the wheel cylinder. See FIGURE 4. Use
only HYSTER APPROVED parts.
2. Install the wheel cylinder (9) on the back plate (3).
Make sure the special fitting for removing the air is in
the top hole. Put Loctite271onthethreadsofthecaps-
crews (7). Tighten the two capscrews with the 7/16 inch
thread to 78 to 91 N.m (58 to 67 lbf ft). Tighten the two
capscrews with the 1/2 inch thread to 91 to 102 N.m (67
to 75 lbf ft).
3. Put the retainer pins (13) that hold the brake shoes
through the back plate. Install the back plate on the axle
housing.
4. See FIGURE 3. Tightenthetwospecialcapscrews(6)
for the parking brake levers (8) to 245 N.m (180 lbf ft).
Tightenthecapscrewsthatholdthebackplatetotheaxle
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.
5. Install the parking brake levers (8) and cable (4). In-
stall the snap rings (1). Install the cable guide (5) and
snap ring on the crank (25) 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 and
17) in the pivot plate (12). 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”isseenon
the left brake assembly. Install the pivot plate (12) on the
right brake assembly so that the letter “R” is seen.
7. Lubricate the back plate with a small amount of
greasewheretheshoestouch.Installthebrakeshoes.In-
stall the retainer spring assembly (18). Put a spring seat,
spring,andretaineronthepin.Pushtheretainerontothe
pin and rotate the retainer 90 degrees to lock the pin into
the retainer. Install the other spring assembly.
8. Put an anti–seize compound on the threads of the ad-
juster wheel (22). Install the adjuster wheel assembly
between the two brake shoes. Make sure the adjuster
wheel 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.

7
9. Install the link in the adjuster wheel actuator (23). Put
the adjuster wheel actuator in the hole in the brake shoe.
Fasten the spring (20) to the adjuster wheel actuator and
the brake shoe. The spring must be installed in the posi-
tion shown in FIGURE 5. Install the return springs for
the brake shoes . Make sure the return springs (2 and 14)
are installed in the correct positions. See FIGURE 5. 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 (16) to align the adjuster
wheel actuator.
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 6. and FIGURE 7.
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 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
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 nuts to 237 to
305 N.m (175 to 225 lbf ft).
3. Tilt the mast backward or lift the truck 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. Repeat this operation several times.
4. The service brakes must be adjusted before the park-
ing brake can be adjusted. See FIGURE 9. and the fol-
lowing paragraphs in this section for the correct adjust-
ment of the parking brake.

Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

8
FIGURE 5. INSTALLATION OF THE SPRINGS
FRONT
LEFT SIDE
RIGHT SIDE
FRONT
9524
1. SPRING FOR (LEFT) SHOE (MAROON)
2. SPRING FOR (RIGHT) SHOE (GRAY)
3. ADJUSTER LINK, UPPER
4. ADJUSTER LINK, LOWER
1
2
3
4
1
1
1
2
2
2
3
3
3
4

9
FIGURE 6. LOCATION OF THE GREASE SEALS
1. OUTER SEAL
2. INNER SEAL
1
2
3
3. BRAKE DRUM
12879
FIGURE 7. INSTALLATION OF THE INNER
GREASE SEAL
9518
PARKING BRAKE
(See FIGURE 9.)
If the lever assembly for the parking brake must be re-
moved from the frame, use the following procedure
(See FIGURE 9.):
1. Use blocks next to the wheels to make sure the lift
truck can not move. Release the parking brake.
2. Turn the adjustment knob (5) so that the link (17)
is at the bottom of the adjustment slot (18).
3. Removethecotterpin(22)andpin(23)todiscon-
nect the parking brake cable from the brake as-
sembly.
4. Remove the cotter pin and anchor pin (8) that
connectthelink(4)totheparkingbrakeassembly
(3).
5. Remove the nuts (10) and washers that hold the
parking brake assembly to the bracket (16). Re-
move the capscrews (9) and spacers (12).
6. Remove the cotter pin, washer, and anchor pin
(13) from the link (17).
(See FIGURE 9.)
If the lever assembly for the parking brake was removed
from the frame, use the following procedure for instal-
lation:
1. Make sure the parking brake lever is in the re-
leased position. Turn the adjustment knob (5) un-
til the link (17) is adjusted to the bottom of the ad-
justment slot (18).
2. Install the ends of the cables into the compensa-
tor (15). Install the anchor pin (13), washer, and
cotter pin into the parking brake assembly. Make
sure the anchor pin is through the link and com-
pensator.
3. Install the mounting bolts (9) through the cable
clamps (11) and spacers (12). Mount the assem-
bly to the bracket (16).
4. Before tightening the the mounting capscrews
(9), push down the parking brake assembly to
make sure it is in contact with the frame bracket
(19).
5. The following procedure must be used to connect
the link (4) to the parking brake assembly (3) and
the brake pedal assembly (6): put the parking
brake lever (3) in the applied position. Install the
anchor pin (8) in the hole in the link (4) that will
adjust the bottom side of the parking brake pedal
to 28 mm (1.1 in) above the frame. See
FIGURE 9. Install the cotter pins. Install the re-
turn spring (25) in an empty hole in the link (4).
6. With the brake in the applied position, adjust and
tightenthenuts(14)ontheendofthecable(20)to

10
remove all the free–play from the release handle
(7).
7. With the parking brake applied, adjust the switch
(24) so that the lever on the switch moves 1 to 3
mm (.04 to .12 in) beyond the operating point.
Adjust The Parking Brake
(See FIGURE 9.)
Make sure that the service brakes are adjusted and the
operation of the automatic adjuster mechanism is cor-
rect before the parking brake is adjusted.
1. Turn the adjustment knob (5) to raise the link (17) and
tighten the parking brake cables (2). Turn the adjust-
ment knob until the parking brakes are fully applied
when the pedal is used to apply the parking 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 metres in 10 metres (1.5 ft in 10 ft)].
3. With the parking brake applied, adjust the nuts (14) to
remove any free play from the release handle (7).
4. Check the operation of the switches on the parking
brake as described in CHECKS AND ADJUST-
MENTS.

11
FIGURE 8. SERVICE BRAKE
6. LOCKNUT
7. MASTER CYLINDER
8. BRAKE ASSEMBLY
9. BRAKE LINES
1. CAPSCREW
2. BRAKE PEDAL
3. FLOORPLATE
4. LOCKNUT
5. PUSH ROD
12836
95 mm (3.7 in)
1
2
4
5 6
7
8
9
3
9

12
FIGURE 9. PARKING BRAKE
8. ANCHOR PIN
9. MOUNTING CAPSCREW
10. NUT
11. CLAMP
12. SPACER
13. ANCHOR PIN
14. NUT
15. COMPENSATOR
16. BRACKET, FRAME
1. BRAKE ASSEMBLY
2. BRAKE CABLES
3. PARKING BRAKE ASSEMBLY
4. LINK
5. ADJUSTMENT KNOB
6. PARKING BRAKE PEDAL
7. RELEASE HANDLE
8
9
10
11
12
13
15
16
17
6, APPLIED POSITION
6, RELEASED POSITION
12838
17. LINK
18. ADJUSTMENT SLOT
19. FRAME BRACKET
20. CABLE
21. CRANK
22. COTTER KEY
23. PIN
24. SWITCH
25. RETURN SPRING
5
3
11
12
18
12837
1
2
4
5
7
9
14
19
20
28 mm (1.1 in)
3 9
9
21
22
23
24
25

13
MASTER CYLINDER
1. Remove the floor plates from the lift truck for access
to the master cylinder.
2. Loosen and remove the two brake hydraulic lines
from the master cylinder. Disconnect the wire at the
switch on the reservoir.
3. Remove the cotter pin, washer, and pin from the push
rod end that is attached to the brake linkage lever arm.
4. Remove the capscrews, washers, and nuts that hold
the master cylinder to the bracket assembly and remove
the master cylinder from the lift truck.
Cleaning And Inspection
CAUTION
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 lin-
ings.
Inspect the bore of the master cylinder for holes or
scratches. Replace the master cylinder assembly if there
is damage.
Repair
See the repair procedures for the master cylinder in
FIGURE 11.
Installation (See FIGURE 10.)
Use the reverse order of Removal to install the master
cylinder. Check the adjustment of the brake pedal as de-
scribed in CHECKS AND ADJUSTMENTS.
FIGURE 10. MASTER CYLINDER
4. RETURN SPRING
5. BODY
6. PIN
7. SEAL
8. SECONDARY
PISTON
12595
1. CAP
2. RESERVOIR
3. SEAL
9. SEAL
10. SPRING
11. PRIMARY PISTON
12. WASHER
13. RETAINER RING
14. DUST COVER
15. ROD
16. LOCK NUT
17. CLEVIS
18. PRIMARY FLUID CHAMBER
19. SECONDARY FLUID
CHAMBER
20. FLOAT
21. SWITCH (FLUID LEVEL)
17
4
1
2
3
5 6
8 9
10
7
11 12
13
14
15 16
18
19
7 7
20
21

Hyster a216 (j40 xm) forklift service repair manual

Recommended

Recommended

More Related Content

Similar to Hyster a216 (j40 xm) forklift service repair manual

Similar to Hyster a216 (j40 xm) forklift service repair manual (20)

More from fjjkskekfsmem

More from fjjkskekfsmem (20)

Recently uploaded

Recently uploaded (20)

Hyster a216 (j40 xm) forklift service repair manual