This is a very practical manual

1. SERVICE REPAIR
E45XM E50XM E55XM E60XM E65XM [F108]

2. 1800 SRM 574 Description and Operation
General
This section has a description and the service pro-
cedures for the parts of the brake system. The brake
system includes the following parts: master cylinder,
brake shoes, wheel cylinders, parking brake system,
and seat brake system. A troubleshooting 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 4 and Figure 5.
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 1.
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 direc-
tion 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 ad-
juster wheel. The adjuster wheel can turn only when
there is clearance between the lining of the brake
shoe and the brake drum. The adjuster wheel can
also be turned with a tool. A slot in the back plate
gives access to the adjuster wheel.
1. BRAKE PEDAL
2. MASTER CYLINDER
3. BRAKE ASSEMBLY
4. BRAKE FLUID RESERVOIR
Figure 1. Service Brake System
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3. Description and Operation 1800 SRM 574
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 2.
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
A and C. The supply holes in the cylinder body supply
fluid as the flow moves from one chamber to the other
chamber. The fluid returns to the reservoir through
the bypass holes when the pistons are fully retracted.
See Figure 2.
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 3.
1. SECONDARY SPRING
2. SEAL
3. SECONDARY PISTON
4. PRIMARY SPRING
5. PRIMARY PISTON
6. PRIMARY FLUID CHAMBER
7. SECONDARY FLUID CHAMBER
8. BYPASS HOLES
9. SUPPLY HOLES
Figure 2. Master Cylinder Brake OFF and Brake RELEASED
2

4. 1800 SRM 574 Service Brakes Repair
Figure 3. Master Cylinder Brake APPLIED
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 in the instrument cluster.
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 drums. The design of
the parking brake linkage adjusts each cable so the
tension is the same when the lever is moved to apply
the parking brake.
Service Brakes Repair
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 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 re-
stricted area with special ventilation. Protec-
tive clothing and a respirator must be used.
1. If the lift truck must be put on blocks for mainte-
nance or repair, see How to Put Lift Truck on
Blocks in the Operating Manual or Periodic
Maintenance of your vehicle. Tilt mast fully
backward. Put blocks under mast. Tilt mast for-
ward until wheels just touch the floor. Stop mo-
tor. Put blocks under frame of lift truck.
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5. Service Brakes Repair 1800 SRM 574
NOTE: On N30XMH, N30XMH2 (C210) and
V30ZMD (D210/E210) lift trucks, the tilt func-
tion is not installed.
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, use a small screwdriver to push adjuster
actuator away from adjuster wheel. Use a brake
adjustment tool or a screwdriver to turn adjuster
wheel to loosen brake shoes. 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 cleaning procedure
in this section.
6. Make a note of the arrangement of the parts. See
Figure 4 and Figure 5. Remove return springs
with spring pliers.
1. WHEEL CYLINDER
2. RETURN SPRING
3. RETURN SPRING
4. ANCHOR
5. ANCHOR GUIDE
6. BACK PLATE
7. BRAKE SHOE
8. RETAINER AND SPRING ASSEMBLY (4)
9. CABLE GUIDE
10. CABLE
11. ADJUSTER WHEEL ACTUATOR
12. ADJUSTER WHEEL
13. PARKING BRAKE CABLE
14. ADJUSTER ACTUATOR SPRING
15. BRAKE SHOE
16. PARKING BRAKE LINK
17. PARKING BRAKE LINK SPRING
18. PARKING BRAKE LEVER
19. PIVOT PIN, RETAINER, AND SPRING WASHER
Figure 4. Brake Assembly (Left Brake Assembly Shown)
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6. 1800 SRM 574 Service Brakes Repair
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. CABLE GUIDE
10. CABLE
11. ADJUSTER WHEEL ACTUATOR
12. ADJUSTER WHEEL
13. PARKING BRAKE CABLE
14. ADJUSTER ACTUATOR SPRING
15. BRAKE SHOE
16. PARKING BRAKE LINK
17. PARKING BRAKE LINK SPRING
18. PARKING BRAKE LEVER
19. PIVOT PIN, RETAINER, AND SPRING WASHER
20. WASHER
21. RETAINER
22. ANCHOR
23. SPACER
Figure 5. Service Brake Parts
7. Remove retainers, springs, and anchor pins that
hold brake shoes to back plate.
8. Disengage cable from adjuster wheel actuator.
Remove cable, washer, and cable guide. Remove
anchor guide.
9. Move brake shoes away from each other to dis-
engage brake shoes from wheel cylinder. Dis-
connect parking brake lever from parking brake
cable as brake assembly is removed from back
plate. The parking brake lever has a hook that
engages parking brake cable.
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7. Service Brakes Repair 1800 SRM 574
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.
10. Make a note of the arrangement of parts and
disassemble brake assembly. Remove parking
brake link and spring if they are still engaged
with brake shoes. The parking brake link and
spring will often fall from the brake assembly
when the brake assembly is removed from the
back plate. The adjuster wheel will also disen-
gage from the brake shoes after the brake assem-
bly is removed.
11. Remove spring for adjuster wheel actuator. Re-
move adjuster wheel actuator from brake shoe.
Loosen nut and remove anchor and spacer from
brake shoe.
12. Use a screwdriver or small pry bar to move apart
the ends of the retainer. Remove spring washer
and pivot pin to remove parking brake lever from
brake shoe.
13. Disconnect brake line from wheel cylinder. Re-
move capscrews that hold wheel cylinder to back
plate and remove wheel cylinder.
14. Remove push rods, dust covers, pistons, cups,
and spring from wheel cylinder. See Figure 6.
NOTE: The back plate is not normally removed from
the axle housing for brake repairs. Eight special cap-
screws are used to fasten the back plate to the axle
mount and the locking function of the capscrews is
reduced if they are removed. These capscrews are
tightened to 255 N•m (188 lbf ft).
1. PUSH ROD (2)
2. DUST COVER (2)
3. PISTON (2)
4. CUP (2)
5. SPRING
6. WHEEL CYLINDER BODY
7. INLET PORT
8. SPECIAL FITTING
9. DUST COVER
Figure 6. Wheel Cylinder
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8. 1800 SRM 574 Service Brakes Repair
CLEAN
WARNING
DO NOT use an oil solvent to clean the mas-
ter cylinder, wheel cylinder, or the brake lin-
ings. Use a solvent 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 operate
correctly if oil, grease, or brake fluid is on the
brake linings.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
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.
3. When 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 a DAN-
GEROUS FIBERS warning label on plastic bag
or airtight container.
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.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the
air.
INSPECT
1. Inspect bore of wheel cylinder for holes or
scratches. Replace wheel cylinder assembly if
there is any damage.
2. Inspect return springs for wear or damage. In-
spect back plate for wear where brake shoes
touch back plate. Replace a worn or damaged
back plate.
WARNING
The brake shoes on both wheels must be re-
placed if any shoe is damaged. The brake per-
formance on both ends of an axle must be equal
or the lift truck can be difficult to steer when
the brakes are applied.
3. Inspect brake shoes for cracks or damage. If
linings or shoes are worn or damaged, replace
brake shoes. Maximum wear is to within 1 mm
(0.025 in.) of contact with rivets or metal shoe on
bonded linings. Brake shoes must be replaced in
complete sets. Inspect brake drums for cracks or
damage. Replace any damaged parts.
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 diame-
ter 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. If wheel cylinder was disassembled for repair, as-
semble wheel cylinder. See Figure 6. Use only
HYSTER APPROVED parts.
2. Install wheel cylinder on back plate and tighten
two capscrews to 18 to 27 N•m (13 to 20 lbf ft).
Connect brake line to wheel cylinder.
3. Install parking brake lever. See Figure 5. Use
pivot pin, spring washer, and retainer to fasten
parking brake lever to brake shoe. Close the ends
of the retainer to fasten the pivot pin in position.
4. Install anchor and spacer in brake shoe. Install
adjuster wheel actuator in brake shoe.
5. Fasten adjuster actuator spring to adjuster
wheel actuator and brake shoe.
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10. Service Brakes Repair 1800 SRM 574
6. Put an antiseize compound on threads of adjuster
wheel. Turn adjuster wheel into adjuster nut so
adjuster assembly is in its shortest position. This
action permits brake drum to be easily installed
over the brake shoes.
WARNING
The threads of the adjuster wheel are not the
same for each side. The adjuster wheel for the
right brake has left-hand threads. The adjuster
wheel for the left brake has right-hand threads.
If the adjuster assemblies are installed on
the wrong side, the brake shoe clearance will
increase when the brakes are applied. This
would result in a loss of braking ability.
7. Install adjuster wheel between two brake shoes.
Make sure adjuster wheel will be toward rear of
lift truck. Move brake shoes apart so adjuster
wheel is held in position and adjuster actuator
spring is in tension.
8. Lubricate back plate with a small amount of
grease where brake shoes touch. Install brake
shoes on anchor and engage push rods of wheel
cylinder. Engage parking brake lever in slot in
parking brake cable as brake shoes are installed
on back plate.
9. Put an anchor pin that holds brake shoes through
back plate. Put a spring seat, spring, and re-
tainer on anchor pin. Push retainer on to anchor
pin and rotate retainer 90 degrees. Make sure
retainer is in correct position. Install another re-
tainer spring assembly.
10. Install link, parking brake, and spring between
parking brake lever and brake shoe.
11. Install other spring retainers that hold brake
shoes. Make sure parking brake link and spring
are correctly engaged after spring retainers are
installed.
12. Install anchor guide on anchor. Install cable
guide on its anchor.
13. Fasten cable to adjuster wheel actuator and put
cable around cable guide. Raise adjuster wheel
actuator against spring tension and connect ca-
ble to anchor.
14. Use the correct tools to install the return springs.
Install return spring. Install washer and return
spring. The shape of the return springs permits
them to be installed correctly in only one posi-
tion. The arrangement of the return springs on
the anchors is shown in Figure 7.
1. ADJUSTER ACTUATOR LINK
2. RETURN SPRING
3. RETURN SPRING
4. ANCHOR
Figure 7. Return Springs
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11. 1800 SRM 574 Service Brakes Repair
15. Make sure bottom edge of adjuster wheel actua-
tor is just above center of teeth of adjuster wheel.
Check for correct installation if alignment is not
correct.
16. Clean bearings and lubricate them with wheel
bearing grease. Install bearings and seals in
brake drum. Install assembly on axle housing.
See Figure 8, Figure 9, and Figure 10.
1. OUTER SEAL
2. INNER SEAL
3. BRAKE DRUM
Figure 8. Grease Seals Location N30XMH,
N30XMH2 (A210, C210), V30ZMD (D210, E210)
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.
17. Adjust hub bearings by tightening nut to 68 N•m
(50 lbf ft) while rotating hub. Loosen nut until
hub turns freely with no end play. Tighten nut
to 3 N•m (25 lbf in) and lock in place at first
alignment position at or above 3 N•m (25 lbf in),
bend lock plate over nut.
1. OUTER SEAL
2. INNER SEAL
3. BRAKE DRUM
Figure 9. Oil Seal Location E2.00-3.20XM
(E45-65XM, E45-65XM2) (F108), E2.00-3.20XM
(E45-65Z) (G108)
Figure 10. Inner Grease Seal Installation
9

12. Service Brakes Repair 1800 SRM 574
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 15 teeth.
18. Adjust clearance of brake shoes. Put a brake
adjustment tool or a screwdriver through slot in
back plate. Use the tool to rotate adjuster wheel.
The actuator for the adjuster wheel will only
permit rotation in one direction. Turn adjuster
wheel until brake shoes have expanded against
brake drum and hub will not turn. Use a small
screwdriver to lift actuator away from adjuster
wheel and turn adjuster wheel approximately
15 teeth in opposite direction. The brakes will
adjust to the correct clearance when they are
applied while the lift truck is traveling in the
REVERSE direction.
19. Put liquid sealant on flange of axle shaft. Install
axle shaft and capscrews. Tighten capscrews to
90 N•m (66 lbf ft).
ADJUST
1. Remove air from brake hydraulic system. See
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 RE-
VERSE and push on brake pedal to permit ad-
justing mechanism to operate. Repeat this oper-
ation several times.
4. The service brakes must be adjusted before the
parking brake can be adjusted. See Figure 11
and the following paragraphs in this section for
the correct adjustment of the parking brake.
10

13. 1800 SRM 574 Service Brakes Repair
1. CAPSCREW
2. BRAKE PEDAL
3. FLOOR PLATE
4. LOCK NUT
5. PUSH ROD
6. LOCK NUT
7. MASTER CYLINDER
8. SWITCH
9. BRAKE ASSEMBLY
10. BRAKE LINES
Figure 11. Service Brake Adjustment
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14. Parking Brake Repair 1800 SRM 574
Parking Brake Repair
REMOVE AND DISASSEMBLE
1. Use blocks next to the wheels to make sure the
lift truck cannot move. Release the parking
brake. See Figure 13.
2. Turn the adjustment knob so that the link is at
the bottom of the adjustment slot.
3. Remove the cotter pin and anchor pin that con-
nect the bar to the parking brake assembly. Dis-
card the cotter pin.
4. Remove the nuts and washers that hold the park-
ing brake assembly to the bracket. Remove the
capscrews and spacers.
5. Remove the cotter pin, washer, and anchor pin
from the link.
6. The service brake assembly must be removed be-
fore the parking brake cables can be removed
from the backplate of the service brake. A snap
ring ( Figure 5) holds the sheath of the parking
brake cable in the backplate of the service brake.
Remove the snap ring and remove the parking
brake cable from the backplate.
ASSEMBLE AND INSTALL
The parking brake cables must be installed in the
backplate before the service brake is installed. A
snap ring holds the sheath of the parking brake ca-
ble in the backplate of the service brake. Install the
parking brake cable in the backplate and install the
snap ring that holds the sheath of the parking brake
cable in the backplate. See Figure 13.
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 new
cotter pin into the parking brake assembly. Make
sure the anchor pin is through the link and com-
pensator.
3. Install the mounting bolts through the cable
clamps and spacers. Mount the assembly to the
bracket.
4. Before tightening the mounting capscrews, make
sure the parking brake assembly is in contact
with the frame bracket.
NOTE: Perform the adjustment in Step 5 on lift
trucks built before March 7, 2000, and Step 6 on lift
trucks built after March 7, 2000.
5. The following procedure must be used to connect
the bar to the parking brake assembly and the
brake pedal assembly: put the parking brake
lever in the applied position and align the bot-
tom edge of the brake pedal assembly with the
top edge of the frame bracket. See Figure 13. Use
the mounting holes that allow the best alignment
of the bar. Install the cotter pins.
6. Loosen the socket head screw located on the park
brake pedal adjustment plate. The socket head
screw can be loosened from the access port lo-
cated on front of the cowl. See Figure 12. Adjust
the park brake pedal adjustment plate to achieve
a 5 to 6 mm (0.20 to 0.24 in.) clearance between
the park brake pedal adjustment plate and the
park brake pedal assembly. See Figure 14.
7. 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.
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15. 1800 SRM 574 Parking Brake Repair
1. COWL
2. ACCESS PORT
Figure 12. Adjusting Plate Access
ADJUST
Make sure that the service brakes are adjusted and
the operation of the automatic adjuster mechanism
is correct before the parking brake is adjusted. See
Figure 13.
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
parking brake, when in good condition and cor-
rectly adjusted, will hold a lift truck with a capac-
ity load 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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