Hyster (p005) h80 ft forklift service repair manual

SERVICE REPAIR
H80FT H90FT H100FT H110FT H120FT [P005]

1800 SRM 1247 General
General
DRY BRAKE SYSTEM
NOTE: The dry brake system is used only on lift
truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005).
This section has service procedures for the dry brake
system. The dry brake system includes the follow-
ing parts: master cylinder and parking brake system
(see Figure 1) and brake shoes and wheel cylinders
(see Figure 4).
1. PARK BRAKE HANDLE ASSEMBLY
2. ADJUSTMENT KNOB
3. PARK BRAKE CABLES
4. INCHING/BRAKE PEDAL
5. MASTER CYLINDER AND BOOSTER
6. BRAKE ASSEMBLY
7. BRAKE POSITION SENSOR (RIGHT-HAND
SIDE)
Figure 1. Dry Brake System
WET BRAKE SYSTEM
NOTE: The wet brake system is used on all lift truck
models covered in this SRM.
The wet brake system in this section includes the fol-
lowing parts: master cylinder and parking brake sys-
tem. See Figure 2 and Figure 3.
NOTE: LIFT TRUCK MODEL S4.0, 4.5, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004) SHOWN.
2. INCH/BRAKE PEDAL
3. BOOSTER ASSEMBLY
4. PARK BRAKE LEVERS
5. PLANETARY CARRIER HOUSING (LEFT-HAND
SIDE SHOWN)
6. WET DISC BRAKE HOUSING
8. ADJUSTMENT KNOB
9. BRAKE POSITION SENSOR (LEFT-HAND SIDE
SHOWN)
10. MASTER CYLINDER
11. CYLINDER BLOCK
Figure 2. Wet Brake System for Lift Truck
Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005)
1

Service Brakes Repair (Dry Brake) 1800 SRM 1247
The wet disc brakes are a component of the wet
brake drive axle. The brake discs are located inside
the planetary carrier housing at each end of the
drive axle. See Drive Axle and Differential As-
sembly Repair, (Wet Brake) 1400 SRM 1246 for
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005),
Drive Axle and Differential Assembly Repair,
(Wet Brake) 1400 SRM 1318 for lift truck models
S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) or
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) for
the removal, assembly and installation procedures.
NOTE: LIFT TRUCK MODEL S6.0FT, S7.0FT (S135FT,
S155FT) (D024, E024) SHOWN
2. INCH/BRAKE PEDAL
3. BOOSTER ASSEMBLY
4. ADJUSTMENT KNOB
5. PLANETARY CARRIER HOUSING (LEFT-HAND
SIDE SHOWN)
6. WET DISC BRAKE HOUSING
8. BRAKE POSITION SENSOR
9. MASTER CYLINDER
10. CYLINDER BLOCK
11. PARK BRAKE LEVERS
Figure 3. Wet Brake System for Lift Truck
Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
Service Brakes Repair (Dry Brake)
NOTE: The procedures in this section apply on to lift
truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
equipped with the dry brake system.
2

1800 SRM 1247 Service Brakes Repair (Dry Brake)
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. See the procedure How to Put Lift Truck on
Blocks in the section Periodic Maintenance
8000 SRM 1248 or the Operating Manual.
Start the engine and tilt the mast fully back-
ward. 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 tab and remove the nut, lock-
plate, washer and bearing cone.
4. Put grease on the floor so that the wheel assem-
bly will slide easily from the axle tube. Pull the
wheel assembly from the lift truck. If the wheel
assembly cannot be removed easily, use a small
screwdriver to push 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.
NOTE: During disassembly, note the arrangement of
parts to aid in re-assemble of the brake system.
5. Remove the primary, secondary return springs
and tension spring with spring pliers and remove
the anchor pin from the primary brake shoe. See
Figure 4.
6. Remove the pressure springs that hold the brake
shoes to the backing plate.
7. Disconnect the parking brake cable from park
brake lever. See Figure 4.
WARNING
When the brake shoes are removed, do not cre-
ate dust in the air. See the Clean procedure in
this section.
8. Remove brake shoes.
9. Remove the auto adjuster assembly from the
backing plate. See Figure 5.
10. Disconnect the brake line from the wheel cylin-
der. Remove wheel cylinder from backing plate.
See Figure 5.
11. If damaged, remove the backing plate from the
axle housing. Discard the eight mounting lock
bolts.
3

1. RETAINER
2. SECONDARY RETURN SPRING
3. SECONDARY BRAKE SHOE
4. PRESSURE SPRING
5. AUTO ADJUSTER LINK
6. ADJUSTER WHEEL
7. AUTO ADJUSTMENT ASSEMBLY
8. PARKING BRAKE CABLE
9. TENSION SPRING
10. PRIMARY BRAKE SHOE
11. PARK BRAKE LEVER
12. STRUT
13. PRIMARY RETURN SPRING
14. ANCHOR PIN
15. BACKING PLATE
16. WHEEL CYLINDER
Figure 4. Brake Assembly (Left-Hand Shown)
4

1. WHEEL CYLINDER CAPSCREWS
2. AUTO ADJUSTER CAPSCREW
3. ADJUSTER WHEEL ACCESS PLUGS
4. BRAKE LINE
Figure 5. Auto Adjuster and Wheel Cylinder
Mount Location
CLEAN
WARNING
DO NOT use an oil solvent to clean the brake
linings, use a solvent approved for cleaning of
brake parts. Do not permit oil or grease on the
brake linings, the brakes will not operate cor-
rectly if oil, grease, or brake cleaning fluid is
on the brake linings. Oil and grease will cause
damage and leaks in the seals of a brake sys-
tem.
Small amounts of water in the brake system
can cause reduced braking if the water reaches
the wheel cylinders and is subject to high tem-
peratures. DO NOT allow water entry into the
brake system. If water is present, remove all
water and refill the system with Dexron III
from a sealed container. Unfiltered shop air
can contain substantial amounts of water. DO
NOT use unfiltered shop air to blow out brake
components.
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.
CAUTION
Do not permit brake cleaning fluid to contact
the master cylinder or wheel cylinder. Brake
cleaning fluid will cause damage and leaks in
seals of the brake system.
1. Do not release brake lining dust from the brake
linings into the air when the brake drum is re-
moved.
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.
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, spray at a distance so that the dust is not
released into the air.
3. When the brake lining dust is wet, clean the
parts. Put any cloth or towels in a plastic bag
or an airtight container while they are still wet.
Put a 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.
5

INSPECT
WARNING
Small amounts of water in the brake system
can cause reduced braking if the water reaches
the wheel cylinders and is subject to high tem-
peratures. DO NOT allow water entry into the
brake system. If water is present, remove all
water and refill the system with Dexron III
from a sealed container. Unfiltered shop air
can contain substantial amounts of water. DO
NOT use unfiltered shop air to blow out brake
components.
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.
CAUTION
Do not permit brake cleaning fluid to contact
the master cylinder or wheel cylinder. Brake
cleaning fluid will cause damage and leaks in
seals of the brake system.
1. Inspect the bore of the wheel cylinder for holes or
scratches. Replace the wheel cylinder assembly
if there is any damage.
2. Inspect wheel cylinder parts for dirt or water.
Clean any dirt or water present in the wheel
cylinder parts using a lint free cloth.
3. Inspect the primary, secondary and tension
springs for wear and 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.
4. Inspect the park brake lever and strut. If dam-
aged, replace primary and secondary brake shoe
assembly.
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.
5. 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 linings. Brake shoes
must be replaced in complete sets. Inspect the
brake drums for cracks or damage. Replace any
damaged parts.
6. Inspect the brake drum for deep grooves or other
damage.
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 317.5 mm (12.4 in.). If the internal diameter
is larger than the limit, replace the brake drum.
7. The teeth of the adjuster wheels must not be
worn. The adjuster wheel must turn freely.
Check the adjuster links for damage. See Fig-
ure 4 and Figure 5. Replace the auto adjuster
assembly if there is any damage.
8. Make sure the parking brake cables are in good
condition. Replace parking brake cables if worn
or damaged.
9. Check the grease seals and the surfaces of the
seals for wear or damage. Replace damaged
seals.
ASSEMBLE AND INSTALL
1. If removed, install backing plate using eight new
lock bolts to the axle housing using tightening
sequence, see Figure 6. Tighten bolts to 340 to
375 N•m (251 to 277 lbf ft).
NOTE: Replace wheel cylinder if there is any damage
or it is not working properly.
2. Install the wheel cylinder on the backing plate
and tighten capscrews to 20 to 25 N•m (15 to
19 lbf ft). Connect the brake line to the wheel
cylinder. See Figure 5.
6

NOTE: Replace auto adjuster assembly if there is any
damage or it is not working properly.
3. Install the auto adjuster assembly on the backing
plate between the two brake shoes and tighten
capscrew to 120 to 140 N•m (89 to 103 lbf ft). See
Figure 4 and Figure 5.
4. Lubricate the backing plate with small amount
of lithium grease where the brake shoes touch.
Figure 6. Backing Plate to Axle Housing
Tightening sequence
NOTE: The park brake lever and strut are a compo-
nent of the primary brake shoe. If damaged, replace
primary and secondary brake shoe assembly.
5. Install the primary and secondary brake shoes on
the push rod of wheel cylinder and auto adjuster
link. See Figure 4.
6. Connect the parking brake cable to park brake
lever.
7. Install pressure springs to hold the brake shoes
to the backing plate.
8. Install the primary and secondary return
springs, and tension spring to the brake shoe.
See Figure 4.
9. Coat threads of the adjuster wheels with anti-
seize compound. Turn the adjuster wheels so
that the adjuster assembly is in its shortest po-
sition. This action permits the brake drum to be
easily installed over the brake shoes.
NOTE: Seal and bearings are to be installed flush
with the hub. Seal is to be installed with no grease
or oil on outside surface.
10. Clean the bearings and lubricate them with
wheel bearing grease. Install the bearings and
seals in the wheel hub. Install the assembly on
the axle housing. See Figure 7 and Figure 8.
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 the wheel and slide the wheel toward
the axle housing. Install the outer bearing and nut.
11. Install the washer, lock plate and wheel adjust-
ment nut. See Figure 9. To align the bearing
rollers, tighten the wheel adjustment nut to 28
to 32 N•m (21 to 24 lbf ft) and rotate the hub 2
revolutions in both directions. To seat the wheel
bearings, tighten the wheel adjustment nut to
400 to 480 N•m (295 to 354 lbf ft). Back off the
wheel adjustment nut to zero end play. Preload
the wheel bearings by tightening the wheel ad-
justment nut to 28 to 32 N•m (21 to 24 lbf ft). Ro-
tate the hub 3 complete revolutions in both direc-
tions. Verify the wheel adjustment nut torque is
28 to 32 N•m (21 to 24 lbf ft) and that the torque
stabilizes at that specification.
7

1. INNER SEAL
2. OUTER SEAL
3. BRAKE DRUM
4. INNER BEARING
5. OUTER BEARING
Figure 7. Grease Seals and Bearing Locations
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
the two adjuster wheels equally, approximately 20
teeth.
8

Figure 8. Inner Grease Seal Installation
1. AXLE SHAFT
2. WHEEL ADJUSTMENT NUT
3. LOCK PLATE
4. WASHER
5. HUB
Figure 9. Wheel Adjustment
12. To manually adjust the brakes, it is necessary to
turn the adjuster wheels. See Figure 4. Remove
the two access plugs in the adjustment slots lo-
cated on the back side of the backing plate. Place
an adjuster tool and screwdriver through the slot
in the backing plate. See Figure 5. Push the ad-
juster lever away from the adjuster wheel, in the
direction indicated in Figure 10 and turn the ad-
juster wheel until the brake shoe just touches the
brake drum. Use the adjuster tool to loosen the
adjuster wheel approximately 20 teeth. Adjust
the brake shoe for the other adjuster wheel us-
ing the same method. See Figure 10. Make sure
to install the access plugs after the adjustment is
complete. See Figure 5.
13. Install the drive wheels. Remove the lift truck
from the blocks. Operate the lift truck in the
FORWARD and REVERSE directions. Stop the
lift truck 10 times in each direction. This pro-
cedure causes the brake shoes to wear a small
amount and fit the brake drum better.
1. ADJUSTER LEVER
2. ADJUSTER WHEEL
3. ADJUSTER LINK
Figure 10. Auto Adjuster Assembly
14. Coat the flange of the axle shaft with liquid
sealant, Hyster Part Number 264159. Install
the axle shaft and capscrews. Tighten the cap-
screws in the sequence shown in Figure 11 to 90
to 99 N•m (66 to 73 lbf ft).
Figure 11. Axle Shaft Tightening Sequence
9

Parking Brake Repair 1800 SRM 1247
ADJUST
1. Remove the air from the brake hydraulic system.
See Brake System Air Removal.
2. Install the wheel on the hub. Tighten the wheel
nuts to 610 to 680 N•m (450 to 502 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 mechanism to operate.
Repeat this operation several times.
4. The service brakes must be adjusted before the
parking brake can be adjusted. See Figure 13
and the following paragraphs in this section for
the correct adjustment of the parking brake.
Parking Brake Repair
REMOVE AND DISASSEMBLE
NOTE: For removal and disassembly procedures for
a dry brake system use Step 1 through Step 5. For
the wet brake system use Step 1 through Step 4 and
Step 6.
If the handle assembly for the parking brake must be
removed from the cowl, use the following procedure.
For dry brake system see Figure 13 and for wet brake
system see Figure 14 and Figure 15.
1. Block the front and rear side of the wheels to
make sure the lift truck cannot move. Release
the parking brake handle assembly.
2. Remove the four capscrews that fasten the
bracket for the parking brake to the cowl. Re-
move the bracket and parking brake handle
assembly.
3. Loosen the jam nuts that fasten the threaded
ends of the parking brake cables to the parking
brake handle assembly.
4. Turn the adjustment knob counterclockwise un-
til the parking brake cables are loosened. Dis-
connect the cables from the equalizer links.
5. The service brake assembly must be removed be-
fore the parking brake cable can be removed from
the back plate of the service brake. See Fig-
ure 12. A snap ring holds the sheath of the park-
ing brake cable in the back plate of the service
brake. Remove the snap ring and remove the
parking brake cable from the back plate. See Fig-
ure 12.
1. PARKING BRAKE CABLE
2. SHEATH
3. SNAP RING
4. SERVICE BRAKE ASSEMBLY
5. BACK PLATE
Figure 12. Parking Brake Cable Removal for
Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
120FT) (N005, P005) With Dry Brake System
6. The cotter pin, clevis pin, and cable clamps must
be removed from the parking brake levers before
the parking brake cables can be removed. See
Figure 14 and Figure 15.
10

1800 SRM 1247 Parking Brake Repair
Figure 13. Parking Brake Lever Adjustment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Dry Brake System
11

Legend for Figure 13
A. RIGHT HAND SIDE B. LEFT HAND SIDE
1. PARKING BRAKE HANDLE ASSEMBLY
2. ADJUSTMENT KNOB
3. PARKING BRAKE CABLES
6. BRAKE ASSEMBLY
8. ADJUSTMENT SLOT (UNDERNEATH SPRING)
9. EQUALIZER LINK
10. NUT
11. CAPSCREW
12. PARKING BRAKE BRACKET
13. JAM NUTS
14. PARKING BRAKE CABLE BRACKET
A. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 120FT) (N005, P005)
B. S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004)
2. ADJUSTMENT KNOB
3. EQUALIZER LINKS
5. NUT
6. CAPSCREW
7. BRAKE POSITION SENSOR (RIGHT SIDE
SHOWN)
11. CLEVIS PIN
12. COTTER PIN
13. PARKING BRAKE LEVER
14. CABLE CLAMPS
15. PARKING BRAKE BRACKET
16. JAM NUTS
17. PARKING BRAKE CABLE BRACKET
12

Figure 14. Parking Brake Lever Adjustment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Wet Brake System
13

Figure 15. Parking Brake Lever Adjustment for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) (Wet Brake System)
14

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A. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) B. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
2. ADJUSTMENT KNOB
3. EQUALIZER LINKS
5. NUT
6. CAPSCREW
11. CLEVIS PIN
12. COTTER PIN
13. PARKING BRAKE LEVER
14. CABLE CLAMPS/MOUNTING BRACKET
15. JAM NUTS
ASSEMBLE AND INSTALL
NOTE: For assemble and install procedures for a dry
brake system use Step 1, Step 3, Step 4, Step 6 and
Step 7. For the wet brake system use Step 2, Step 3,
and Step 5 through Step 7.
If the lever assembly for the parking brake was re-
moved from the cowl, use the following procedure for
installation:
1. The parking brake cables must be installed in the
back plate before the service brake is installed.
See Figure 12. A snap ring holds the sheath of
the parking brake cable in the back plate of the
service brake. Install the parking brake cable
in the back plate and install the snap ring that
holds the sheath of the parking brake cable in
the back plate. See Figure 12.
2. The parking brake cables must be installed on
the parking brake levers located on the wet brake
drive axle and the cables loosely clamped to the
frame and axle in the correct position before con-
necting cables to the equalizer links located on
the parking brake handle assembly. See Fig-
ure 14 and Figure 15.
3. Make sure the parking brake handle is in the re-
leased position. Turn the adjustment knob until
the equalizer link is adjusted to the bottom of the
adjustment slot. For Dry Brake system, see Fig-
ure 13. For Wet Brake system, see Figure 14 and
Figure 15.
4. Adjust the jam nuts on the ends of the cable as-
semblies so that the threads of the cable sheaths
extend 23 to 26 mm (0.90 to 1.02 in.) above their
support plate in the lever assembly. See Fig-
ure 13.
5. Adjust the jam nuts on the ends of the parking
cables so that the threads of the cable are level
in the parking brake handle assembly and not
pulling on the equalizer links with the parking
brake handle assembly in the released position.
See Figure 14 and Figure 15.
6. Install the round ends of the parking brake ca-
bles in their slots in the equalizer link. Tighten
the upper jam nuts to hold the sheaths of the
parking brake cables in the parking brake cable
bracket.
7. Use the four capscrews, washers, and nuts and
fasten the bracket to the inside of the cowl.
Tighten park brake cable clamps on frame and
axle.
ADJUST
Dry Brake System
Make sure the service brakes are adjusted and the
operation of the automatic adjuster mechanism is
correct before the parking brake cables are adjusted.
Wet Brake System
Make sure the park brake levers are adjusted be-
fore the parking brake cables are adjusted. See
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004) and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005), Drive
Axle and Differential Assembly Repair, (Wet
Brake) 1400 SRM 1318 for lift truck models S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024) or Drive
Axle and Differential Assembly Repair, (Wet
Brake) 1400 SRM 1344 for lift truck models H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006) for park
brake lever adjustment procedures.
15

Master Cylinder Repair 1800 SRM 1247
Lift Trucks With a MONOTROL®
Pedal or
Forward Reverse Lever
The switch energizes the seat warning circuit when
hand lever is released. This switch puts the trans-
mission in NEUTRAL by de-energizing the direction
solenoid. There is also a switch on the left-hand side
of bracket. This switch prevents engine from start-
ing unless parking brake is applied.
CAUTION
On lift trucks equipped with the wet brake sys-
tem, check the dash display to verify the trans-
mission oil is at operating temperature, 49 to
66 C (120 to 150 F) before adjusting the park-
ing brake adjustment knob.
1. To adjust the parking brake, turn the adjustment
knob to raise the equalized link and tighten the
parking brake cables shown in Figure 13, Fig-
ure 14 and Figure 15. Do not tighten the adjust-
ment so that the brake is applied when the lever
is released. The lever for the parking brake has a
lock. Use your thumb or finger to release the lock
on the lever when the parking brake is released.
NOTE: Before doing Step 2 and Step 3, make sure
the parking brake is correctly adjusted. The parking
brake is correctly adjusted when it takes 125 N
(28 lbf) force (6 clicks) to fully apply the parking
brake for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and 200 N (45 lbf) force (6
clicks) to fully apply the parking brake for lift
truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005),
S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) and
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006).
2. For new brakes, test the operation of the parking
brake. The lift truck, with a capacity load, must
not move when parking brake is applied on a 7.5
percent grade [a slope that increases .75 m in
10 m (9 in. in 10 ft)].
3. For burnished brakes, test the operation of the
parking brake. The lift truck, with a capacity
load, must not move when parking brake is ap-
plied on a 15 percent grade [a slope that increases
1.5 m in 10 m (1.5 ft in 10 ft)].
Master Cylinder Repair
REMOVE
NOTE: The removal procedure in this section is the
same for both dry and wet brake systems.
1. Remove the floor plate, kick plate, and seal plate
from the lift truck for access to the master cylin-
der and booster assembly.
2. Remove master cylinder hoses and brake pres-
sure transducer:
a. For lift truck models S4.0, 4.5, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, S100FT-
BCS; S120FTS; S120FTPRS) (G004)
and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005), remove and tag the brake
booster supply and return hoses from the
master cylinder and booster assembly. Plug
hoses to prevent hoses from draining. Dis-
connect the connector at the brake pressure
transducer, and remove brake pressure
transducer. See Figure 16.
b. For lift truck models S6.0FT, S7.0FT
(S135FT, S155FT) (D024, E024), remove
and tag the accumulator to booster hose,
the booster and accumulator supply hose,
the brake hose, and booster return hose.
Plug hoses to prevent hoses from draining.
Disconnect the connector at the brake pres-
sure transducer, and remove brake pressure
transducer. See Figure 17.
16

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Hyster (p005) h80 ft forklift service repair manual