PART NO. 897658

1800 SRM 570

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

•

When lifting parts or assemblies, make sure that all slings, chains or cables
are correctly fastened and that the load being lifted is balanced. Make sure
that the crane, cables and chains have the capacity to support the weight of
the load.

•

Do not lift heavy parts by hand. Use a lifting mechanism.

•

Wear safety glasses.

•

DISCONNECT THE BATTERY CONNECTOR before doing any
maintenance or repair on electric lift trucks. Disconnect the battery ground
cable on internal combustion lift trucks.

•

Always use correct blocks to prevent the unit from rolling or falling. See
“How To Put The Lift Truck On Blocks” in the OPERATING MANUAL or
the PERIODIC MAINTENANCE section.

•

Keep the unit and working area clean and in order.

•

Use the correct tools for the job.

•

Keep the tools clean and in good condition.

•

Always use

HYSTER

APPROVED

parts when making repairs.

Replacement parts must meet or exceed the specifications of the original
equipment manufacturer.

•

Make sure that all nuts, bolts, snap rings and other fastening devices are
removed before using force to remove parts.

•

Always fasten a DO NOT OPERATE sign to the controls of the unit when
making repairs or if the unit needs repairs.

•

Make sure you follow the DANGER, WARNING and CAUTION notes in
the instructions.

•

Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels.
Make sure that you follow the necessary safety precautions when handling
these fuels and when working on these fuel systems.

•

Batteries generate flammable gas when they are being charged. Keep fire and
sparks away from the area. Make sure the area has ventilation.

1

INTRODUCTION

GENERAL

This section has the description and repairs for the brake
system. These parts include the park brake, service
brake and master cylinder, the disassembly and assem-
bly of the service brakes and the park brakes. The elec-
trically released park brake is also described in this sec-
tion. Checks and Adjustments are described at the end of
this section.

DESCRIPTION

The J30XMT, J35XMT, J40XMT, J1.60XMT,
J1.80XMT and J2.00XMT lift trucks feature dual hy-
draulically operated service disc brakes and mechani-
cally operated park disc brakes. Both brake systems op-
erate independently of each other although they both use
a single disc mounted on the bevel gear shaft of the
transaxle for braking. The location provides a mechani-

cal advantage for effective braking. The service brake
master cylinder and separate reservoir are sealed. The
reservoir has a level sensor connected to a warning light
in the instrument panel, which displays when the brake
fluid is low. The service brake is actuated by the large
pedal located in the operator’s compartment. The pedal
can be operated with either the left or right foot. The
park brake is set by a pedal operated by the operator’s
left foot. The park brake is released by operating the re-
lease lever located on the left side of the instrument pan-
el. Both a warning buzzer and indicator light are used to
remind the operator to set and release the park brake.

The lift truck may also be furnished with an optional
electrically operated park brake. When furnished, the
park brake applies when the operator leaves the seat of
the lift truck. The park brake mechanism is attached to
the park brake linkage at the front of the lift truck and
replaces the standard park brake linkage.

REPAIRS

SERVICE BRAKE PADS
(See FIGURE 1 and FIGURE 2)

Removal




To access the brakes, the mast and carriage must be
raised and a safety chain installed. Follow the
instructions in section PERIODIC MAINTE-
NANCE, 8000 SRM 528 or 8000 SRM 584, SAFETY
PROCEDURES WHEN WORKING NEAR THE
MAST.

1. Move the lift truck to a safe, level area. Block the
tires. Raise the carriage high enough to chain the
carriage so that it does not move. Disconnect the battery.

2. Remove the capscrews retaining the disc brake
shield and remove the disc brake shield.

3. Remove the spring clips retaining the pins on both
ends of the service brake caliper.

4. Remove the pins and the brake pads.

NOTE:

The original brake pad installed in the carrier

side of the service brake is affixed to the carrier side with
hot glue. Use a screwdriver to pry the pad from the carri-
er side. Clean the carrier side before installing a replace-
ment pad.

Installation

1. Install the brake pads in both the carrier side and the
cam side of the caliper.

2. Install the pins to retain the pads.

3. Install the spring clips to retain the pins.

4. Install the disc brake shield.

5. Remove the air from the brake system. See
REMOVE AIR FROM BRAKE SYSTEM.

6. Connect the battery. Remove the safety chain and
lower the mast. Remove the blocks from the tires.

2

1. BRAKE SHIELD
2. CAPSCREWS
3. WASHERS
4. BRACKET
5. SCREW
6. SERVICE BRAKE CALIPER
7. NUT
8. RETAINER PIN
9. SPRING CLIP

10. BUSHING

11. WASHER

12. PARKING BRAKE CALIPER
13. BRACKET

1

2

3

4

5

6

7

FIGURE 1 – SERVICE BRAKE ARRANGEMENT

5

7

8

9

10

10

11

11

12

13

SERVICE BRAKE CALIPER

Removal




To access the brakes, the mast and carriage must be
raised and a safety chain installed. Follow the
instructions in section PERIODIC MAINTE-
NANCE, 8000 SRM 528 or 8000 SRM 584, SAFETY
PROCEDURES WHEN WORKING NEAR THE
MAST.

1. Move the lift truck to a safe, level area. Block the
tires. Raise the carriage high enough to chain the
carriage so that it does not move. Disconnect the battery.

2. Remove the capscrews and lockwashers retaining
the disc brake shield and remove the disc brake shield.

3. Disconnect and cap the hydraulic brake lines to the
service brakes. Cap the ports of the service brake to
prevent dirt from entering the system.

4. Remove the last two capscrews and lockwashers
retaining the service brake bracket to the transaxle.
Remove the bracket containing the service brake
assembly from the brake disc.

Installation

1. Align the service brake assembly with the brake
disc and align the service brake bracket with the
transaxle housing.

2. Install the service brake housing and the disk brake
shield to the transaxle housing using the three capscrews
and lockwashers. Tighten the capscrews to 41 N

m (30

lbf ft).

3

1. INSERT
2. PISTON
3. DUST COVER
4. PISTON SEAL

5. BLEEDER SCREW
6. RETAINER PIN
7. BUSHING
8. SPRING CLIP

9. DISC PAD

10. CARRIER

11. CAPSCREW

12. WASHER
13. LOCKNUT

1

2

3

4

5

6

7

8

9

10

11

12

13

5

FIGURE 2 – SERVICE BRAKE CALIPER

3. Check to see that the service brake assembly slides
freely within the mounting bracket. If the brake does not
move freely, loosen the two nuts that hold the brake
assembly together. Tighten the nuts to 19 N

m (14 lbf ft)

and check again for free movement. The service brake
must be free to float.

4. Remove the caps from the service brake assembly
and the hydraulic brake lines and connect the lines to the
brake assembly. It may be necessary to bleed the air
from the system.

5. Bleed the air from the brake system.

6. Install the disc brake shield between the transaxles,
using the four capscrews and lockwashers.

7. Remove the safety chain and lower the carriage to
the floor. Remove the blocks from the tires and connect
the battery. Check the level of brake fluid. Check the
operation of the service brake before returning the lift
truck to service.

Disassembly

1. After the service brakes have been removed from
the lift truck, remove the two nuts retaining the brake
caliper halves together.

2. Remove the spring clips retaining pins on both ends
of the brake caliper and remove the discs. Separate the
brake halves, by removing the capscrews and spacers.

3. Remove the dust cover, piston and piston seal from
the caliper.

WARNING

Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer. Wear eye protection.

CAUTION

DO NOT use an oil solvent to clean the brake caliper.
Use a solvent approved for cleaning of brake parts.
Do not permit oil or grease in the brake fluid or on
the brake components or the brake pads.

4. Clean and inspect the piston and the caliper bore for
scores, erosion, or pitting. Replace the piston if any of
these conditions are noted. The caliper should not be
honed. Replace the complete assembly if these
conditions are noted.

5. Measure the brake disc pads. The minimum
measurement for the pads is – 0.76 mm (0.03 in).
Replace the pads if necessary.

4

Assembly

1. Lubricate a new piston seal with clean brake fluid
and install the seal onto the piston. Assemble the piston
into the brake caliper bore. Install a new dust cover.

2. Install the capscrews, spacers and nut to hold the
caliper halves together. Do not tighten the capscrews
and nut completely until the brake assembly is installed.
See INSTALLATION–SERVICE BRAKES.

3. Align and install the pins and the brake discs in the
brake assembly. Install the spring clips to retain the pins.

PARK BRAKE CALIPER
(See FIGURE 3)

Removal

WARNING

To access the brakes, the mast and carriage must be
raised and a safety chain installed. Follow the
instructions in PERIODIC MAINTENANCE, 8000
SRM 528 or 8000 SRM 584, SAFETY PROCE-
DURES WHEN WORKING NEAR THE MAST.

1. Park the lift truck in a level area, block the wheels.
Disconnect the battery. Release the park brake. Raise
the carriage high enough to chain the carriage so that it
does not move.

2. Remove the capscrews retaining the disc brake
shield and remove the disc brake shield.

3. Remove the cotter pin and the clevis pin retaining
the rod ends to the brake lever.

4. The park brake assembly may be removed from the
transaxle by removing the last capscrew and lockwasher
retaining the bracket and brake assembly to the
transaxle. Disassemble the brake assembly by removing
the two capscrews, spacers and nuts. Separate the
caliper halves. Retain the spacers removed from
between the caliper halves for use at assembly.

Installation

1. Align the carrier and cam sides of the brake in the
park brake bracket. Align the spacers between both

sides. Install a spacer under the head of the capscrews
and install the capscrews through the caliper halves and
the spacer. Install another spacer on the opposite side of
the capscrew and install the nut. Tighten the nut to 29
N

m (21 lbf ft) torque, then turn the nut an additional

one half turn.

2. Install the bracket and brake assembly on the
transaxle using the top capscrew and washer. Tighten
the capscrews to 41 N

m (30 lbf ft). Install the bottom

capscrew when installing the disc brake shield.

3. Align the brake lever and the rod end. Install the
clevis pin through the lever and rod end. Install a new
cotter pin to retain the clevis pin.

4. Check to make certain that the park brake assembly
can float within the brake bracket.

5. Install the disc brake shield using the four
capscrews removed at assembly.

6. Remove the safety chain and lower the carriage to
the floor. Remove the blocks from the tires and connect
the battery. Check the operation of the park brake before
returning the lift truck to service.

Disassembly

1. After the park calipers have been removed from the
lift truck, remove the two nuts retaining the brake
caliper halves (carrier side and cam side) together.
Remove the capscrews, bushings, spacers and both the
disc pads.

2. Remove the cotter pin, nut, washer, push pin, spring
and back-up plate from the cam side of the park brake
caliper.

WARNING

Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer. Wear eye protection.

CAUTION

DO NOT use an oil solvent to clean the brake caliper.
Use a solvent approved for cleaning of brake parts.
Do not permit oil or grease in the brake fluid or on
the brake components or the brake pads.

5

1. CARRIER SIDE
2. DISC PAD
3. CAM SIDE
4. DISC PAD
5. BACK-UP PLATE
6. PUSH PIN
7. SPRING
8. COTTER PIN
9. NUT

10. WASHER

11. LEVER

12. CAPSCREW
13. BUSHING
14. NUT
15. SPACER

1

2

3

4

5

6

7

11

8

9

10

12

13

15

13

14

FIGURE 3 – PARKING BRAKE CALIPER

FL1043

3. Clean and inspect the bushings and spacers for wear
or elongated holes. Inspect the spring for damage.
Replace any damage parts if these conditions are noted.

4. Measure the disc pads. The minimum thickness of
cam side park brake disc pad is 6.60 mm (0.26 in).
Replace the disc pads if the cam side pad is less than the
specified thickness. The brake disc pads must be
replaced in pairs.

Assembly

1. Install the disc pad in the carrier side. Install the
back-up plate and the disc pad in the cam side.

2. Install the park brake in the park brake bracket. See
INSTALLATION–PARK BRAKES.

MASTER CYLINDER

Removal




To access the brakes, the mast and carriage must be
raised and a safety chain installed. Follow the

instructions in PERIODIC MAINTENANCE, 8000
SRM 528 or 8000 SRM 584, SAFETY PROCE-
DURES WHEN WORKING NEAR THE MAST.

1. Move the lift truck to a safe, level area. Block the
tires. Raise the carriage high enough to chain the
carriage so that it does not move. Disconnect the battery.

2. Remove the floor plates.

3. Loosen one of the hydraulic brake lines to the
service brakes and drain the brake fluid from the
reservoir into a suitable container. Plug the brake line
and the fitting on the service brake.

4. Remove and discard the cotter pin retaining the
master cylinder to the brake pedal. Remove the washer
and clevis pin and remove the master cylinder from the
pedal.

5. Remove the capscrew and washers retaining the
master cylinder to the block.

6. Remove the clamp retaining the hose to the master
cylinder from the reservoir and disconnect the hose.

7. Wipe the exterior of the master cylinder to remove
any surface dirt.

6

Installation

1. Align the master cylinder with the block and install
the washers and the capscrew. Note that one washer
should be positioned on each side of the block.

2. Align the fork end of the master cylinder with the
pedal and install the clevis pin, washer and a new cotter
pin.

3. Install the hose from the reservoir on the master
cylinder. Install the clamp to retain the hose.

4. Remove the plugs from the brake line and the
service brake. Attach the brake line to the service brake.

5. Fill the brake reservoir with brake fluid. The brake
fluid used for the service brakes shall meet the
requirements of SAE J1703 and Federal Motor Vehicle
Safety Standard–FMVSS 116 (DOT 3). The capacity of
the reservoir is 1.1 litre (37 oz).

6. Remove the air from the brake system. See
REMOVE AIR FROM BRAKE SYSTEM.

7. Install the floor plates.

8. Connect the battery. Remove the safety chains and
lower the carriage. Remove the blocks from the tires.

Disassembly
(See FIGURE 4)

WARNING

Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.

1. Pull back on the rubber boot and using snap ring
pliers, remove the snap ring from the cylinder body.
Remove the push rod and fork end.

2. Remove the secondary cup, piston, washer, main
cup, spring retainer, spring and valve from the cylinder
body.

3. Discard the valve, main cup, washer, secondary cup
and boot.

WARNING

Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer. Wear eye protection.

CAUTION

DO NOT use an oil solvent to clean the brake caliper.
Use a solvent approved for cleaning of brake parts.
Do not permit oil or grease in the brake fluid or on
the brake components or the brake pads.

4. Wash all metal components in clean brake fluid and
dry using a clean, regulated compressed air supply.

5. Inspect the cylinder body bore for scoring or pitting.
Replace the complete assembly if the body is defective.

6. Inspect the fork end for damage or elongated holes.
Replace the fork end if damaged or holes are elongated.

7. Check that the spring is not cracked or distorted.
Replace the spring if it is cracked or distorted.

1. CYLINDER BODY
2. VALVE
3. SPRING
4. RETAINER
5. MAIN CUP
6. WASHER
7. PISTON
8. SECONDARY CUP

1

2

3

4

5

6

7

8

9

10

11

FIGURE 4 – MASTER CYLINDER

9. SNAP RING

10. RUBBER BOOT

11. FORK END

Assembly

1. Coat all the parts using clean brake fluid prior to
assembly.

7

2. Install the valve, spring, spring retainer, main cup,
washer, secondary cup, piston and secondary cup into
the piston.




Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.

3. Install the rubber boot on the fork end. Align the
fork end and rubber boot with the secondary cup. Install
the snap ring.

4. Install the master cylinder. See MASTER
CYLINDER–INSTALLATION.

FOOT OPERATED PARK BRAKE LEVER
ASSEMBLY (See FIGURE 5)

Removal




To access the service brakes, the mast and carriage
must be raised and a safety chain installed. Follow
the instructions in PERIODIC MAINTENANCE,
8000 SRM 528 or 8000 SRM 584, SAFETY PROCE-
DURES WHEN WORKING NEAR THE MAST.

1. Move the lift truck to a safe, level area. Block the
wheels. Raise the carriage high enough to safety chain
the carriage so that it does not move. Disconnect the
battery.

2. Remove the brake release lever by removing the
cotter pin and washer retaining the lever to the park
brake assembly. Remove the top overhead guard
mounting capscrew, lockwasher and nut and remove the
lever and bracket.

3. Remove the nut retaining the ball stud to the
bellcrank. Loosen the jam nut on the ball stud and
remove the ball stud from the brake cable. Remove the
brake cable return spring. Remove the cotter pin and
washer retaining the brake cable and cam block to the
park brake lever assembly. Remove the clevis pin and
remove the cam block and brake cable from the park
brake assembly.

4. Identify the wires to the park brake switch and
remove nuts from the wires. Remove the nuts and

washers retaining the switch and insulator to the plate
assembly.

5. To remove the park brake lever assembly, remove
the two capscrews, lockwashers, washers and nuts from
the park brake mounting bracket welded to the cowl.

NOTE:

The three plain washers are used on the lower

mounting bolt as a spacer. Remove the park brake as-
sembly from the lift truck.

6. If necessary, remove the switch mounting plate
assembly by removing the nuts and washers.




Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.

7. To remove the bellcrank, remove the nuts and
washers retaining the brake rods to the bellcrank. Use a
pair of snap ring pliers to remove the snap ring and
washer retaining the bellcrank to the mounting bracket
on the early production models. On the later production
models remove the capscrew, washer, shims and the self
lubed washer.

Installation




Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.

1. On the early production models, install the
bellcrank on the mounting bracket using the washer and
snap ring. On the later production models install the self
lubed washer, shims (as required) washer and capscrew.
Install the brake rods in the bellcrank and install the
washers and nuts.

2. Install the switch plate assembly to the park brake
lever assembly.

3. Align the park brake lever assembly with the
mounting bracket on the cowl. Install the capscrews,
lockwashers, plain washers and nuts to retain the brake
assembly to the mounting bracket.

8

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

40

17

18 19

16

43

20

21

22

26

23

25

26

27

27

28

29

30

29

28

31

30

1. CAM BLOCK
2. HEX. NUT
3. SWITCH
4. INSULATION
5. HEX. NUT
6. HEX. NUT
7. LOCKWASHER
8. PLATE ASSEMBLY, SWITCH
9. PLATE ASSEMBLY

10. WASHER, SPACER

11. BRAKE ASSEMBLY, PARK

12. CAPSCREW
13. BRACKET, BRAKE RELEASE
14. RELEASE ASSEMBLY PARK BRAKE
15. CABLE, PARK BRAKE
16. WASHER
17. SPRING, BRAKE RELEASE
18. WASHER
19. HEX. NUT
20. BALL JOINT
21. WASHER
22. BELLCRANK
23. WASHER
24. LOCKWASHER
25. LINK AND BUSHING ASSEMBLY
26. PIN, LINK PIVOT
27. BALL JOINT
28. JAM NUT
29. ROD
30. YOKE END
31. PIN, YOKE END
32. COTTER PIN
33. CAPSCREW (NOTE 1)
34. WASHER (NOTE 1)

24

35. SHIM (AS REQD.) (NOTE 1)
36. WASHER, SELF LUBE (NOTE 1)
37. SNAP RING (SEE NOTE 2)
38. BRACKET
39. NUT
40. PIN
41. WASHER
42. PIN
43. LOCKWASHER

33

34

35

36

21

22

25

26

37

36

LATER
PRODUCTION

EARLY
PRODUCTION

NOTE 1:

USED ON LATER PRODUCTION ONLY

NOTE 2:

USED ON EARLY PRODUCTION ONLY

FIGURE 5 – FOOT OPERATED PARK BRAKE

39

38

19

32

19

41

42

40

19

39

28

28

9

NOTE: Position the three plain washers on the lower
capscrew, between the park brake assembly and the
switch plate assembly for use as a spacer.

4. Install the park brake switch and insulator on the
plate assembly using the two nuts. Connect the wires to
the proper terminals on the switch.

5. Install the brake cable through the bracket welded to
the cowl. Position the spring on the brake cable and
install the ball stud on the cable end. Install the ball stud
in the bellcrank and secure using the nut.

6. Position the clevis pin half way through the park
brake lever assembly. Align and install the brake cable
end. Push the clevis pin completely through the park
brake lever assembly and install the cam block, washer
and a new cotter pin.

7. Install the brake release lever in the mounting
bracket. Align the end of the lever with the hole in the
park brake lever assembly and install the washer and a
new cotter pin. Align the bracket with the leg of the cowl
and the overhead guard and install the capscrew,
washers and nuts. Tighten the nuts to 134 N

m (99 lbf ft)

torque.

8. Adjust the park brakes. See PARK BRAKE
ADJUSTMENT.

9. Connect the battery. Remove the safety chains and
lower the carriage. Remove the blocks from the wheels.

ELECTRICALLY RELEASED PARK
BRAKE (See FIGURE 6)

NOTE:

This section does not apply to the

J1.60XMT, J1.80XMT and J2.00XMT lift trucks as
this option is not available for these models.

Mechanical Operation

NOTE:

If there is no electrical power, the park brake

can be released mechanically.




Before releasing the park brake mechanically:
1. Block wheels to prevent movement.
2. Put a “DO NOT OPERATE” tag in the operator’s
compartment.

To release the electrically released park brake mechani-
cally, remove the capscrew located in the top side of the

brake solenoid cover. See FIGURE 6, Item 35. Thread
the capscrew into the top center hole of the brake sole-
noid until the park brake is released. Before returning
the lift truck to service, remove the capscrew from the
top center hole and replace it in the side hole.




DO NOT remove the brake solenoid cover when the
capscrew is in the center position and fully engaged.
The return spring used on the brake cable has ten-
sion and can release the cover with enough force to
cause injury.

Removal




To access the park brakes, the mast and carriage
must be raised and a safety chain installed. Follow
the instructions in PERIODIC MAINTENANCE,
8000 SRM 528, SAFETY PROCEDURES WHEN
WORKING NEAR THE MAST.

1. Park the lift truck in a level area, block the wheels.
Disconnect the battery. Before attempting to
disassemble the electrically released park brake
manually release the brake. Raise the carriage high
enough to safety chain the carriage so that it does not
move.

2. Remove the capscrews retaining the disc brake
shield and remove the disc brake shield.

3. Remove the solenoid cover by removing the two
nuts and lockwashers retaining the cover to the front of
the cowl and removing the two capscrews, lockwashers
and nuts retaining the left hand overhead guard leg to the
cowl. Install brake release service tool 2310010 over the
solenoid and the mounting bracket on the cowl retaining
the brake solenoid. Turn the capscrew on the special tool
down to release the brakes.

4. Remove the cotter pins retaining the yoke end pins
in the yokes and park brake caliper lever. Remove the
yoke end pins from the yokes.

5. Remove the nut retaining the ball joint to the
bellcrank. Remove the ball joint and switch actuator
bracket from the end of the park brake cable.

10

43

41

41

42

42

40

39

38

37

36

44

35

34

33

32

31

35

36

38

39

40

29

30

45

46

28

27

26

25

24

23

22

21

20

19

18

17

16

5

15

14

13

5

12

11

10

9

8

7

6

5

4

49

3

2

1

1. CAPSCREW
2. LOCKWASHER
3. SOLENOID, BRAKE RELEASE
4. LOCKWASHER
5. HEX. NUT
6. LOCKWASHER
7. CAPSCREW
8. ROD, GUIDE
9. COUPLING

10. PLATE AND BEARING ASSEMBLY

11. HEX. NUT

12. SPRING
13. “E” RING
14. PLATE
15. FLAT WASHER
16. HEX. NUT
17. CABLE, PARK BRAKE
18. CAPSCREW
19. LOCKWASHER

20. HEX. NUT
21. BRACKET, SWITCH MOUNTING
22. CAPSCREW
23. SPACER
24. SWITCH
25. LOCKWASHER
26. HEX. NUT
27. BRACKET, SWITCH ACTUATOR
28. BALL JOINT
29. WASHER
30. SPRING, BRAKE RELEASE
31. HEX. NUT
32. CASTLE NUT
33. COTTER PIN
34. BELLCRANK
35. HEX. NUT
36. LOCKWASHER
37. LINK AND BUSHING ASSEMBLY
38. BALL JOINT

39. JAM NUT
40. ROD
41. YOKE END
42. PIN, YOKE END
43. COTTER PIN
44. PIN, LINK PIVOT
45. CAPSCREW
46. WASHER
47. SHIM (AS REQD.)
48. WASHER, SELF LUBE
49. LABEL
50. WASHER

47

48

50

29

29

FIGURE 6 – ELECTRICALLY RELEASED PARK BRAKE

11




The return spring used on the brake cable has ten-
sion and can release with enough force to cause an in-
jury.

6. Carefully remove the hex. nut, washers, E-ring and
spring from the end of the park brake cable.




Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.

7. Remove the capscrew and washers retaining the
bellcrank to the bracket. The link and bushing assembly
along with the rods, yokes and ball joints can be
removed as an assembly.

8. Remove the E-ring retaining the upper portion of
the cable assembly to the plate. Remove the cable from
the adapter. Remove the brake cable and the adapter.
Remove the special tool.

9. Remove the plunger from the solenoid. Carefully
install the spring compression tool 2308410 through the
solenoid and the bottom plate so the seal and bushing in
the solenoid are not damaged. Install and tighten the
washer and nut until the washer contacts the bottom
plate. Use a crane or overhead lifting device to compress
the spring just enough to relieve the pressure on the
bottom plate. Remove the bottom two nuts from the
guide rods. Relieve the pressure from spring by
lowering the crane or overhead lifting device.

10. Remove the nut and washer from the spring
compression tool. Carefully remove the spring
compression tool. Remove the bottom plate, spring and
guide plate.

NOTE:

The bottom six nuts remaining on the guide

rods are set to the proper dimension for compressing the
spring. DO NOT loosen the lower six nuts remaining on
the guide rods.

11. Remove the guide rods using the upper nuts to back
the rods out of the solenoid.

12. Remove the capscrews and lockwashers retaining
the solenoid to the lift truck frame.

13. Identify and tag the wires to the brake switch.
Remove the electrical wires to the switch. Remove the
capscrews, nuts and washers retaining the switch and
spacer to the bracket.

14. Remove the two capscrews, nuts and washers to
remove the switch bracket.

Installation




Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer. Wear eye protection.

1. Clean and inspect all components for damage or
elongated holes. Inspect the spring for damage. Replace
any damaged parts if these conditions are noted.

2. Install the switch bracket on the cowl using the
capscrews, washers and nuts.

3. Align and install the spacer between the switch and
the switch bracket. Install the capscrew through the
bracket, spacer, washers and the switch. Install the nuts
on the capscrews. Connect the electrical wires to the
switch.

4. If the guide rods were removed, apply sealant
251099 or equivalent to the threads of the guide rods.
Install the guide rods into the solenoid until the
measurement from the mounting plate to the bottom of
the guide rods is 195 mm (6.59 in). Tighten the nuts on
the guide rods to maintain the proper dimension. Align
the guide plate, spring and lower plate on the guide rods.

5. Carefully install spring compression tool 2308410
through the solenoid, guide plate, spring and bottom
plate. Install the washer and nut on the bottom of the
special tool. Temporarily install two flat one inch
spacers between the solenoid mounting capscrews and
the top of the guide plate. Use a crane or overhead lifting
device to compress the spring until the bottom plate
contacts the bottom of the lower six nuts on the guide
rods. Install the three flat washers, and six nuts on the
guide rods.

6. Remove the nut and washer retaining the spring
compression tool 2308410. Carefully remove the spring
compression tool. Take care when removing the special
tool not to damage the oil seal and bushing in the
solenoid.

12

7. Apply sealant 251099 or equivalent to the upper
threads of the adapter. Locate the adapter on the top
center of the guide plate. Lightly lubricate the plunger
oil seal and O-ring located inside the plunger using
silicone grease Dow 3452 or equivalent. Install the
plunger in the solenoid. Install the adapter on the threads
of the plunger rod.

8. Position the flat washer on the top of the bottom
plate. Install the lockwasher and nut on the brake cable.
Install the brake cable through the opening in the bottom
plate and the flat washer. Install the brake cable on the
adapter. The minimum thread engagement of the brake
cable into the adapter is 11 mm (0.43 in).

9. Install brake release tool 2310010 over the solenoid
and mounting bracket. Turn down on the capscrew to
make certain that the brakes are in the released position
to provide clearance for assembly purposes. Remove
the two flat spacers installed in Step 5. Install the upper
E-ring to retain the brake cable to the bottom plate.

10. Install the lower brake cable through the bracket on
the lower cowl. Install the lower E-ring to retain the
brake cable. Install the flat washer, jam nut and switch
actuator bracket. Install the ball joint on the brake cable.
The minimum thread engagement of the cable into the
ball stud is 12 mm (0.47 in).

11. Align and install the bellcrank, along with the link
and bushing assembly, rods, yokes and ball joints using
the washers and capscrew to retain the bellcrank. Kits
are available to update the early production parts to the
later production parts, refer to the parts manual. Make
certain that there is clearance between the top of the
bellcrank and the mounting bracket. Remove the brake
release tool 2310010.

12. Make certain that the park brake calipers are
properly adjusted. Refer to ADJUSTMENT–PARK
BRAKE. Align and install the yoke end pins in the
yokes and park brake caliper lever. Install new cotter
pins.

13. Cycle the park brake twenty times. Allow five
seconds between each activation. Adjust the park brake.
Refer to ADJUSTMENT–PARK BRAKE.

14. Align and install the disc brake shield using the
capscrews. Install the electrically released park brake
cover.

15. Remove the safety chain and lower the mast.
Remove the blocks from the wheels. Connect the
battery.

16. Test the electrically released park brake on a 15%
grade with a rated load before returning the lift truck to
service.

ELECTRICALLY RELEASED PARK
BRAKE–ELECTRICAL COMPONENTS
(See FIGURE 7)

NOTE:

This section does not apply to the

J1.60XMT, J1.80XMT and J2.00XMT lift trucks as
this option is not available for these models.

The electrical components for operating the electrically
released park brake are located in the rear compartment
and on the cowl to the left of the steering wheel. The so-
lenoid that activates the brakes two seconds after the op-
erator leaves the seat without applying the brakes is lo-
cated under a cover on the front of the cowl. On the elec-
trically released park brake the switch to activate the
brake light is on the control box which is located on the
lift truck frame.

The rear compartment has a mounting plate for a termi-
nal strip, a relay, two resistor assemblies and a diode as-
sembly. The manual switch for setting the park brake is
mounted in a control box, located to the left of the steer-
ing wheel. Along with the switch, the control box con-
tains a 30 amp fuse and a control module.

Control Box–Removal

1. Park the lift truck in a level area, block the wheels.
Disconnect the battery.

2. Remove the three capscrews and washers to remove
the cover.

13

30

31

32

33

34

35

36

37

5

6

7

8

9

10 11

12

13

14

15

2

3

3

1

9

8

1

2 3

4

16

17

18

19

20

21

22

23

24

25

26

27

28

29

1. CAPSCREW
2. LOCKWASHER
3. WASHER
4. PLATE, COVER
5. LABEL
6. SWITCH
7. STANDOFF
8. CAPSCREW
9. LOCKWASHER

10. CONTROL MODULE

11. PLATE, MOUNTING

12. CAPSCREW
13. NUT
14. FUSE BLOCK
15. FUSE, 30 AMP
16. CAPSCREW

17. WASHER, EXTERNAL TOOTH
18. RELAY
19. TERMINAL BLOCK
20. PLATE, MOUNTING
21. CAPSCREW
22. WASHER
23. RESISTOR ASSEMBLY
24. DIODE ASSEMBLY
25. WASHER
26. CAPSCREW
27. WIRE
28. TERMINAL, PUSH-ON
29. TERMINAL, RING
30. NUT
31. WASHER
32. CAPSCREW

33. COVER, SOLENOID
34. LABEL
35. CAPSCREW
36. COVER, FRONT COWL
37. COWL WELDMENT

FIGURE 7 – COWL, COVERS AND ELECTRICAL COMPONENTS–

ELECTRICALLY RELEASED PARK BRAKE

14

3. Identify and tag the wires to the switch. Remove the
switch by removing the nut on the outside of the cover.

4. Use a fuse puller to remove the fuse.

5. Identify and tag the wires to the control module.
Remove the capscrews and washers retaining the
control module to the mounting plate.

6. To remove the mounting plate the solenoid cover
must be removed. See REMOVAL–ELECTRICALLY
RELEASED PARK BRAKE. Remove the nuts,
washers, lockwashers and capscrews retaining the
mounting plate and the front cowl cover to the cowl
weldment.

Control Box–Installation

1. Align the mounting plate with the cowl and front
cowl weldment. Install the capscrews, washers,
lockwashers and nuts. Install the solenoid cover.

2. Install the control module using the capscrews and
washers. Connect the electrical wires.

3. Install the fuse.

4. Install the switch on the cover. Connect the
electrical wires to the switch.

5. Align the solenoid on the mounting bracket and
install the capscrews and lockwashers. Make certain
that the two electrical wires extend through the cowl to
the control module.

6. Apply sealant 501702904 to the upper threads of the
guide rods and install them in the base of the solenoid.

7. Install the cover on the control box using the three
capscrews and washers.

8. Remove the blocks from the wheels. Connect the
battery.

Terminal Block–Removal

1. Park the lift truck in a level area, block the wheels.
Disconnect the battery.

2. Open the rear compartment cover.

3. Tag and identify the wires to the relay. Remove the
wires. Remove the capscrew and external tooth washer
retaining the relay to the mounting plate.

4. Remove the resistor assemblies and the diode
assembly.

5. Remove the capscrews and washers retaining the
terminal strip to the mounting plate.

6. Remove the mounting plate by removing the three
capscrews and washers retaining the mounting plate to
the panel.

Terminal Block–Installation

1. Install the mounting plate on the panel using the
three capscrews and washers.

2. Install the terminal strip on the mounting plate using
the capscrews and washers.

3. Install the diode assembly and the resistor
assemblies on the terminal block. Refer to the wiring
diagrams and schematics.

4. Install the relay on the mounting plate using the
capscrew and external tooth washer. Connect the wires
to the relay.

5. Close the rear compartment cover.

6. Remove the blocks from the wheels. Connect the
battery.

CHECKS AND ADJUSTMENTS

PARK BRAKE ADJUSTMENT

The park brake must hold the truck with a rated load on a
15% grade using the park brake pedal actuation only.




To access the park brakes, the mast and carriage
must be raised and a safety chain installed. Follow

15

the instructions in PERIODIC MAINTENANCE,
8000 SRM 528 or 8000 SRM 584, SAFETY PROCE-
DURES WHEN WORKING NEAR THE MAST.

The park brake may be adjusted in three different loca-
tions. Before making any adjustments, park the lift truck
in a level area and block the wheels. Release the park
brake. Check to make certain that the brake pads are
contacting the brake caliper evenly. If the pads are not
contacting the caliper evenly, the park brake must be ad-
justed. Remove the cotter pin and the yoke end pin. Ad-
just the park brake caliper by:

a. Lubricate the push pins, the bore of the caliper

body caliper lever and caliper lever washer using
Anti-Seize Hyster P/N 316865 or equivalent. See
FIGURE 3 for component identification. Refer
to PERIODIC MAINTENANCE, 8000 SRM
528 or 8000 SRM 584.

b. Coat all other mating surfaces of the brake link-

age with multi-purpose grease. See FIGURE 5 or
FIGURE 6. Refer to PERIODIC MAINTE-
NANCE, 8000 SRM 528 or 8000 SRM 584.

c. Remove the cotter pins from the castle nuts.

Tighten the castle nuts to 1.5 N

m (15 lbf in).

d. Back off on the castle nut by four flats (240




e. Check the clearance between the brake pad and

brake disc. The clearance between the brake pad
and disc must be 0.30-0.38 mm (0.012-0.015 in).

f. Install new cotter pins to retain the castle nuts. If

the nut must be moved to provide access to install
the cotter pin, the castle nut should be tightened.

g. Install the yoke end pins to attach the yokes to the

cam levers. Install new cotter pins to retain the
yoke end pins.

The brake cable length can be adjusted at the end con-
nected to the bellcrank located on the bottom of the
cowl. To adjust the length of the cable, remove the jam
nut retaining the ball stud to the bellcrank. Loosen the
jam nut on the end of the ball stud retaining the brake
cable. Turn the ball stud clockwise to decrease the
length of the brake cable. Turn the ball stud counter-
clockwise to increase the length of the cable. Decreasing
the cable length will increase the brake pressure. When
increasing the cable length, the minimum thread en-
gagement of the cable into the ball stud is 12 mm (0.47
in).

The other adjustment can be made by removing the cot-
ter pin and the clevis pin retaining the rod ends to the
brake levers. Lengthen or shorten the rod ends as re-
quired. Turn the rod ends clockwise to shorten the length
of the rod end and to increase the braking capability.
Install the clevis pin and cotter pin after the proper ad-
justment has been made. Both rods ends should be ad-
justed equally.

SERVICE BRAKE ADJUSTMENT

No adjustments can be made to the service brake. Re-
place the brake pads if the brakes are not functioning
properly. Refer to REMOVAL and INSTALLATION
SERVICE BRAKE PADS.

The service brake pedal with 22.7kg (50 lbs) of force ap-
plied to the pedal should measure 69.9 mm (2.75 in)
minimum from the floor to the rear top of the pedal or
44.5 mm (1.75 in) minimum from the floor to the front
top of the pedal.

REMOVE AIR FROM BRAKE SYSTEM

1. Fill the master cylinder reservoir with brake fluid.

2. Put one end of a rubber hose on the special fitting of
the wheel cylinder. Put the other end of the hose into a
clear container of brake fluid.

3. Loosen the bleeder screw at the wheel cylinder one
turn so that the air can be removed from the brake
system. Slowly push the brake pedal and hold it at the
end of its stroke. Close the special fitting.

4. Check the level of the brake fluid in the reservoir for
the master cylinder during the procedure. Make sure to
keep the brake fluid at the correct level.

5. Repeat Step 3 and Step 4 until there are no bubbles
in the container.

6. Repeat the procedure for the other wheel cylinder.

If there is still air in the system, the air must be removed
from the master cylinder. Push on the brake pedal with a
steady stroke. Release the pedal slowly. Repeat this pro-
cedure until there are no air bubbles entering the reser-
voir.

16

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

The brakes do not operate equally.

Oil or brake fluid is on the disc pads.

The disc pads are worn.

The brake calipers have a defect. (Check for dirt or corro-
sion between the piston and the cylinder if the friction pad
does not release the brake.)

A brake line has a restriction.

Park brake is adjusted wrong.

Both brakes do not release.

Park brake is adjusted wrong.

The master cylinder needs repair.

The seals are damaged because of oil in the brake fluid.

The brake pedal is hard to push.

The linkage for the brake pedal is wrong.

Oil or brake fluid is on the disc pads.

The master cylinder needs repair.

The brake pedal travels too far.

Air is in the brake system.

The linkage for the brake pedal is wrong.

The brake system has a leak.

The brakes make too much noise.

The disc pads are worn.

The brake calipers have a defect. (Check for dirt or corro-
sion between the piston and the cylinder if the disc pads
do not release the brake disc.)

The brakes do not stop the lift truck.

Oil, water, or brake fluid is on the disc pads.

The disc pads are worn.

The brake calipers needs repair.

The master cylinder needs repair.

The park brake will not hold.

Oil, water, or brake fluid is on the disc pads.

The park brake linkage is not adjusted correctly.

The disc pads are worn.

The park brake will not release.

The park brake linkage is not adjusted correctly.

The linkage needs repair.

The optional park brake needs adjustment.

TECHNICAL PUBLICATIONS

1800 SRM 570

2/97 ( 9/96) (6/95) (5/95) (12/94) (5/94) Litho in U.S.A.

TECHNICAL PUBLICATIONS