1800SRM803-1482623(03-2000)-EN

BRAKE SYSTEMA1.00-1.50XL (A20-30XL) [C203]

PART NO. 1482623 1800 SRM 803

SAFETY PRECAUTIONSMAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctlyfastened, and that the load being lifted is balanced. Make sure the crane, cables, andchains 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 repairon 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 PUTTHE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-nance section.

Keep the unit clean and the working area clean and orderly.

Use the correct tools for the job.

Keep the tools clean and in good condition.

Always use HYSTER APPROVED parts when making repairs. Replacement partsmust meet or exceed the specifications of the original equipment manufacturer.

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

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

Be sure to follow the WARNING and CAUTION notes in the instructions.

Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuelare flammable. Be sure to follow the necessary safety precautions when handling thesefuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparksaway from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in thismanual:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTIONIndicates a condition that can cause property damage!

Brake System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1Description and Operation ................................................................................................................................ 1Master Cylinder Repair ..................................................................................................................................... 3

Remove and Disassemble .............................................................................................................................. 3Clean and Inspect .......................................................................................................................................... 4Assemble and Install ..................................................................................................................................... 4

Service and Parking Brakes Repair.................................................................................................................. 5Remove and Disassemble .............................................................................................................................. 5Clean .............................................................................................................................................................. 6Inspect ............................................................................................................................................................ 6Assemble and Install ..................................................................................................................................... 7

Brake System Air Removal ............................................................................................................................... 7Service Brakes Adjustment ............................................................................................................................... 8Brake Pedal Adjustment ................................................................................................................................... 8Parking Brake Adjustment ............................................................................................................................... 9Troubleshooting.................................................................................................................................................. 9

This section is for the following models:

A1.00-1.50XL (A20-30XL) [C203]

2002 HYSTER COMPANY i

"THEQUALITYKEEPERS"

HYSTERAPPROVEDPARTS

1800 SRM 803 Description and Operation

GeneralThis section has a description and the service procedures for the brake system. The parts of the brake systeminclude the master cylinder, brake shoes, wheel cylinders, pedals and linkage, and parking brake system.

Description and OperationThe master cylinder has a housing, a piston with twocups, a return spring, and a check valve. See Fig-ure 1 and Figure 2. The fluid reservoir is part of themaster cylinder. When the brake pedal is pushed,the push rod moves the piston assembly in the mas-ter cylinder. The primary cup pushes the brake fluidthrough the check valve to the wheel cylinders. Thesecondary cup keeps the fluid that is above the pri-mary cup in the master cylinder.

When the brake pedal is released, the return springpushes the piston assembly against the retainerwasher. The return springs for the brake shoescause the pistons in the wheel cylinders to retract.Some of the brake fluid in the wheel cylinders flowsthrough the brake lines to the check valve in themaster cylinder. The pressure in the brake linesmoves the check valve from its seat. The fluid flowsthrough the check valve to the master cylinder bore.

When the brake pedal is quickly released, the returnspring on the brake pedal moves the piston fasterthan the brake fluid can flow around the check valve.To prevent cavitation, holes are drilled in the piston.Fluid from the inlet port flows through the holes inthe piston and fills the pressure chamber. The flow ofthe brake fluid through the holes in the piston bendsthe lip of the primary cup and permits the brake fluidto enter the pressure chamber.

The check valve permits brake fluid from the pres-sure chamber to flow to the brake lines when thebrake pedal is pushed. When the brake pedal is re-leased, the pressure in the brake lines is greater thanthe pressure in the pressure chamber. The checkvalve then moves against the spring pressure to per-mit brake fluid to return to the pressure chamber.The check valve returns to its seat when the pressure

in the brake lines decreases to less than the springpressure. This action keeps a low pressure in thewheel cylinders to hold the lips of the seals againstthe bores. This low pressure prevents leaks in thewheel cylinders.

A small hole is drilled between the inlet port andthe pressure chamber. The hole is just below theprimary cup when the piston is against the stopwasher. The hole is a compensator port to permitbrake fluid to flow between the reservoir and thepressure chamber. The brake fluid expands becauseof the heat generated by using the brakes. Theadditional volume from the expansion of the brakefluid flows through the compensator port when thepedal is fully released. If the push rod is adjusted sothat there is no clearance, the primary cup can closethe compensator port. This condition can cause thebrakes to be applied without pushing the pedal.

A service brake assembly is installed on each of thetwo load wheels. The parts of the brake system areshown in Figure 4, Figure 5, and Figure 6. Whenthe brake pedal is pushed, brake fluid flows from themaster cylinder and extends the pistons of the wheelcylinders. The pistons in the wheel cylinders expandthe brake shoes against the brake drums.

The parking brake system uses the service brakeshoes. When the lever is moved to apply the parkingbrake, the cables actuate linkage to expand thebrake shoes against the brake drums.

The clearance between the brake shoes and the brakedrum is adjusted manually. The adjuster wheel isadjusted through a hole in the back plate of the brakeassembly.

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Description and Operation 1800 SRM 803

1. PARKING BRAKE LEVER2. CABLE ADJUSTMENT3. LEFT BRAKE CABLE4. RIGHT BRAKE CABLE5. BRAKE LINE TO WHEEL CYLINDER6. BRAKE PEDAL7. PUSH ROD

8. RETURN SPRING9. MASTER CYLINDER10. BRAKE HOSE FROM MASTER CYLINDER11. BRAKE DRUM12. BRAKE ASSEMBLY13. BACK PLATE14. BLEEDER SCREW

Figure 1. Service and Parking Brake System Diagram

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1800 SRM 803 Master Cylinder Repair

Master Cylinder RepairREMOVE AND DISASSEMBLE1. Remove the floor plate. See Figure 1 and Fig-

ure 2. Disconnect the clevis from the brake pedaland remove the push rod from the master cylin-der. Disconnect the brake hose from the mastercylinder port. Install a plug in the master cylin-der port and brake hose to prevent leakage of thebrake fluid.

2. Remove the bolts and the master cylinder fromthe frame. Drain the fluid from the reservoir.

3. Put the master cylinder in a vise with soft jawsas shown in Figure 3.

WARNINGThere is a spring behind the piston. Do not per-mit the spring to be released and cause injury.

4. Hold the piston against the spring with a screw-driver. See Figure 3. Remove the snap ring andcarefully remove the piston assembly and spring.

5. Remove the check valve and the spring. Use athin rod as a driver to remove the check valveand tube fitting.

1. PUSH ROD2. DUST COVER3. SNAP RING4. DOUBLE LIP CUP5. PISTON6. CUP PROTECTOR7. PRIMARY CUP8. CUP RETAINER

9. RETURN SPRING10. VALVE BODY11. CHECK VALVE SPRING12. CHECK VALVE13. TUBE FITTING14. DIAPHRAGM GASKET15. RESERVOIR COVER16. RETAINER

Figure 2. Master Cylinder

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Master Cylinder Repair 1800 SRM 803

1. PISTON 2. MASTERCYLINDER

Figure 3. Remove Piston

CLEAN AND INSPECT

CAUTIONDO NOT use mineral oil solvent to clean themaster cylinder. Use alcohol or a solvent ap-proved for cleaning brake parts to clean themaster cylinder.

Inspect the bore of the master cylinder for holes orscratches. Replace the master cylinder assembly ifthere is damage. Install a new repair kit in the mas-ter cylinder.

ASSEMBLE AND INSTALL1. Use a repair kit. Install the parts in the order

shown in Figure 2. Hold the piston in the cylin-der with a screwdriver as shown in Figure 3.Make sure the snap ring is in the correct posi-tion.

2. Install the check valve assembly. Install the di-aphragm gasket and reservoir cover. Install thedust cover.

3. Fasten the master cylinder to the frame. Installthe push rod into the master cylinder and connectthe clevis to the pedal.

4. Check the clearance between the push rod andthe piston. Loosen the lock nut and turn the pushrod on the master cylinder clockwise (as viewedfrom the rear of the truck) to remove all slackbetween the piston and the push rod.

5. Fill the reservoir with SAE J1703 brake fluid.Operate the brake pedal to remove air from themaster cylinder. Connect the hydraulic line tothe master cylinder.

CAUTIONDo not permit brake fluid to flow from thebleeder screw on to any part of the axle. Thebrake fluid can cause damage to the oil anddust seals on the axle and cause a lubricationproblem inside of the mast pivots. Brake fluidwill also damage the paint on the lift truck.

6. Remove the air from the system as described inBrake System Air Removal in this manual.

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1800 SRM 803 Service and Parking Brakes Repair

Service and Parking Brakes RepairREMOVE AND DISASSEMBLE

WARNINGBrake linings can contain dangerous fibers.Breathing the dust from these brake liningsis a cancer or lung disease hazard. Do notcreate dust! Do not clean brake parts withcompressed air or by brushing. Use vacuumequipment approved for brake dust or followthe cleaning procedure in this section. Whenthe brake drums are removed, do not createdust.

Do not sand, grind, chisel, hammer, or changelinings in any way that will create dust. Anychanges to brake linings must be done in a re-stricted area with special ventilation. Protec-tive clothing and a respirator must be used.

1. Put the lift truck on blocks under the frame sothat the load wheels are raised from the floor.Remove the load wheels. See Figure 4, Figure 5,and Figure 6.

Figure 4. Brake Assembly

2. Remove the hub cap from the end of the hub. Re-move the cotter pin and the castle nut from theend of the spindle. Remove the outer bearingcone. Remove the hub and brake drum from the

spindle. Do not permit the hub and brake drumto drop on the spindle and damage the greaseseal.

1. OUTER BEARING2. INNER BEARING3. GREASE SEAL4. WHEEL ASSEMBLY5. BRAKE DRUM6. WEAR SLEEVE7. BRAKE ASSEMBLY

8. SPINDLE9. WHEEL NUT10. WASHER11. CASTLE NUT12. COTTER PIN13. HUB CAP

Figure 5. Wheel and Bearing Assembly

3. Remove the spring and adjuster linkage from thebrake shoes. See Figure 6. Remove the retainersprings that hold the brake shoes to the backplate. Remove the strap plate. Remove the brakeshoes. Disconnect the parking brake cable fromthe actuating lever on the brake shoes.

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Service and Parking Brakes Repair 1800 SRM 803

NOTE: RIGHT-HAND BRAKE SHOWN.

1. WHEEL CYLINDER2. STRAP PLATE3. RETURN SPRING4. CROSS STRUT5. BRAKE SHOE6. RETAINER SPRING

7. PARKING BRAKELEVER

8. PARKING BRAKECABLE

9. ADJUSTER WHEEL10. SPRING11. BRAKE DRUM

Figure 6. Brake Assembly

4. Disconnect the brake line at the wheel cylinder.

5. Remove the wheel cylinder from the back plate.

6. If the parking brake cables must be replaced,disconnect them from the lever assembly on thecowl. Remove the cables from the lift truck.

CLEAN

WARNINGCleaning solvents can be flammable and toxicand can cause skin irritation. When usingcleaning solvents, always follow the safetyinstructions of the solvent manufacturer.

CAUTIONDo not use an oil solvent to clean the wheelcylinder. Use a solvent approved for cleaningof brake parts. Do not permit oil or grease inthe brake fluid or on the brake linings.

1. Do not release brake lining dust from the brakelinings into the air when the brake drum is re-moved.

CAUTIONDo not permit oil or grease on the brake linings.Use a brake cleaning fluid as necessary to cleanlinings that will not be replaced.

2. Use a solvent approved for cleaning of brakeparts to wet the brake lining dust. Follow theinstructions and cautions of the manufacturerfor the use of the solvent. If a solvent spray isused, spray at a distance so that the dust is notreleased into the air.

INSPECT1. Check the bore of the wheel cylinder for holes or

scratches. Replace the wheel cylinder if there isany damage. Always install a new repair kit inthe wheel cylinder as minimum service if damageis not found in the wheel cylinder.

2. Check the return springs for damage. Inspect theback plate for wear where the brake shoes touchthe back plate. Grind the back plate to make itsmooth if it has grooves worn in it.

3. Inspect the brake shoes for cracks or damage. Ifthe brake shoes are worn or damaged, replace thebrake shoes. If a brake shoe is damaged, bothbrake shoes must be replaced as a unit.

4. Inspect the brake drum for grooves or other dam-age. If the brake surface of the brake drumshas grooves, use a lathe to make a clean, smoothbrake surface. The normal inside diameter ofthe brake drum is 180.00 to 180.27 mm (7.09 to7.10 in.). The limit (wear limit) of the inside di-ameter is 182.27 mm (7.18 in.). If the internaldiameter of the brake drum is greater than thelimit, the brake drum must be replaced.

5. When the brake lining dust is wet, clean theparts. Put any rags or towels in a plastic bagor an airtight container while they are still wet.Put a DANGEROUS FIBERS warning label onthe plastic bag or airtight container.

6. Any cleaning rags that will be washed must becleaned so that fibers are not released into theair.

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1800 SRM 803 Brake System Air Removal

7. The teeth of the adjuster wheel must not be worn.The adjuster wheel must turn freely. Check theadjuster links for damage.

8. Make sure the parking brake levers in both of thebrake assemblies move freely.

9. Check the surfaces of the seals for wear or dam-age.

ASSEMBLE AND INSTALL1. Assemble the wheel cylinder. Use only HYSTER

APPROVED parts. See Figure 4, Figure 5, andFigure 6.

2. Install the wheel cylinder on the back plate ofthe spindle assembly with the two washers andcapscrews. Tighten the capscrews.

3. Assemble the brake components on the backplate of the spindle assembly. Install the brakeshoes, springs, lever for the parking brake, crossstrut, and strap plate. The strap plate at the topof the brake assembly holds the brake shoes inposition. Tighten the two capscrews in the strapplate to 10 2 Nm (88 17.7 lbf in).

4. Connect the parking brake cable to the actuatinglever on the brake shoes.

5. Put NEVER-SEEZ on the threads of the ad-juster wheel. Turn the adjuster wheel into theadjuster nut so that the adjuster assembly is inthe shortest position.

6. Install the adjuster wheel assembly and the re-turn springs for the brake shoes. Make sure theadjuster wheel is installed toward the rear of thelift truck and is aligned with the adjustment slotwhen it is installed.

7. If the inner bearing assembly was removed, lu-bricate the inner wheel bearing with multipur-pose grease. See Periodic Maintenance 8000

SRM 798 for the correct lubricant. Install the in-ner bearing into the bore of the brake drum. In-stall the wear sleeve and a new grease seal in thebore next to the inner bearing.

8. Carefully install the brake drum onto the spin-dle and brake assembly. Lubricate the cone ofthe outer bearing; then install the cone into theopening between the brake drum and the spin-dle.

9. Install the washer, lockwasher, and nut. Tightenthe nut to 68 Nm (50 lbf ft) while rotating thebrake drum. Back off the nut one-quarter turn.Tighten the nut to 3 Nm (25 lbf in) or to thefirst alignment position after 3 Nm (25 lbf in).Install the cotter pin to hold the nut. Install thehub cap.

10. Install the load wheels. Tighten the wheel nutsto 140 Nm (103 lbf ft).

11. Check the wheel for end play. If end play is ob-served, repeat Step 9 and Step 10.

12. Adjust the clearance of the brake shoes. See Ser-vice Brakes Adjustment in this manual.

13. If the parking brake cables were removed, installthem in the brake lever assembly on the cowl.See Figure 1. The cable for the right-hand brakefits in the cable holder at the right of the leverassembly. Tighten the cable nuts and install thelever assembly in the lift truck with the two cap-screws, washers, and nuts. Adjust the parkingbrake as described in Parking Brake Adjustmentin this manual.

14. Remove the air from the brake system as de-scribed in Brake System Air Removal in thismanual.

15. Raise the lift truck and remove the blocks fromunder the truck. Check the operation of thebrakes.

Brake System Air Removal1. Before the air is removed from the brake sys-

tem, make sure the service brakes are adjustedcorrectly. Make sure the reservoir is filled withbrake fluid. Make sure you do not drain thereservoir and put additional air into the systemduring this procedure.

2. Put one end of a rubber hose on the bleeder screwon the side of the master cylinder. Put the otherend of the hose into a clear container of brakefluid. Loosen the bleeder screw one turn. Slowlypush the brake pedal and hold it at the end of itsstroke. Close the bleeder screw and release the

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Brake Pedal Adjustment 1800 SRM 803

brake pedal. Repeat the procedure until no airbubbles come from the rubber hose.

3. Put one end of a rubber hose on the bleeder screwof the wheel cylinder. Put the other end of thehose into a clear container of brake fluid. Loosenthe bleeder screw one turn. Slowly push thebrake pedal and hold it at the end of its stroke.Close the bleeder screw. Repeat the procedureuntil there are no bubbles in the container.Tighten the bleeder screw to 2.5 1.5 Nm (2213 lbf in).

4. Check the level of the brake fluid in the reser-voir for the master cylinder during the procedure.Make sure you do not drain the reservoir and putair into the brake system. Repeat the procedurefor the other wheel cylinder. If air still remainsin the system, the air must be removed from themaster cylinder. Slowly push on the brake pedal.Release the pedal slowly. Repeat this procedureuntil no air bubbles enter the reservoir.

Service Brakes AdjustmentUse the procedure that follows to manually adjustthe brakes after repairs are made.

1. Put the lift truck on blocks so that the loadwheels are raised from the surface and can berotated. Use a brake adjuster tool to adjust thebrake shoes so that the brake drum will notrotate. Use the brake adjuster tool to loosen theadjuster wheel until the brake shoes permit thebrake drum to rotate.

2. Remove the lift truck from the blocks. Operatethe lift truck in the FORWARD and REVERSEdirections. Stop the lift truck 10 times in eachdirection to check the operation of the brakes.

NOTE: If the lift truck is operated in wet conditionsor areas with high humidity, the brakes can makea high-pitch noise when the brakes are first applied.This occurrence normally happens after the lift truckhas not been used for a day or more. If the noise doesnot stop after the first few times that the brakes areapplied, begin Troubleshooting procedures.

Brake Pedal AdjustmentCheck and adjust the brake pedal and the push rod ofthe master cylinder, if the brake shoes were replacedor adjusted.

1. Loosen the jam nut for the adjustment capscrew.See Figure 7.

2. Adjust the brake pedal height to 74 mm (2.9 in.)by adjusting the capscrew.

3. Tighten the jam nut. Make sure that the adjust-ment does not change.

NOTE: 74 mm is the perpendicular dimension fromthe top of the floor plate to the bottom edge of thebrake pedal pad.

1. BRAKE PEDAL2. JAM NUT AND CAPSCREW

Figure 7. Adjust Brake Pedal

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1800 SRM 803 Troubleshooting

Parking Brake AdjustmentMake sure that the service brakes are adjusted cor-rectly. See Figure 1. Test the operation of the park-ing brake. The parking brake, when in good condi-tion and correctly adjusted, will hold a lift truck witha capacity load on a 15% grade [a slope of 1.5 m in10 m (a slope of 1.5 ft in 10 ft)]. The adjustment forthe parking brake is below the lever assembly on thecowl.

Put blocks in front and back of the drive tires. Re-lease the parking brake lever. Adjust the cable hous-ings so that the parking brake lever can travel fournotches on the ratchet as it is applied. Put the park-ing brake lever in the released position (this is thefirst position on the ratchet). Adjust the nuts on thecable housings so that the ball ends of the cables aretight in the equalizer link under the lever.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The brakes do not operateequally.

Oil or brake fluid is on the linings. Replace linings.

The linings are worn or hardened. Replace linings.

The brake lines have a restriction. Clear brake lines or replace.

The brake shoes or backplates havedamage.

Replace brake shoes or backplate.

The drum is worn unevenly. Replace brake drum.

One brake does not release. The shoes require more clearance. Increase clearance between shoe anddrum.

A shoe is damaged. Replace shoes.

A return spring is damaged. Replace return spring.

The brake lines have a restriction. Clear brake lines or replace.

A parking cable is damaged. Replace parking cable.

The wheel bearings are adjusted tootight.

Adjust wheel bearing clearance.

The wheel cylinder is damaged. Replace wheel cylinder.

The backplate is damaged. Replace backplate.

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Troubleshooting 1800 SRM 803


Both brakes do not release. The parking brake is not released. Repair or replace park brake cable.

The push rod in the master cylinderrequires more clearance.

Replace push rod and/or mastercylinder.

The master cylinder is damaged. Replace master cylinder.

The shoes require more clearance. Increase clearance between shoe anddrum.

The use of oil, instead of brake fluid,in the system caused damage to theseals.

Flush the system with brake fluid un-til oil is purged. Replace seals.

The brake pedal is difficult topush.

There is not enough clearance for thepush rod.


The linings are too hard. Replace linings.

Water or oil is on the linings. Replace linings.


The wheel cylinders are damaged. Replace wheel cylinders.

The pedal return spring is damaged. Replace return spring.

The brake pedal does nothave enough resistance.

Air is in the brake system. Remove air from the system.

The master cylinder is loose. Tighten master cylinder mountinghardware.

The shoes are damaged. Replace shoes.

A brake drum has a crack. Replace brake drum.

A backplate is damaged. Replace backplate.

A wheel cylinder is damaged. Replace wheel cylinder.

The linings do not fit the brakedrums.

Replace shoes and/or brake drum.

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1800 SRM 803 Troubleshooting


The brake pedal travels toofar.


The shoes require adjustment. Adjust brake shoe clearance.

The linings are worn. Replace linings.

The clearance at the push rod is toogreat.


The brake pedal moves to thefloor.



The brake system has a leak. Tighten fittings or replace brakelines.

The brakes make too muchnoise.

Oil, water, or brake fluid is on the lin-ings.

Clean linings or replace.


A shoe is damaged. Replace shoes.

Dirt is on the linings. Clean linings or replace.

The brakes do not stop thetruck.

Oil, water or brake fluid is on the lin-ings.



The wheel cylinders are damaged. Replace wheel cylinders.

The shoes are not adjusted correctly. Adjust brake shoe clearance.


The parking brake will nothold.

Oil, water, or brake fluid is on the lin-ings.


The parking brake cables requirecorrect adjustment.

Adjust parking brake cable.

A parking brake cable is damaged. Replace parking brake cable.

The brake linings are worn. Replace brake linings.

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Troubleshooting 1800 SRM 803


The parking brake handlever will not release thebrake.

The parking brake cable must beloosened.

Adjust parking brake cable.

The parking brake cables are dam-aged.

Replace parking brake cable.

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TECHNICAL PUBLICATIONS

1800 SRM 803 3/00 Printed in United Kingdom

tocBrake SystemSafety Precautions Maintenance and RepairGeneralDescription and OperationMaster Cylinder RepairRemove and DisassembleClean and InspectAssemble and Install

Service and Parking Brakes RepairRemove and DisassembleCleanInspectAssemble and Install

Brake System Air RemovalService Brakes AdjustmentBrake Pedal AdjustmentParking Brake AdjustmentTroubleshooting

Documents

1800SRM803-1482623(03-2000)-EN