Maintenance

%5$.( 6<67(0
GP/GLP/GDP16-20AF/BF
(GP/GLP/GDP030-040AF/BF) [A810];
GC/GLC030-040AF [B809];
GLP/GDP16-20AF
(GP/GLP/GDP030-040AF) [B810]

PART NO. 524168420 1800 YRM 540

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure 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 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 YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
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 fuel are
flammable. Be sure to 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 is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Brake System Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description and Operation................................................................................................................................... 1
Service Brake.................................................................................................................................................. 1
Parking Brake.................................................................................................................................................. 2
Service Brakes Repair......................................................................................................................................... 2
Remove and Disassemble .............................................................................................................................. 2
Clean............................................................................................................................................................... 5
Inspect............................................................................................................................................................. 5
Assemble and Install ....................................................................................................................................... 5
Adjust .............................................................................................................................................................. 8
Parking Brake Repair........................................................................................................................................... 9
Remove and Disassemble .............................................................................................................................. 9
Assemble and Install ....................................................................................................................................... 10
Adjust .............................................................................................................................................................. 10
Master Cylinder Repair........................................................................................................................................ 10
Remove ........................................................................................................................................................... 10
Disassemble.................................................................................................................................................... 10
Clean and Inspect ........................................................................................................................................... 12
Assemble ........................................................................................................................................................ 12
Install............................................................................................................................................................... 12
Service Brakes Adjustment ................................................................................................................................. 12
Brake System Air Removal.................................................................................................................................. 13
Parking Brake Not Applied Switch Test ............................................................................................................... 13
Parking Brake Switch Test (Foot Directional Control Pedal Only) ....................................................................... 13
Inching/Brake Pedal Adjustment.......................................................................................................................... 14
Torque Specifications .......................................................................................................................................... 14
Troubleshooting ................................................................................................................................................... 16

This section is for the following models:

GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030-040AF/BF) [A810];

GC/GLC030-040AF [B809];
GLP/GDP16-20AF (GP/GLP/GDP030-040AF) [B810]

©2002 Yale Materials Handling Corp. i

1800 YRM 540 Description and Operation

General
This section has a description and the service procedures for the parts of the brake system. The brake system
includes the following parts: master cylinder, brake shoes, wheel cylinders, inching/brake pedal and linkage, and
parking brake system. A troubleshooting section is included at the end of this section.

Description and Operation

SERVICE BRAKE lips of the seals against the bores. This low pressure
prevents leaks, but cannot apply the brake shoes.
A service brake assembly is installed at each end of the
drive axle. See Figure 1, Figure 2, and Figure 3.

The master cylinder has a housing, a piston with two

ring cups, a return spring, and a check valve assembly.
The reservoir for the fluid is separate from the master
cylinder. When the brake pedal is pushed, the push rod
moves the piston assembly. The primary cup forces
the brake fluid through the check valve to the wheel
cylinders. The secondary cup keeps the fluid that is
above the primary cup in the master cylinder. The fluid
pressure from the master cylinder causes the pistons in
the wheel cylinder to move out. The movement of the
pistons causes the brake shoes to expand against the
drum.

When the brake pedal is released, the return spring

pushes the piston assembly back against the retainer
washer. The return springs for the brake shoes force the
fluid that is in the wheel cylinders back through the lines
to the check valve. The pressure in the lines moves the
check valve from its seat. The fluid flows around the
check valve to the master cylinder bore.

When the brake pedal is released quickly, the return

spring moves the piston faster than 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. The fluid bends the lip of the
primary cup and permits fluid to enter the pressure
chamber. 1. BRAKE FLUID RESERVOIR
2. PARKING BRAKE LEVER
3. ADJUSTMENT KNOB
The check valve assembly permits fluid from the pres- 4. INCHING/BRAKE PEDAL
sure chamber to flow to the lines when the brake pedal 5. MASTER CYLINDER
is pushed. When the pressure in the pressure chamber 6. PARKING BRAKE CABLES
is greater than pressure in the lines, the check valve 7. BRAKE ASSEMBLY
will open. When the brake pedal is released, the pres-
sure in the lines is greater than the pressure in the Figure 1. Brake System
pressure chamber. The check valve assembly then A very small hole is drilled between the inlet port and
moves against the spring pressure to permit fluid to re- the pressure chamber. The hole is just in front of the
turn to the pressure chamber. The check valve assem- primary cup when the piston is against the stop washer.
bly returns to its seat when the pressure in the lines The hole is a compensator port to permit fluid to flow
decreases to less than the spring pressure. This action between the reservoir and the pressure chamber.
keeps a low pressure in the wheel cylinders to hold the The fluid expands because of the heat from using the

1
Service Brakes Repair 1800 YRM 540

brakes. The additional volume of the expanded fluid can turn only when there is clearance between the lining
flows through the compensator port when the pedal is and the brake drum. The adjuster wheel can also be
fully released. If the push rod is adjusted so there is no turned manually. A hole in the back plate is used to get
clearance, the compensator port can be closed by the access to the adjuster wheel.
primary cup. This condition can cause the brakes to be
applied without pushing the pedal. PARKING BRAKE
The clearance between the brake shoes and the brake The parking brake system uses the service brake
drum is adjusted automatically. The adjuster linkage shoes. Additional linkage activates the parking brake
turns the adjuster wheel to adjust the clearance. The system. When the lever is moved to apply the parking
primary (front) shoe and the adjuster links move with the brake, the cables and linkage expand the brake shoes
drum during a stop when the lift truck is moving in the against the drums. The parking brake linkage adjusts
REVERSE direction. The linkage permits the adjuster each cable so the tension is the same when the lever
lever to rotate the adjuster wheel. The adjuster wheel is moved to apply parking brake.

Service Brakes Repair

REMOVE AND DISASSEMBLE 4. Pull wheel assembly from lift truck. If wheel assem-
bly cannot be removed easily, use small screwdriver
WARNING to push adjuster actuator away from adjuster wheel.
Use brake adjuster or screwdriver to turn adjuster
Brake linings can contain dangerous fibers. Inhal-
wheel to loosen brake shoes. Remove hub and
ing the dust from these brake linings is a cancer
drum assembly. Do not damage grease seal when
or lung disease hazard. Do not make dust! Do not
removing hub.
clean brake parts with compressed air or by brush-
ing. Use vacuum equipment approved for brake
dust or follow the cleaning procedure in this sec- WARNING
tion. When the brake drums are removed, do not When the brake shoes are removed, do not make
create dust. dust in the air. See the Clean procedure in this sec-
tion.
Do not sand, grind, chisel, hammer, or change lin-
ings in any way that will make dust. Any changes 5. Make note of arrangement of the parts. See Fig-
to brake linings must be done in a restricted area ure 2 and Figure 3. Use spring pliers to remove
with special ventilation. Protective clothing and a return springs.
respirator must be used.
6. Remove retainers, springs, and anchor pins that
1. Remove capscrews that hold axle shaft to hub. Re- hold brake shoes to back plate.
move axle shaft. Install plug in axle shaft housing
to prevent oil from leaking from housing. 7. Disengage link from actuator for adjuster wheel.
Remove link and anchor guide.
2. Put lift truck on blocks. See procedure How to Put
Lift Truck on Blocks in Periodic Maintenance sec- 8. Move brake shoes away from each other to disen-
tion or Operating Manual. Start engine and tilt gage them from wheel cylinder. Disconnect parking
mast fully backward. Put blocks under mast. Tilt brake lever from parking brake cable as brake as-
mast fully forward until wheels are off ground. Put sembly is removed from back plate. (The parking
grease on floor under wheels so that wheel assem- brake lever has a hook that engages the parking
bly will slide easily from axle tube. Tilt mast back- brake cable.)
ward until wheels are just touching ground. Stop
engine. Put blocks under frame of lift truck.

3. Bend lockplate and remove nut that holds axle bear-

ing. Remove washer and bearing cone.

2
1800 YRM 540 Service Brakes Repair

1. WHEEL CYLINDER 9. ACTUATOR SPRING 16. PARKING BRAKE LINK

2. RETURN SPRING 10. LINK 17. PARKING BRAKE LEVER
3. PLUG 11. ADJUSTER WHEEL SPRING
4. ANCHOR ACTUATOR 18. PARKING BRAKE LEVER
5. ANCHOR GUIDE 12. ADJUSTER WHEEL 19. PIVOT PIN
6. BACK PLATE ASSEMBLY 20. ACTUATOR LEVER
7. BRAKE SHOE 13. PARKING BRAKE CABLE
8. RETAINER SPRING 14. ADJUSTER SPRING
ASSEMBLY (4) 15. BRAKE SHOE

Figure 2. Brake Assembly (Left Brake Assembly Shown)

3
Service Brakes Repair 1800 YRM 540

1. WHEEL CYLINDER 9. ACTUATOR SPRING 17. PARKING BRAKE LEVER

2. RETURN SPRING 10. LINK SPRING
3. PLUG 11. ADJUSTER WHEEL 18. PARKING BRAKE LEVER
4. ANCHOR ACTUATOR 19. PIVOT PIN
5. ANCHOR GUIDE 12. ADJUSTER WHEEL 20. ACTUATOR LEVER
6. BACK PLATE 13. PARKING BRAKE CABLE
7. BAKE SHOE 14. ADJUSTER SPRING
8. RETAINER SPRING 15. BRAKE SHOE
ASSEMBLY (4) 16. PARKING BRAKE LINK

Figure 3. Service Brake Parts

NOTE: The adjuster wheel for the left brake is not the is removed from the back plate. The adjuster wheel
same as the adjuster wheel for the right brake. The will also disengage from the brake shoes after the
adjuster wheel for the right brake has left-hand threads. brake assembly is removed.

9. Make note of arrangement of parts and disassem- 10. Remove spring for adjuster wheel actuator. Re-
ble brake assembly. Remove parking brake link and move adjuster wheel actuator from brake shoe.
spring if they are still engaged with brake shoes.
11. Use screwdriver or small prybar to separate ends of
The parking brake link and spring will frequently fall retainer. Remove pivot pin to remove parking brake
from the brake assembly when the brake assembly lever from brake shoe.

4
1800 YRM 540 Service Brakes Repair

12. Disconnect brake line from wheel cylinder. Remove INSPECT

capscrews that hold wheel cylinder to back plate
and remove wheel cylinder. 1. Inspect bore of wheel cylinder for holes or
scratches. Install new wheel cylinder assem-
13. Remove push rods, dust covers, pistons, cups, and bly if there is any damage.
spring from wheel cylinder. See Figure 4.
2. Inspect return springs for wear or damage. Inspect
NOTE: The back plate is not normally removed from back plate for wear where brake shoes touch back
the axle housing for brake repairs. The back plate is plate. If back plate is worn or damaged, remove
fastened to the axle mount with six special nuts. The any grooves or install new back plate.
locking function of the nuts is decreased if they are re-
moved. These nuts are tightened to 102 N•m (75 lbf ft).
WARNING
CLEAN New brake shoes must be installed in complete
sets. Install new brake shoes on both wheels if any
shoe is damaged. The brake performance on both
WARNING ends of an axle must be equal or the lift truck can
DO NOT use an oil solvent to clean the master cylin- be difficult to steer when the brakes are applied.
der, wheel cylinder, or the brake linings. Use a sol-
vent approved for cleaning of brake parts. Do not 3. Inspect brake shoes for cracks or damage. If linings
permit oil or grease in the brake fluid or on the brake or shoes are worn or damaged, install new brake
linings. Oil and grease will cause damage and leaks shoes. Maximum wear is to within 1 mm (0.039 in.)
in the seals of a brake system. The brakes will not of contact with rivets or metal shoe on bonded lin-
operate correctly if oil, grease, or brake fluid is on ings.
the brake linings.
4. Inspect brake drums for wear, cracks, or damage.
Cleaning solvents can be flammable and toxic and Install new parts as necessary.
can cause skin irritation. When using cleaning sol-
vents, always follow the safety instructions of the 5. Inspect brake drum for deep grooves or other dam-
solvent manufacturer. age.

NOTE: Do not release brake lining dust into the air when If grooves must be removed from brake drums, do
the brake drum is removed. not grind more than 1.5 mm (0.060 in.) from inside
diameter of brake drum. Maximum limit of inside
1. Use solvent approved for cleaning brake parts to diameter is 255.5 mm (10.06 in.). If inside diameter
wet brake lining dust. Follow manufacturer’s in- is larger than limit, install new brake drum.
structions and cautions for use of solvent. If sol-
vent spray is used, do not make brake lining dust 6. Check teeth of adjuster wheel for wear. (The ad-
with spray. juster wheel must turn freely.) Check the adjuster
links for damage.

CAUTION 7. Make sure parking brake cables are in good condi-

Do not permit oil or grease on the brake linings. Use tion.
a brake cleaning fluid as necessary to clean linings
8. Check grease seals and seal surfaces for wear or
that will be used again.
damage.
2. Clean parts when brake lining dust is wet. Put rags
or towels in plastic bag or airtight container while ASSEMBLE AND INSTALL
still wet. Put DANGEROUS FIBERS warning label
1. If wheel cylinder was disassembled for repair, as-
on plastic bag or airtight container.
semble wheel cylinder. See Figure 4. Use only
Any cleaning rags that will be washed must be YALE APPROVED parts.
cleaned so that fibers are not released into the air.
2. Install wheel cylinder on back plate. Connect brake
line to wheel cylinder.

5
Service Brakes Repair 1800 YRM 540

3. Install parking brake lever. See Figure 3. Use pivot 7. Lubricate back plate with small amount of grease
pin and retainer to fasten parking brake lever to where brake shoe touches back plate. Use retainer
brake shoe. Close ends of retainer to fasten pivot spring assemblies to mount brake shoe and actu-
pin in position. ator assembly to back plate. Put anchor pin that
holds brake shoes through the back plate.
4. Lubricate back plate with small amount of grease
where brake shoe touches back plate. Engage 8. Put spring seat, spring, and retainer onto anchor
parking brake cable in slot in parking brake lever pin. Push retainer onto anchor pin and rotate re-
as brake shoes are installed on the back plate. Use tainer 90 degrees. Make sure retainer is in correct
retainer spring assemblies to mount brake shoe as- position. Install another retainer spring assembly.
sembly to back plate. Put anchor pin that holds Make sure brake shoe engages push rod (see Fig-
brake shoes through back plate. ure 4).

5. Put spring seat, spring, and retainer onto anchor 9. Fasten adjuster actuator spring to adjuster wheel
pin. Push retainer onto anchor pin and rotate re- actuator and brake shoe.
tainer 90 degrees. Make sure retainer is in correct
position. Install another retainer spring assembly. 10. Put antiseize compound on threads of adjuster
Make sure brake shoe engages push rod (see Fig- wheel. Turn adjuster wheel into adjuster nut so
ure 4). adjuster assembly is in its shortest position. This
allows brake drum to be installed easily over brake
6. Attach actuator for adjuster wheel to actuator lever. linings.

1. PUSH ROD (2) 4. CUP (2) 7. INLET PORT

2. DUST COVER (2) 5. SPRING 8. SPECIAL FITTING
3. PISTON (2) 6. WHEEL CYLINDER BODY 9. DUST COVER

Figure 4. Wheel Cylinder

6
1800 YRM 540 Service Brakes Repair

Align height of axle housing with hub bearings. Put

WARNING grease under wheel and slide wheel toward axle
The threads of the adjuster wheel are not the same housing. Install outer bearing and nut.
for each side. The adjuster wheel for the right brake
has left-hand threads. The adjuster wheel for the 20. Adjust hub bearings by tightening nut to 205 N•m
left brake has right-hand threads. (151 lbf ft) while rotating hub. Loosen nut until hub
turns freely. (The torque must be less than 27 N•m
If the adjuster assemblies are installed on the (20 lbf ft).)
wrong side, the brake shoe clearance will increase
when the brakes are applied. This would result in 21. Tighten nut to 34 N•m (25 lbf ft) or to first-alignment
a loss of braking ability. position after 34 N•m (25 lbf ft). Bend lockplate over
nut.
11. Install adjuster wheel between two brake shoes.
Make sure adjuster wheel will be toward rear of lift
truck. Separate brake shoes so that adjuster wheel
CAUTION
is held in position and adjuster actuator spring is in If there is too much clearance, the automatic
tension. adjusters will not operate. If the clearance is
too small, the automatic adjuster cannot turn the
12. Install link and spring between parking brake lever adjuster wheel to increase the clearance. The
and brake shoe. adjuster wheel will not turn until the brake shoes
wear. If the adjuster wheel does not move for a
13. Install other spring retainers that hold the brake long operating period, the adjuster link can wear a
shoes. Make sure parking brake link and spring spot on the adjuster wheel so that it will not turn
are correctly engaged after spring retainers are in- correctly.
stalled.
22. Adjust clearance of brake shoes. Put brake ad-
14. Install anchor guide on anchor. Install link onto an- juster or screwdriver through slot in back plate. Use
chor and actuator lever. tool to rotate adjuster wheel. (The actuator for the
adjuster wheel will only permit rotation in one direc-
15. Install actuator spring.
tion.) Turn adjuster wheel until brake shoes have
NOTE: The shape of the return springs permits them to expanded against brake drum and hub will not turn.
be installed correctly in only one position. Use small screwdriver to lift actuator away from ad-
juster wheel. Turn adjuster wheel approximately 15
16. Use correct tools to install return springs. teeth in opposite direction.

17. Make sure bottom edge of adjuster wheel actuator The brakes will adjust to the correct clearance when
is just above center of adjuster wheel teeth. Check they are applied while the lift truck is travelling in the
installation if alignment is not correct. REVERSE direction.

18. Clean bearings and lubricate them with wheel bear- 23. Put liquid sealant on flange of axle shaft. Install axle
ing grease. Install bearings and seals in brake shaft and capscrews. Tighten capscrews to 66 N•m
drum. Install assembly on axle housing. See Fig- (49 lbf ft).
ure 5 and Figure 6.

19. To prevent damage to inner oil seal, hub and drum

assembly can be temporarily fastened to wheel.

7
Service Brakes Repair 1800 YRM 540

A. PNEUMATIC TIRE B. CUSHION TIRE

1. OUTER SEAL 2. INNER SEAL 3. BRAKE DRUM

Figure 5. Grease Seals Location

ADJUST
NOTE: The service brakes must be adjusted before the
parking brake can be adjusted.

1. Remove air from brake system. See Brake System

Air Removal.

2. Install wheel on hub. For GP/GLP/GDP16-

20AF/BF (GP/GLP/GDP030-040AF/BF) lift truck
models, tighten nuts to 204 to 225 N•m (150
to 166 lbf ft). For GC/GLC030-040AF and
GLP/GDP16-20AF (GP/GLP/GDP030-040AF)
lift truck models, tighten nuts to 129 N•m (95 lbf ft).

3. Start engine and tilt mast backward to remove

blocks. Push on brake pedal. Pedal must not touch
floor plate. Move lift truck in REVERSE and push
Figure 6. Inner Grease Seal Installation on brake pedal to permit adjuster mechanism to
operate. Repeat this operation several times.

8
1800 YRM 540 Parking Brake Repair

Parking Brake Repair

REMOVE AND DISASSEMBLE 2. Remove two capscrews that fasten bracket for park-
ing brake to cowl. Remove bracket and brake lever
If the lever assembly for the parking brake must be re- assembly.
moved from the cowl, use the following procedure. See
Figure 7. 3. Loosen jam nuts that fasten threaded ends of brake
cables to brake lever assembly.
1. Use blocks next to wheels to make sure lift truck
cannot move. Release parking brake lever. 4. Turn adjuster knob counterclockwise until brake ca-
bles are loosened. Disconnect cables from link.

1. BRAKE FLUID RESERVOIR 8. ADJUSTMENT SLOT

2. PARKING BRAKE LEVER 9. LINK
3. ADJUSTMENT KNOB 10. YOKE
4. INCHING/BRAKE PEDAL 11. CABLE BRACKET
5. MASTER CYLINDER 12. ADJUSTMENT SCREW
6. PARKING BRAKE CABLES 13. CABLE NUT
7. BRAKE ASSEMBLY

Figure 7. Parking Brake Lever Adjustment

9
Master Cylinder Repair 1800 YRM 540

NOTE: The service brake assembly must be removed 6. Rotate the knob clockwise three turns to pull up
before the parking brake cable can be removed from the the yoke. Check that the lever stays in the Applied
backplate. position.

5. Remove snap ring that holds outer cover of parking 7. Use the adjustment screws to adjust the cable
brake cable in backplate. Remove parking brake length by setting the cable bracket to 7 to 8 mm
cable from backplate. (0.28 to 0.31 in.), dimension H in Figure 7. Tighten
the lock nuts for the adjustment screws.
ASSEMBLE AND INSTALL
8. Rotate the knob clockwise to get the correct brake
If the lever assembly for the parking brake was removed force. See the Adjust section.
from the cowl, use the following procedure for installa-
tion: ADJUST
NOTE: The parking brake cables must be installed in Make sure the service brakes are adjusted and the op-
the backplate before the service brake is installed. eration of the automatic adjuster mechanism is correct
before the parking brake is adjusted.
1. Install parking brake cable in backplate. Install snap
ring that holds outer cover of parking brake cable in 1. Turn adjustment knob to raise link and tighten park-
backplate. See Figure 7. ing brake cables. Turn adjustment knob until park-
ing brakes are fully applied when lever is used to
2. Make sure parking brake lever is in Released posi- apply the parking brake.
tion. Turn adjustment knob until link is adjusted to
bottom of adjustment slot. 2. Test operation of parking brake.

3. Adjust the nuts on the ends of the cable assemblies The lift truck with a capacity load must not move
to the center of the threads. when the parking brake is applied on a 15% grade
[a slope that increases 1.5 m vertically per 10 m of
4. Use the adjustment screws to set the cable bracket horizontal distance].
to 4 mm (0.16 in.), dimension H as shown in Fig-
ure 7. 3. Check operation of parking brake switches as de-
scribed in Parking Brake Not Applied Switch Test
5. Install the cables onto the yoke and cable bracket. and Parking Brake Switch Test (Foot Directional
Control Pedal Only).

Master Cylinder Repair

REMOVE DISASSEMBLE
1. Remove floor plates from lift truck to access master 1. Remove dust boot and push rod. Put bottom of
cylinder. See Figure 8. master cylinder into container. Push on piston to
remove brake fluid from cylinder.
2. Remove brake hydraulic line from master cylinder.
Disconnect remote reservoir hose from master
cylinder. Plug hose to prevent reservoir from WARNING
draining. Keep control of the piston as it is removed so that
the return spring does not suddenly release the pis-
3. Remove lock pin and pin from rod end that is at- ton from the bore with enough force to cause an in-
tached to push rod. jury.
4. Remove capscrews, washers, and nuts that hold 2. Put master cylinder into vise with soft jaws. (Clamp
master cylinder to bracket assembly. Remove mas- on mounting flange only.) Push on piston to release
ter cylinder from lift truck. tension on snap ring. Remove snap ring, washer,
and piston.

10
1800 YRM 540 Master Cylinder Repair

1. ROD END 5. SNAP RING 9. PISTON SEAL 13. RETAINER

2. NUT 6. CYLINDER HOUSING 10. PISTON 14. SPRING
3. PUSH ROD 7. SEAL 11. SPACER 15. CHECK VALVE
4. BOOT 8. FITTING 12. PISTON CUP 16. VALVE SEAT

Figure 8. Master Cylinder

11
Service Brakes Adjustment 1800 YRM 540

3. Remove all seals from piston. 3. Install spacer, piston cup, and retainer onto piston.
Make sure lip of piston cup faces spring.
4. Remove spring, check valve, and valve seat.
4. Install new check valve and seat into cylinder bore.
CLEAN AND INSPECT Install spring and piston assembly into bore. Use
screwdriver to push on piston assembly until snap
CAUTION ring groove is visible. Install snap ring.
DO NOT use an oil solvent to clean the master cylin- 5. Install boot and push rod.
der, wheel cylinder, or the brake linings. Use a sol-
vent approved for cleaning of brake parts. Do not INSTALL
permit oil or grease in the brake fluid or on the lin-
ings. 1. Install master cylinder on lift truck. Install cap-
screws, washers, and nuts that hold master
1. Clean master cylinder parts with acceptable sol- cylinder to bracket assembly. See Figure 8.
vent.
2. Install pin and lock pin in rod end that is attached to
2. Inspect the bore of the master cylinder for holes or push rod.
scratches. Install a new master cylinder assembly
if there is damage. 3. Remove plug from hose. Connect remote reservoir
hose to master cylinder. Install brake hydraulic line
3. Inspect the piston for scratches or damage. Install on master cylinder.
new piston if there is damage.
4. Install floor plates on lift truck.
ASSEMBLE
5. Check adjustment of brake pedal as described in
1. Lubricate parts with new brake fluid. Use YALE Inching/Brake Pedal Adjustment.
APPROVED parts only. See Figure 8.

2. Install piston seal onto piston.

Service Brakes Adjustment

NOTE: The following procedure is for new brake shoes. 3. Use small screwdriver to push automatic adjuster
If the lift truck has been operated for more than 25 hours lever away from adjuster wheel. Use adjuster tool
and has correct pedal height, the brakes normally will to loosen adjuster wheel approximately 15 teeth.
not need adjustment.
4. Remove lift truck from blocks. Operate lift truck
1. Put the lift truck on blocks so drive wheels can be in FORWARD and REVERSE directions. Stop lift
rotated. See How to Put Lift Truck on Blocks in Pe- truck 10 times in each direction.
riodic Maintenance section or Operating Manual.
This procedure causes the brake shoes to wear a
2. Use adjuster tool to rotate adjuster wheel so teeth small amount to better fit the brake drum.
of adjuster wheel move down. This expands the
brake shoes. Adjust brake shoes so that wheel will
not rotate.

12
1800 YRM 540 Parking Brake Switch Test (Foot Directional Control Pedal Only)

Brake System Air Removal

Adjust the service brakes before the air is removed from 4. Allow the brake pedal to completely return to the
the brake system. top of the stroke. Repeat Step 1 through Step 3
until there are no air bubbles in container.
1. Fill master cylinder reservoir with brake fluid.
5. Check brake fluid level in master cylinder reservoir
2. Put one end of rubber hose on special fitting of during procedure. Keep brake fluid at correct level.
wheel cylinder. Put other end of hose into clear con-
tainer of brake fluid. 6. Repeat procedure for other wheel cylinder. If air re-
mains in system, air must be removed from master
3. Loosen special fitting at wheel cylinder one turn so cylinder. Push on brake pedal with smooth stroke.
that air can be removed from brake system. Slowly Release pedal slowly. Repeat this procedure until
push brake pedal and hold it at end of stroke. Close no air bubbles enter reservoir.
special fitting.

Parking Brake Not Applied Switch Test

The Parking Brake Not Applied switch is in the operator seat. This switch actuates a buzzer on the instrument
cluster. If the operator leaves the seat for more than 1 second without applying the parking brake, the buzzer will
sound continuously for 6 seconds. The buzzer operates when the key switch is in the ON or OFF position.

Parking Brake Switch Test (Foot Directional Control Pedal Only)

After the parking brake has been adjusted, the opera- 3. Turn ignition switch to START. If parking brake
tion of the parking brake switch must be tested. switch operates correctly, starter will not energize.
Turn ignition switch to OFF.
WARNING 4. Apply parking brake with parking brake lever.
The parking brake switch prevents the starter mo-
tor from being energized when the parking brake The two-circuit microswitch will open the electric cir-
is not applied. The switch also de-energizes the cuit for the Foot Directional Control control (de-en-
solenoids to put the powershift transmission in ergize the solenoids for the powershift transmission
NEUTRAL. and permit the starter circuit to be energized with
the ignition switch).
If the switch is not adjusted correctly, the engine
can be started with the parking brake released. 5. Turn ignition switch to START. Starter will operate
if parking brake switch operates correctly. Turn ig-
1. Put lift truck on blocks so that drive wheels are off nition switch to OFF.
ground. See How to Put Lift Truck on Blocks in Pe-
riodic Maintenance section or Operating Manual. 6. Check wires for parking brake switch if results of
Put blocks at each side of steering tires to prevent Step 2 through Step 5 are not correct.
movement of lift truck.
NOTE: The transmission must be in NEUTRAL any
2. Release parking brake. time the parking brake lever is applied.

The two-circuit microswitch will close the electric 7. Apply parking brake and start engine. Push parking
circuit for the Foot Directional Control control (en- brake lever toward Released position, but do not
ergize the solenoids for the powershift transmission push release button. Parking brake will stay locked
and de-energize the starter circuit). in ON position.

8. If results of the test are not correct, check for wear

and damage. Make repairs as necessary and re-
peat Step 1 through Step 7.

13
Torque Specifications 1800 YRM 540

Inching/Brake Pedal Adjustment

The following adjustment procedure gives a small 3. Use adjustment capscrew to set pedal height (di-
amount of transmission "inching" as the brakes are ap- mension M) to 160 to 170 mm (6.3 to 6.7 in.).
plied (called as inching/brake "overlap"). This overlap
makes the inching function smooth on small grades. 4. Install inching cable and adjust cable to remove any
As the inching/brake pedal is pushed in, inching/brake free movement in cable. After cable is installed,
overlap occurs. The brakes start to apply and the there must not be any free movement in lever when
transmission clutch packs begin to disengage. See brake pedal is applied.
Figure 9.
5. The brake/inching overlap is a combination of di-
Check and adjust the inching/brake pedal if the control mensions F and O (see Figure 9). Dimension F is
valve was removed for repairs. the stroke of the inching/brake pedal from the pedal
set height (dimension M) to the pedal height when
NOTE: If the lift truck has been operated for more than the bellcrank begins to move. The correct dimen-
25 hours since the brake shoes were installed, and the sion for F is 5 ±2.5 mm (0.20 ±0.10 in.).
operation of the brakes is normal, go to Step 1. If the lift
truck has new brake shoes, first adjust the brake shoes 6. Dimension O (see Figure 9) is the stroke of the
as described in Service Brakes Adjustment. inching/brake pedal until the push rod begins to
move. The correct dimension for O is 24 +5 mm
1. Adjust length of push rod so that dimension E is (0.95 +0.19 in.). Turn the adjusting capscrew un-
5 mm (0.20 in.). Tighten jam nut on rod end. til it touches the crank. Then, loosen the adjusting
capscrew 3.5 to 4.5 turns to set the correct overlap.
2. Adjust free movement (dimension D) of push rod by
turning adjustment capscrew. Turn capscrew until
push rod touches piston of master cylinder, then
loosen capscrew 1/2 to 3/4 turn. Tighten jam nut.

Torque Specifications
Back Plate to Axle Mount Capscrews Wheel Nuts[GP/GLP/GDP16-20AF/BF
102 N•m (75 lbf ft) (GP/GLP/GDP030-040AF), GLP/GDP16-20AF
(GP/GLP/GDP030-040AF)]
Wheel Stud Assembly Nuts 204 to 225 N•m (150 to 166 lbf ft)
127 N•m (94 lbf ft)
Wheel Capscrews GC/GLC030-040AF
Axle Shaft Capscrews 129 N•m (95 lbf ft)
66 N•m (49 lbf ft)

14
1800 YRM 540 Torque Specifications

1. INCHING/BRAKE PEDAL 5. MASTER CYLINDER 9. ADJUSTMENT CAPSCREW,

2. RETURN SPRING 6. CRANK PEDAL HEIGHT
3. ADJUSTMENT CAPSCREW, 7. ADJUSTMENT CAPSCREW, 10. BELLCRANK
OVERLAP PUSH ROD CLEARANCE 11. INCHING SPOOL
4. FLUID RESERVOIR 8. PUSH ROD 12. CABLE

Figure 9. Inching/Brake Pedal Adjustment

15
Troubleshooting 1800 YRM 540

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The brakes do not correctly There is air in the brake system. Repair system to prevent air from en-
stop the lift truck. tering. Remove air from the system.

The mount for the master cylinder is Tighten fasteners.

loose.

Brake shoes are worn or damaged. Install new brake shoes.

The linings are too hard. Install new correct lining.

A brake drum is cracked. Install new part.

A backplate is damaged. Install new part.

A wheel cylinder is leaking or does not Repair or install new parts. Remove air
operate correctly. from the system.

The brake linings do not fit the brake Install correct linings. Machine brake
drums. drums.

The master cylinder is damaged. Install new master cylinder. Remove

air from the system.

Water or oil is on the brake linings. Clean or install new linings.

One brake does not release. A brake shoe is damaged. Install new parts.

A return spring is wrong. Install new correct spring.

The brake lines have a restriction. Remove restriction or install new lines.
Remove air from the system.

A parking brake cable is damaged or Adjust cable or install new parts.

needs adjustment.

The wheel cylinder is damaged. Repair or install new parts. Remove air
from the system.

The backplate is worn or damaged. Repair or install new parts.

The brakes make too much Dirt, oil, water, or brake fluid is on the Clean or install new linings.
noise. linings.

The brake linings are worn. Install new linings.

The brake drum is damaged. Repair or install new brake drum.

A brake shoe is worn or damaged. Install new brake shoe(s).

16
1800 YRM 540 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The brakes do not operate Oil or brake fluid is on the linings. Repair leak. Clean or install new lin-
equally. ings.

The linings are worn or hard. Install new linings.

A wheel cylinder is leaking. Repair or install new parts. Remove air

from the system.

The brake linings are not correctly in- Install brake linings correctly.
stalled.

The backplate or brake shoes are Repair or install new parts.

damaged.

The brake drums are not round. Check to make sure there is adequate
material to allow for machining. Ma-
chine brake drums to make them round
or install new drums.

The shoes are adjusted too tight. Adjust brakes. Check adjuster linkage.

Both brakes do not release. The parking brake is not released. Release parking brake.

The parking brake cables need adjust- Adjust or install new cables.
ment.

There is not enough clearance at the Adjust the clearance between the push
end of the push rod in the master cylin- rod and the piston.
der.

The master cylinder is damaged. Install new master cylinder. Remove

air from the system.

The brake shoes are adjusted too tight. Check operation of adjuster linkage.
Adjust brakes.

The brake pedal travels too Air in the brake system. Remove air from the system. Check for
far. leaks.

Brake fluid level low. The brake system Fill brake fluid reservoir to the correct
has a leak. level. Repair leak. Remove air from the
system.

The brake shoes are not adjusted cor- Check operation of adjuster linkage.
rectly. Adjust brakes.

The brake linings are worn. Install new linings.

17
Troubleshooting 1800 YRM 540

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The brake pedal travels too One of the dual brake circuits is not op- Repair or install new parts.
far. (Cont.) erating.

There is too much clearance at the end Adjust the clearance between the push
of the push rod in the master cylinder. rod and the piston.

The master cylinder is worn or dam- Repair or install new master cylinder.
aged. Remove air from the system.

The parking brake will not hold Parking brake not adjusted correctly. Use adjustment knob on parking brake
the lift truck. lever to adjust holding force. See ad-
justment procedure for correct specifi-
cations.

Oil, water, or brake fluid is on the lin- Clean or install new linings.
ings.

The parking brake cables need adjust- Install new parts. Lubricate and adjust
ment or lubrication or have damage. cables.

The parking brake will not re- The parking brake lever is adjusted too Adjust parking brake. See adjustment
lease. tight. procedure for correct specifications.

The parking brake cables need adjust- Install new parts. Lubricate and adjust
ment or lubrication or have damage. cables.

18
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

1800 YRM 540 5/02 Printed in U.S.A.