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Hyster B60-80XT, Manual

The Hyster B60-80XT is a powerful and versatile forklift designed to handle heavy loads with ease. This user-friendly machine comes with a comprehensive manual that can be downloaded for free from our website, providing operators with valuable insights and instructions for optimal performance.

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Brakes

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

1

Description .........................................................................................................................................................

1

W/B60-80XT ...................................................................................................................................................

1

W20-40XTA, W20-40XTC, W20-30XTR, W60-80XT ....................................................................................

2

C60-80XT, CA60-80XT/XT2, T5XT ...............................................................................................................

2

Repairs - General ...............................................................................................................................................

2

Brake Shoe Removal ..........................................................................................................................................

2

W/B60-80XT, W20-40XTA, W20-40XTC, W20-30XTR.................................................................................

2

C60-80XT .......................................................................................................................................................

4

CA/C60-80XT/XT2, T5XT ..............................................................................................................................

5

Brake Shoe Installation.....................................................................................................................................

6

W/B60-80XT, W20-40XTA, W20-40XTC, W20-30XTR.................................................................................

6

C60-80XT2, CA60-80XT, T5XT .....................................................................................................................

7

Brake Linkage Removal ....................................................................................................................................

7

W/B60-80XT ...................................................................................................................................................

7

C60-80XT .......................................................................................................................................................

9

CA60-80XT/XT2, T5XT..................................................................................................................................

11

Brake Linkage and Cable Installation .............................................................................................................

13

W/B60-80XT ...................................................................................................................................................

13

C60-80XT .......................................................................................................................................................

13

CA60-80XT/XT2, T5XT..................................................................................................................................

14

Brake Adjustment..............................................................................................................................................

14

W/B60-80XT, W20-40XTA, W20-40XTC, W20-30XTR.................................................................................

14

C60-80XT, CA60-80XT/XT2, T5XT ...............................................................................................................

15

Brake Linkage Adjustment ...............................................................................................................................

16

C60-80XT, CA60-80XT/XT2, T5XT ...............................................................................................................

16

Troubleshooting..................................................................................................................................................

18

This section is for the following models:

W60-80XT [E135];

B/C60-80XT [B199];

C60-80XT2 [A499];

CA60-80XT [A498];

T5XT [E142];

W20-40XTA [A453];
W20-40XTC [A454];

W20-30XTR [A455]

©2003 HYSTER COMPANY

i

Summary of Contents for B60-80XT

Page 1: ... C60 80XT2 CA60 80XT T5XT 7 Brake Linkage Removal 7 W B60 80XT 7 C60 80XT 9 CA60 80XT XT2 T5XT 11 Brake Linkage and Cable Installation 13 W B60 80XT 13 C60 80XT 13 CA60 80XT XT2 T5XT 14 Brake Adjustment 14 W B60 80XT W20 40XTA W20 40XTC W20 30XTR 14 C60 80XT CA60 80XT XT2 T5XT 15 Brake Linkage Adjustment 16 C60 80XT CA60 80XT XT2 T5XT 16 Troubleshooting 18 This section is for the following models ...

Page 2: ...erated by the linkage interrupts the power to the drive motor when the brake is applied The brake and cutout switch when properly adjusted operate simultaneously W B60 80XT A spring applies the brake when the steering handle is in the vertical position or parallel to the floor See Figure 1 The steering handle has a cam that moves a cam follower attached to a bellcrank The bellcrank is attached thr...

Page 3: ... and specifications Frame Hydraulic System Industrial battery Main control Valve Mast repair Fasteners Schematics diagrams Steering axle Steering system Wire harness repair And more Click Here Get all the content after purchase Thank you very much ...

Page 4: ...e it can reconnect Tag the connector DO NOT CON NECT WARNING The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected To prevent electrical shock and personal injury discharge the capacitor before inspecting or repairing any component Wear safety glasses Make certain the battery has been disconnected Discharge the capac itors in the controller ...

Page 5: ... drum and pivot pins and out of the slot in the brake release arm 9 If the brake shoe and lining assembly require further disassembly remove the two nuts from the spring retainer bolt Disassemble the spring seats spring and spring retainer bolt Note that the spring retainer bolt head has a slotted head to keep the bolt from turning 10 Loosen the setscrews and remove the adjusting screws from the b...

Page 6: ...ET 23 CAPSCREW 24 CAPSCREW 25 LOCKWASHER 26 SPACER Figure 3 Brake Shoe Assembly W20 40XTA W20 40XTC W20 30XTR W60 80XT C60 80XT See Figure 4 1 Raise the drive wheel off the floor Block the lift truck See the section Periodic Maintenance 8000 SRM 281 Refer to WARNINGS in Repairs General 2 Disconnect the battery connector 3 Remove the drive unit compartment hood to ac cess the brakes 4 Discharge the...

Page 7: ...at washer retaining the arm cam weldment to the support weldment Remove the capscrew and lockwasher supporting the centering shaft to the support weldment Remove the support weldment Check the bushing in the support weldment for elongation or damage Replace the bushing if necessary Refer to WARNINGS in Repairs General CA C60 80XT XT2 T5XT See Figure 5 1 Remove the two jam nuts from the bottom of t...

Page 8: ... Figure 3 for the W20 40XTA W20 40XTC W20 30XTR and W60 80XT 1 Assemble the setscrew seat and setscrew in the brake shoe and lining assembly Do not tighten the setscrew completely Install the adjusting screws into the brake shoe Refer to Brake Adjustment W B60 80XT before tightening the setscrews 2 Insert the spring retainer bolt through the brake shoes and adjusting screws Install the spring seat...

Page 9: ...m weldment Install the snap rings on the pivot pins Refer to WARNINGS in Repairs General Assemble the grease fittings into the pivot pins Grease the pivot pins 6 Install the capscrew and washer to retain the support weldment to the centering shaft Install the washer and a new cotter pin to attach the arm cam weldment to the support bracket 7 Adjust the brakes Refer to Brake Adjustment 8 Install th...

Page 10: ...IN 7 YOKE RH THREAD 8 JAM NUT 9 THREADED ROD 10 SWITCH PLATE 11 CAPSCREW 12 LOCK NUT 13 NUT 14 BRACKET 15 WIRE HARNESS 16 SWITCH 17 CAPSCREW 18 LOCKWASHER 19 WASHER 20 CLAMP 21 CLAMP 22 WASHER 23 LOCKWASHER 24 CAPSCREW 25 SUPPORT 26 LOCKWASHER 27 CAPSCREW 28 E RING Figure 6 Brake Linkage W B60 80XT 8 ...

Page 11: ...retaining the clevis pin to the upper threaded brake rod 34 and the bell crank 46 Remove the clevis pin 8 Remove the snap rings 45 retaining the bell crank 46 to the disc Refer to WARNINGS in Repairs General Remove the pin 44 and bell crank 46 from the disc 50 9 Remove the cotter pins retaining the clevis pins 28 to the arm and cam 36 and the brake rod 34 Remove the clevis pins 28 and the brake ro...

Page 12: ...Brake Linkage Removal 1800 SRM 535 Figure 7 Brake Linkage CA60 80XT 10 ...

Page 13: ...ift truck see the section Periodic Maintenance 8000 SRM 281 Refer to WARNINGS in Repairs General 2 Disconnect the battery connector 3 Remove the drive unit compartment hood to ac cess the brakes 4 Discharge the traction motor controller capaci tor Refer to WARNINGS in Repairs General 5 Remove the two capscrews and lockwashers re taining covers 14 and 15 Remove the capscrew 12 and lockwasher 13 Rem...

Page 14: ...Brake Linkage Removal 1800 SRM 535 Figure 8 Brake Linkage C60 80XT2 T5XT 12 ...

Page 15: ...ower clevis pins to be installed in the brake release cam and the upper bellcrank In stall the clevis pins and new cotter pins Tighten the setscrew and remove the shim 3 Install the same shim on the lower side of the brake release cam Loosen the setscrew and ad just the lower adjusting nut to obtain the same clearance Tighten the setscrew when a clear ance of 0 38 to 0 76 mm 0 015 to 0 030 in is o...

Page 16: ...8 5 Run cable 30 through steer column 24 and align the yoke end 38 to the centering shaft Place washers 39 into position and attach with cotter pins 40 Check that cable rests on cable bracket 41 6 Attach the two capscrews and lockwashers that hold covers 14 and 15 into place Insert cap screw 12 and lockwasher 13 7 Replace the drive unit compartment hood 8 Reconnect the battery connector Brake Adju...

Page 17: ... wheel off the floor Block the lift truck see the section Periodic Maintenance 8000 SRM 281 Refer to WARNINGS in Repairs General 2 Disconnect the battery connector 3 Remove the drive unit compartment hood to ac cess the brakes 4 Discharge the traction motor controller capaci tor Refer to WARNINGS in Repairs General 5 Make certain the hand brake levers are released Release the parking brake Install...

Page 18: ...n to temporarily connect the lower yoke of the upper brake rod to the short arm on the bellcrank Rotate the bellcrank until the drill bit or rod bottoms out on the under side of the steer tower plate Retain the bellcrank in this position during Step 3 Step 4 and Step 5 3 Press down on the forward arm on the brake cam lever until the pin bottoms in the slots in both brake rod weldments Adjust the u...

Page 19: ...art of the upper rod weldment Install the cotter pin Tighten the yoke locking nut 10 Check the service brake adjustment with the parking brake OFF a The brake lining must not drag on the brake drum when the hand brake levers are re leased b The brakes must meet the applicable stop ping distance and or draw bar drag require ments without the hand brake levers bottom ing out on the direction speed c...

Page 20: ...e levers are not applied and the parking brake is OFF Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Brake makes noise Brake needs adjusting Adjust Brake shoes worn Replace Brake shoes have oil or grease on them Clean or replace shoes Brake will not stop unit cor rectly Brake linkage or shoes not properly adjusted Adjust Brake shoes worn Replace Brake spring broken Replace Brake shoes ...

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