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Brake System Dry

Brake System Dry

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0% found this document useful (0 votes)
175 views30 pages

Brake System Dry

Brake System Dry

Uploaded by

NAVA
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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DRY BRAKE SYSTEM

H8.00-12.00XM (H170-280HD)
[F007, G007, H007];
H13.00-14.00XM (H300-330HD)
[E019, F019, G019];
H16.00XM-6 (H360HD) [E019, F019, G019];
H10.00-12.00XM-12EC
(H360HD-EC) [E019, F019, G019]

PART NO. 1494141 1800 SRM 937


SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, 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 HYSTER 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 hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Dry Brake System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Operation............................................................................................................................................................ 2
Service Brakes ............................................................................................................................................... 2
Parking Brake................................................................................................................................................ 3
Air Tank Repair ................................................................................................................................................. 4
Relief Valve .................................................................................................................................................... 4
Drain Valve .................................................................................................................................................... 5
Brake Pedal Valve Repair.................................................................................................................................. 5
Remove ........................................................................................................................................................... 5
Disassemble, Inspect, and Assemble ............................................................................................................ 6
Install ............................................................................................................................................................. 6
Air Chambers Repair ......................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Disassemble ................................................................................................................................................... 7
Inspect ............................................................................................................................................................ 7
Assemble ........................................................................................................................................................ 9
Install ............................................................................................................................................................. 9
Actuator Arms Repair........................................................................................................................................ 9
Remove ........................................................................................................................................................... 9
Inspect ............................................................................................................................................................ 10
Install ............................................................................................................................................................. 10
Brake Assemblies Repair................................................................................................................................... 11
Brake Shoe, Remove ...................................................................................................................................... 11
Camshaft, Remove......................................................................................................................................... 13
Clean .............................................................................................................................................................. 13
Inspect ............................................................................................................................................................ 14
Camshaft, Install ........................................................................................................................................... 14
Brake Shoe, Install ........................................................................................................................................ 15
Air Dryer ............................................................................................................................................................ 15
Description ..................................................................................................................................................... 15
Cartridge ........................................................................................................................................................ 15
Remove....................................................................................................................................................... 15
Install ......................................................................................................................................................... 17
Filter............................................................................................................................................................... 17
Remove....................................................................................................................................................... 17
Install ......................................................................................................................................................... 17
Quick-Release Valve........................................................................................................................................... 17
Governor Check and Adjustment for Air Compressor ..................................................................................... 18
Brake Shoes Adjustment ................................................................................................................................... 18
Specifications...................................................................................................................................................... 20
Troubleshooting.................................................................................................................................................. 21

This section is for the following models:

H8.00-12.00XM (H170-280HD) [F007, G007, H007];


H13.00-14.00XM (H300-330HD) [E019, F019, G019];
H16.00XM-6 (H360HD) [E019, F019, G019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019, G019]

©2010 HYSTER COMPANY i


"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1800 SRM 937 Description

General
This section has the description and the service procedures for the parts of the brake system. The section
Perkins Diesel Engines, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH) 600 SRM 705 or Perkins Tier 2
Diesel Engines, 1100 (VK) 600 SRM 1068 has the service procedures for the air compressor.

Description
The brake system has two pedals, one pedal valve, in the air tank. A pressure switch activates a warn-
one air tank, and two brake assemblies. See Figure 1. ing light and an alarm on the instrument panel when
The pedal valve operates the service brakes and has the air pressure is less than 483 kPa (70 psi). The air
a linkage that disengages the transmission. tank has a relief valve to limit pressure in the system
and a drain valve to release water caused by conden-
A friction disc brake assembly is installed behind the sation. An air compressor on the engine keeps pres-
planetary hub on each end of the drive axle. The sure in the tank. A governor controls the pressure
air tank is installed in the right-hand channel of the developed by the compressor.
frame. An air pressure gauge indicates the pressure

A. PARK CIRCUIT
1. BRAKE ASSEMBLY 8. BRAKE LIGHT SWITCH (ONLY WITH LIGHTS)
2. ACTUATOR ARM 9. BRAKE PEDAL VALVE
3. AIR CHAMBER 10. AIR TANK
4. QUICK-RELEASE VALVE 11. RELIEF VALVE
5. PARK BRAKE SWITCH (START ENGINE WITH 12. DRAIN VALVE
BRAKE "ON"; ENGAGE TRANSMISSION WITH 13. GOVERNOR
BRAKE "OFF") 14. AIR COMPRESSOR
6. QUICK-RELEASE DOUBLE CHECK VALVE 15. AIR DRYER (OPTIONAL)
7. PARK BRAKE VALVE

Figure 1. Brake System Diagram

1
Operation 1800 SRM 937

Operation
SERVICE BRAKES The pressure of the air at the outlet port pushes the
piston in the brake pedal valve against the balance
The operation of the service brakes is controlled by spring. As the force of the brake air pressure becomes
the brake pedal valve. See Figure 2 and Figure 5. equal to the force of the spring, the piston moves up
When the right-side (service brake) pedal is pushed, and the inlet valve closes. When the pedal is pushed
the piston moves to the seat on the inlet valve. This further, the greater force that is applied through the
action closes the exhaust passage. As the piston spring gives higher air pressure at the air chambers.
moves farther, the inlet valve opens. Air from the This action applies the brakes with greater force.
tank flows from the inlet port to the outlet port. The
air from the outlet port flows through a check valve The piston moves off the seat on the inlet valve when
and a quick-release valve to the air chambers on the the pedal is released. This action opens the exhaust
drive axle. The pressure of the air moves a piston port and releases the air pressure. The sudden de-
assembly in each air chamber. The pistons actuate crease in air pressure opens the exhaust port of the
the brake camshafts. The brake camshafts push the quick-release valve. The brakes are released quickly
brake shoes against the brake drums to apply the as a result. Return springs in the brake assemblies
service brakes. pull the brake shoes away from the drums.

Figure 2. Brake System Schematic

2
1800 SRM 937 Operation

The left-side (inch/brake) pedal is mechanically The operation of the parking brake system is initi-
coupled with the right-side pedal and also operates ated by pulling out the red knob on the instrument
the service brakes. The inch/brake pedal also has a panel. This will electrically activate the park brake
linkage that is connected to the transmission control valve. In normal operation, the knob on the valve is
valve. The linkage disengages the transmission as pushed in (released). When the knob is pushed in, air
the operator depresses the inch/brake pedal. The pressure from the tank compresses the large springs
transmission is in NEUTRAL when the inch/brake in the park chambers of the brake air chambers. This
pedal is fully depressed. The linkage engages the action releases the brakes. Constant air pressure is
transmission as the operator releases the inch/brake necessary to keep the brakes released.
pedal.
When the knob on the parking brake valve is pulled
PARKING BRAKE out, the air pressure in the park chambers is released
through the parking brake valve. This action causes
The parking brake system operates the service brake the springs to apply the brakes for parking. The
assemblies. Large springs in the air chambers pro- springs automatically apply the brakes if the system
vide the energy to apply the brakes for parking. See loses air pressure.
Table 1.

Table 1. Air Chambers Operation

BRAKES RELEASED. The knob on the parking


brake valve is pushed in. Air pressure enters
chamber A, compresses spring B, and releases
brakes. Air pressure keeps the power spring
compressed during operation of the truck.

SERVICE BRAKES APPLIED. The brake or


inch/brake pedal is pushed in. Air pressure enters
chamber C, pushes the diaphragm and piston, and
applies the brakes.

3
Air Tank Repair 1800 SRM 937

Table 1. Air Chambers Operation (Continued)

PARKING BRAKES APPLIED. The knob on the


parking brake valve is pulled out. Air pressure is
released from chamber A. Spring B pushes a rod and
the piston to apply the brakes.

BRAKES MANUALLY RELEASED. Release bolt


D is used to hold the power spring in the compressed
position. This procedure allows air chamber and
brake assembly repair or towing when the system
does not have air pressure.

Air Tank Repair


WARNING
Make sure that air pressure is released from air
tank before making repairs to air system. Pull
stem of relief valve to release air.

Do the following when you remove or install air tank:

1. Clean area around fittings of tank.

2. Release air pressure from air tank. Disconnect


all air lines at tank. Put caps on open lines.

3. Remove bolts from brackets for tank. Slide tank


as necessary to remove top brackets from frame.
Remove tank.

4. When installing air tank, connect air lines as


shown in Figure 1. Make sure that drain valve is
in lowest position. Start engine and check tank
and air lines for leaks.

RELIEF VALVE
The relief valve is installed in a tee fitting on the
tank. See Figure 3. The pressure setting of the re- 1. SPRING CAGE 4. CHECK BALL
lief valve is 1034 kPa (150 psi). The pressure setting 2. VALVE STEM 5. BODY
3. SPRING
cannot be adjusted. Replace relief valve if parts have
defects or damage. Figure 3. Relief Valve

4
1800 SRM 937 Brake Pedal Valve Repair

DRAIN VALVE
Disassemble drain valve as necessary. See Figure 4.
Replace any damaged parts. Use water to clean di-
aphragm. Apply thin layer of grease to valve seat
during assembly.

A. COMPRESSOR B. OPERATING
OPERATING BRAKES
1. VALVE BODY 4. OUTLET VALVE
2. INLET VALVE 5. COVER
3. SUMP CHAMBER 6. INLET FITTING

Figure 4. Drain Valve

Brake Pedal Valve Repair


REMOVE 3. Disconnect air line for pedal valve at fitting to-
ward back of air tank. Put caps on open fitting
WARNING and line.
Make sure that air pressure is released from air 4. Disconnect black wires at pressure switch at
tank before making repairs to air system. Pull check valve. Also disconnect blue and brown
stem of relief valve to release air. wires at pressure switch (MONOTROL® system
only) on inch/brake pedal.
1. Apply parking brakes.
5. Disconnect air lines at brake pedal valve.
2. Tilt cab. Use relief valve to release all air pres-
sure from air tank. See Figure 5. 6. Remove brake pedal valve from floor plate by
loosening four bolts if necessary.

5
Brake Pedal Valve Repair 1800 SRM 937

DISASSEMBLE, INSPECT, AND


ASSEMBLE
NOTE: The brake pedal valve normally is not com-
pletely disassembled. The cartridge assembly has
most of the parts that move. Replacement of the car-
tridge assembly is the normal repair.

1. Carefully remove two capscrews at bottom of


brake pedal valve. The capscrews hold the car-
tridge against a spring. Remove cartridge from
body of brake pedal valve.

2. Clean bore for cartridge. Inspect end of piston in


brake pedal valve. Make sure that end of piston
is clean. Replace piston or brake pedal valve if
end of piston has damage.

3. If installing the original cartridge, check inlet


valve. Make sure that seat surfaces on inlet
valve and body of cartridge are clean and free of
defects.

4. If piston return spring was removed, install


spring over piston.

5. Make sure that cartridge has new O-rings. In-


stall cartridge in body of valve. Install capscrews NOTE: ITEMS 7 THROUGH 17 ARE PARTS OF THE
for cartridge. CARTRIDGE.

INSTALL 1. PEDAL ASSEMBLY


2. CUP SPRING
1. Install brake pedal valve on floor plate with four 3. BALANCE SPRING
bolts. Connect air lines from manifold. The lines 4. SNAP RING
5. PISTON
from the manifold are for the outlet/inlet ports of 6. RETURN SPRING
the brake valve. See Figure 1. 7. INLET VALVE
8. SEAL
2. Connect air line at fitting on manifold. Connect 9. GUIDE TUBE
black wires to pressure switch at manifold as nec- 10. EXHAUST DIAPHRAGM
essary. Connect black wires to pressure switch at 11. CARTRIDGE BODY
12. SCREW
inch/brake pedal as necessary. 13. SNAP RING
14. O-RING
3. Connect air line for pedal valves at fitting toward 15. RETURN SPRING
back of air tank. 16. O-RING
17. O-RING
4. Operate brake system and check brake pedal 18. CAPSCREW (2)
valve and lines for leaks. 19. PISTON SEAL
20. VALVE BODY
21. OUTLET (TO AIR CHAMBERS)
22. INLET (FROM TANK)

Figure 5. Brake Pedal Valve

6
1800 SRM 937 Air Chambers Repair

Air Chambers Repair


REMOVE spring. To compress the power spring, turn
nut on release bolt until release bolt stops
WARNING moving out.
Put blocks under wheels so the lift truck can- NOTE: On the H8.00-12.00XM (H170-280HD) mod-
not move. The parking brakes cannot be ap- els, the release bolt, washer, and nut are kept in
plied after air chambers are removed. a receptacle on the air chamber. Securely engage
release bolt in piston before you start to turn nut.
1. Put blocks under wheels so the lift truck cannot
See Figure 6. On H13.00-14.00XM (H300-330HD),
move.
H16.00XM-6 (H360HD), and H10.00-12.00XM-12EC
2. Use parking brake valve to release parking (H360HD-EC) models, the release bolt is installed in
brake. the piston.

3. Disconnect clevises on air chambers at actuator 1. Use release bolt to fully compress power spring.
arms. See Table 1 and Figure 6.
2. Measure or make a mark for position of clevis on
4. Turn adjustment screw (Figure 7) on each actua- piston rod. Remove clevis, but do not remove jam
tor arm to move arm away from air chamber. The nut.
piston rods will extend with force when air pres-
3. Clean outside of air chamber. Make marks for
sure is released from air chambers.
alignment on body parts and ring clamps. If ring
NOTE: The stroke of the air chamber is as follows: clamps are assembled in the wrong position, the
H8.00-12.00XM (H170-280HD) 63.5 mm (2.5 in.) clamps can cause interference during installa-
H13.00-14.00XM (H300-330HD), H16.00XM-6 tion. If air chamber has a breather tube, discon-
(H360HD), and H10.00-12.00XM-EC (H360HD- nect tube at one of elbows on chamber.
EC) 76.2 mm (3.0 in.)
4. Carefully remove ring clamp for head of air
chamber. Remove head, release bolt, power
WARNING spring, and piston as an assembly. Remove
Make sure that air pressure is released from air diaphragm.
tank before making repairs to air system. Pull
stem of relief valve to release air. 5. A return spring is compressed between the case
and the service brake chamber. Tighten jam nut
5. Apply parking brakes. Release all air pressure on piston rod against chamber to hold spring.
from air tank.
6. Carefully remove ring clamp for service brake
6. Put tags on air lines. Disconnect air lines at air chamber. Remove case and diaphragm. Disas-
chambers. Put caps on open lines. semble parts of service brake chamber as neces-
sary.
7. Remove air chambers from brackets on drive
axle. 7. Hold push rod against spring. Remove screw and
plate at bottom of push rod. Remove push rod
DISASSEMBLE and spring from case.

8. Remove bushings and seal for push rod.


WARNING
The air chamber has a power spring. The INSPECT
spring can cause injury if it is suddenly re-
leased. Never disassemble an air chamber un- Clean and inspect all parts of air chamber. Replace
til you have manually compressed the power worn or damaged parts as necessary.

7
Air Chambers Repair 1800 SRM 937

1. DIAPHRAGM 15. LOCK NUT


2. PISTON 16. HARDENED WASHER
3. POWER SPRING 17. SERVICE BRAKE CHAMBER
4. SPRING GUIDE 18. RETURN SPRING
5. HEAD 19. PISTON ROD
6. BREATHER TUBE* 20. SCREW
7. CAP 21. PUSH ROD PLATE
8. SCREW 22. RING CLAMP
9. RELEASE BOLT 23. NUT
10. WASHER 24. BOLT
11. NUT 25. FLANGE CASE
12. PIN* 26. PUSH ROD BUSHING
13. CLEVIS 27. PUSH ROD SEAL
14. JAM NUT 28. PUSH ROD

*H13.00-14.00XM (H300-330HD), H16.00XM-6 (H360HD), AND H10.00-12.00XM-12EC (H360HD-EC)

Figure 6. Air Chamber Parts

8
1800 SRM 937 Actuator Arms Repair

ASSEMBLE NOTE: If warning tags were removed during disas-


sembly, install tags on bolts for ring clamp on head
NOTE: If replacing fittings for air lines on the case, assembly.
use Teflon® tape or pipe sealant on threads. Tighten
fittings to 34 N•m (25 lbf ft) maximum. 6. Install clevis in its original position on piston rod.
Tighten jam nut to 47 to 68 N•m (35 to 50 lbf).
1. Replace seal and bushings for push rod. See Fig-
ure 6. Lightly lubricate these parts with multi- 7. Release power spring. On H8.00-12.00XM
purpose grease and install parts in case. (H170-280HD) models, turn nut on re-
lease bolt until release bolt can be removed.
2. Lightly lubricate push rod with multipurpose Install release bolt in its receptacle on
grease. Put return spring in case and install case. On H13.00-14.00XM (H300-330HD),
push rod over spring. Push rod through bore and H16.00XM-6 (H360HD), and H10.00-12.00XM-
install other plate and screw on rod. 12EC, (H360HD-EC) models, turn release bolt
all the way into head of air chamber. Close cap.
3. Install return spring and piston in service brake
chamber. Use nut for clevis to hold parts.
INSTALL
4. Make sure that flanges for diaphragm are clean
1. Install air chambers on brackets on axle. DO
and smooth. Install diaphragm in case. Install
NOT install flat washers between chambers and
service brake chamber over diaphragm and then
brackets. Install hardened washers and lock
install ring clamp. Make sure that you align
nuts. Tighten nuts to 135 to 156 N•m (100 to
marks on parts. Tighten nuts as follows:
115 lbf ft).
H8.00-12.00XM (H170-280HD) 27 to 34 N•m
(20 to 25 lbf ft) 2. Connect air lines to air chambers.
H13.00-14.00XM (H300-330HD),
H16.00XM-6 (H360HD), and H10.00- 3. Start engine and run engine until air pressure
12.00XM-12EC (H360HD-EC) 34 to 47 N•m gauge shows at least 620 kPa (90 psi). Push in
(25 to 35 lbf ft) park brake knob to release park brakes.

5. Make sure that flanges for other diaphragm 4. Use adjustment screw (Figure 7) to move actua-
are clean and smooth. Install diaphragm over tor arm to clevis. Connect actuator arm to clevis.
push rod. Install head assembly on diaphragm
and then install ring clamp. Make sure to align 5. Adjust brakes as described in Brake Shoes Ad-
marks on parts. Tighten nuts according to justment. Check for leaks and check for correct
Step 4. Connect breather tube as necessary. operation of brake system.

Actuator Arms Repair


REMOVE 4. Remove snap ring and washer(s) from end of
brake camshaft. Pull actuator arm off camshaft.
WARNING
Put blocks under wheels so the lift truck can-
not move. Brakes cannot be applied after actu-
ator arms are removed.

1. Push in park brake knob to release parking


brakes (system must have normal air pressure).

2. Disconnect actuator arm from clevis on air cham-


ber. See Figure 7.
1. ADJUSTMENT SCREW
3. Turn adjustment screw on actuator arm to move
arm away from clevis. Figure 7. Actuator Arm

9
Actuator Arms Repair 1800 SRM 937

INSPECT

WARNING
If parking brakes are applied, piston rods of
the air chambers will extend suddenly and can
cause an injury. Apply parking brakes to pre-
vent application of brakes by accident.

Inspect actuator arm for damage. Rotate adjustment


screw to make sure that worm drive operates freely.
Replace actuator arm if worm drive does not operate
correctly. Do not repair actuator arms.

INSTALL
1. If parking brakes were applied, release parking
brakes to retract piston rods.

2. Apply antiseize compound to splines of camshaft. NOTE: A [±1.6 mm (0.063 in.)] IS THE CORRECT PO-
3. Install actuator arm against washer(s) on brake SITION OF THE ACTUATOR ARM.
camshaft. Use original number of washers. In-
Chamber
stall washer(s) that was removed from end of Model A
Size
camshaft. Install new snap ring on camshaft.
H8.00-12.00XM 30 71.0 mm
NOTE: Add washers as necessary to keep end clear- (H170-280HD) (2.812 in.)
ance of camshaft to 1.5 mm (0.060 in.) maximum.
See Figure 18. H13.00-14.00XM 36 66.7 mm
(H300-330HD), (2.625 in.)
4. Turn adjustment screw until actuator arm has H16.00XM-6
alignment with clevis. Connect actuator arm to (H360HD), H10.00-
clevis. See Figure 8 for correct position of actua- 12.00XM-12EC
tor arm. Adjust clevis and actuator arm as nec- (H360HD-EC)
essary.
Figure 8. Actuator Arm Installation
5. Adjust brakes as described in Brake Shoes Ad-
justment.

10
1800 SRM 937 Brake Assemblies Repair

Brake Assemblies Repair


BRAKE SHOE, REMOVE H16.00XM-6 (H360HD), and H10.00-12.00XM-12EC
(H360HD-EC) models, release bolt is installed in the
piston.
WARNING
Brake linings can contain dangerous fibers. In- 3. Turn adjustment screw on actuator arm so that
haling dust from these brake linings is a cancer the clearance increases between brake shoes and
or lung disease hazard. Do not make dust! Do drum. Turn screw until brake shoes are fully
not clean brake parts with compressed air or retracted.
by brushing. Use vacuum equipment approved
for brake dust or follow cleaning procedure in 4. Remove drive wheels. Use the procedure in the
this section. When brake drums are removed, Periodic Maintenance section for your lift
do not create dust. truck.

Do not sand, grind, chisel, hammer, or change 5. Remove brake drum. Use capscrews in threaded
linings in any way that will make dust. Any holes to push drum from hub. Do not release
changes to brake linings must be done in a re- dust from brake linings into air when drum is
stricted area with special ventilation. Protec- removed. To clean drum and other brake parts,
tive clothing and a respirator must be used. see Clean.

1. Start engine and tilt mast backward. Put blocks 6. Remove snap rings, retainers, and felt washers
under channels of outer mast. Tilt mast forward from anchor pins. See Figure 9.
to raise drive wheels from floor. Put blocks under
frame of lift truck. 7. Cut lock wire and remove capscrews that hold
anchor pins.
WARNING
The air chamber has a power spring. The WARNING
spring will apply the brakes if system loses air Wear eye protection. Do not hit steel parts with
pressure. Do not service a brake assembly un- a steel hammer. Parts can break and cause in-
til you have manually compressed the power jury.
spring.
8. Use a brass drift to remove top anchor pin. See
2. Apply parking brakes. Use release bolt to com- Figure 10.
press and hold power spring in air chamber. See
9. Rotate top shoe to release tension of return
Figure 6. Turn nut on release bolt until release
spring. Remove shoe. See Figure 11.
bolt stops moving out.
10. Remove bottom anchor pin (see Step 8) and sec-
NOTE: On H8.00-12.00XM (H170-280HD) mod-
ond shoe.
els, release bolt, washer, and nut are kept in a
receptacle on the air chamber. Securely engage 11. Release retainers for rollers and remove rollers
release bolt in piston before you start to turn nut. from brake shoes. See Figure 12.
See Figure 6. On H13.00-14.00XM (H300-330HD),

11
Brake Assemblies Repair 1800 SRM 937

1. BRAKE CAMSHAFT 13. CLAMP 25. RIVET


2. THRUST WASHER 14. CAPSCREW 26. SNAP RING
3. SEAL 15. WASHER 27. ANCHOR PIN RETAINER
4. BUSHING 16. ACTUATOR ARM 28. FELT WASHER
5. CAPSCREW 17. WASHER 29. BRAKE ANCHOR PIN
6. WASHER 18. SNAP RING 30. CAPSCREW
7. SPIDER 19. RETAINER 31. LOCK WIRE
8. GASKET 20. ROLLER 32. BUSHING
9. CAMSHAFT BRACKET 21. RETURN SPRING 33. LOCKWASHER
10. GREASE FITTING 22. PIN 34. CAPSCREW
11. WASHER 23. BRAKE SHOE 35. DUST SHIELD
12. CAPSCREW 24. BRAKE SHOE LINING

Figure 9. Brake Assembly

Figure 10. Top Anchor Pin Removal


Figure 11. Shoe Removal

12
1800 SRM 937 Brake Assemblies Repair

CAUTION
Do not use an oil solvent to clean wheel cylin-
der. Use a solvent approved for cleaning of
brake parts. Do not permit oil or grease in
brake fluid or on brake linings.

2. Use a solvent approved for cleaning of brake


parts to wet brake lining dust. Follow instruc-
tions and cautions of the manufacturer for use
of solvent. If solvent spray is used, do not make
brake lining dust with spray.

3. When brake lining dust is wet, clean parts. Put


any rags or towels in a plastic bag or an airtight
1. RETAINER
container while they are still wet. Put a DAN-
Figure 12. Roller Removal GEROUS FIBERS warning label on plastic bag
or airtight container.
CAMSHAFT, REMOVE
1. Remove brake shoes. See Brake Shoe, Remove.

2. Disconnect actuator arm at clevis on air chamber.

3. Remove snap ring and washer(s) from end of


camshaft. Pull actuator arm off camshaft. See
Figure 9.

4. Check for wear at camshaft bushings as shown


in Figure 13. If radial clearance of camshaft is
more than 0.76 mm (0.030 in.) on a dial indicator
setup, replace bushings. See the section Plane-
tary Drive Axle, (Dry System) 1400 SRM 945
to remove planetary hub. Remove washer(s) and
seal from camshaft and pull camshaft from spi-
der. Use a driver of the correct size to remove
1. RADIAL CLEARANCE MEASUREMENT
bushings from spider and bracket. See Figure 14.
Figure 13. Camshaft Bushing Wear Check
5. Remove thrust washer and seal from camshaft.

CLEAN
1. Carefully remove brake drum. Do not release
dust from brake linings into air when brake drum
is removed.

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.

Figure 14. Bushing Removal

13
Brake Assemblies Repair 1800 SRM 937

4. Any cleaning rags that will be washed must be CAMSHAFT, INSTALL


cleaned so that fibers are not released into the
air. 1. Make sure that capscrews for spider have correct
torque. See Figure 16.
INSPECT
2. If camshaft bracket was removed, install gasket
1. Inspect spider, camshaft, rollers, anchor pins, and bracket on spider. Tighten capscrews as fol-
and return spring for wear and damage. Check lows:
for expanded holes for pins, worn bushings, Grade 5 = 88 to 136 N•m (65 to 100 lbf ft)
broken welds, cracks, corrosion, and incorrect Grade 8 = 122 to 163 N•m (90 to 120 lbf ft)
alignment. Replace worn or damaged parts.
3. Install new bushings for camshaft in spider and
2. Inspect brake shoes. Check for wear at holes for bracket if necessary. Use driver of correct size.
anchor pins and notches for rollers. Also check See Figure 14.
for rust, loose rivets, broken welds, and incorrect
4. Install new seals for camshaft. Install both seals
alignment. Replace brake shoes that have dam-
as shown in Figure 17.
age. Replace brake shoes or linings when thick-
ness of linings is no more than 6.35 mm (0.25 in.) 5. Put thrust washer on camshaft. Apply multipur-
at thinnest point. Always replace brake shoes or pose grease to journals of camshaft and bushings.
linings as sets. Carefully install camshaft through spider and
bracket. Make sure that camshaft turns freely
3. Inspect brake drum as follows:
in bushings.
a. Check for deep grooves, cracks, distortion,
6. Install planetary gear assembly.
and other damage. Replace drum that has
damage.

b. Measure inside diameter of drum at several


locations with drum caliper or micrometer.
See Figure 15. The maximum inside diam-
eter of the 419.1 mm (16.5 in.) brake drum,
including wear, is 422.15 mm (16.620 in.). If
diameter is larger than this maximum, re-
place brake drum. If brake drums require
grinding, never grind more than 2.03 mm
(0.080 in.) from diameter.

Bolt Size Torque


7/16"-20 81 to 102 N•m (60 to 75 lbf ft)
1/2"-20 115 to 156 N•m (85 to 115 lbf ft)
9/16"-18 176 to 224 N•m (130 to 165 lbf ft)
5/8"-18 244 to 312 N•m (180 to 230 lbf ft)

Figure 16. Spider Capscrews Torque

Figure 15. Brake Drum Measurement

14
1800 SRM 937 Air Dryer

5. Install return spring between brake shoes. See


Figure 11. Move upper shoe over spider and in-
stall anchor pin as in Step 3. Repeat Step 4.

6. Install lock wire in capscrews for anchor pins.

7. Apply antiseize compound to splines of camshaft.


Install inner washer(s) and actuator arm on
camshaft. Install outer washer(s) and snap ring.

NOTE: Add washers as necessary to keep end clear-


ance of camshaft to 1.5 mm (0.060 in.) maximum.
See Figure 18.

8. Connect actuator arm at clevis on air chamber.


Use adjustment screw to move actuator arm as
1. LIP OF SEAL 3. SPIDER necessary. See Figure 8 for correct position of
2. BRACKET actuator arm after installation. Adjust clevis and
actuator arm as necessary.
Figure 17. Seal Installation
9. Install brake drum and drive wheels.
BRAKE SHOE, INSTALL
10. Adjust brakes according to the procedure in
1. Install rollers and retainers on brake shoes. See Brake Shoes Adjustment.
Figure 12.

2. Install new bushings for anchor pins in spider


if necessary. Make sure that holes in bushings
have alignment with holes for capscrews that
hold pins.

3. Put lower brake shoe on spider. Use brass drift


to install anchor pin. Make sure that flat on pin
has alignment with hole for capscrew.

4. Install felt washers, retainers, and snap rings for


anchor pin. Install capscrew and tighten it to
13.5 N•m (10 lbf ft) minimum. Figure 18. Camshaft End Clearance

Air Dryer
DESCRIPTION 2. Shut down engine.

The optional air dryer is for drying of the com- 3. Operate quick release valve to remove air pres-
pressed air supplied by the compressor by extracting sure.
the moisture present in the air. See Figure 19.
CAUTION
CARTRIDGE
First remove nut installed on short leg side-end
Remove of the bracket.

NOTE: The air dryer is located on the right side of the 4. Remove nuts holding bracket.
engine mounted to the frame. 5. Remove cartridge and O-ring.
1. Lower the mast.

15
Air Dryer 1800 SRM 937

1. PORT 1 (SUPPLY) 6. LONG SIDE BRACKET NUTS (OPPOSITE SIDE


2. PORT 2 (DELIVERY) NOT SHOWN)
3. PORT 3 (EXHAUST) 7. CARTRIDGES
4. SPRING
5. SHORT SIDE BRACKET NUTS (OPPOSITE SIDE
NOT SHOWN)

Figure 19. Air Dryer

16
1800 SRM 937 Quick-Release Valve

Install 2. Shut down engine.

1. Install new O-rings and cartridge. 3. Operate quick release valve to remove air pres-
sure.
2. Replace nuts on bracket.
4. Release spring and pull out filter.
NOTE: The part number for the cartridge includes
the required O-rings. Install
FILTER 1. Push in filter.

Remove 2. Replace spring.

1. Lower the mast.

Quick-Release Valve
WARNING
Make sure that air pressure is released from air
tank before making repairs to air system. Pull
stem of relief valve to release air.

The quick-release valve is installed on the mounting


plate with the main control valve. See Figure 20.
The valve can be serviced without removal. Carefully
remove cover to inspect parts or replace diaphragm.
Replace quick-release valve if seat of exhaust port
has damage such as broken pieces or deep scratches.

1. BODY 5. PLATE
2. DIAPHRAGM 6. SPRING
3. O-RING 7. CAPSCREW (4)
4. COVER 8. EXHAUST PORT

Figure 20. Quick-Release Valve

17
Brake Shoes Adjustment 1800 SRM 937

Governor Check and Adjustment for Air Compressor


1. Start engine. When governor is correctly ad-
justed, air will be released from exhaust port
when air pressure gauge indicates 862 kPa
(125 psi). The governor is installed next to air
tank above axle.

2. If air pressure does not reach 862 kPa (125 psi),


turn adjustment screw clockwise to increase
pressure. See Figure 21. Turn adjustment screw
counterclockwise to decrease pressure.

The governor also must cause air pressure to in-


crease when air pressure has decreased to less than
724 kPa (105 psi). Replace a governor that does not
operate correctly.

1. ADJUSTMENT SCREW
2. EXHAUST PORT

Figure 21. Governor Adjustment

Brake Shoes Adjustment


than the value in the table, adjust brakes as fol-
WARNING lows:
Put blocks under wheels so the lift truck can-
not move when parking brakes are released. a. For the first adjustment, turn adjustment
screw on actuator arm until brake lining
1. Release parking brakes. Apply and release ser- touches drum.
vice brakes several times.
b. Turn adjustment screw in opposite direction.
2. Measure distance A when service brakes are Turn adjustment screw for only one or two
released. Apply service brakes and measure clicks to get minimum clearance at lining.
distance B. Brake air pressure must be at least Rotate drum to check clearance when that
586 kPa (85 psi) for this measurement. procedure is possible.
3. Subtract A from B and compare remainder with NOTE: The lining at the center of the shoe moves
table in Figure 22. If the remainder is less than 0.06 mm (0.0025 in.) when adjustment screw is ro-
the value in the table, brake adjustment is not tated 90 degrees.
necessary. If the remainder is equal to or more

18
1800 SRM 937 Brake Shoes Adjustment

Model Chamber Size B A Must Be Less Than:


H8.00-12.00XM (H170-280HD) 24 5.08 cm (2.0 in.)
H13.00-14.00XM (H300-330HD), H16.00XM-6 30 6.35 cm (2.5 in.)
(H360HD), and H10.00-12.00XM-12EC (H360-EC)

A. BRAKES OFF B. BRAKES ON


1. ADJUSTMENT SCREW 3. AIR CHAMBER (TYPICAL)
2. ACTUATOR ARM

Figure 22. Brakes Adjustment Check

19
Specifications 1800 SRM 937

Specifications
GOVERNOR CYCLE
Compressor ON 724 kPa (105 psi)
Compressor OFF 862 kPa (125 psi)
RELIEF VALVE SETTING 1034 kPa (150 psi)
LOW AIR PRESSURE WARNING 483 kPa (70 psi) (Later Production)
BRAKES
Size
H8.00-12.00XM (H170-280HD) 419.1 × 127.0 mm (16.5×5 in.)
H13.00-14.00XM (H300-330HD), H16.00XM-6 (H360HD), 419.1 × 177.8 mm (16.5×7 in.)
and H10.00-12.00XM-12EC (H360-EC)
Drum
Maximum inside diameter, including wear 422.15 mm (16.620 in.)
TORQUE VALUES
Air Fittings in Air Chambers 34 N•m (25 lbf ft) Maximum
Nuts, Air Chamber Ring Clamps
H8.00-12.00XM (H170-280HD) 27 to 34 N•m (20 to 25 lbf ft)
H13.00-14.00XM (H300-330HD), H16.00XM-6 (H360HD), 34 to 47 N•m (25 to 35 lbf ft)
and H10.00-12.00XM-12EC (H360-EC)
Jam Nut, Clevis 47 to 68 N•m (35 to 50 lbf ft)
Lock Nuts, Air Chamber Studs 13.5 N•m (10 lbf ft) Minimum
Capscrew, Brake Anchor Pin 13.5 N•m (10 lbf ft) Minimum
Capscrew, Spider See Figure 16.
Capscrew, Camshaft Bracket
Grade 5 88 to 136 N•m (65 to 100 lbf ft)
Grade 8 122 to 163 N•m (90 to 120 lbf ft)

20
1800 SRM 937 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

SERVICE BRAKES

Brakes do no apply enough Brake shoes are not correctly ad- Adjust brake shoes.
force to stop lift truck, or justed.
brakes do not operate.

Linings or drums have excessive Install new brake shoes.


wear.

Oil or grease is on brake linings. Clean linings or install new brake


shoes.

Air compressor has a defect. Repair or replace air compressor.

Air system (lines, fittings, tank Replace or repair defective compo-


valves, ring clamps on air cham- nent to seal air system.
bers) has leaks.

Air lines have restrictions. Repair or replace air lines.

Governor has a defect or incorrect Repair or adjust governor.


adjustment.

Brake pedal valve has a defect. Repair or replace valve.

Quick-release valve has a defect (air Repair or replace valve.


leak).

Defective diaphragm(s) in air cham- Replace diaphragm(s).


ber(s).

Actuator arm(s) is defective or incor- Replace or adjust actuator arm.


rectly installed.

Bent or broken air chamber Replace air chamber bracket.


bracket(s).

Defective or incorrect brake shoe(s). Install new brake shoes.

A camshaft has damage or does not Repair or replace damaged camshaft.


rotate freely.

A brake drum is not round. Repair or install a new brake drum.

Oil or water is in air system. Remove oil or water from air system.

Brakes apply force too Brake pedal valve has a defect. Repair or replace valve.
quickly.

21
Troubleshooting 1800 SRM 937

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Lift truck pulls to one side Brake linings have different friction Install new brake shoes.
when brakes are applied. materials.

One brake assembly has damage or Repair damage or adjust brakes.


incorrect adjustment.

Oil or grease is on one set of linings. Clean lining or install new brake
shoes.

One air chamber has a defect. Repair or replace air chamber.

An air line for an air chamber has a Install new brake lines.
leak or restriction.

A brake drum has a defect. Install new brake drum.

Tires do not have equal inflation. Inflate tires properly.

Brakes do not release or re- Brake pedal valve has a defect. Repair or replace valve.
lease too slowly.

A shoe return spring is broken. Install new spring.

A piston return spring (in air cham- Install new spring.


ber) is broken.

Air leakage from spring chamber(s) Replace seals.


at push rod seal(s).

A camshaft(s) does not rotate freely. Repair damaged camshaft.

Air lines have restrictions. Install new brake lines.

Quick-release valve has a defect. Replace or repair valve.

Exhaust ports of pedal Air leakage from spring chamber(s) Replace seals.
valves have air leakage (all at push rod seal(s).
brakes released).

Brake pedal valve has a defective Repair or replace valve.


seal.

22
1800 SRM 937 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

SERVICE BRAKES, PARK FUNCTION


(REVIEW CAUSES UNDER SERVICE BRAKES ALSO)

Parking brake does not re- Air pressure is too low. Repair or replace compressor or leak-
lease. age.

Parking brake valve has a defect. Repair or replace valve.

Parking brake electrical switch is de- Replace electrical switch.


fective.

Spring chamber(s) has a defective di- Replace diaphragm.


aphragm or leak.

Parking brake does not ap- Brake shoes are not correctly ad- Adjust brakes.
ply enough force to hold lift justed.
truck.

Linings or drums have excessive Install new brake shoes.


wear.

Parking brake valve has a defect. Replace valve.

Spring(s) in air chamber(s) is broken. Replace spring(s).

A release bolt keeps a spring par- Adjust release bolt.


tially compressed.

23
NOTES

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24
TECHNICAL PUBLICATIONS

1800 SRM 937 4/10 (3/07)(12/03)(9/03)(7/02)(2/01) Printed in U.S.A.

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