Brake System Dry
Brake System Dry
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]
• 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.
• 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.
• 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
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
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.
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.
3
Air Tank Repair 1800 SRM 937
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
5
Brake Pedal Valve Repair 1800 SRM 937
6
1800 SRM 937 Air Chambers Repair
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.
7
Air Chambers Repair 1800 SRM 937
8
1800 SRM 937 Actuator Arms Repair
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.
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.
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
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
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.
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.
13
Brake Assemblies Repair 1800 SRM 937
14
1800 SRM 937 Air Dryer
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
16
1800 SRM 937 Quick-Release Valve
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.
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.
1. BODY 5. PLATE
2. DIAPHRAGM 6. SPRING
3. O-RING 7. CAPSCREW (4)
4. COVER 8. EXHAUST PORT
17
Brake Shoes Adjustment 1800 SRM 937
1. ADJUSTMENT SCREW
2. EXHAUST PORT
18
1800 SRM 937 Brake Shoes Adjustment
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
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.
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
Lift truck pulls to one side Brake linings have different friction Install new brake shoes.
when brakes are applied. materials.
Oil or grease is on one set of linings. Clean lining or install new brake
shoes.
An air line for an air chamber has a Install new brake lines.
leak or restriction.
Brakes do not release or re- Brake pedal valve has a defect. Repair or replace valve.
lease too slowly.
Exhaust ports of pedal Air leakage from spring chamber(s) Replace seals.
valves have air leakage (all at push rod seal(s).
brakes released).
22
1800 SRM 937 Troubleshooting
Parking brake does not re- Air pressure is too low. Repair or replace compressor or leak-
lease. age.
Parking brake does not ap- Brake shoes are not correctly ad- Adjust brakes.
ply enough force to hold lift justed.
truck.
23
NOTES
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