PARKING BRAKE

H40.00-52.00XM-16CH

(H1050HD-CH, 1150HD-CH) [E117, F117]

PART NO. 1565789

1800 SRM 1117

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 Mainte-
nance section.

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement 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!

Parking Brake

Table of Contents

TABLE OF CONTENTS

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

Description and Operation ................................................................................................................................

Parking Brake Valve Replacement ...................................................................................................................

Remove ...........................................................................................................................................................

Clean and Inspect ..........................................................................................................................................

Install .............................................................................................................................................................

Parking Brake Caliper Repair ..........................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Inspect ............................................................................................................................................................

Install .............................................................................................................................................................

Bleed Brakes ..................................................................................................................................................

Adjust .............................................................................................................................................................

Brake Pad Repair...............................................................................................................................................

Inspect ............................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Seals Repair .......................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Specifications......................................................................................................................................................

Torque Requirements ....................................................................................................................................

Wear Limits....................................................................................................................................................

Lining to Disc Clearance ...............................................................................................................................

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

This section is for the following models:

H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1800 SRM 1117

Parking Brake Valve Replacement

General

This manual has the description, operation, and re-
pair procedures for the components of the parking
brake system.

The main components of the parking brake system
are:
• Parking brake valve
• Parking brake caliper
• Brake pad
• Parking brake switch
• Solenoid valve

Description and Operation

The hydraulic pump supplies the oil to operate the
service and parking brake. The parking brake is op-
erated via a parking brake valve, integrated in the
main manifold. See the section Diagrams 8000 SRM
1153 for the E117 lift trucks and Diagrams 8000
SRM 1236 for the F117 lift trucks.

The accumulator charge valve controls charging rate
and pressure of oil in the accumulator for the brake
system. The accumulator charge valve stops charg-
ing when accumulator pressure reaches upper limit
of 20.5 MPa (2974 psi). When accumulator pressure
reaches the lower limit of 16.5 MPa (2394 psi), the ac-
cumulator charge valve allows oil to flow from the hy-
draulic pump to the charge accumulator. The accu-
mulator supplies oil pressure to the park brake valve
for releasing parking brake.

The parking brake system uses a spring-applied
caliper and is installed at the rear of the differen-
tial. Under normal conditions, the red knob on the
instrument panel is pushed in, and an electrical
signal triggers the parking brake valve. Oil pressure
compresses the spring and the parking brake is re-
leased. The parking brake is applied by pulling out
the red knob on the instrument panel. The parking
brake valve position changes, and oil pressure in the
parking brake cylinder is relieved. This causes the
springs to apply the brakes for parking. The spring
automatically applies the brake if the system loses
oil pressure. The minimum system oil pressure is
10.35 MPa (1501 psi).

Parking Brake Valve Replacement

REMOVE

Place the lift truck on a solid, level surface.

Put blocks in front and back of tires so the vehicle
cannot move.

Disconnect electrical connector.

WARNING

Before disconnecting any hydraulic lines,
release pressure from hydraulic circuit as fol-
lows:
1.

Shut off engine and completely lower mast.
Install blocks at wheels to prevent vehicle
from moving.

Operate brake pedal until hydraulic pres-
sure is released.

Remove electrical solenoid.

NOTE: The parking brake valve is a cartridge inte-
grated in the main manifold.

Remove parking brake valve/cartridge.

CLEAN AND INSPECT

WARNING

Cleaning solvents are flammable and toxic and
can cause skin irritation. When using clean-
ing solvents, always follow the solvent manu-
facturer’s recommended safety precautions.

Clean parts in solvent. Inspect parts and bores for
scratches. Lubricate parts with clean hydraulic oil
for assembly.

Parking Brake Caliper Repair

1800 SRM 1117

INSTALL

NOTE: Replace valve if there are scratches or other
damage.

Install parking brake valve/cartridge in main
manifold.

Install electrical solenoid.

Connect electrical connector.

Operate system and check for leaks and correct
operation of parking brake system. Remove air
from brake system as described in Parking Brake
Caliper Repair, Bleed Brakes.

Parking Brake Caliper Repair

REMOVE

Place the lift truck on a solid, level surface.

Put blocks in front and back of tires so vehicle
cannot move.

Remove cap.

Loosen lock nut.

Turn setscrew counterclockwise until brake pads
no longer touch brake disc.

Slowly release pressure from accumulator. See
the section Accumulator 1800 SRM 1036.

WARNING

Before disconnecting any hydraulic lines,
release pressure from hydraulic circuit as fol-
lows:
1.

Shut off engine and completely lower mast.
Install blocks at wheels to prevent vehicle
from moving.

Operate brake pedal until hydraulic pres-
sure is released.

Disconnect hydraulic line at caliper.

Cap open line.

WARNING

Brake linings can contain dangerous fibers.
Breathing dust from these linings can be a can-
cer or lung disease hazard. Do not make dust!
Do not clean brake parts with compressed
air or by brushing.

Use vacuum equipment

approved for brake dust or follow the cleaning
procedure in this section. When calipers are
removed, do not make dust.

Do not sand, grind, chisel, hammer, or change
linings in any way that will make dust. Any
changes to linings must be done in a restricted
area with special ventilation. Protective cloth-
ing and a respirator must be used.

Remove bolts that hold caliper to bracket. See
Figure 1 and Figure 2. Remove caliper and brake
linings.

DISASSEMBLE

Disassemble caliper to remove and service as neces-
sary.

INSPECT

Inspect parts and bores for scratches. If there are
scratches or other damage, replace damaged parts.
Inspect rotor as shown in Figure 3.

1800 SRM 1117

Parking Brake Caliper Repair

LOCK NUT

FLAT WASHER

CAPSCREW

HARDENED WASHER

YOKE ASSEMBLY

DISC BRAKE

LOCK NUT

SEAL ASSEMBLY

SPECIAL SCREW (LONG)

10. HARDENED WASHER
11. BRAKE ADAPTER
12. BRAKE DISC ASSEMBLY

Figure 1. Parking Brake Assembly

INSTALL

NOTE: Brake setting is required after mounting new
brake pads or brake disc, as well as during all repair
stages and in the event of insufficient braking per-
formance.

NOTE: All mounting and setting work must be car-
ried out on the brake when cold.

Remove cap.

Release lock nut and turn setscrew counterclock-
wise until ram comes to rest against face of pis-
ton.

Mount caliper to bracket and secure with bolts.

Mount pressure connection and apply the neces-
sary release pressure to brake until bank of disc
springs are completely pretensioned.

Adjust brakes.

Parking Brake Caliper Repair

1800 SRM 1117

BRAKE HOUSING

RETAINING RING

PISTON STOP

PISTON

CAP

145 MM LONG BOLTS

RETAINING CUP

DUST BOOT

BRAKE PADS

10. FRICTION SLEEVE
11. MAGNET
12. CUP SEAL
13. CUP SEAL

14. SETSCREW
15. LOCKING NUT
16. NUT
17. COTTER PIN
18. O-RING SEAL
19. O-RING SEAL
20. O-RING SEAL
21. DISC SPRING
22. WEAR PLATE
23. RAM
24. BLEEDER
25. WASHER
26. ADAPTER

Figure 2. Parking Brake Caliper

1800 SRM 1117

Parking Brake Caliper Repair

MAXIMUM ROTOR WEAR 1.5 mm (0.06 in.)

MINIMUM ROTOR THICKNESS 11.0 mm
(0.43 in.)

ROTOR THICKNESS 13.0 mm (0.51 in.)

Figure 3. Inspect Rotor for Parking Brake

Caliper

BLEED BRAKES

WARNING

Remove air from the brake system after each
installation or repair of hydraulic or brake sys-
tem components or hydraulic lines. The brakes
will not operate correctly with air in the system
and can cause injury or damage.

WARNING

Properly discard hydraulic fluid that is re-
moved from the brake system. Hydraulic fluid
that is removed can be contaminated and
cause damage, loss of braking, and serious
personal injury.

WARNING

Use only the type of hydraulic fluid specified
by Hyster. Do not use or mix different types
of hydraulic fluid. The wrong hydraulic fluid
can damage rubber parts of the caliper and can
cause damage, loss of braking, and serious per-
sonal injury.

Place the lift truck on a solid, level surface.

Put blocks on both sides (front and back) of the
tires to prevent movement of the lift truck.

Put a clear tube on the bleeder screw. Place the
other end of the clear tube in a container of clean
hydraulic fluid.

Bleed parking brake.

NOTE: Keep the parking brake activated during
bleeding of the brake, because the spring pressure
automatically applies the brake if the system loses
oil pressure.

a. With the engine running, activate the park-

ing brake with an electrical signal, which
triggers the parking brake valve.

b. Loosen the bleeder screw until no air bubbles

appear in the container of fluid.

Tighten the bleeder screw to 20 to 27 N•m
(15 to 20 lbf ft). Release the pressure to the
brake.

d. Release the pressure of the parking brake

with an electrical signal.

WARNING

Do not try to find hydraulic leaks by putting
your hand on hydraulic components under
pressure.

Hydraulic oil can be injected into

the body by the pressure.

Check for fluid leaks.

ADJUST

NOTE: During this adjustment process, the parking
brake must be released and the disc springs preten-
sioned.

Put blocks in front and back of tires so the vehicle
cannot move.

Remove cap.

Release lock nut and turn setscrew clockwise un-
til brake pads touch brake disc.

Turn setscrew counterclockwise and set clear-
ance specified. See Table 1.

Hold setscrew in position and tighten lock nut.

Replace cap and tighten.

Brake Pad Repair

1800 SRM 1117

Bleed piston chamber using bleeder. See Fig-
ure 2.

Operate brake valve several times and check
braking efficiency of parking brake on a slope.

Table 1. Brake Pad Adjustment

Type

Adjustment Screw

Clearance mm (in.)

Revolutions

Minimum

0.5 mm (0.020 in.)

1/4

Rated Clearance

1.0 mm (0.039 in.)

1/2

Small

M16 (size 8)

Maximum

1.5 mm (0.059 in.)

3/4

Minimum

1.0 mm (0.039 in.)

2/5

Rated Clearance

2.0 mm (0.079 in.)

4/5

Large

M20 (size 10)

Maximum

3.0 mm (0.118 in.)

1-1/5

Brake Pad Repair

NOTE: The brake pads are maintenance free. All
that is required here is a check for damaged parts
and inspection to ensure that the brake disc spins
freely.

INSPECT

The thickness of the brake lining must be subjected
to a visual inspection at regular intervals, which de-
pends on vehicle usage, but every 6 months at the lat-
est. In the event of a minimal residual lining thick-
ness, these intervals must be reduced accordingly in
order to avoid major damage to the brake or disk.
• Small brake: Minimum residual thickness 1.0 mm

(0.039 in.) per brake lining plate [6 mm (0.236 in.)
carrier plate thickness]

• Large brake: Minimum residual thickness 2.0 mm

(0.079 in.) per brake lining plate [8 mm (0.315 in.)
carrier plate thickness]

REMOVE

CAUTION

If the pressure hose is too short, it must be dis-
connected in order to allow the brake to be re-
moved. Step 2 and Step 3 must be performed
beforehand. Then release pressure by actuat-
ing hand brake valve.

NOTE: During this adjusting process, the parking
brake must be released.

Release cap and unscrew. See Figure 2.

Release lock nut and turn setscrew clockwise un-
til it is flush with inside of piston.

Press back ram bolt using a suitable screwdriver
until it comes to rest against piston.

NOTE: In the event there is insufficient clearance
to remove brake pads, brake must be completely re-
moved. To do this, pull 145 mm (5.708 in.) long bolts
out of brake housing.

Depending on free space available, release one of
two 145 mm (5.708 in.) long bolts, remove cotter
pin, unscrew nut, and pull 145 mm (5.708 in.)
long bolt out of brake housing. Remove brake
pads.

INSTALL

NOTE: If magnets do not have sufficient force, they
must also be replaced. Remove by prying out with a
screwdriver.

NOTE: When brake has been completely removed,
pressure hose must be reconnected to brake housing.
Brake must then be bled.

Replace brake pads and insert 145 mm (5.708 in.)
long bolts into brake housing. Verify magnets
have sufficient force to hold brake pads.

Secure to bracket with 145 mm (5.708 in.) long
bolts, nuts, and cotter pins.

Adjust brakes. See Parking Brake Caliper Re-
pair, Adjust.

1800 SRM 1117

Specifications

Seals Repair

REMOVE

Release lock nut and turn setscrew clockwise un-
til it is flush with inside of piston.

Release pressure by actuating hand brake valve;
then remove pressure hose and completely re-
move brake. The disc springs are now completely
depressurized.

Remove piston stop and remove retaining ring
from housing.

Remove bank of disc springs and piston.

INSTALL

CAUTION

Verify mounting direction of seal rings, other-
wise leaks may occur.

CAUTION

When mounting new seal rings, use caution
not to damage sealing lip by using a suitable
mounting needle with rounded edges.

NOTE: When replacing piston, sliding and sealing
surfaces must be greased lightly using lubricating
grease.

Replace seals as needed.

Replace remaining individual parts in reverse or-
der of removal.

Install caliper assembly and adjust. See Parking
Brake Caliper Repair, Adjust.

Specifications

TORQUE REQUIREMENTS

Table 2. Torque Requirements

Component

Torque

Lining snap fastener screws

5 to 6 N•m (44 to 53 lbf in)

Bleeder screws

20 to 27 N•m (15 to 20 lbf ft)

WEAR LIMITS

Table 3. Wear Limits

Component

Replace

Disc

Wear exceeds maximum of 1.524 mm (0.06 in.).

Housing

Large end bore diameter exceeds 101.68 mm (4.003 in.) or small end bore exceeds
63.63 mm (2.505 in.).

Linings

Thickness is less than 3 mm (0.118 in.) from piston or housing.

Piston

Large end diameter is worn to less than 101.47 mm (3.995 in.) or small end is worn to
less than 63.37 mm (2.495 in.).

Troubleshooting

1800 SRM 1117

LINING TO DISC CLEARANCE

Table 4. Lining to Disc Clearance

Maximum

2.54 mm (0.100 in.)

Minimum

0.5 mm (0.020 in.)

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The parking brake does not
release.

The hydraulic pressure is too low.

Check for low fluid level, air in sys-
tem, restricted lines, fluid leaks,
damaged seals, or seals installed
backward.

The piston is cocked in the bore.

Replace piston if large end diameter
is less than 101.47 mm (3.995 in.) or
the small end is less than 63.37 mm
(2.495 in.).

Replace housing if the

large end of bore exceeds 101.68 mm
(4.003 in.) or the small end of the
bore exceeds 63.63 mm (2.505 in.).

No electrical signal.

Check/repair electrical connector.

The parking brake will not
apply.

The springs in the brake caliper are
damaged.

Replace springs.

The piston is cocked in the bore.

Replace piston if large end diameter
is less than 101.47 mm (3.995 in.) or
the small end is less than 63.37 mm
(2.495 in.).

Replace housing if the

large end of bore exceeds 101.68 mm
(4.003 in.) or the small end of the
bore exceeds 63.63 mm (2.505 in.).

The caliper is locked in the released
position.

Move the stud nut to the end of the
stud.

1800 SRM 1117

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The brake does not hold.

Brake is not properly adjusted.

Adjust the brake.

Linings or disc is excessively worn.

Replace linings when the thick-
ness of the lining is less than 3 mm
(0.118 in.) from the piston or hous-
ing.

Replace the disc when wear

exceeds a maximum of 1.524 mm
(0.06 in.).

Linings are contaminated with oil or
grease.

Replace linings.

The springs in the brake caliper are
damaged.

Replace springs.

Damaged seals.

Wrong type of fluid is being used.

Drain, flush, and refill with the
correct fluid.

Replace O-rings and

backup rings.

Spring cap turned when hydraulic
pressure was applied to the brake.

Replace O-rings and backup rings.

Damaged springs.

Brake is not properly adjusted.
Springs worn.

Replace the springs and adjust the
brake.

Lack of lubrication.

Replace the springs and apply an an-
tiseize compound to the springs.

Damaged linings or disc.

Brake is not properly adjusted. Lin-
ings are dragging.

Adjust brake.

Replace parts as

needed.

The caliper is seized on the slide
pins.

Clean, replace, or repair slide pins or
caliper. Replace linings.

The piston is cocked in the bore.

Replace piston if large end diameter
is less than 101.47 mm (3.995 in.) or
the small end is less than 63.37 mm
(2.495 in.).

Replace housing if the

large end of bore exceeds 101.68 mm
(4.003 in.) or the small end of the
bore exceeds 63.63 mm (2.505 in.).

NOTES

____________________________________________________________

TECHNICAL PUBLICATIONS

1800 SRM 1117

8/05 (8/04)(7/04) Printed in United Kingdom

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