PARKING BRAKE

H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236];
H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];
H16.00-22.00XM-12EC
(H400-500HD/HDS-EC) [B214];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH,
RS46-41S CH, RS46-41L CH, RS46-41LS CH, RS45-24IH,
RS45-28IH, RS46-33IH, RS46-37IH, RS46-38S IH,
RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117];
H16XM-12, H18XM-12, H20XM-12, H22XM-12 (H400HD,
H450HD, H500HD, H550HD) [B236];
H16XM-12EC, H18XM-12EC, H22XM-12EC (H400HD-EC,
H450HD-EC, H500HD-EC) [C214]; RS45-27CH, RS45-31CH,
RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS CH,
RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH,
RS46-38LS IH (RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S,
RS46-41LS) [C222]; H36XMS-12, H40XM-12, H44XM-12, H48XM-12
(H800HD, H1050HD) [B917]; H40XM-16CH,
H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH
(H1050HD, H1150HD) [G117]

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 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.
Parking Brake Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Parking Brake Valve Replacement ................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Clean and Inspect .......................................................................................................................................... 2
Install ............................................................................................................................................................. 2
Parking Brake Caliper Repair........................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Disassemble ................................................................................................................................................... 2
Inspect ............................................................................................................................................................ 5
Install ............................................................................................................................................................. 5
Bleed Brakes .................................................................................................................................................. 5
Adjust ............................................................................................................................................................. 6
Brake Pad Repair............................................................................................................................................... 6
Inspect ............................................................................................................................................................ 6
Remove ........................................................................................................................................................... 6
Install ............................................................................................................................................................. 7
Seals Repair ....................................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Install ............................................................................................................................................................. 7
Specifications...................................................................................................................................................... 7
Torque Requirements .................................................................................................................................... 7
Wear Limits.................................................................................................................................................... 8
Lining to Disc Clearance ............................................................................................................................... 8
Troubleshooting ................................................................................................................................................. 8

This section is for the following models:

H16.00-18.00XM/XMS-12 (H400-450HD/HDS) [A236];

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];
H16.00-22.00XM-12EC (H400-500HD/HDS-EC) [B214];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117];
H16XM-12, H18XM-12, H20XM-12, H22XM-12 (H400HD, H450HD,
H500HD, H550HD) [B236];
H16XM-12EC, H18XM-12EC, H22XM-12EC (H400HD-EC,
H450HD-EC, H500HD-EC) [C214];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L
IH, RS46-38S IH, RS46-38LS IH (RS45-27, RS45-31, RS46-36,
RS46-41L, RS46-41S, RS46-41LS) [C222];
H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917];
H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH
(H1050HD, H1150HD) [G117]

©2012 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1800 SRM 1117
General
This manual has the description, operation, and re-
pair procedures for the components of the parking
brake system.
Description and Operation
The hydraulic pump supplies the oil to operate the
service and parking brake. The parking brake is
operated via a parking brake valve, integrated in
the main manifold. See the manual Diagrams 8000
SRM 1153 for E117 lift trucks, Diagrams 8000 SRM
1236 for B222 lift trucks, Diagrams 8000 SRM 1491
for C222 lift trucks, Diagrams 8000 SRM 1261 for
A917 and F117 lift trucks, Diagrams 8000 SRM
1281 for B214 lift trucks, Diagrams 8000 SRM 1486
for C214 lift trucks, Diagrams 8000 SRM 1312 for
A236 lift trucks, and Diagrams 8000 SRM 1487 for
B236 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) for the A917, B222, C222,
E117, and F117, lift trucks and 17.5 MPa (2539 psi)
for A236, B236, B214, and C214 lift trucks. When
accumulator pressure reaches the lower limit of
16.5 MPa (2394 psi) for the A917, B222, C222, E117,
and F117, lift trucks and 11.6 MPa (1683 psi) for
Parking Brake Valve Replacement
REMOVE
1. Place the lift truck on a solid, level surface.
2. Put blocks in front and back of tires so the vehicle
cannot move.
3. Disconnect electrical connector.
WARNING
Before disconnecting any hydraulic lines,
release pressure from hydraulic circuit as fol-
lows:
Parking Brake Valve Replacement
The main components of the parking brake system
are:
• Parking brake valve
• Parking brake caliper
• Brake pad
• Parking brake switch
• Solenoid valve
A236, B236, B214, and C214 lift trucks, the accu-
mulator charge valve allows oil to flow from the
hydraulic pump to the charge accumulator. The
accumulator 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) for the A917, B222, C222,
E117, and F117 lift trucks. The minimum system oil
pressure for A236, B236, B214, and C214 lift trucks
is 4.6 MPa (667 psi).
a. Shut off engine and completely lower mast.
Install blocks at wheels to prevent vehicle
from moving.
b. Operate brake pedal until hydraulic pres-
sure is released.
4. Remove electrical solenoid.
NOTE: The parking brake valve is a cartridge inte-
grated in the main manifold.
5. Remove parking brake valve/cartridge.
1
Parking Brake Caliper Repair
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.
INSTALL
NOTE: Replace valve if there are scratches or other
damage.
Parking Brake Caliper Repair
REMOVE
1. Place the lift truck on a solid, level surface.
2. Put blocks in front and back of tires so vehicle
cannot move.
3. Remove cap.
4. Loosen lock nut.
5. Turn setscrew counterclockwise until brake pads
no longer touch brake disc.
6. Slowly release pressure from accumulator. See
the section Brake Accumulator 1800 SRM
1036.
WARNING
Before disconnecting any hydraulic lines,
release pressure from hydraulic circuit as fol-
lows:
a. Shut off engine and completely lower mast.
Install blocks at wheels to prevent vehicle
from moving.
b. Operate brake pedal until hydraulic pres-
sure is released.
7. Disconnect hydraulic line at caliper.
2
1800 SRM 1117
1. Install parking brake valve/cartridge in main
manifold.
2. Install electrical solenoid.
3. Connect electrical connector.
4. 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.
8. 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.
9. 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.
1800 SRM 1117 Parking Brake Caliper Repair

1. LOCK NUT 7. LOCK NUT

2. FLAT WASHER 8. SEAL ASSEMBLY
3. CAPSCREW 9. SPECIAL SCREW (LONG)
4. HARDENED WASHER 10. HARDENED WASHER
5. YOKE ASSEMBLY 11. BRAKE ADAPTER
6. DISC BRAKE 12. BRAKE DISC ASSEMBLY

Figure 1. Parking Brake Assembly

3
Parking Brake Caliper Repair 1800 SRM 1117

1. BRAKE HOUSING 14. SETSCREW

2. RETAINING RING 15. LOCKING NUT
3. PISTON STOP 16. NUT
4. PISTON 17. COTTER PIN
5. CAP 18. O-RING SEAL
6. 145 MM LONG BOLTS 19. O-RING SEAL
7. RETAINING CUP 20. O-RING SEAL
8. DUST BOOT 21. DISC SPRING
9. BRAKE PADS 22. WEAR PLATE
10. FRICTION SLEEVE 23. RAM
11. MAGNET 24. BLEEDER
12. CUP SEAL 25. WASHER
13. CUP SEAL 26. ADAPTER

Figure 2. Parking Brake Caliper

4
1800 SRM 1117
INSPECT
Inspect parts and bores for scratches. If there are
scratches or other damage, replace damaged parts.
Inspect rotor as shown in Figure 3.
1. MAXIMUM ROTOR WEAR 1.5 mm (0.06 in.)
2. MINIMUM ROTOR THICKNESS 11.0 mm
(0.43 in.)
3. ROTOR THICKNESS 13.0 mm (0.51 in.)
Figure 3. Inspect Rotor for Parking Brake
Caliper
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 perfor-
mance.
NOTE: All mounting and setting work must be car-
ried out on the brake when cold.
1. Remove cap.
2. Release lock nut and turn setscrew counterclock-
wise until ram comes to rest against face of pis-
ton.
3. Mount caliper to bracket and secure with bolts.
4. Mount pressure connection and apply the neces-
sary release pressure to brake until bank of disc
springs is completely pretensioned.
5. Adjust brakes.
Parking Brake Caliper Repair
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.
1. Place the lift truck on a solid, level surface.
2. Put blocks on both sides (front and back) of the
tires to prevent movement of the lift truck.
3. Put a clear tube on the bleeder screw. Place the
other end of the clear tube in a container of clean
hydraulic fluid.
4. 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.
c. 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.
5
Brake Pad Repair 1800 SRM 1117

2. Remove cap.
WARNING
Do not try to find hydraulic leaks by putting 3. Release lock nut and turn setscrew clockwise un-
your hand on hydraulic components under til brake pads touch brake disc.
pressure. Hydraulic oil can be injected into
the body by the pressure. 4. Turn setscrew counterclockwise and set clear-
ance specified. See Table 1.
5. Check for fluid leaks.
5. Hold setscrew in position and tighten lock nut.
ADJUST 6. Replace cap and tighten.
NOTE: During this adjustment process, the parking
7. Bleed piston chamber using bleeder. See Fig-
brake must be released and the disc springs preten-
ure 2.
sioned.
8. Operate brake valve several times and check
1. Put blocks in front and back of tires so the vehicle
braking efficiency of parking brake on a slope.
cannot move.

Table 1. Brake Pad Adjustment

Type Adjustment Screw Clearance mm (in.) Revolutions

Minimum 0.5 mm (0.020 in.) 1/4
Small M16 (size 8) Rated Clearance 1.0 mm (0.039 in.) 1/2
Maximum 1.5 mm (0.059 in.) 3/4
Minimum 1.0 mm (0.039 in.) 2/5
Large M20 (size 10) Rated Clearance 2.0 mm (0.079 in.) 4/5
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
depends on vehicle usage, but no less than every 6
months. In the event of a minimal residual lining
thickness, these intervals must be reduced accord-
ingly 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.
1. Release cap and unscrew. See Figure 2.
2. Release lock nut and turn setscrew clockwise un-
til it is flush with inside of piston.
3. Press back ram bolt using a suitable screwdriver
until it comes to rest against piston.

6
1800 SRM 1117
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.
4. 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.
Seals Repair
REMOVE
1. Release lock nut and turn setscrew clockwise un-
til it is flush with inside of piston.
2. Release pressure by actuating hand brake valve;
then remove pressure hose and completely re-
move brake. The disc springs are now completely
depressurized.
3. Remove piston stop and remove retaining ring
from housing.
4. Remove bank of disc springs and piston.
INSTALL
CAUTION
Verify mounting direction of seal rings, other-
wise leaks may occur.
Specifications
TORQUE REQUIREMENTS
Table 2. Torque Requirements
Component
Lining snap fastener screws
Bleeder screws
Specifications
NOTE: When brake has been completely removed,
pressure hose must be reconnected to brake housing.
Brake must then be bled.
1. Replace brake pads and insert 145 mm (5.708 in.)
long bolts into brake housing. Verify magnets
have sufficient force to hold brake pads.
2. Secure to bracket with 145 mm (5.708 in.) long
bolts, nuts, and cotter pins.
3. Adjust brakes. See Parking Brake Caliper Re-
pair, Adjust.
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.
1. Replace seals as needed.
2. Replace remaining individual parts in reverse or-
der of removal.
3. Install caliper assembly and adjust. See Parking
Brake Caliper Repair, Adjust.
Torque
5 to 6 N•m (44 to 53 lbf in)
20 to 27 N•m (15 to 20 lbf ft)
7
Troubleshooting 1800 SRM 1117

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.).

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 The hydraulic pressure is too low. Check for low fluid level, air in sys-
release. 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.

8
1800 SRM 1117
PROBLEM POSSIBLE CAUSE
The parking brake will not The springs in the brake caliper are
apply. damaged.
The piston is cocked in the bore.
The caliper is locked in the released
position.
The brake does not hold. Brake is not properly adjusted.
Linings or disc is excessively worn.
Linings are contaminated with oil or
grease.
The springs in the brake caliper are
damaged.
Damaged seals. Wrong type of fluid is being used.
Spring cap turned when hydraulic
pressure was applied to the brake.
Damaged springs. Brake is not properly adjusted.
Springs worn.
Lack of lubrication.
Troubleshooting
PROCEDURE OR ACTION
Replace springs.
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.).
Move the stud nut to the end of the
stud.
Adjust the brake.
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.).
Replace linings.
Replace springs.
Drain, flush, and refill with the
correct fluid. Replace O-rings and
backup rings.
Replace O-rings and backup rings.
Replace the springs and adjust the
brake.
Replace the springs and apply an an-
tiseize compound to the springs.
9
Troubleshooting 1800 SRM 1117

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Damaged linings or disc. Brake is not properly adjusted. Lin- Adjust brake. Replace parts as
ings are dragging. needed.

The caliper is seized on the slide Clean, replace, or repair slide pins or
pins. 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.).

10
 TECHNICAL PUBLICATIONS

1800 SRM 1117 1/12 (7/11)(3/11)(7/07)(12/06)(7/06)(5/06)(8/05)(8/04)(7/04) Printed in U.S.A.