SERVICE BRAKE

RS45-27CH, RS45-30CH, RS45-27IH,

RS46-33CH, RS46-30IH, RS46-36CH,
RS46-33IH [A222]; HR45-25, HR45-27,
HR45-31, HR45-40S, HR45-36L, HR45-40LS,
HR45-45LSX, HR45H [A227, B227];
H36.00-48.00E (H800-1050E) [D117];
H36.00-48.00E-16CH (H800-1050E-16CH) [D117];
H20.00-32.00F (H440-700F/FS) [E008];
H40.00-52.00XM-16CH
(H1050HD-CH, 1150HD-CH) [E117, F117]

PART NO. 1531822 1800 SRM 1038

 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!
Service Brake Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
E117, F117 Only............................................................................................................................................. 2
Repair ................................................................................................................................................................. 2
General ........................................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Drive Wheels and Tires............................................................................................................................. 2
Brake Housing ........................................................................................................................................... 3
Spindle and Brake Cover .......................................................................................................................... 5
Disassemble ................................................................................................................................................... 6
Clean .............................................................................................................................................................. 8
Ground and Polished Parts....................................................................................................................... 8
Parts With Rough Finish .......................................................................................................................... 8
Wet Disc Brake and Axle Assembly ......................................................................................................... 8
Inspect ............................................................................................................................................................ 9
Face Seals .................................................................................................................................................. 9
Disc............................................................................................................................................................. 9
Wear Limits ........................................................................................................................................... 9
Replace ........................................................................................................................................................... 9
Parts........................................................................................................................................................... 9
Assemble ........................................................................................................................................................ 10
Brake Housings ......................................................................................................................................... 10
Install ............................................................................................................................................................. 12
Hub Oil Seals............................................................................................................................................. 12
Double Seals .......................................................................................................................................... 12
Single Seal ............................................................................................................................................. 13
Spindle and Brake Cover .......................................................................................................................... 14
Brake Housing ........................................................................................................................................... 15
Drive Wheels and Tires............................................................................................................................. 18
Pressure Switch ............................................................................................................................................. 22
Replace ....................................................................................................................................................... 22
Accumulator................................................................................................................................................... 22
Brake Pedal Valves (Treadle Valves) Repair .................................................................................................... 22
All Models Except E117................................................................................................................................. 22
Remove....................................................................................................................................................... 22
Clean and Inspect...................................................................................................................................... 22
Install ......................................................................................................................................................... 22
E117, F117...................................................................................................................................................... 26
Remove....................................................................................................................................................... 26
Clean and Inspect...................................................................................................................................... 26
Install ......................................................................................................................................................... 26
Brake System Air Removal ............................................................................................................................... 26
Specifications...................................................................................................................................................... 27
Brake Coolant ................................................................................................................................................ 30
Coolant Change Intervals ......................................................................................................................... 30
Normal Maintenance ............................................................................................................................ 30
Hydraulic Fluid.............................................................................................................................................. 30
Troubleshooting.................................................................................................................................................. 30

©2005 HYSTER COMPANY i

Table of Contents Service Brake

TABLE OF CONTENTS (Continued)

This section is for the following models:

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,

RS46-36CH, RS46-33IH [A222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,
HR45-45LSX, HR45H [A227, B227];
H36.00-48.00E (H800-1050E) [D117];
H36.00-48.00E-16CH (H800-1050E-16CH) [D117];
H20.00-32.00F (H440-700F/FS) [E008];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]

ii
1800 SRM 1038 Description and Operation

General
For the service brake system, there are oil-cooled brakes at the drive wheels. This service manual has infor-
mation on how to repair the oil-cooled brakes. This service manual also includes troubleshooting and specifi-
cations.

Description and Operation

A tandem pump supplies the oil to operate the brake
system. The oil from the pump goes through the ac-
cumulator charge valve. The oil from the accumula-
tor charge valve goes to the accumulator, brake pedal
valve, and reduction valve. Oil that is not needed
by the brake circuit flows to the main control valve.
The reduction valve for the parking brake controls
the maximum pressure supplied to the brake circuit.
There is a pressure switch connected to the brake cir-
cuit to operate a warning light for the operator when
brake pressure is low. A second pressure switch will
activate the brake lights. The other reduction valve
supplies oil to the remote control valve.
The accumulator stores oil to operate the brakes
when the engine is not running. The service brake
pedal (treadle valve) controls the pressure of oil to
the service brake piston at each drive wheel. There
are friction (rotating discs) and stationary discs as-
sembled in the housing. Two to ten friction discs are
used in the housing depending on the requirements
of the brake system. Each friction disc is assembled
between stationary discs. The friction discs are
rotating with the wheel hub. A piston, moved by
hydraulic pressure, pushes the discs together for
the braking action. The brake pedal controls the
pressure to each of the pistons. See Figure 1.

Figure 1. Wet Disc Brake Housing

1
Repair 1800 SRM 1038

Legend for Figure 1

1. BRAKE HOUSING COVER CAPSCREW 17. PISTON RETURN SPRING GUIDE
2. BRAKE HOUSING COVER WASHER 18. PISTON RETURN SPRING
3. BLEEDER SCREW 19. PISTON RETURN SPRING PLUG
4. FORCED COOLING INLET PLUG 20. BRAKE HOUSING PLUG
5. BRAKE HOUSING COVER PLUG 21. FACE SEAL ASSEMBLY
6. INLET FITTING PLUG 22. TEMPERATURE SENSOR BRACKET
7. BRAKE HOUSING COVER CAPSCREW
8. AXLE COVER HOUSING WASHER 23. TEMPERATURE SENSOR BRACKET WASHER
9. AXLE COVER HOUSING CAPSCREW 24. TEMPERATURE SENSOR BRACKET
10. PISTON SEAL 25. TEMPERATURE SENSOR PLUG
11. PISTON SEAL SPACER 26. FILL AND LEVEL PLUG
12. PISTON 27. MAGNETIC DRAIN PLUG
13. STATIONARY DISC 28. INLET FITTING PLUG
14. FRICTION DISC 29. BRAKE INLET FITTING
15. STATIONARY BRAKE HOUSING DISC SPACER 30. FORCED COOLING OUTLET PLUG
16. BRAKE HOUSING

The right-hand pedal only activates the service
brakes. The left-hand pedal first activates an elec-
trical signal and, via the APC 100 controller, will
fully disengage the transmission. Then the service
brakes will be activated. The left-hand pedal is the
brake pedal.
E117, F117 ONLY
Cooling oil for the oil-cooled brakes comes from the
cover end of the tri-section pump. This oil flows
through the thermostatic bypass valve to the service
brakes at each drive wheel. If the oil is above 70 C
(158 F), the valve will direct the flow of oil through
the air-to-oil heat exchanger before it goes to the
brakes. A check valve keeps the pressure in the
brake assemblies at less then 140 kPa (20 psi). Oil
from the brakes returns to the hydraulic tank.

Repair
GENERAL 1. Place lift truck on a solid, level surface.

The service brake assemblies are hydraulically actu-
ated wet brakes. Most repairs are seal replacement
at the hub and brake housing. Replace these seals
anytime the hub is removed.
REMOVE
Drive Wheels and Tires
WARNING
Support the truck with safety stands. Do not
work under a truck supported only by jacks.
Always wear safety glasses.
NOTE: The final drive assemblies can be removed
with the drive axle installed in the lift truck. If the
drive axle must be removed, do the following steps.
If the drive axle will not be removed, do only the re-
quired steps.
2. Put blocks on each side (front and back) of steer
tires to prevent movement of lift truck. See Fig-
ure 2.
3. Put mast in vertical position.
4. Put a block under each outer mast channel.
WARNING
Verify the jack has a rated capacity to raise the
lift truck or personal injury may occur. See
the nameplate for the correct weight of the lift
truck.
NOTE: If the hydraulic system is not operating, use
a hydraulic jack under the drive axle.
5. Tilt mast fully forward until drive tires are raised
from the surface.

2
1800 SRM 1038 Repair

WARNING
The tires and wheels can weigh approximately
750 kg (1653 lb). Verify the lifting device has
the rated capacity to lift the tires and wheels
or personal injury may occur.

11. Remove wheel and tire from lift truck.

Brake Housing
1. Apply brakes ten to twenty times until accumu-
lated hydraulic brake pressure is released.

2. Remove end drive. See the section Planetary

Gear Axle 1400 SRM 47 (E008 only) or Plane-
tary Gear Axle 1400 SRM 1171.

3. Remove inner face seal from inside the brake

housing. See Figure 3.

1. STEER AXLE/STEER TIRES

2. DRIVE AXLE/DRIVE TIRES

Figure 2. Put the Lift Truck on Blocks

CAUTION
Do not place blocks under fuel or hydraulic
hoses or lift truck damage may occur.

6. Put additional blocks under frame behind the

drive tires.

WARNING
Completely remove air pressure from tire be-
fore it is removed from lift truck. Because dual 1. BRAKE HOUSING
2. FACE SEAL
wheels are installed, remove air pressure from
both tires. Air pressure in tires can cause tire Figure 3. Brake Housing
and wheel parts to explode, causing serious in-
jury or death. 4. Remove the outer face seal from the wheel hub.
See Figure 4.
7. Remove air from tire.
5. Place a container on inner side of the brake hous-
8. Remove valve core to verify that all air is out of ing.
inner tube.
6. Disconnect the coolant input line.
9. Push a wire through valve stem to verify the stem
does not have a restriction. 7. Place cap on line.

10. Remove wheel nuts and clamps.

3
Repair 1800 SRM 1038

11. Drain the coolant until no oil flows from the out-
put port.

12. Remove the two magnetic drain plugs.

13. Drain all the oil that remains in the brake hous-
ing.

14. Record the amount of oil that is being drained

from the brake housing.

15. Remove the brake lines from the brake housing.

16. Put caps on lines.

17. Clean the magnetic drain plugs.

18. Install and tighten the drain plugs to 27 N•m

(20 lbf ft).

19. Remove temperature sensor, if fitted.

1. WHEEL HUB 20. Remove bleeder screw and inlet fittings for the
hydraulic lines. See Figure 6.
Figure 4. Wheel Hub

8. Drain coolant until no oil flows from the input

port. See Figure 5.

1. BLEEDER SCREW
2. HYDRAULIC INLET FITTING, O-RING TYPE
3. HYDRAULIC INLET FITTING, TAPERED SEAT
TYPE
1. LH HOUSING COOLANT INPUT PORT
2. RH HOUSING COOLANT INPUT PORT Figure 6. Bleeder Screw and Inlet Fittings
3. RH HOUSING COOLANT OUTPUT PORT
4. MAGNETIC DRAIN PLUGS
5. LH HOUSING COOLANT OUTPUT PORT WARNING
Verify the lifting device has the rated capacity
Figure 5. Coolant Input Port
to lift the brake assembly.
9. Disconnect coolant output line.
21. Support the brake assembly using a lifting de-
10. Put cap on line. vice.

4
1800 SRM 1038 Repair

22. Remove the capscrews that fasten the cover to

the brake housing. See Figure 7.

1. CAPSCREW

Figure 7. Brake Housing Capscrews

1. LIFTING DEVICE 2. BRAKE HOUSING
CAUTION
Do not damage spindle when removing the Figure 8. Brake Housing
brake assembly.

23. Carefully slide the brake assembly away from

the spindle using the lifting device. See Figure 8.

24. Remove all gasket material from surfaces.

Spindle and Brake Cover

NOTE: On some axle assemblies, the brake cover
is mounted between the spindle and axle housing
flanges. To remove the spindle and brake cover, use
the following procedure.

Remove the spindle first followed by the brake cover.

1. Support the cover of the brake housing with a

lifting device.
1. STUD
2. Remove two of the capscrews that fasten the
Figure 9. Brake Housing Studs
brake cover and spindle to the axle housing.
Replace them with two studs. See Figure 9. NOTE: If necessary, tap the brake cover with a rubber
or plastic hammer to separate it from the spindle.
3. Remove the remaining capscrews.
5. Use a lifting device to remove the brake cover.
4. Hold the spindle against the axle housing.
See Figure 10.

5
Repair 1800 SRM 1038

1. Put the appropriate pry bars under the inner di-

ameter of the piston to lift the piston out of the
housing. The two piston seals and the seal spacer
are removed when the piston is removed from the
housing. See Figure 12.

1. LIFTING DEVICE 2. BRAKE COVER

Figure 10. Brake Cover

NOTE: If necessary, tap the spindle with a rubber or Figure 12. Piston, Piston Seals, and Seal
plastic hammer to separate it from the axle housing. Spacer
6. Use a lifting device to remove the spindle. See 2. Remove the stationary discs and the friction
Figure 11. discs from the brake housing. See Figure 13.

1. LIFTING DEVICE 2. SPINDLE

Figure 11. Spindle

7. Remove all gasket material from the mounting

surfaces of the cover, spindle, and axle housing. 1. STATIONARY DISC 2. FRICTION DISC

DISASSEMBLE Figure 13. Stationary and Friction Disc

NOTE: Some brake assemblies use a spacer and stan-

WARNING dard stationary disc. Some use a single thick-splined
To prevent serious eye injury, always wear safe stationary disc as the first disc against the housing
eye protection when doing maintenance or ser- instead of a spacer and standard stationary disc com-
vice. bination. Brake housings are designed to use only
one type of disc configuration. Do not interchange
parts.

6
1800 SRM 1038 Repair

3. Remove the disc spacer from the bottom of the

brake housing. See Figure 14.

1. PISTON RETURN SPRING ASSEMBLY

Figure 15. Piston Return Spring

1. DISC SPACER

Figure 14. Disc Spacer

WARNING
The piston return spring applies pressure to
the plug. Use the following procedure or the
spring can push the plug out of the housing
with enough force to cause serious personal in-
jury.

NOTE: If necessary, remove the four piston return

spring assemblies with the following procedure. 1. PRESS

4. Put the brake housing on a bench so that the Figure 16. Plug
outboard side is toward you. See Figure 15.

WARNING
Observe all WARNINGS and CAUTIONS pro-
vided by the press manufacturer concerning
press operation to avoid serious personal in-
jury and possible damage to components.

5. Use a press to apply and keep pressure on the

plug. See Figure 16.

6. Slowly release pressure while loosening the plug

until the threads are completely disengaged and 1. HOUSING
the spring is fully expanded. See Figure 17. 2. SPRING, FULLY EXPANDED
3. SHOULDER
4. SPRING GUIDE

Figure 17. Piston Return Spring

7
Repair
7. Remove the plug and pin assembly, the spring,
and the spring guide from the housing.
NOTE: Two types of spring guides are used. One type
of guide has a pin on the bottom that is installed in-
side the spring. The other type of guide has a hole
in the bottom so that the end of the pin is installed
inside the guide. See Figure 18.
8. Inspect the O-ring on the plug. If necessary, re-
move and replace the O-ring.
1. SPRING GUIDE, HOLE TYPE
2. SPRING GUIDE, PIN TYPE
3. SPRING
4. O-RING
5. PIN AND PLUG ASSEMBLY
Figure 18. Piston Return Spring Assembly
CLEAN
CAUTION
The bearing cones can be damaged if the cones
are dried by rotating with compressed air.
The parts, except the bearing cones, can be dried with
compressed air.
NOTE: Dry the parts immediately after the parts are
cleaned and washed.
Dry the parts with soft, clean paper or rags.
NOTE: Apply the fluid used in the brake housing to
the cleaned and the dried parts that are not damaged
and are to be assembled.
Apply a special material that prevents corrosion and
rust to all surfaces. If parts are to be stored, put the
8
1800 SRM 1038
parts in a special paper that prevents corrosion and
rust.
Ground and Polished Parts
WARNING
To prevent serious eye injury, always wear safe
eye protection when doing maintenance or ser-
vice.
If you use cleaning solvents, hot solution tanks,
or alkaline solutions incorrectly, serious per-
sonal injury can occur. To prevent serious
personal injury, follow the instructions sup-
plied by the manufacturer of these products.
Do NOT use gasoline to clean parts. Gasoline
can explode and cause serious personal injury.
CAUTION
Use only solvent cleaners to clean ground or
polished metal parts. Hot solution tanks or wa-
ter and alkaline solutions will damage these
parts. Isopropyl alcohol, kerosene, or diesel
fuel can be used for this purpose.
1. Use solvent cleaner to clean surfaces.
2. If necessary, remove gasket material from parts.
Parts With Rough Finish
NOTE: Do not clean friction discs. Wipe off each disc
with a clean rag before applying brake cooling fluid
to their surfaces during assembly.
Parts must remain in hot solution tanks until com-
pletely cleaned and heated.
1. Clean with cleaning solvent or in a hot solution
tank with a weak alkaline solution.
2. Remove parts from the hot solution and wash
them with water until the hot solution is re-
moved.
Wet Disc Brake and Axle Assembly
NOTE: Before the assembly is cleaned, close or put
a cover over all openings. Breathers or vents in the
axle assembly are some examples of openings.
1. Use steam to clean the outside of the wet disc
brake and axle assembly.
1800 SRM 1038 Repair

INSPECT
NOTE: Inspect all the parts before assembling the
wet disc brake. Check all parts for wear and re-
place the damaged parts. Replacing worn or dam-
aged parts prevents the failure of the assembly later.
Face Seals
Inspect the rubber elements and metal rings for
wear, damage, or distortion. If there is a problem
with either ring, always replace both rings with a
matched pair of rings. A matched pair is two new
rings or two used rings that have been run together.
Do not use one new and one used ring or two used
rings that were not run together or leaks may occur.
See Figure 19.
Remove the plug opposite the inlet fitting. The plug
is at 9 o’clock on the right hand side and at 3 o’clock
on the left hand side when viewed from the center-
line of the truck. When removed a measurement can
be made from the housing to the back of the piston.
With the brakes not activated, the value measured
from the edge of the housing to the piston should be
slightly less than 127 mm (5 in.). If the brake stroke
measurement is 13 mm (0.525 in.) or more, replace
the brakes. The measurement of the new brakes
stroke will be between 3 to 7 mm (0.134 to 0.269 in.).
Table 1. Friction Disc
Overall Thickness
Disc Size
Limit
330 mm (13 in.) 4.25 mm (0.167 in.)
432 mm (17 in.) 4.87 mm (0.192 in.)
560 mm (22 in.) 5.56 mm (0.219 in.)

Table 2. Stationary Disc

Overall Thickness
Disc Size
Limit
330 mm (13 in.) 2.76 mm (0.109 in.)
432 mm (17 in.) 3.07 mm (0.121 in.)
432 mm (17 in.) 4.44 mm (0.175 in.)

1. METAL SEALING RINGS 560 mm (22 in.) 5.41 mm (0.213 in.)

2. RUBBER ELEMENTS
REPLACE
Figure 19. Face Seal Assembly
Parts
Disc
NOTE: The threads must be clean and not damaged
NOTE: If discs are reusable, maintain disc stack or-
so that accurate adjustments and correct torque val-
der.
ues can be applied to fasteners and parts.
If any of the following conditions exist with a friction
Replace worn or damaged parts of the wet disc brake
or stationary disc, replace full disc stack:
assembly. The following are some examples to check:
• Thickness worn beyond limits
• Replace any fasteners if the corners of the head are
• Uneven wear
worn.
• Localized surface damage
• Replace the washers, if damaged.
• Warpage
• Replace the oil seals, face seals, and gaskets when
• Scoring
the components are separated from each other.
• Damaged splines
• Clean the parts before applying silicone gasket ma-
Wear Limits terial.
• Remove small damage from the parts that have
NOTE: If thickness of any friction or stationary disc is machined or ground surfaces. Use a fine-tooth file,
less than or equal to overall thickness limits, replace india stone, emery cloth, or crocus cloth for this
full disc stack. See Table 1 and Table 2. purpose.

9
Repair
• Clean and repair the threads of the fasteners and
the holes. Use a tap or a die of the correct size or a
fine-tooth file for this purpose.
CAUTION
The threads must be clean and not damaged so
that accurate adjustments and correct torque
values can be applied to fasteners and parts.
• Tighten all fasteners to the correct torque value.
See Specifications.
ASSEMBLE
Brake Housings
WARNING
To prevent serious eye injury, always wear safe
eye protection when doing maintenance or ser-
vice.
The piston return spring applies pressure to
the plug. Use the following procedure or the
spring can push the plug out of the housing
with enough force to cause serious personal in-
jury.
NOTE: If the piston return spring assemblies were re-
moved, the assemblies must be installed in the hous-
ing.
Two types of spring guides are used. One type of
guide has a pin on the bottom that is installed in-
side the spring. The other type of guide has a hole in
the bottom so that the end of the pin is installed in
the guide. Use the correct parts for the piston return
spring assembly. Do not mix parts of the different as-
semblies. Use only one type of spring guide on each
brake housing assembly. See Figure 18.
1. Put the brake housing so that the wheel hub side
of the housing is toward you.
2. Install the O-ring on the plug.
3. Put the spring guide inside the brake housing
below the plug hole. Verify the flat area of the
guide is against the housing.
4. Install the spring on top of the guide.
5. Put the plug and pin assembly in the hole in the
brake housing and through the return spring.
10
1800 SRM 1038
6. Apply and hold pressure on the plug while the
plug is installed into the housing. Verify that the
pin is correctly installed in the spring guide and
that the flat areas on the spring guide are against
the housing. See Figure 15.
7. When the threads fully engage the housing, re-
lease the pressure on the plug. See Figure 17.
8. Tighten the plug to 60 to 75 N•m (44 to 55 lbf ft).
9. Put the brake housing on a bench. The cover side
of the housing must be toward you.
10. Install the disc spacer in the bottom of the brake
housing. See Figure 14.
NOTE: If a thick-splined stationary disc is used in-
stead of the spacer and standard stationary disc, it
must be installed against the housing. Next, install
a friction disc followed by a standard stationary disc
and continue to complete the stack. Brake housings
are designed to use only one type of disc configura-
tion. Do not interchange parts.
11. Install the disc pack.
a. Apply the same fluid used in the brake cool-
ing system to the disc surfaces as the discs
are installed.
b. Install a stationary disc in the housing. The
first stationary disc must be against the disc
spacer. Make sure the splines on the outer
diameter of the stationary disc engage the
splines in the brake housing. Verify the wide
spaces on the outer diameter of the disc are
over the return spring assemblies. See Fig-
ure 13.
c. Install a friction disc in the housing. See
Figure 20.
d. Complete the installation of the disc pack.
Repeat steps Step b and Step c until the com-
plete disc pack is installed.
12. Align all of the teeth on the inner diameter of the
friction discs. When the discs are aligned, the
wheel hub can be installed without damaging the
discs.
13. Lubricate the outside diameter of the piston, the
housing bore, and the seals with the same fluid
used in the brake system.
1800 SRM 1038 Repair

15. Put the first seal in the space between the hous-
ing and the piston. The rubber part of the seal
must be toward you. Push on the seal until
the complete plastic bottom surface of the seal
touches the shoulder of the piston. See Fig-
ure 23.

1. FRICTION DISC

Figure 20. Friction Disc

14. Lower the piston into the housing until the piston
is installed on the guides of the return springs.
Verify the surfaces on the piston and the hous-
ing are not damaged when the piston is installed.
See Figure 21. 1. PLASTIC SEAL BODY
2. ROUND SPACER
3. RUBBER ELEMENT SEAL ENERGIZERS

Figure 22. Piston Seal Arrangement

1. PISTON

Figure 21. Piston Installation

CAUTION
To prevent housing or piston damage, use fin- A. RUBBER PART OUT
gers or a non-metallic object to install the seals
and round spacer. Fluid can leak between the 1. INNER PISTON SEAL
housing and the piston if the surfaces are dam- Figure 23. Inner Piston Seals
aged.

NOTE: The sealing arrangement between the piston

and the housing consists of one spacer and two piston
seals. See Figure 22.

11
Repair
NOTE: An O-ring or garter spring seal spacer may
be used. If the O-ring is damaged, replace it with a
garter spring seal spacer.
16. Install the spacer around the outer diameter of
the piston. Push on the spacer until the entire
bottom surface of the spacer touches the top of
the first seal. See Figure 22 and Figure 24.
1. ROUND SPACER, O-RING, OR GARTER
SPRING TYPE
Figure 24. O-ring or Garter Spring Seal Spacer
17. Put the second seal in the space between the
housing and the piston on top of the first seal.
The rubber part of the seal must be away from
you. Install the second seal according to the fol-
lowing procedure:
a. Push on the seal until the seal touches the
spacer. Make sure the seal is correctly in-
stalled in the housing. The seals must be
parallel to each other. Install the complete
seal with this method. See Figure 22 and Fig-
ure 25.
INSTALL
Hub Oil Seals
NOTE: Single- or double-hub oil seals are used on all
brake housings with forced cooling and most brake
housings with sump cooling. See Figure 26.
12
1800 SRM 1038
A. RUBBER PART AWAY
1. OUTER PISTON SEAL
Figure 25. Outer Piston Seal
Double Seals
WARNING
To prevent serious eye injury, always wear safe
eye protection when doing maintenance or ser-
vice.
To avoid serious personal injury, be careful
when using Permatex. Follow the manufac-
turer’s instructions for safe use to prevent
irritation to eyes and skin. Wash after skin
contact. If the Permatex gets in eyes, flush
eyes with water for 15 minutes. Have eyes
checked by doctor.
1. Position the wheel hub so that the wheel hub is
flat on the floor.
2. Apply Permatex 51D or its equivalent to the
outer diameter of the seal casing.
3. Put the outer seal into the bore so the stamping
on the seal casing is toward you.
4. Use a suitable driver and a leather or plastic mal-
let to install the seal. Tap on the driver until the
seal casing is even with the top of the bore.
NOTE: When installed, the inner seal pushes the first
or outer seal into the correct position.
5. Install the inner seal with the stamping on the
bottom, over the outer seal.
1800 SRM 1038 Repair

1. INNER BEARING CUP

2. INNER BEARING CONE
3. OUTER SEAL
4. INNER SEAL
A. APPLY PRESSURE HERE
Figure 26. Double Seal
1. INNER BEARING CONE
6. Use a suitable driver and a leather or plastic mal- 2. INNER BEARING CUP
let to install the seal. Tap on the driver until the 3. SINGLE HUB
4. SEAL
seal casing is even with the top of the bore.
Figure 27. Single-Hub Seal With Flanges
Single Seal

1. Position the wheel hub so that the wheel hub is

flat on the floor.

2. Apply Permatex 51D or its equivalent to the

outer diameter of the seal casing.

3. Position the seal over the bore so that the metal

part of the seal is up.

CAUTION
Do not apply pressure to the inner metal part of
the seal. Apply pressure only to the outer diam-
eter of the ring on the seal. The application of
pressure to the inner diameter of the ring dam-
ages the seal.

NOTE: On seals with flanges, tap on the sleeve until

the flange touches the outer surface of the hub. See
Figure 27. A. DO NOT STRIKE HERE
1. INNER BEARING CONE
NOTE: On seals without flanges, press the seal in the 2. INNER BEARING CUP
hub until the top of the seal is even with the outer 3. SINGLE HUB
surface of the hub. See Figure 28. 4. SEAL

4. Use a sleeve that is installed on the outer metal Figure 28. Single-Hub Seal Without Flanges
flange of the seal and a leather or plastic mallet
to install the seal.

13
Repair 1800 SRM 1038

Spindle and Brake Cover
If necessary, install the spindle and the cover of the
brake housing on the axle housing according to the
following procedure:
4. Apply a bead of silicone gasket material on the
spindle flange where the brake cover will mount.
Make sure to go around each capscrew hole. See
Figure 30.

WARNING
Small amounts of acid vapor are present when
applying some silicone gasket materials. To
prevent possible serious personal injury, make
sure there is good ventilation in the work
area. If the silicone gasket material gets in
your eyes, flush your eyes with water for 15
minutes. Have your eyes checked by a doctor.

NOTE: On some axle assemblies, the brake cover

is mounted between the spindle and axle housing
flanges. Use the following procedure to install the
spindle and brake cover; but first, install the brake
cover followed by the spindle.
1. SPINDLE FLANGE
2. SILICONE BEAD
1. Install two studs opposite each other on the axle
housing flange. Verify the studs are long enough Figure 30. Spindle Flange
to support the spindle and brake cover.
5. Use a lifting device to install the brake cover over
2. Apply a bead of silicone gasket material on the the spindle and onto the housing. Make sure the
mounting surface of the axle housing flange. The drain hole is located at the bottom of the cover
bead must go around each capscrew hole. See when installed. See Figure 31.
Figure 29.

1. AXLE FLANGE
2. SILICONE BEAD

Figure 29. Axle Flange Figure 31. Spindle and Brake Cover

3. Use a lifting device to install the spindle on the

guide studs. Make sure the spindle cannot fall
before removing the lifting device. See Figure 29.

14
1800 SRM 1038
6. Install the capscrews and washers. See Fig-
ure 32. Remove the guide studs and install the
remaining two capscrews and washers. Tighten
the capscrews to the torque specified. See Spec-
ifications.
1. CAPSCREWS
Figure 32. Spindle and Brake Cover Capscrews
Brake Housing
CAUTION
Do not exceed a 3 mm (0.118 in.) diameter bead
of silicone gasket material. Too much gasket
material blocks the passages and damages the
components.
1. Apply a 3.0 mm (0.118 in.) diameter continuous
bead of silicone gasket material on the mounting
surface of the brake housing. The bead must go
Repair
around each capscrew hole and port. Flatten or
smear the bead of silicone around the ports. Be
careful not to get silicone into the ports or brake
housing bore. See Figure 33.
1. BRAKE HOUSING
2. SILICONE BEAD
Figure 33. Brake Housing
2. Connect a lifting device to the brake housing so
that the bores for the bleeder screw and the inlet
fitting in the housing are aligned with the correct
holes in the cover.
3. Install two studs in the brake housing. The studs
are installed opposite each other. Make the stud
by removing the head of a housing-to-cover cap-
screw. Cut a flat-bladed screwdriver slot in the
end of the stud without the threads. The studs
help install the housing correctly on to the cover.
4. Lift the housing on to the cover so that the studs
go through the holes in the cover. Verify the bores
for the bleeder screw and the inlet fitting are
aligned with the holes in the cover. Push and
hold the brake housing against the cover. See
Figure 34.
5. Install the capscrews and washers that fasten
the brake housing to cover.
6. Remove the two assembly studs and install the
last two capscrews and washers.
15
Repair 1800 SRM 1038

SEAT FITTING MORE THAN 47 N•m

(35 lbf ft).

(2) O-ring fitting: Verify all of the threads

are clean. Inspect the O-ring. Replace
the O-ring if it is damaged. Install the
fitting in the brake housing. Tighten
the fitting to 34 to 47 N•m (25 to
35 lbf ft).

c. Plug: The plug is opposite from the inlet fit-

ting for the hydraulic line. Tighten the plug
to 34 to 47 N•m (25 to 35 lbf ft).

10. Check the brake housing for leaks with the fol-
lowing procedure:

a. Put a plug in the coolant inlet and outlet

ports on the inboard side of the cover of the
brake housing cover. See Figure 5.

b. Remove plug at top of brake housing cover.

Install a 0.375-in. pipe thread adapter or
1. LIFTING DEVICE
2. BRAKE HOUSING a 0.875-in O-ring fitting adapter and male
fitting for an air hose.
Figure 34. Brake Housing
c. Connect an air pressure gauge and regu-
7. Tighten the capscrews to the specified torque. lator assembly to the male fitting on the
See Specifications. adapter. The gauge must measure pressure
accurately to 7 bar (102 psi). See Figure 35.
8. Remove the lifting device from the brake hous-
ing. d. Connect an auxiliary air supply system to
the gauge and regulator assembly. See Fig-
9. Install and tighten the following components on ure 35.
the back (inboard) side of the cover of the brake
housing. See Figure 6.

a. Bleeder screw: Tighten to 20 to 27 N•m (15

to 20 lbf ft).

CAUTION
Use the correct fitting. You cannot replace a
tapered seat fitting with an O-ring fitting. You
cannot replace an O-ring fitting with a tapered
seat fitting. If the wrong fitting is used, the
housing and the fitting will be damaged.

b. Inlet fitting for the hydraulic line: A tapered

seat fitting or an O-ring fitting.
A. TO REGULATOR AND AIR SUPPLY
(1) Tapered seat fitting: Verify all of the
threads are clean. Install the fitting in 1. ADAPTER
2. GAUGE AND MALE HOSE FITTING
the brake housing. Tighten the fitting 3. AIR LINE
to 34 to 47 N•m (25 to 35 lbf ft) BUT
DO NOT TIGHTEN THE TAPERED Figure 35. Leak Test

16
1800 SRM 1038
e. Apply 7 bar (102 psi) of pressure to the brake
housing. Turn the regulator to the CLOSED
position. Look at the gauge for 3-5 minutes.
The pressure in the brake housing must re-
main at 7 bar (102 psi).
f. If pressure falls below 7 bar (102 psi), find
the cause of the loss of pressure. See the
following procedure:
(1) Apply a soap and water solution to the
capscrews, the fittings, and the joints.
(2) Apply and hold 7 bar (102 psi) of pres-
sure in the brake housing.
(3) If bubbles appear at any external loca-
tion, service the cause of the leak.
(4) If bubbles do not appear at any external
location, there is an internal leak. Re-
move the wheel hub. Inspect the spin-
dle to hub seal, face seal, and seal sur-
face on the spindle for possible causes of
leaks. Repair or replace as necessary.
(5) Remove the plugs from the inlet and
outlet ports.
(6) Remove the air pressure gauge and reg-
ulator assembly.
11. Install end drive. See the section Planetary
Gear Axle 1400 SRM 47 (E008 only) or Plan-
etary Gear Axle 1400 SRM 1171.
12. Connect hydraulic lines.
13. Loosen the plug in the top of the cover of the hous-
ing. When the housing is filled, the loose plug
permits air to escape.
14. Put the transmission in neutral.
15. Start the engine.
16. Shut down the engine when oil leaks from the
loose plug in the cover of the housing.
NOTE: The minimum torque for the pipe type plug is
27 N•m (20 lbf ft)
NOTE: The minimum torque for the O-ring type plug
is 81 to 102 N•m (60 to 75 lbf ft)
Repair
17. Tighten the plug.
18. Bleed the brakes as follows for full hydraulic sys-
tems:
WARNING
When you loosen any brake system hydraulic
connection, you must bleed the brakes to re-
move all air from the system. Air can prevent
hydraulic pressure from applying the brakes
properly which could increase stopping dis-
tances and result in serious personal injury.
NOTE: Always start at the point in the system that
is furthest from the master cylinder and work back
toward the master cylinder.
a. Slowly apply low hydraulic pressure to the
brake. Loosen the bleeder screw. Continue
to apply pressure 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); then
release the pressure to the brake.
19. Bleed the brakes as follows for air/hydraulic or
mechanical actuator systems:
WARNING
When you loosen any brake system hydraulic
connection, you must bleed the brakes to re-
move all air from the system. Air can prevent
hydraulic pressure from applying the brakes
properly which could increase stopping dis-
tances and result in serious personal injury.
NOTE: Always start at the point in the system that
is furthest from the master cylinder and work back
toward the master cylinder.
a. Apply the brake pedal; then loosen the
bleeder screw. Tighten the bleeder screw to
20 to 27 N•m (15 to 20 lbf ft) before you re-
lease the brake pedal so that air is not pulled
back into the system. Repeat this procedure
until no air bubbles appear in the container
of fluid when you apply the brake pedal.
20. Fill the axle housing and the wheel ends with
fluid as described in the section Planetary Gear
Axle for the lift truck.
17
Repair 1800 SRM 1038

Drive Wheels and Tires

WARNING
Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage be-
fore use. When air pressure is added to the tire,
use a chuck that fastens onto the valve stem of
the inner tube. Verify there is enough air hose
to permit the operator to stand away from the
safety cage when air pressure is added to the
tire.
Do not sit or stand by the safety cage. Do not
use a hammer to try and correct the position of
the side flange or lock ring when the tire has
air pressure greater than 20 kPa (3 psi).
1. Put tire in a safety cage. See Figure 36.
2. Add 20 kPa (3 psi) of air pressure to the tire.
CAUTION
Check all wheel nuts after 2 to 5 hours of op-
eration: when new lift trucks begin operation
and on all lift trucks when the wheels have
been removed and installed. Tighten the nuts
as shown in Figure 38, Figure 39, Figure 40,
Figure 41 and Figure 42. When the nuts stay
tight for eight hours, the interval for checking
the torque can be extended to 500 hours.
6. Tighten the wheel nuts as shown in Figure 38,
Figure 39, Figure 40, Figure 41 and Figure 42.
First, tighten the nuts to 35 N•m (26 lbf ft), then
tighten to 100 N•m (74 lbf ft). Check for cor-
rect alignment of wheel parts and inside wheel-
to-hub alignment after tightening nuts 1 through
4. Finally, tighten the nuts to the torque value
shown in Figure 38, Figure 39, Figure 40, Fig-
ure 41 and Figure 42.

NOTE: If installation is not correct, remove all air

pressure from the tire. Remove valve core to verify
all air pressure has been removed and make adjust-
ments. Clearance at ends of lock ring should be 13
to 25 mm (0.5 to 1 in.) when tire has the correct air
pressure.

3. Verify all wheel parts are correctly installed. See

Figure 37.

4. Tap lock ring lightly to verify it is in the seat.

WARNING
The tires & wheels can weigh approximately
750 kg (1653 lb). Verify the lifting device has
the rated capacity to lift the tires and wheels
or personal injury may occur. Figure 36. Add Air to the Tires

5. Install wheels on lift truck.

18
1800 SRM 1038 Repair

1. SIDE FLANGE 7. RIM CLAMP

2. WHEEL RIM 8. HUB
3. FLANGE SEAT 9. WEDGE BAND
4. VALVE STEM 10. SPACER
5. LOCK RING 11. DRIVER
6. O-RING

Figure 37. Wheel Arrangements

19
Repair 1800 SRM 1038

Figure 39. Wheel Nut Tightening Sequence

(A227, B227)

A. STEER WHEEL
B. DRIVE WHEEL

Figure 38. Wheel Nut Tightening Sequence

(A222)

A. STEER WHEEL
B. DRIVE WHEEL

Figure 40. Wheel Nut Tightening Sequence

(D117)

20
1800 SRM 1038 Repair

A. STEER WHEEL
B. DRIVE WHEEL

Figure 41. Wheel Nut Tightening Sequence

(E008)

A. STEER WHEEL
B. DRIVE WHEEL

Figure 42. Wheel Nut Tightening Sequence

(E117, F117)

21
Brake Pedal Valves (Treadle Valves) Repair
PRESSURE SWITCH
Replace
This lift truck has two pressure switches. One switch
will activate warning light for low pressure in the op-
erator’s cab. The other switch will activate the brake
lights.
WARNING
Before disconnecting any hydraulic lines, re-
lease pressure from the hydraulic circuit as fol-
lows:
• Shut engine off and completely lower car-
riage. Install blocks at wheels to prevent lift
truck from moving.
Brake Pedal Valves (Treadle Valves) Repair
ALL MODELS EXCEPT E117
Remove
NOTE: For the location of brake pedal valves start-
ing with D117 1682 and after and E008 wet brakes,
see the section Hydraulic Plate, Serial Numbers
1642, 1644, 1664, 1665, 1679, 1682, and After
(D117 Only) 1900 SRM 1012.
NOTE: Do NOT disassemble the valve assembly.
This assembly is replaced as a unit if damaged.
WARNING
Before disconnecting any hydraulic lines, re-
lease pressure from the hydraulic circuit as fol-
lows:
a. Shut off the engine and completely lower
the carriage. Install blocks at the wheels to
prevent the lift truck from moving.
b. Operate the lift/lower lever and the brake
pedals until the hydraulic pressure is re-
leased.
1. Put tags for identification on the lines. See Fig-
ure 43 and Figure 44.
2. Disconnect the lines from the brake pedal valve.
3. Put caps on the open lines.
22
1800 SRM 1038
• Operate the lift/lower lever and brake pedals
until hydraulic pressure is released.
1. Disconnect the electrical connector.
2. Remove switch from cab manifold.
3. Install new switch on cab manifold.
4. Connect electrical connector.
5. Remove air from hydraulic system and check
pressure at the switch as described in the section
.
ACCUMULATOR
For detailed information on the accumulator, see the
section Accumulator 1800 SRM 1036.
NOTE: It is normally not necessary to disassemble
the actuator assembly from the pedal or to remove
the pedal just to repair or replace the valve.
4. If the pedal assembly will be repaired or re-
placed, remove the three screws that fasten the
assembly to the mount plate.
5. If necessary, remove the two U-bolts, actuator,
return springs, and pivot pin of the pedal.
6. Remove the two nuts and washers that fasten the
valve assembly to the pedal base plate.
Clean and Inspect
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.
Clean the parts in solvent. Inspect the spool and
bores for scratches. If there are scratches or other
damage, the parts must be replaced. Lubricate the
parts with clean hydraulic oil for assembly.
Install
1. Install the valve assembly using the two nuts and
washers that fasten the valve assembly to the
pedal base plate. See Figure 43 and Figure 44.
1800 SRM 1038 Brake Pedal Valves (Treadle Valves) Repair

Figure 43. Brake and Inching Brake Pedal Valve (Treadle Valve) Arrangement Until D117 E 01550

23
Brake Pedal Valves (Treadle Valves) Repair 1800 SRM 1038

Legend for Figure 43

A. REAR VIEW D. LEFT SIDE VIEW
B. FRONT VIEW E. BOTTOM VIEW
C. RIGHT SIDE VIEW
1. MOUNT PLATE FOR BRAKE PEDAL 8. BRAKE VALVE
2. BRAKE PEDAL 9. INCHING BRAKE VALVE
3. INCHING PEDAL 10. INCHING VALVE
4. CAM PLATE 11. MOUNT PLATE FOR INCHING PEDAL
5. ACTUATOR 12. CAM AND LINK
6. PEDAL BASE 13. ACTUATOR
7. PIVOT POINT OF INCHING PEDAL 14. BASE OF VALVE HOUSING

2. If removed, install the two U-bolts, actuator, re- 5. Operate the system and check the valve connec-
turn springs, and pivot pin of the pedal. tions for leaks.

3. Install the valve and pedal assembly using the 6. Remove the air from the hydraulic system as de-
three screws that fasten the assembly to the scribed in Brake System Air Removal.
mount plate.

4. Install the lines to the brake pedal valve.

Legend for Figure 44

A. RIGHT SIDE VIEW C. REAR VIEW
B. FRONT VIEW
1. MOUNT PLATE 6. BRAKE VALVE
2. BRAKE PEDAL 7. DECLUTCH/BRAKE VALVE
3. DECLUTCH/BRAKE PEDAL 8. ACTUATOR
4. ACTUATOR 9. BASE OF VALVE HOUSING
5. PEDAL BASE

24
1800 SRM 1038 Brake Pedal Valves (Treadle Valves) Repair

Figure 44. Brake and Declutch/Brake Pedal Valve (Treadle Valve) Arrangement D117 E 01550 and
After and E008 Wet Brakes

25
Brake System Air Removal
E117, F117
Remove
WARNING
Before disconnecting any hydraulic lines, re-
lease pressure from the hydraulic circuit as fol-
lows:
a. Shut off the engine and completely lower
the carriage. Install blocks at the wheels to
prevent the lift truck from moving.
b. Operate the lift/lower lever and the brake
pedals until the hydraulic pressure is re-
leased.
NOTE: The brake treadle valve is mounted to the
base of the operator’s cab in line with the brake
pedal.
1. Put tags for identification on the lines.
2. Disconnect the lines from the brake treadle
valve.
3. Put caps on the open lines.
4. If valve assembly will be repaired or replaced,
remove bolts that fasten brake treadle valve as-
sembly to the floor plate of cab.
Brake System Air Removal
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.
1. Fill the hydraulic tank to the correct level.
NOTE: Keep the engine operating at idle speed to
maintain the pressure.
2. Operate the engine to charge the accumulator to
maximum pressure.
3. Push the brake pedals down as far as possible.
4. Connect one end of a hose to the special fitting on
the brake caliper or other components.
5. Place other end of the hose in a container filled
with clean hydraulic fluid.
26
1800 SRM 1038
Clean and Inspect
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.
Clean the parts in solvent. Inspect the spool and
bores for scratches. If there are scratches or other
damage, the parts must be replaced. Lubricate the
parts with clean hydraulic oil for assembly.
Install
1. Install valve assembly using bolts that fasten
valve assembly to floor of the cab.
2. Install the lines to the brake treadle valve.
3. Operate the system and check the valve connec-
tions for leaks.
4. Remove the air from the hydraulic system as de-
scribed in Brake System Air Removal.
6. To remove the air, loosen the fitting and operate
the correct pedal until no air is seen coming out
of the hose in the container.
7. Tighten the fitting after air stops coming out and
before disconnecting the hose.
8. Connect the hose at each of the following points:
a. Special fitting at the highest point of the aux-
iliary brake caliper, D117 and E008 only.
b. Special fitting at the parking brake caliper.
c. Special fittings at each wheel brake assem-
bly.
9. Do Step b and Step c of Step 8 again after waiting
approximate 2 hours to remove the last of the air.
1800 SRM 1038 Specifications

Specifications
NOTE: Tighten all fasteners to the correct torque value. See Figure 45, Figure 46, Table 3, and Table 4.

Figure 45. Wheel Hub and Brake Housing

Table 3. Wheel Hub and Brake Housing Torque Chart

Item
Description
Number
1 Cover-to-Planetary Spider
Capscrew
2 Piston Return Spring Plug
3 Cover and Spindle to Axle
Housing Internal, Mount
4 Cover and Spindle to Axle M16 × 2.00
Housing capscrew, External
M20 × 2.50
Mount
5 Planetary Spider to Wheel
Hub Capscrew
Size Torque
7/16"-14 82 to 102 N•m (60 to 75 lbf ft)
1/2"-13 116 to 156 N•m (85 to 115 lbf ft)
82 to 102 N•m (60 to 75 lbf ft)
5/8"-11 244 to 312 N•m (180 to 230 lbf ft)
3/4"-10 450 to 542 N•m (332 to 400 lbf ft)
7/8"-9 678 to 881 N•m (500 to 650 lbf ft)
7/8"-14 678 to 881 N•m (500 to 650 lbf ft)
1"-12 938 to 1288 N•m (692 to 950 lbf ft)
1-1/4"-12 2305 to 2983 N•m (1700 to 2200 lbf ft)
270 to 350 N•m (199 to 258 lbf ft)
500 to 650 N•m (369 to 479 lbf ft)
3/8"-16 48 to 68 N•m (35 to 50 lbf ft)
1/2"-13 116 to 156 N•m (85 to 115 lbf ft)
3/4"-10 450 to 542 N•m (332 to 400 lbf ft)

27
Specifications 1800 SRM 1038

Table 3. Wheel Hub and Brake Housing Torque Chart (Continued)

Item
Description Size Torque
Number
6 Bearing Adjusting Nut Lock 3/8"-16 48 to 68 N•m (35 to 50 lbf ft)
Plate Capscrew
7/16"-14 81 to 102 N•m (60 to 75 lbf ft)
7 Cover-to-Brake Housing 9/16"-12 169 to 224 N•m (125 to 165 lbf ft)
Capscrew
M16 × 2.00 270 to 350 N•m (199 to 258 lbf ft)
M20 × 2.50 500 to 650 N•m (369 to 479 lbf ft)
5/8"-11 244 to 312 N•m (180 to 230 lbf ft)
3/4"-10 450 to 542 N•m (332 to 400 lbf ft)
3/4"-16 488 to 637 N•m (360 to 470 lbf ft)
7/8"-9 678 to 881 N•m (500 to 650 lbf ft)
8 Brake Driver to Wheel Hub 3/4"-10 450 to 542 N•m (332 to 400 lbf ft)
Capscrew (Not Shown)
7/8"-14 780 to 1017 N•m (575 to 750 lbf ft)
1"-14 1152 to 1491 N•m (850 to 1100 lbf ft)

28
1800 SRM 1038 Specifications

Figure 46. Brake Housing Cover

Table 4. Brake Housing Cover Torque Chart

Item
Description Torque
Number
1 Hydraulic Bleeder Screw 20 to 27 N•m (15 to 20 lbf ft)
2 Plug Minimum 14 N•m (10 lbf ft)
3 Housing Cover Plug, Pipe Plug Minimum 27 N•m (20 lbf ft)
Housing Cover Plug—O-ring Plug 81 to 102 N•m (60 to 75 lbf ft)
4 Coolant Fill/Level Plug, Sump Cooling Only Minimum 47 N•m (35 lbf ft)
5 Plug Minimum 14 N•m (10 lbf ft)
6 Hydraulic Fluid Inlet Fitting, Tapered Seat 34 to 47 N•m (25 to 35 lbf ft)
7 Hydraulic Fluid Inlet Fitting, O-ring 34 to 47 N•m (25 to 35 lbf ft)
8 Magnetic Drain Plugs, Cooling System Minimum 27 N•m (20 lbf ft)
9 Coolant Input Port Plugs 81 to 102 N•m (60 to 75 lbf ft)
10 Optional Hydraulic Fluid Inlet Plug 34 to 47 N•m (25 to 35 lbf ft)

29
Troubleshooting 1800 SRM 1038

Table 4. Brake Housing Cover Torque Chart (Continued)

Item
Description Torque
Number
11 Plug Minimum 14 N•m (10 lbf ft)
12 Coolant Output Port Plug 81 to 102 N•m (60 to 75 lbf ft)

BRAKE COOLANT Coolant Change Intervals

The following specifications are for sump and forced Normal Maintenance
cooling systems with hub seals.
Change the fluid in the brake housing as specified in
Coolant Specification the operator’s manual of the lift truck.
Petroleum Base SAE See the operator’s
HYDRAULIC FLUID
10W, SAE 20W or SAE manual of the lift truck
10W30 Use only the brake hydraulic fluid specified by the
manufacturer of the vehicle. Do not use different hy-
draulic fluids. The wrong fluid will damage the seals
on the piston.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Low or no pressure to brake. Leakage of brake actuation fluid. See brake leaks actuation fluid in
this troubleshooting section.

Vehicle does not move. Damaged hydraulic system. Repair hydraulic system.

Brakes dragging. More than 1.4 bar (20 psi) pressure Repair hydraulic system so pressure
applied when brakes released. is less than 1.4 bar (20 psi) when
brakes released and while truck is
operating in any mode.

Damaged piston return spring as- Repair or replace piston return

sembly. spring assembly.

Piston not returning. Check piston seals and seal separator

for swelling or damage. Replace as
necessary.

Wrong cooling and/or actuation fluid Check piston seals and seal separa-
used. tor for swelling or damage. Replace
as necessary. Purge system and use
specified fluid.

30
1800 SRM 1038 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Noticeable change or de- Inadequate pressure to apply Check brake apply system. Check
crease in stopping perfor- brakes. for leakage in brake system or brakes
mance. and correct cause.

Worn or damaged discs. Inspect and replace discs if necessary.

Overheated seals and/or discs. Inspect and replace discs and seals if
necessary.

Dirty or contaminated cooling fluid. Drain and flush hydraulic oil. Re-
place with approved fluid. In some
cases, it may be necessary to replace
discs. Replace filter.

Brake does not fully apply. Damaged hydraulic system. Repair hydraulic system.

Leakage of brake actuation fluid. See brake leaks actuation fluid in

this troubleshooting section.

Brakes feel spongy/soft. Brake system not properly bled. Bleed brakes and brake system.

Brake leaks actuation fluid. Worn or damaged piston seal. Replace piston seals.

Melted or extruded piston seals. Correct cause of overheating and re-

place seals.

Corrosion, pitting, wear or other Clean, smooth, rework, or replace af-

damage, marks, scratches to piston fected parts.
and/or brake housing bore in area of
seal/sealing lips.

Loose bleeder screw Tighten bleeder screw to 20 to

27 N•m (15 to 20 lbf ft).

Loose inlet fitting or plugs. Tighten inlet fitting to 34 to 47 N•m

(25 to 35 lbf ft).

Damaged inlet fitting, plugs, or Replace inlet fitting or plug and

seats. O-ring if used. Repair or resurface
area or replace as necessary.

31
Troubleshooting 1800 SRM 1038

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Coolant leaking out of brake Face seal damaged, worn, or improp- Reinstall and/or replace face seal.
housing. erly installed.

Loose drain plug, fill plug, or forced Tighten plug.

cooling plug.

Damaged plug. Replace plug.

Deteriorated or inadequate sealant Disassemble, clean, reseal, and re-

used at joint. assemble joint.

Low brake pressure indica- There is not enough charge volume • Replace high pressure filter mani-
tor light ON. to keep the accumulator charged. fold if it is clogged.
• Check pre-charge accumulator.
• Check charge settings.

Axle housing filling with oil, Worn or damaged spindle to hub Replace spindle to hub seal. Check
forced cooling systems only, seal. seal and journals.
and may be forced out the
breather.

Brush hair lodged in grease under Do not use brush to apply grease to
hub-to-spindle seal lip. seal areas.

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 TECHNICAL PUBLICATIONS

1800 SRM 1038 8/05 (3/05)(8/04)(7/04)(11/03)(11/02) Printed in U.S.A.