BRAKE SYSTEM

N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]

PART NO. 1590938 1800 SRM 1188

...... N30ZDR................................................................................. 5 This section is for the following models: N35ZDR..................................Brake System Table of Contents TABLE OF CONTENTS Introduction....................................................... 4 Install ........................... N30ZDRS.......................................................................................... N35-40ZRS [A265] ©2008 HYSTER COMPANY i ............................................................................................... 1 Electric Brake......................................................................................................................................... 3 Remove ............................................................................................ 1 General ............................................................................................................................................................................................................................................................................................................................................................................................................... N45ZR [C264]................................................. 4 Troubleshooting..... 2 Air Gap ................ N35-40ZR [D470].................................................. 1 Discharging the Capacitors..............................................................

RIGHT SIDE minals with a screwdriver or jumper wire. discharge the capacitor(s). Throughout this section. block the lift truck to prevent unexpected movement. Re. Block the drive create dangerous operating conditions. arms. DO NOT short across the motor controller ter- A. and never put power to the controller while any When working with the electrical systems of the power wires are disconnected. it is necessary to discharge the capacitors of any controller terminal or motor terminal to the controllers associated with each circuit affected. LEFT SIDE B. DO NOT connect the mined by an operator standing in the operator com. This section contains the description and replace. The capacitor in the transistor controller(s) can hold an electrical charge after the battery is disconnected. the high current flow from the SRM 1191 for information on parking brake wiring battery can cause personal injury or property and the brake foot switch. If a tool causes systems. Turn the key switch to you have both authorization and training. the battery. Move the lift truck to a safe. Make certain that the battery has been disconnected. To prevent an electrical shock and personal injury. the OFF position and attach a DO NOT OPER- pairs and adjustments that are not correct can ATE tag to the control handle. NOT operate a lift truck that needs repairs. See the section Electrical System 2200 a short circuit. partment facing the forks. C. always disconnect DISCHARGING THE CAPACITORS the battery.1800 SRM 1188 Introduction Introduction GENERAL immediately. ment procedures for the spring applied. electri- cally-released parking brake. forward will refer to travel Some checks and adjustments are done with in the direction of the forks and left and right deter. Before performing any tests or adjustments. Remove the key from the key switch. battery until the procedure tells you to do so. level area and com- DO NOT make repairs or adjustments unless pletely lower the mast. Some parts associated Disconnect the battery before opening the elec- with the brake system are not covered in this section trical compartment covers or inspecting or re- because they are more closely associated with other pairing the electrical system. Make sure to use proper proce- dure when servicing the controller. Never short truck. damage. FORWARD TRAVEL Figure 1. Wear safety glasses. Truck Orientation CAUTION To avoid controller damage. discharge the capacitor(s) before inspecting or repairing any component in the electrical compartments. Report the need for repairs to your supervisor 1 . DO wheel to prevent unexpected movement. See Figure 1. Never have any metal on your fingers. attach a DO NOT OPERATE tag on the steering wheel. If repair is necessary. WARNING 1. Metal items can accidentally make an electrical connection and cause injury. the battery connected. or neck.

BRAKE ASSEMBLY Figure 3. INSULATED JUMPER WIRES 4. Disconnect the battery power cable connector from the truck connector located on the right side of the frame. See Figure 3. Discharge the capacitor in the controllers by connecting a 200-ohm. releasing the brake. FLOOR MAT 5. MAST TRUNNIONS 3. The electric brake is controlled by the master controller. 2-WATT RESISTOR Figure 2. See 1. Remove the resistor after discharging the capacitors. It consists of a spring-applied. See Figure 2. 4. TRACTION MOTOR 6. The master controller breaks the power supply to the brake coil. the master controller will complete the circuit to the brake coil. electrically-released brake mounted directly to the drive motor. engaging the electric brake when the truck is stopped. FRAME Figure 4. BATTERY COMPARTMENT 4.Electric Brake 1800 SRM 1188 2. NEGATIVE CONNECTION (B ) 3. 200-OHM. The electric brake may be manually released for towing by inserting two standard 1/4-20 × 1-1/4 in. 3. POSITIVE CONNECTION (B+) 2. Remove the operator compartment cover. Brake Location 2 . 2. capscrews into the two threaded holes in the top of the brake assembly. Pull the battery cable connector handle to separate the battery connector from the truck connector. 1. Discharging the Capacitors Electric Brake The electric brake is located in the drive unit com- partment mounted to the top of the traction motor. After receiving input signals from the floor switches and a traction input from the multifunction control handle. Pressing the emergency disconnect will apply the electric brake immediately in any mode of operation. 2-watt resistor across the controller B+ and B terminals of the motor controller.

NOTE: During brake operation. FEELER GAUGE 4.015 in.40 mm (0. Manual Release AIR GAP CAUTION The brake is not adjustable. 1. PRESSURE PLATE Figure 6. Check the air gap to determine if replacement is necessary. The air gap should be checked for minimum and 2. Listen to verify the brake releases and applies in one smooth operation. single-click noise. 2. Replace the entire brake assembly. A double-clicking noise indicates that one side of the brake is releasing before the other due to internal damage or tam- pering. STATOR 3.20 to 0. Air Gap enter any of the six locations. the air gap has been altered by internal damage or tam- pering. See Remove. ASSEMBLY HOLES Figure 4. If the air gap allows the maximum feeler gauge to Figure 5. If the air gap is too tight for a minimum feeler gauge to enter any of the six locations.). 6.1800 SRM 1188 Electric Brake 5. 1. See Remove. A double-clicking noise indicates that one side of the brake is releasing before the other.008 to 0. See Remove. replace the entire brake assembly. NOTE: The air gap is very thin and may not be checked visually. See Figure 5. 3 . SERVICE CAPSCREWS 2. BRAKE ASSEMBLY 4. 4. SERVICE PORTS 3. Check for correct air gap by measuring the distance between the bottom of the stator and the top of the pressure plate with the brake applied (disconnected) using feeler gauges. Replace the entire brake assembly. 1. the brake should en- gage and release with a solid. Air gap should measure 0. Check the three outer socket head screws for ap- propriate torque to secure the brake to the motor. Dimensions are not to scale and are for location references only. AIR GAP maximum clearance at the six locations shown in 3.

See Figure 7. motor housing. Install the hub onto the motor shaft. RETAINING RING REMOVE 6. position and listen for the electric brake to re- lease. lockwashers. Remove the DO NOT OPERATE tag from the control handle and remove the blocks from drive 6. 7. Recover replaced as a complete assembly. Block the drive wheel to prevent unexpected movement. Turn the key switch to the groove in the hub with the Woodruff key and the OFF position and attach a DO NOT OPER. drive motor. Figure 7. Lift the brake assembly up off the hub and the wheel. Electric Brake stallation procedures for the electric brake. Check the electric the Woodruff key. 1. If the brake fails to function. ATE tag to the control handle. Position the brake assembly onto the hub. lockwashers. Refer to Periodic Maintenance 8000 SRM 1197. LOCKWASHER Figure 6.Electric Brake 1800 SRM 1188 1. 3. Install the retaining ring onto the motor shaft to ure 7. Install brake wiring harness to the main wiring harness as removed. brake before each shift for proper operation. Install the Woodruff key to the motor shaft. Pull the battery cable connector holes in the motor housing (as removed) and handle to separate the battery connector from secure using four capscrews. Disconnect the battery power cable connector 3. Move the lift truck to a safe. and washers securing the brake assembly to the 6. washers. 4. Align pletely lower the mast. Align from the truck connector located on the right side the brake mounting slots with the mounting of the frame. WOODRUFF KEY The following procedures detail the removal and in. Open the drive unit compartment door. CAPSCREW 3. Remove the hub from the motor shaft. 2. level area and com. Disconnect the electric brake wiring harness from the main wiring harness near the electric 5. Remove the four capscrews. Check for proper operation. See Fig. INSTALL 1. 4. Remove the retaining ring securing the hub to The brake assembly is nonadjustable and contains no the motor shaft. service parts. Connect the battery. secure the hub. 2. 5. 4 . Secure the drive unit compartment door closed. Check Locations (Typical Brake) 4. WASHER 5. and the truck connector. Turn key switch to the ON brake assembly. it must be 8. ELECTRIC BRAKE AND HUB 2.

Check brake coil resistance. truck loaded to specification. Replace the brake assembly. Turn key switch to the ON position. Brake coil defective. Internal mechanical damage to Replace the brake assembly. Load exceeds truck capacity. Key switch is in the OFF position. Resis- tance should read 11.9 ohms ±1. Excessive wear. Replace the brake assembly. Handle only approved load weight. Friction surfaces are worn out. REV position. Wiring or controller malfunction(s). Replace the brake assembly. Electric brake will not apply. Connect or clean battery connections. 5 . Springs are too weak. charged.0 ohm. Refer to wiring diagrams. Replace the brake assembly. connector. Charge if necessary.1800 SRM 1188 Troubleshooting Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Electric brake will not re. Battery is not connected or is dis. Replace brake assembly if nec- essary. brake. lease. Replace the brake assembly. Brake coil is defective. Replace the brake assembly. Foot switches not engaged or not Check battery voltage at brake coil working properly. Multifunction handle not in FWD or Set multifunction handle to FWD or REV position. Electric brake does not hold Oil or grease on the friction surfaces. Brake components worn or damaged.

Oil or grease in brake. Replace brake assembly.Troubleshooting 1800 SRM 1188 PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Brake drags or gets hot. 6 . Resistance should read 11. Check air gap is within 0.007 to 0. necessary. Incorrect brake air gap. Excessive wear. Check coil resistance. Brake coil defective. Charge if are loose or dirty. Replace brake assembly.0 ohm. Replace brake assembly if gap is not within specification. Battery is discharged or connections Clean battery connections.015 inch.9 ohms ±1.