BRAKE SYSTEM

N35ZDR, N45ZR [C264];

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

PART NO. 1590938 1800 SRM 1188

Brake System Table of Contents

TABLE OF CONTENTS

Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 1
Electric Brake..................................................................................................................................................... 2
Air Gap ........................................................................................................................................................... 3
Remove ........................................................................................................................................................... 4
Install ............................................................................................................................................................. 4
Troubleshooting.................................................................................................................................................. 5

This section is for the following models:

N35ZDR, N45ZR [C264];

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

2008 HYSTER COMPANY i

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

2. Disconnect the battery power cable connector

from the truck connector located on the right side
of the frame. Pull the battery cable connector
handle to separate the battery connector from
the truck connector.

3. Remove the operator compartment cover.

4. Discharge the capacitor in the controllers by

connecting a 200-ohm, 2-watt resistor across the
controller B+ and B terminals of the motor
controller. Remove the resistor after discharging
the capacitors. See Figure 2.

1. POSITIVE CONNECTION (B+)

2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR

Figure 2. Discharging the Capacitors

Electric Brake
The electric brake is located in the drive unit com-
partment mounted to the top of the traction motor.
It consists of a spring-applied, electrically-released
brake mounted directly to the drive motor. See
Figure 3. The electric brake is controlled by the
master controller. After receiving input signals from
the floor switches and a traction input from the
multifunction control handle, the master controller
will complete the circuit to the brake coil, releasing
the brake. The master controller breaks the power
supply to the brake coil, engaging the electric brake
when the truck is stopped. Pressing the emergency
disconnect will apply the electric brake immediately
in any mode of operation. The electric brake may
be manually released for towing by inserting two
standard 1/4-20 1-1/4 in. capscrews into the two
threaded holes in the top of the brake assembly. See 1. FRAME
Figure 4. 2. MAST TRUNNIONS
3. BATTERY COMPARTMENT
4. FLOOR MAT
5. TRACTION MOTOR
6. BRAKE ASSEMBLY

Figure 3. Brake Location

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1800 SRM 1188 Electric Brake

5. If the air gap is too tight for a minimum feeler

gauge to enter any of the six locations, the air
gap has been altered by internal damage or tam-
pering. Replace the entire brake assembly. See
Remove.

NOTE: During brake operation, the brake should en-

gage and release with a solid, single-click noise. A
double-clicking noise indicates that one side of the
brake is releasing before the other.

6. Listen to verify the brake releases and applies

in one smooth operation. A double-clicking noise
indicates that one side of the brake is releasing
before the other due to internal damage or tam-
pering. Replace the entire brake assembly. See
Remove.

1. SERVICE CAPSCREWS
2. SERVICE PORTS
3. BRAKE ASSEMBLY
4. ASSEMBLY HOLES

Figure 4. Manual Release

AIR GAP

CAUTION
The brake is not adjustable. Check the air gap
to determine if replacement is necessary.

NOTE: The air gap is very thin and may not be

checked visually. Dimensions are not to scale and
are for location references only.

1. Check the three outer socket head screws for ap-

propriate torque to secure the brake to the motor.

2. 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. Air
gap should measure 0.20 to 0.40 mm (0.008 to
0.015 in.). See Figure 5.
1. STATOR
3. The air gap should be checked for minimum and 2. AIR GAP
maximum clearance at the six locations shown in 3. PRESSURE PLATE
Figure 6. 4. FEELER GAUGE

4. If the air gap allows the maximum feeler gauge to Figure 5. Air Gap
enter any of the six locations, replace the entire
brake assembly. See Remove.

3
Electric Brake 1800 SRM 1188

1. ELECTRIC BRAKE AND HUB

2. CAPSCREW
3. LOCKWASHER
Figure 6. Check Locations (Typical Brake) 4. WASHER
5. RETAINING RING
REMOVE 6. WOODRUFF KEY

The following procedures detail the removal and in-
stallation procedures for the electric brake.
The brake assembly is nonadjustable and contains no
service parts. If the brake fails to function, it must be
replaced as a complete assembly. Check the electric
brake before each shift for proper operation. Refer to
Periodic Maintenance 8000 SRM 1197.
1. Move the lift truck to a safe, level area and com-
pletely lower the mast. Turn the key switch to
the OFF position and attach a DO NOT OPER-
ATE tag to the control handle. Block the drive
wheel to prevent unexpected movement. See Fig-
ure 7.
Figure 7. Electric Brake
7. Remove the retaining ring securing the hub to
the motor shaft.
8. Remove the hub from the motor shaft. Recover
the Woodruff key.
INSTALL
1. Install the Woodruff key to the motor shaft. Align
the groove in the hub with the Woodruff key and
Install the hub onto the motor shaft.
2. Install the retaining ring onto the motor shaft to
secure the hub.

2. Disconnect the battery power cable connector
from the truck connector located on the right side
of the frame. Pull the battery cable connector
handle to separate the battery connector from
the truck connector.
3. Position the brake assembly onto the hub. Align
the brake mounting slots with the mounting
holes in the motor housing (as removed) and
secure using four capscrews, lockwashers, and
washers. See Figure 7.

3. Open the drive unit compartment door.
4. Disconnect the electric brake wiring harness
from the main wiring harness near the electric
brake assembly.
5. Remove the four capscrews, lockwashers, and
washers securing the brake assembly to the
drive motor.
6. Lift the brake assembly up off the hub and the
motor housing.
4. Install brake wiring harness to the main wiring
harness as removed.
5. Connect the battery. Turn key switch to the ON
position and listen for the electric brake to re-
lease. Check for proper operation.
6. Secure the drive unit compartment door closed.
Remove the DO NOT OPERATE tag from the
control handle and remove the blocks from drive
wheel.

4
1800 SRM 1188 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Electric brake will not re- Key switch is in the OFF position. Turn key switch to the ON position.
lease.

Battery is not connected or is dis- Connect or clean battery connections.

charged. Charge if necessary.

Wiring or controller malfunction(s). Refer to wiring diagrams.

Excessive wear. Replace the brake assembly.

Brake coil is defective. Check brake coil resistance. Resis-

tance should read 11.9 ohms 1.0
ohm. Replace brake assembly if nec-
essary.

Foot switches not engaged or not Check battery voltage at brake coil
working properly. connector.

Multifunction handle not in FWD or Set multifunction handle to FWD or

REV position. REV position.

Electric brake will not apply. Internal mechanical damage to Replace the brake assembly.
brake.

Electric brake does not hold Oil or grease on the friction surfaces. Replace the brake assembly.
truck loaded to specification.

Friction surfaces are worn out. Replace the brake assembly.

Springs are too weak. Replace the brake assembly.

Load exceeds truck capacity. Handle only approved load weight.

Brake components worn or damaged. Replace the brake assembly.

Brake coil defective. Replace the brake assembly.

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Troubleshooting 1800 SRM 1188

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Brake drags or gets hot. Battery is discharged or connections Clean battery connections. Charge if
are loose or dirty. necessary.

Excessive wear. Replace brake assembly.

Brake coil defective. Check coil resistance. Resistance

should read 11.9 ohms 1.0 ohm.

Oil or grease in brake. Replace brake assembly.

Incorrect brake air gap. Check air gap is within 0.007 to 0.015
inch. Replace brake assembly if gap
is not within specification.