Hyster G001 Operating instructions

Hyster G001 (H30-35FT, H40FTS) Internal Combustion
Engine Trucks Service Repair Manual

BRAKE SYSTEM
S30-35FT, S40FTS [F010];
H1.6-1.8FT, H2.0FTS (H30-35FT, H40FTS)
[G001];
S50CT [B267];
H2.0-2.5CT (H50CT) [B274];
S2.0-3.5FT (S40-70FT, S55FTS) [H187];
H2.0-3.5FT (H40-70FT) [P177]
PART NO. 4120224 1800 SRM 1743

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 ex-
ceed 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 flamma-
ble. 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.

©2014 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Dry Brake System ...............................................................................................................................................1
Wet Brake System .............................................................................................................................................. 1
Service Brakes Repair (Dry Brake) ........................................................................................................................2
Remove and Disassemble ................................................................................................................................... 2
Clean ....................................................................................................................................................................9
Inspect ............................................................................................................................................................... 10
Assemble and Install ........................................................................................................................................ 10
Adjust .................................................................................................................................................................18
Inching Overlap Adjustment ............................................................................................................................18
Parking Brake Repair ........................................................................................................................................... 19
Remove and Disassemble ................................................................................................................................. 19
Dry Brake System .........................................................................................................................................19
Wet Brake System ........................................................................................................................................ 21
Assemble and Install ........................................................................................................................................ 23
Dry Brake System .........................................................................................................................................23
Wet Brake System ........................................................................................................................................ 23
Adjust .................................................................................................................................................................23
Master Cylinder Repair ........................................................................................................................................ 24
Remove (Dry Brake) ..........................................................................................................................................24
Disassemble (Dry Brake) ..................................................................................................................................25
Clean and Inspect (Dry Brake) .........................................................................................................................27
Assemble (Dry Brake) .......................................................................................................................................27
Bench Bleed Master Cylinder (Dry Brake) ......................................................................................................27
Install and Adjust (Dry Brake) ........................................................................................................................ 27
Remove (Wet Brake) ......................................................................................................................................... 28
Disassemble (Wet Brake) ................................................................................................................................. 29
Clean and Inspect (Wet Brake) ........................................................................................................................ 30
Assemble (Wet Brake) ...................................................................................................................................... 31
Install and Adjust (Wet Brake) ........................................................................................................................ 31
Service Brakes Adjustment (Dry Brake) ..............................................................................................................32
Brake System Air Removal ...................................................................................................................................32
Using Pressure Bleed System .......................................................................................................................... 32
Using Brake Pedal Pressure ............................................................................................................................ 33
Brake Pedal Adjustment .......................................................................................................................................33
Free Pedal Adjustment ......................................................................................................................................... 34
Torque Specifications ............................................................................................................................................ 36
This section is for the following models:
(S30-35FT, S40FTS ) [F010];
H1.6-1.8FT, H2.0FTS (H30-35FT, H40FTS) [G001];
(S50CT) [B267];
H2.0-2.5CT (H50CT) [B274];
S2.0-3.5FT (S40-70FT, S55FTS) [H187];
H2.0-3.5FT (H40-70FT) [P177]
Table of Contents
i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

Thanks very much for your reading,
Want to get more information,
Please click here, Then get the complete
manual
NOTE:
If there is no response to click on the link above,
please download the PDF document first, and then
click on it.
Have any questions please write to me:
[e-mail]

General
DRY BRAKE SYSTEM
This section has service procedures for dry brake
system. Dry brake system includes the following
parts: master cylinder, brake shoes, wheel
cylinders, and parking brake system. See Figure 1.
1. PARK BRAKE LEVER
2. ADJUSTMENT KNOB
3. PARK BRAKE CABLES
4. INCHING/BRAKE PEDAL
5. MASTER CYLINDER
6. BRAKE ASSEMBLY
7. BRAKE POSITION SENSOR (RIGHT HAND
SIDE)
Figure 1. Brake System
WET BRAKE SYSTEM
Wet brake system in this section includes the
following parts: master cylinder and parking brake
system. See Figure 2.
Wet disc brakes are a component of wet brake drive
axle. Brake discs are located inside planetary
carrier housing on left side of drive axle. See Drive
Axle Repair (Wet Brake) 1400SRM1679 for
remove and install procedures. See Figure 2.
1. PARK BRAKE HAND LEVER
2. INCH/BRAKE PEDAL
3. MASTER CYLINDER AND BOOSTER
4. PARK BRAKE LEVER
5. WET DISC BRAKE HOUSING
6. PLANETARY CARRIER HOUSING (RIGHT SIDE
SHOWN)
7. BRAKE OIL SUPPLY HOSE
8. ADJUSTMENT KNOB
9. BRAKE POSITION SENSOR
10. BRAKE POSITION SENSOR CONNECTOR
11. BRAKE OIL RESERVOIR
12. PARKING BRAKE CABLE BRACKET
13. PARKING BRAKE CABLE
Figure 2. Wet Brake System for Lift Truck Model
H2.0-3.5FT (H40-70FT) (P177)
1800 SRM 1743 General
1

Service Brakes Repair (Dry Brake)
REMOVE AND DISASSEMBLE
WARNING
Brake linings can contain dangerous fibers.
Breathing the dust from these brake linings is a
cancer or lung disease hazard. DO NOT create
dust! DO NOT clean brake parts with compressed
air or by brushing. Use vacuum equipment ap-
proved for brake dust or follow the cleaning pro-
cedure in this section. When the brake drums are
removed, DO NOT create dust.
DO NOT sand, grind, chisel, hammer, or change
linings in any way that will create dust. Any
changes to brake linings must be done in a re-
stricted area with special ventilation. Protective
clothing and a respirator must be used.
1. Remove capscrews that hold axle shaft to the
hub. Remove axle shaft.
2. See procedure How to Put Lift Truck on Blocks
in Periodic Maintenance for your lift truck
or Operating Manual for your lift truck. Put
lift truck on blocks so drive wheels can be re-
moved. Remove drive wheels.
3. Perform following steps for lift truck models
• S50CT (B267)
• H2.0-2.5CT (H50CT) (B274)
a. Bend bearing lockwasher tabs to release
locknut.
b. Remove nut, lockwasher, locknut, and roller
bearing from hub/brake assembly. See Fig-
ure 3.
WARNING
When the brake shoes are removed, do not create
dust in the air. See the Clean procedure in this
section.
c. Pull wheel assembly from lift truck. If wheel
assembly cannot be removed easily, use a
small screwdriver to push adjuster actuator
away from adjuster wheel. Use a brake ad-
justment tool or a screwdriver to turn ad-
juster wheel to loosen brake shoes. Remove
hub and drum assembly. DO NOT damage
grease seal when removing hub.
d. Remove inner oil seal, inner bearing, and
wear sleeve from hub. See Figure 3.
Service Brakes Repair (Dry Brake) 1800 SRM 1743
2

1. CAPSCREW
2. DRIVE AXLE SHAFT
3. LOCKNUT
4. BEARING LOCKWASHER
5. WASHER
6. HUB/BRAKE ASSEMBLY
7. HUB BOLT
8. ROLLER BEARING
9. OUTER SEAL
10. INNER BEARING
11. INNER OIL SEAL
12. WEAR SLEEVE
13. BRAKE ASSEMBLY
14. LEFT BRAKE LINE
15. DRIVE AXLE MOUNTING CAPSCREW
16. DRIVE AXLE MOUNTING NUT
17. DIFFERENTIAL COVER
18. RIGHT BRAKE LINE
19. DRIVE AXLE CENTER SECTION UNIVERSAL
JOINT
20. UNIVERSAL JOINT
21. DUST COVER
22. INPUT SHAFT (YOKE)
23. BRAKE MANIFOLD
24. HANGER ASSEMBLY
Figure 3. Drive Axle Components, Lift Truck Models S50CT (B267) and H2.0-2.5CT (H50CT) (B274)
1800 SRM 1743 Service Brakes Repair (Dry Brake)
3

4. Perform following steps for lift truck models
• S30-35FT, S40FTS (F010)
• H1.6-1.8FT, H2.0FT (H30-35FT,
H40FTS) (G001)
• S2.0-3.5FT (S40-70FT, S55FTS) (H187)
• H2.0-3.5FT (H40-70FT) (P177)
a. Bend lock plate and remove nut that holds
axle bearing. Remove washer and bearing
cone.
WARNING
When the brake shoes are removed, DO NOT cre-
ate dust in the air. See the Clean procedure in this
section.
b. Pull wheel assembly from lift truck. If wheel
assembly cannot be removed easily, use a
small screwdriver to push adjuster actuator
away from adjuster wheel. Use a brake ad-
justment tool or a screwdriver to turn ad-
juster wheel to loosen brake shoes. Remove
hub and drum assembly. DO NOT damage
grease seal when removing hub.
NOTE: Note arrangement of brake parts during
disassembly to aid in assembly.
5. Remove return springs with spring pliers.
See Figure 4 and Figure 5 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS (H187)
• H2.0-3.5FT (H40-70FT) (P177)
See Figure 6 and Figure 7 for lift truck models
• S30-35FT, S40FTS (F010)
• H1.6-1.8FT, H2.0FTS (H30-35FT,
H40FTS) (G001)
• S50CT [B267]
• H2.0-2.5CT (H50CT) (B274)
6. Remove retainers, springs, and anchor pins
that hold brake shoes to back plate.
7. Disengage link from adjuster wheel actuator.
Remove link, washer, and pivot plate. Remove
anchor guide.
8. Move brake shoes away from each other to dis-
engage brake shoes from wheel cylinder. Dis-
connect parking brake lever from parking brake
cable as brake assembly is removed from back
plate. Parking brake lever has a hook that en-
gages parking brake cable.
NOTE: Adjuster wheel for left brake is not same as
adjuster wheel for right brake. Adjuster wheel for
left brake has left-hand threads.
9. Remove parking brake link and spring if they
are still engaged with brake shoes. Parking
brake link and spring will often fall from brake
assembly when brake assembly is removed
from back plate. Adjuster wheel will also disen-
gage from brake shoes after brake assembly is
removed.
10. Remove spring for adjuster wheel actuator. Re-
move adjuster wheel actuator from brake shoe.
11. Use a screwdriver or small pry bar to move
apart ends of retainer. Remove spring washer
and pivot pin to remove parking brake lever
from brake shoe.
12. Disconnect brake line from wheel cylinder. Re-
move capscrews that hold wheel cylinder to
back plate and remove wheel cylinder.
Service Brakes Repair (Dry Brake) 1800 SRM 1743
4