Hyster G001 Repair Manual Download Page 4 | Manualshive

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©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

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Summary of Contents for G001

Page 1: ...Hyster G001 H30 35FT H40FTS Internal Combustion Engine Trucks Service Repair Manual ...

Page 2: ...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 ...

Page 3: ...odic 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 ...

Page 4: ...an 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 Adjustm...

Page 5: ... THE QUALITY KEEPERS HYSTER APPROVED PARTS ...

Page 6: ...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 admin servicemanualperfect com ...

Page 7: ... 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 HOUSI...

Page 8: ... 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 Whe...

Page 9: ...SEMBLY 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 ...

Page 10: ...ve 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...

Page 11: ...LY 11 ADJUSTER WHEEL 12 ADJUSTER ASSEMBLY 13 PRIMARY BRAKE SHOE 14 PARKING BRAKE LEVER 15 LINK PARKING BRAKE 16 SPRING PARKING BRAKE 17 PIVOT PIN RETAINER AND SPRING WASHER 18 ADJUSTER ACTUATOR SPRING 19 SPRING Figure 4 Brake Assembly Left Hand Shown S2 0 3 5FT S40 70FT S55FTS H187 and H2 0 3 5FT H40 70FT P177 1800 SRM 1743 Service Brakes Repair Dry Brake 5 ...

Page 12: ...JUSTER WHEEL 12 ADJUSTER ASSEMBLY 13 PRIMARY BRAKE SHOE 14 PARKING BRAKE LEVER 15 PARKING BRAKE LINK 16 PARKING BRAKE SPRING 17 PIVOT PIN RETAINER AND SPRING WASHER 18 ADJUSTER ACTUATOR SPRING 19 SPRING 20 RETAINING PIN 21 RETAINING WASHER 22 PARKING BRAKE CABLE Figure 5 Service Brake Parts S2 0 3 5FT S40 70FT S55FTS H187 and H2 0 3 5FT H40 70FT P177 Service Brakes Repair Dry Brake 1800 SRM 1743 6...

Page 13: ...G 9 SPRING ACTUATOR 10 PAWL LEVER 11 SECONDARY BRAKE SHOE 12 ADJUSTER ASSEMBLY 13 ADJUSTER SPRING 14 PARK BRAKE LEVER 15 PRIMARY BRAKE SHOE 16 STRUT Figure 6 Brake Assembly Left Hand Side S30 35FT S40FTS F010 H1 6 1 8FT H2 0FTS H30 35FT H40FTS G001 S50CT B267 and H2 0 2 5CT H50CT B274 1800 SRM 1743 Service Brakes Repair Dry Brake 7 ...

Page 14: ...ASHER 13 PAWL LEVER 14 PARK BRAKE CABLE 15 ADJUSTER ASSEMBLY 16 PLUG 17 SPRING ADJUSTER 18 PRIMARY BRAKE SHOE 19 PARK BRAKE LEVER 20 PIN 21 PLUG 22 BACKING PLATE 23 PIN Figure 7 Service Brake Parts S30 35FT S40FTS F010 H1 6 1 8FT H2 0FTS H30 35FT H40FTS G001 S50CT B267 and H2 0 2 5CT H50CT B274 Service Brakes Repair Dry Brake 1800 SRM 1743 8 ...

Page 15: ...rease will cause dam age and leaks in the seals of a brake system The brakes will not operate correctly if oil grease or brake fluid is on the brake linings Cleaning solvents can be flammable and toxic and can cause skin irritation When using cleaning solvents always follow the safety instructions of the solvent manufacturer 1 DO NOT release brake lining dust from brake linings into the air when b...

Page 16: ... Inspect brake drums for cracks or damage Replace any damaged parts 4 Inspect brake drum for deep grooves or other damage NOTE If grooves must be removed from brake drums DO NOT grind more than 1 5 mm 0 060 in from internal diameter of brake drum Maximum limit of internal diameter of the brake drum is 312 mm 12 28 in for lift truck models S2 0 3 5FT S40 70FT S55FTS H187 H2 0 3 5FT H40 70FT P177 Ma...

Page 17: ... sure adjuster wheel will be toward rear of lift truck Move brake shoes apart so that adjuster wheel is held in position and ad juster actuator spring is in tension 8 Lubricate back plate with a small amount of lithium grease where brake shoes touch Install brake shoes on anchor and engage thepush rods of wheel cylinder Engage theparking brake lever in slot in parking brake cable as brake shoes ar...

Page 18: ...pring c Verify that return springs are properly in stalled as shown in Figure 10 1 RETURN SPRING 2 ANCHOR GUIDE 3 RETURN SPRING 4 ADJUSTER ACTUATOR LINK 5 PIVOT PLATE Figure 9 Return Springs S2 0 3 5FT S40 70FT S55FTS H187 and H2 0 3 5FT H40 70FT P177 Service Brakes Repair Dry Brake 1800 SRM 1743 12 ...

Page 19: ...n The arrangement of return springs on anchors is shown in Figure 11 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 16 Using correct tools install return springs as fol lows a Install return spring b Install washer c Install return spring d Verify that return springs are properly in stalled as shown in Figure 11 1800 SRM 1743 Ser...

Page 20: ...and H2 0 2 5CT H50CT B274 NOTE Seal and bearings are to be installed flush with hub Seal is to be installed with no grease or oil on outside surface 17 Clean bearings and lubricate them with wheel bearing grease Install bearings and seals in brake drum Install assembly on axle housing See Figure 12 and Figure 13 Service Brakes Repair Dry Brake 1800 SRM 1743 14 ...

Page 21: ...1 INNER SEAL 2 OUTER SEAL 3 BRAKE DRUM 4 INNER BEARING 5 OUTER BEARING Figure 12 Grease Seals and Bearing Locations 1800 SRM 1743 Service Brakes Repair Dry Brake 15 ...

Page 22: ...ign bearing rollers tighten wheel ad justment nut to 14 to 18 N m 124 to 159 lbf in and rotate hub 2 revolutions in both directions b To seat wheel bearings tighten wheel adjust ment nut to 175 to 215 N m 129 to 159 lbf ft for lift truck models S2 0 3 5FT S40 70FT S55FTS H187 H2 0 3 5FT H40 70FT P177 c To seat wheel bearings tighten wheel adjust ment nut to 120 to 145 N m 89 to 107 lbf ft for lift...

Page 23: ...rn Use a small screw driver to lift actuator away from adjuster wheel and turn adjuster wheel approximately 20 teeth in the opposite direction Brakes will adjust to correct clearance when they are applied while lift truck is traveling in reverse direction 22 Put liquid sealant Hyster Part Number 264159 on flange of axle shaft Install axle shaft and capscrews Tighten capscrews in cross pattern to a...

Page 24: ...st backward to remove blocks Push on brake pedal Pedal must not touch floor plate Move lift truck in REVERSE and push on brake pedal to permit adjusting mechanism to operate Repeat this operation several times 4 Service brakes must be adjusted before parking brake can be adjusted See Figure 18 and fol lowing paragraphs in this section for correct ad justment of parking brake INCHING OVERLAP ADJUST...

Page 25: ...rews that fasten bracket for parking brake to cowl Remove bracket and brake lever assembly 3 Loosen jam nuts that fasten threaded ends of brake cables to brake lever assembly 4 Turn adjuster knob counterclockwise until brake cables are loosened Disconnect cables from link 5 Service brake assembly must be removed before parking brake cable can be removed from back plate of service brake A snap ring...

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