BRAKE SYSTEM

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]

PART NO. 1580513 1800 SRM 1135

 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!
Brake System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Service Brakes ............................................................................................................................................... 1
Master Cylinder............................................................................................................................................. 1
Brake Position Sensor ................................................................................................................................... 1
Parking Brake................................................................................................................................................ 2
Service Brakes Repair ....................................................................................................................................... 2
Remove and Disassemble .............................................................................................................................. 2
Clean .............................................................................................................................................................. 8
Inspect ............................................................................................................................................................ 9
Assemble and Install ..................................................................................................................................... 9
Adjust ............................................................................................................................................................. 14
Parking Brake Repair........................................................................................................................................ 15
Remove and Disassemble .............................................................................................................................. 15
Assemble and Install ..................................................................................................................................... 16
Adjust ............................................................................................................................................................. 17
Master Cylinder Repair ..................................................................................................................................... 17
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 17
Clean and Inspect .......................................................................................................................................... 17
Assemble ........................................................................................................................................................ 17
Bench Bleed Master Cylinder ....................................................................................................................... 20
Install and Adjust .......................................................................................................................................... 20
Service Brakes Adjustment ............................................................................................................................... 20
Brake System Air Removal ............................................................................................................................... 21
Using Pressure Bleed System ....................................................................................................................... 21
Using Brake Pedal Pressure ......................................................................................................................... 21
Brake Pedal Adjustment ................................................................................................................................... 22
Free Pedal Adjustment ...................................................................................................................................... 23
Torque Specifications ......................................................................................................................................... 24

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]

©2005 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1800 SRM 1135 General

General
This section has a description and the service pro- BRAKE POSITION SENSOR
cedures for the parts of the brake system. The brake
system includes the following parts: master cylinder, This sensor has two applications, one senses the inch/
brake shoes, wheel cylinders, and parking brake sys- brake pedal, and the second senses the park brake
tem. hand lever position. One sensor is located on the left
hand side of the inch/brake pedal shaft. See Fig-
SERVICE BRAKES ure 19. The second sensor is located on the right
hand side of the park brake handle. See Figure 1.
A service brake assembly is installed on the mounts
at each end of the drive axle. See Figure 1. The
parts of the service brake assembly are shown in Fig-
ure 4 for S2.0-3.5FT (S40-70FT, S55FTS) [F187] and
H2.0-3.5FT (H40-70FT) [L177] lift trucks and Fig-
ure 6 for S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001].
When the brake pedal is pushed, fluid pressure from
the master cylinder causes the pistons in the wheel
cylinder to extend. The pistons expand the brake
shoes against the drums.

The clearance between the brake shoes and the brake

drum is adjusted automatically. An adjuster link-
age turns the adjuster wheel to adjust the clearance.
When the lift truck moves in the reverse direction
and the brakes are applied, the rear brake shoe and
the adjuster links move with the drum. This linkage
moves the adjuster lever to rotate the adjuster wheel.
The adjuster wheel can turn only when there is clear-
ance between the lining of the brake shoe and the
brake drum. The adjuster wheel can also be turned
with a tool. A slot in the back plate gives access to
the adjuster wheel.

MASTER CYLINDER
The master cylinder is designed for a single-circuit
system. The master cylinder has a piston that oper-
ates in the bore of the master cylinder. See Figure 2.

NOTE: The reservoir is located to the right of the park 1. PARK BRAKE LEVER
2. ADJUSTMENT KNOB
brake and is attached to the cowl. 3. PARK BRAKE CABLES
4. INCHING/BRAKE PEDAL
The reservoir is equipped with an indicator for low 5. MASTER CYLINDER
fluid level. A float in the reservoir moves up and 6. BRAKE ASSEMBLY
down with the fluid level. When the fluid level is low, 7. BRAKE POSITION SENSOR (RIGHT HAND
a magnet on the float activates a switch in the bot- SIDE)
tom of the reservoir. This switch signals the vehicle
Figure 1. Brake System
system manager (VSM) which illuminates a light in
the display switch cluster (DSC).

1
Service Brakes Repair 1800 SRM 1135

1. ROD END 9. PISTON SEAL

2. NUT 10. PISTON
3. PUSH ROD 11. SPACER
4. BOOT 12. PISTON CUP
5. SNAP RING 13. RETAINER
6. CYLINDER HOUSING 14. SPRING
7. SEAL 15. CHECK VALVE
8. FITTING 16. VALVE SEAT

Figure 2. Master Cylinder

PARKING BRAKE brake shoes against the drums. The design of the
parking brake linkage adjusts each cable so that the
The parking brake system uses the service brake tension is the same when the lever is moved to apply
shoes. Additional linkage activates the parking the parking brake. The park brake sensor is located
brake system. When the lever is moved to apply the on the right side of the park brake handle.
parking brake, the cables and linkage expand the

Service Brakes Repair

REMOVE AND DISASSEMBLE changes to brake linings must be done in a re-
stricted area with special ventilation. Protec-
WARNING tive clothing and a respirator must be used.
Brake linings can contain dangerous fibers. 1. Remove the capscrews that hold the axle shaft to
Breathing the dust from these brake linings the hub. Remove the axle shaft.
is a cancer or lung disease hazard. Do not
create dust! Do not clean brake parts with 2. See the procedure How to Put Lift Truck on
compressed air or by brushing. Use vacuum Blocks in the section Periodic Maintenance
equipment approved for brake dust or follow 8000 SRM 1150, or the Operating Manual.
the cleaning procedure in this section. When Start the engine and tilt the mast fully back-
the brake drums are removed, do not create ward. Put blocks under the mast. Tilt the mast
dust. forward until the wheels just touch the floor.
Stop the engine. Put blocks under the frame of
Do not sand, grind, chisel, hammer, or change the lift truck.
linings in any way that will create dust. Any

2
1800 SRM 1135 Service Brakes Repair

3. Bend the lock plate and remove the nut that 9. Make a note of the arrangement of parts and dis-
holds the axle bearing. Remove the washer and assemble the brake assembly. Remove the park-
the bearing cone. ing brake link and spring if they are still engaged
with brake shoes. The parking brake link and
spring will often fall from the brake assembly
WARNING
when the brake assembly is removed from the
When the brake shoes are removed, do not cre- back plate. The adjuster wheel will also disen-
ate dust in the air. See the Clean procedure in gage from the brake shoes after the brake assem-
this section. bly is removed.
4. Put grease on the floor so that the wheel assem- 10. Remove the spring for the adjuster wheel actu-
bly will slide easily from the axle tube. Pull the ator. Remove the adjuster wheel actuator from
wheel assembly from the lift truck. If the wheel the brake shoe.
assembly cannot be removed easily, use a small
screwdriver to push the adjuster actuator away 11. Use a screwdriver or small pry bar to move apart
from the adjuster wheel. Use a brake adjustment the ends of the retainer. Remove the spring
tool or a screwdriver to turn the adjuster wheel washer and pivot pin to remove the parking
to loosen the brake shoes. Remove the hub and brake lever from the brake shoe.
drum assembly. Do not damage the grease seal
when removing the hub. 12. Disconnect the brake line from the wheel cylin-
der. Remove the capscrews that hold the wheel
5. Make a note of the arrangement of the parts. See cylinder to the back plate and remove the wheel
Figure 3 and Figure 4 for S2.0-3.5FT (S40-70FT, cylinder.
S55FTS) [F187] and H2.0-3.5FT (H40-70FT)
[L177] lift trucks. See Figure 5 and Figure 6 NOTE: For S2.0-3.5FT (S40-70FT, S55FTS) [F187]
for S30FT, S35FT, S40FTS (E010) and H1.6FT, and H2.0-3.5FT (H40-70FT) [L177] lift trucks, the
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) back plate is not normally removed from the axle
[F001] lift trucks. Remove the return springs housing for brake repairs. Eight special capscrews
with spring pliers. are used to fasten the back plate to the axle mount,
and the locking function of the capscrews is reduced
6. Remove the retainers, springs, and anchor pins if they are removed. The capscrews are tightened to
that hold the brake shoes to the back plate. 255 to 306 N•m (188 to 226 lbf ft).
7. Disengage the link from the adjuster wheel actu- NOTE: For S30FT, S35FT, S40FTS (E010) and
ator. Remove the link, washer, and pivot plate. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
Remove the anchor guide. [F001] lift trucks, the back plate is not normally re-
moved from the axle housing for brake repairs.
8. Move the brake shoes away from each other to Six special capscrews are used to fasten the back
disengage the brake shoes from the wheel cylin- plate to the axle mount, and the locking function of
der. Disconnect the parking brake lever from the the capscrews is reduced if they are removed. The
parking brake cable as the brake assembly is re- capscrews are tightened to 152 to 167 N•m (112 to
moved from the back plate. The parking brake 123 lbf ft).
lever has a hook that engages the parking brake
cable. 13. Remove the push rods, dust covers, pistons, cups,
and spring from the wheel cylinder. See Figure 7.
NOTE: The adjuster wheel for the left brake is not
the same as the adjuster wheel for the right brake.
The adjuster wheel for the left brake has left-hand
threads.

3
Service Brakes Repair 1800 SRM 1135

1. WHEEL CYLINDER 11. ADJUSTER WHEEL

2. RETURN SPRING 12. ADJUSTER ASSEMBLY
3. RETURN SPRING 13. PRIMARY BRAKE SHOE
4. ANCHOR 14. PARKING BRAKE LEVER
5. ANCHOR GUIDE 15. LINK, PARKING BRAKE
6. BACK PLATE 16. SPRING, PARKING BRAKE
7. SECONDARY BRAKE SHOE 17. PIVOT PIN, RETAINER, AND SPRING WASHER
8. LEVER 18. ADJUSTER ACTUATOR SPRING
9. PIVOT PLATE 19. SPRING
10. SPRING AND CABLE ASSEMBLY

Figure 3. Brake Assembly (Left-Hand Shown), S2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-3.5FT
(H40-70FT) [L177]

4
1800 SRM 1135 Service Brakes Repair

NOTE: RIGHT-HAND BRAKE ASSEMBLY SHOWN.

1. WHEEL CYLINDER 12. ADJUSTER ASSEMBLY
2. RETURN SPRING 13. PRIMARY BRAKE SHOE
3. RETURN SPRING 14. PARKING BRAKE LEVER
4. ANCHOR 15. PARKING BRAKE LINK
5. ANCHOR GUIDE 16. PARKING BRAKE SPRING
6. BACK PLATE 17. PIVOT PIN, RETAINER, AND SPRING WASHER
7. SECONDARY BRAKE SHOE 18. ADJUSTER ACTUATOR SPRING
8. LEVER 19. SPRING
9. PIVOT PLATE 20. RETAINING PIN
10. ADJUSTER ACTUATOR LINK 21. RETAINING WASHER
11. ADJUSTER WHEEL 22. PARKING BRAKE CABLE

Figure 4. Service Brake Parts, S2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-3.5FT (H40-70FT)
[L177]

5
Service Brakes Repair 1800 SRM 1135

1. BACKING PLATE 9. SPRING (ACTUATOR)

2. RETAINING RING 10. PAWL LEVER
3. LEVER PIN 11. SECONDARY BRAKE SHOE
4. GUIDE PLATE 12. ADJUSTER ASSEMBLY
5. WHEEL CYLINDER 13. ADJUSTER SPRING
6. PAWL LEVER STOPPER 14. PARK BRAKE LEVER
7. SPRING (ANTI-RATTLE) 15. PRIMARY BRAKE SHOE
8. RETURN SPRING 16. STRUT

Figure 5. Brake Assembly (Left Hand Side), S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001]

6
1800 SRM 1135 Service Brakes Repair

1. BOLT 13. PAWL LEVER

2. WHEEL CYLINDER 14. PARK BRAKE CABLE
3. STRUT 15. ADJUSTER ASSEMBLY
4. SPRING 16. PLUG
5. SECONDARY BRAKE SHOE 17. SPRING (ADJUSTER)
6. PLATE 18. PRIMARY BRAKE SHOE
7. SPRING 19. PARK BRAKE LEVER
8. LEVER (STOP) 20. PIN
9. SPRING 21. PLUG
10. WASHER 22. BACKING PLATE
11. SPRING (SHOE HOLD DOWN) 23. PIN
12. WASHER

Figure 6. Service Brake Parts, S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) [F001]

7
Service Brakes Repair 1800 SRM 1135

1. PUSH ROD (2) 6. WHEEL CYLINDER BODY

2. DUST COVER (2) 7. INLET PORT
3. PISTON (2) 8. PRESSURE BLEEDER
4. CUP (2) 9. DUST COVER
5. SPRING

Figure 7. Wheel Cylinder

CLEAN 2. Use a solvent approved for cleaning of brake

parts to wet the brake lining dust. Follow the
WARNING instructions and cautions of the manufacturer
for the use of the solvent. If a solvent spray is
DO NOT use an oil solvent to clean the master
used, spray at a distance so that the dust is not
cylinder, wheel cylinder, or brake linings. Use
released into the air.
a solvent approved for cleaning of brake parts.
Do not permit oil or grease in the brake fluid or 3. When the brake lining dust is wet, clean the
on the brake linings. Oil and grease will cause parts. Put any cloth or towels in a plastic bag
damage and leaks in the seals of a brake sys- or an airtight container while they are still wet.
tem. The brakes will not operate correctly if Put a DANGEROUS FIBERS warning label on
oil, grease, or brake fluid is on the brake lin- the plastic bag or airtight container.
ings.

Cleaning solvents can be flammable and toxic CAUTION

and can cause skin irritation. When using Do not permit oil or grease on the brake linings.
cleaning solvents, always follow the safety Use a brake cleaning fluid as necessary to clean
instructions of the solvent manufacturer. linings that will not be replaced.
1. Do not release brake lining dust from the brake 4. Any cleaning cloths that will be washed must be
linings into the air when the brake drum is re- cleaned so that fibers are not released into the
moved. air.

8
1800 SRM 1135 Service Brakes Repair

INSPECT 7. Check the grease seals and the surfaces of the

seals for wear or damage.
1. Inspect the bore of the wheel cylinder for holes or
scratches. Replace the wheel cylinder assembly ASSEMBLE AND INSTALL
if there is any damage.
1. If the wheel cylinder was disassembled for repair,
2. Inspect the return springs for wear and damage. assemble the wheel cylinder. See Figure 7. Use
Inspect the back plate for wear where the brake only HYSTER APPROVED parts.
shoes touch the back plate. Remove any grooves
or replace a worn or damaged back plate. 2. Install the wheel cylinder on the back plate and
tighten the two capscrews to 18 to 27 N•m (13
to 20 lbf ft). Connect the brake line to the wheel
WARNING
cylinder.
The brake shoes on both wheels must be re-
placed if any shoe is damaged. The brake per- 3. Install the parking brake lever. Use the pivot
formance on both ends of an axle must be equal, pin, spring washer, and retainer to fasten the
or the lift truck can be difficult to steer when parking brake lever to the brake shoe. Close the
the brakes are applied. ends of the retainer to fasten the pivot pin in
position. See Figure 4 for S2.0-3.5FT (S40-70FT,
3. Inspect the brake shoes for cracks or damage. If S55FTS) [F187] and H2.0-3.5FT (H40-70FT)
the linings or shoes are worn or damaged, replace [L177] and Figure 6 for S30FT, S35FT, S40FTS
the brake shoes. Maximum wear is to within (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
1 mm (0.039 in.) of contact with the rivets, or H35FT, H40FTS) [F001] lift trucks.
the metal shoe on bonded linings. Brake shoes
must be replaced in complete sets. Inspect the 4. Fasten the adjuster actuator spring to the ad-
brake drums for cracks or damage. Replace any juster wheel actuator and the brake shoe.
damaged parts.
5. Put antiseize compound on the threads of the ad-
4. Inspect the brake drum for deep grooves or other juster wheel. Turn the adjuster wheel into the
damage. adjuster nut so that the adjuster assembly is in
its shortest position. This action permits the
NOTE: On S2.0-3.5FT (S40-70FT, S55FTS) [F187] brake drum to be easily installed over the brake
and H2.0-3.5FT (H40-70FT) [L177] lift trucks, if shoes.
grooves must be removed from the brake drums, do
not grind more than 1.5 mm (0.060 in.) from the
internal diameter of the brake drum. The maximum WARNING
limit of the internal diameter of the brake drum is The threads of the adjuster wheel are not the
312 mm (12.28 in.). If the internal diameter is larger same for each side. If the adjuster assemblies
than the limit, replace the brake drum. are installed on the wrong side, the brake shoe
clearance will increase each time the brakes
NOTE: On S30FT, S35FT, S40FTS (E010) and are applied. The adjuster wheel for the right
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) brake has right-hand threads. The adjuster
[F001] lift trucks, if grooves must be removed from wheel for the left brake has left-hand threads.
the brake drums, do not grind more than 1.5 mm
(0.060 in.) from the internal diameter of the brake 6. Install the adjuster wheel between the two brake
drum. The maximum limit of the internal diameter shoes. Make sure the adjuster wheel will be to-
of the brake drum is 255.5 mm (10.06 in.). If the ward the rear of the lift truck. Move the brake
internal diameter is larger than the limit, replace shoes apart so that the adjuster wheel is held
the brake drum. in position and the adjuster actuator spring is in
tension.
5. The teeth of the adjuster wheel must not be worn.
The adjuster wheel must turn freely. Check the 7. Lubricate the back plate with a small amount
adjuster links for damage. of lithium grease where the brake shoes touch.
Install the brake shoes on the anchor and engage
6. Make sure the parking brake cables are in good the push rods of the wheel cylinder. Engage the
condition. parking brake lever in the slot in the parking

9
Service Brakes Repair 1800 SRM 1135

brake cable as the brake shoes are installed on

the back plate. CAUTION
2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-
8. Put an anchor pin that holds the brake shoes 3.5FT (H40-70FT) [L177]: Be sure to install the
through the back plate. Put a spring seat, spring, white return spring first and then the black re-
and retainer on the anchor pin. Push the retainer turn spring. See Figure 9. Improper assembly
onto the anchor pin and rotate the retainer 90 can result in brake failure and/or component
degrees. Make sure the retainer is in the correct damage.
position.
NOTE: The shape of the return springs permits them
9. Install the link, parking brake, and spring be- to be installed correctly in only one position. The
tween the parking brake lever and the brake arrangement of the return springs on the anchors is
shoe. shown in Figure 8 and Figure 9.
10. Install the other spring retainer that holds the 14. 2.0-3.5FT (S40-70FT, S55FTS) [F187] and
brake shoes. Make sure the parking brake link H2.0-3.5FT (H40-70FT) [L177]: Using the cor-
and the spring are correctly engaged after the rect tools, install the return springs as follows
spring retainers are installed. (see Figure 9):
11. Install the anchor guide on the anchor. Install a. Install the white spring.
the pivot plate on its anchor.
b. Install the black spring.
12. Lubricate the adjuster cable where it slides in the
pivot plate groove. 15. 2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-
3.5FT (H40-70FT) [L177]: Verify that the return
13. Fasten the link to the adjuster wheel actuator springs are properly installed as shown in Fig-
and put the cable around the pivot plate. Raise ure 9
the adjuster wheel actuator against the spring
tension and connect the link to the anchor.

1. RETURN SPRING 4. ADJUSTER ACTUATOR LINK

2. ANCHOR GUIDE 5. PIVOT PLATE
3. RETURN SPRING

Figure 8. Return Springs, S2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-3.5FT (H40-70FT) [L177]

10
1800 SRM 1135 Service Brakes Repair

1. WHITE SPRING 2. BLACK SPRING

Figure 9. Proper Installation of Return Springs, 2.0-3.5FT (S40-70FT, S55FTS) [F187] and
H2.0-3.5FT (H40-70FT) [L177]

11
Service Brakes Repair 1800 SRM 1135

16. S30FT, S35FT, S40FTS (E010) and H1.6FT, grease under the wheel and slide the wheel toward
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) the axle housing. Install the outer bearing and nut.
[F001]: Use the correct tools to install the return
springs. Install the return spring. Install the 18. Install the washer, lock plate and wheel adjust-
washer and the return spring. The shape of ment nut. To align the bearing rollers, tighten
the return springs permits them to be installed the wheel adjustment nut to 14 to 18 N•m (10 to
correctly in only one position. The arrangement 13 lbf ft) and rotate the hub 2 revolutions in both
of the return springs on the anchors is shown in directions. To seat the wheel bearings, tighten
Figure 10. the wheel adjustment nut to 175 to 215 N•m (129
to 159 lbf ft) for S2.0-3.5FT (S40-70FT, S55FTS)
NOTE: Seal and bearings are to be installed flush [F187] and H2.0-3.5FT (H40-70FT) [L177] lift
with the hub. Seal is to be installed with no grease trucks and to 120 to 145 N•m (89 to 107 lbf ft)
or oil on outside surface. for S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
17. Clean the bearings and lubricate them with [F001] lift trucks. Back off the wheel adjustment
wheel bearing grease. Install the bearings and nut to zero end play. Preload the wheel bearings
seals in the brake drum. Install the assembly on by tightening the wheel adjustment nut to 14
the axle housing. See Figure 11 and Figure 12. to 18 N•m (10 to 13 lbf in). Rotate the hub 3
complete revolutions in both directions. Verify
NOTE: To prevent damage to the inner oil seal when
the wheel adjustment nut torque is 14 to 18 N•m
installing the hub, the hub and drum assembly can
(10 to 13 lbf ft) and that the torque stabilizes at
be temporarily fastened to the wheel. Align the
that specification.
height of the axle housing with hub bearings. Put

1. RETURN SPRING 3. RETURN SPRING

2. GUIDE PLATE 4. SPRING ACTUATOR

Figure 10. Return Springs, S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) [F001]

12
1800 SRM 1135 Service Brakes Repair

1. INNER SEAL 4. INNER BEARING

2. OUTER SEAL 5. OUTER BEARING
3. BRAKE DRUM

Figure 11. Grease Seals and Bearing Locations

13
Service Brakes Repair 1800 SRM 1135

adjuster link can wear a spot on the adjuster

wheel so that it will not turn correctly.

NOTE: If the brake shoes were not replaced, loosen

the adjuster wheel approximately 20 teeth.

20. Adjust the clearance of the brake shoes. Put a

brake adjustment tool or a screwdriver through
the slot in the back plate. Use the tool to rotate
the adjuster wheel. The actuator for the adjuster
wheel will only permit rotation in one direction.
Turn the adjuster wheel until the brake shoes
have expanded against the brake drum and the
hub will not turn. Use a small screwdriver to lift
the actuator away from the adjuster wheel and
Figure 12. Inner Grease Seal Installation turn the adjuster wheel approximately 20 teeth
in the opposite direction. The brakes will adjust
19. Bend the lock plate over the lock nut. See Fig-
to the correct clearance when they are applied
ure 13.
while the lift truck is traveling in the reverse di-
rection.

21. Put liquid sealant, Hyster Part Number 264159,

on the flange of the axle shaft. Install the axle
shaft and capscrews. Tighten the capscrews in
cross pattern to a torque specified below for your
lift truck.

a. For S2.0-3.5FT (S40-70FT, S55FTS) [F187]

lift trucks, tighten between 90 to 99 N•m (66
to 73 lbf ft). See Figure 14.

b. For H2.0-3.5FT (H40-70FT) [L177] lift

trucks, tighten between 90 to 108 N•m
(66 to 80 lbf ft). See Figure 15.

c. For S30FT, S35FT, S40FTS (E010) and

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) [F001] lift trucks, tighten between
52 to 62 N•m (39 to 46 lbf ft). See Figure 14.
1. LOCK PLATE
2. HUB/BRAKE DRUM ASSEMBLY ADJUST
3. DOWEL PIN
1. Remove the air from the brake hydraulic system.
Figure 13. Lock Plate
See Brake System Air Removal.

CAUTION 2. Install the wheel on the hub. Tighten the wheel

nuts to the torque specified below for your lift
If there is too much clearance, the automatic
truck.
adjusters will not operate. If the clearance is
too small, the automatic adjuster cannot turn a. For S2.0-3.5FT (S40-70FT, S55FTS) [F187]
the adjuster wheel to increase the clearance, lift trucks, tighten between 340 to 380 N•m
and the adjuster wheel will not turn until (251 to 280 lbf ft).
the brake shoes wear. If the adjuster wheel
does not move for a long operating period, the

14
1800 SRM 1135 Parking Brake Repair

3. Start the engine and tilt the mast backward to

remove the blocks. Push on the brake pedal. The
pedal must not touch the floor plate. Move the
lift truck in REVERSE and push on the brake
pedal to permit adjusting mechanism to operate.
Repeat this operation several times.

4. The service brakes must be adjusted before the

parking brake can be adjusted. See Figure 16
and the following paragraphs in this section for
the correct adjustment of the parking brake.

Figure 14. Axle Shaft Tightening Sequence,

S2.0-3.5FT (S40-70FT, S55FTS) [F187], S30FT,
S35FT, S40FTS (E010) and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001]

b. For H2.0-3.5FT (H40-70FT) [L177] lift

trucks, tighten between 450 to 500 N•m
(332 to 369 lbf ft).

c. For S30FT, S35FT, S40FTS (E010) and

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) [F001] lift trucks, tighten between Figure 15. Axle Shaft Torque Sequence,
155 to 175 N•m (115 to 130 lbf ft). H2.0-3.5FT (H40-70FT) [L177]

Parking Brake Repair

REMOVE AND DISASSEMBLE 4. Turn the adjuster knob counterclockwise until
the brake cables are loosened. Disconnect the ca-
If the lever assembly for the parking brake must be bles from the link.
removed from the cowl, use the following procedure
(see Figure 16): 5. The service brake assembly must be removed be-
fore the parking brake cable can be removed from
1. Use blocks next to the wheels to make sure the the back plate of the service brake. A snap ring
lift truck cannot move. Release the parking holds the sheath of the parking brake cable in the
brake lever. back plate of the service brake. Remove the snap
ring and remove the parking brake cable from
2. Remove the four capscrews that fasten the
the back plate.
bracket for the parking brake to the cowl. Re-
move the bracket and brake lever assembly.

3. Loosen the jam nuts that fasten the threaded

ends of the brake cables to the brake lever as-
sembly.

15
Parking Brake Repair 1800 SRM 1135

1. PARKING BRAKE LEVER 6. BRAKE ASSEMBLY

2. ADJUSTMENT KNOB 7. BRAKE POSITION SENSOR
3. PARKING BRAKE CABLES 8. ADJUSTMENT SLOT
4. INCHING/BRAKE PEDAL 9. EQUALIZED LINK
5. MASTER CYLINDER 10. NUTS

Figure 16. Parking Brake Lever Adjustment (Left Hand Side Shown)

ASSEMBLE AND INSTALL install the snap ring that holds the sheath of the
parking brake cable in the back plate.
The parking brake cables must be installed in the
back plate before the service brake is installed. See If the lever assembly for the parking brake was re-
Figure 16. A snap ring holds the sheath of the park- moved from the cowl, use the following procedure for
ing brake cable in the back plate of the service brake. installation:
Install the parking brake cable in the back plate and

16
1800 SRM 1135 Master Cylinder Repair

1. Make sure the parking brake lever is in the re- ADJUST

leased position. Turn the adjustment knob until
the link is adjusted to the bottom of the adjust- Make sure the service brakes are adjusted and the
ment slot. operation of the automatic adjuster mechanism is
correct before the parking brake is adjusted.
2. Adjust the jam nuts on the ends of the cable as-
semblies so that the threads of the cable sheaths 1. Turn the adjustment knob to raise the link and
extend 13 to 16 mm (0.51 to 0.63 in.) above their tighten the parking brake cables. Turn the ad-
support plate in the lever assembly. justment knob until the parking brakes are fully
applied when the lever is used to apply the park-
3. Install the round ends of the parking brake ca- ing brake.
bles in their slots in the link. Tighten the upper
jam nuts to hold the sheaths of the parking brake 2. Test the operation of the parking brake. The
cables in their support. lift truck with a capacity load must not move
when the parking brake is applied on a 15 per-
4. Use the four capscrews, washers, and nuts and cent grade [a slope that increases 1.5 m in 10 m
fasten the bracket to the inside of the cowl. (1.5 ft in 10 ft)].

Master Cylinder Repair

REMOVE 2. Remove snap ring, piston seal, and piston.

1. Remove the floor plate, kick plate, and seal plate 3. Remove spacer, piston cup, retainer, spring,
from the lift truck for access to the master cylin- check valve, and valve seat.
der.
NOTE: Install new seals when the master cylinder is
2. Remove the brake hydraulic line from the master disassembled for repair.
cylinder. Disconnect the wire at the brake pres-
sure transducer, which is connected to the bottom CLEAN AND INSPECT
of the master cylinder and remove pressure tran-
ducer. See Figure 17. CAUTION
3. Disconnect the brake fluid supply hose from the DO NOT use an oil solvent to clean the master
master cylinder. Plug hose to prevent reservoir cylinder, wheel cylinder, or brake linings. Use
from draining. a solvent approved for cleaning of brake parts.
Do not permit oil or grease in the brake fluid
4. Remove the brake fluid reservoir and supply hose or on the linings.
from the lift truck.
Inspect the bore of the master cylinder for holes or
5. Remove the cotter pin and rod end pin that is scratches. Replace the master cylinder assembly, if
attached to the brake linkage lever arm. there is damage.

6. Remove capscrews and nuts that hold master ASSEMBLE

cylinder to bracket assembly.
1. Install valve seat, check valve, spring, retainer,
DISASSEMBLE piston cup, and spacer.

2. Install the piston, piston seal, and snap ring.

CAUTION
When the piston is removed or installed, make 3. Install seal, fitting, boot, nut, push rod, and yoke.
sure the cylinder bore and piston are not
scratched or damaged.

1. Remove yoke, push rod, nut, boot, fitting, and

seal. See Figure 18.

17
Master Cylinder Repair 1800 SRM 1135

1. RESERVOIR 9. PUSH ROD

2. RESERVE TANK HOLDER 10. NUT
3. BRAKE FEED HOSE 11. YOKE (CLEVIS)
4. CAPSCREW 12. BRACKET
5. CAPSCREW 13. COTTER PIN
6. BRAKE HOSE 14. ROD END PIN
7. BRAKE PRESSURE TRANSDUCER 15. CAPSCREW
8. MASTER CYLINDER 16. CAPSCREW

Figure 17. Master Cylinder and Reservoir Assembly

18
1800 SRM 1135 Master Cylinder Repair

1. YOKE 7. SEAL 13. RETAINER

2. NUT 8. FITTING 14. SPRING
3. PUSH ROD 9. PISTON SEAL 15. CHECK VALVE
4. BOOT 10. PISTON 16. VALVE SEAT
5. SNAP RING 11. SPACER
6. CYLINDER HOUSING 12. PISTON CUP

Figure 18. Master Cylinder

19
Service Brakes Adjustment 1800 SRM 1135

BENCH BLEED MASTER CYLINDER 6. Apply a layer of multipurpose grease to the

rod end pin and, with twisting motion, insert
NOTE: Master cylinder must be bench bleed before through yoke and the inching/brake pedal. In-
installing it on the lift truck. stall cotter pin into the rod end pin.
1. Place the master cylinder horizontally in a soft 7. Adjust free pedal per the following procedure:
jawed vise.
a. Loosen nut and screw it away from yoke.
2. Connect the brake fluid reservoir supply hose to
the master cylinder. b. Turn push rod counterclockwise, as viewed
from top, until push rod can be moved from
3. Connect hoses to the pressure ports of the mas- side to side.
ter cylinder. Place other end of hoses in a clear
container of brake fluid. c. Turn push rod clockwise until it can no longer
be moved from side to side.
4. Fill the reservoir with brake fluid.
d. Turn push rod counterclockwise 1.5 to 1.75
5. Stroke the master cylinder until all air is purged turns.
from the master cylinder.
e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft).
INSTALL AND ADJUST
f. Verify free pedal is 10 to 12 mm (0.39 to
1. Install brake fluid reservoir, supply hose and 0.47 in.). See Figure 19.
master cylinder on lift truck as an assembly.
Install capscrews and nuts that hold master 8. Flush with brake fluid and air bleed system. See
cylinder to bracket assembly. See Figure 17. Brake System Air Removal.

2. Install brake hydraulic line on master cylinder. 9. Adjust fluid level until level is within 2.5 mm
(0.098 in.) of MAX line or 5 to 7.5 mm (0.19 to
3. Screw assembly of brake pressure transducer 0.29 in.) above large rib on reservoir if MAX line
into master cylinder and tighten to 23 to 28 N•m is not present.
(16.9 to 20.6 lbf ft).
10. Verify all connections are leak-free.
4. Orient master cylinder side of brake hose assem-
bly parallel with brake pressure transducer. 11. Install floor plate, kick plate, and seal plate on
lift truck.
5. Tighten fitting nuts at each end of brake hose
assembly to 13 to 18 N•m (84 to 117 lbf in). 12. Check adjustment of brake pedal as described in
Brake Pedal Adjustment.

Service Brakes Adjustment

The following procedure is for newly installed brake This adjustment expands the brake shoes. Ad-
shoes. If the lift truck has been operated for more just the brake shoes so that the brake drum will
than 25 hours and has correct pedal height, the not rotate.
brakes normally will not need adjustment.
NOTE: If the brake shoes were not replaced, loosen
1. See the procedure How to Put Lift Truck on the adjuster wheel approximately 20 teeth.
Blocks in the Periodic Maintenance section
for your lift truck or the Operating Manual for 3. Push the automatic adjuster lever away from the
your lift truck. Put the lift truck on blocks so adjuster wheel with a small screwdriver. Use the
that the drive wheels can be removed. Remove adjuster tool to loosen the adjuster wheel approx-
the drive wheels. imately 20 teeth (new brake shoes).

2. Use an adjuster tool to rotate the adjuster wheel

so that the teeth of the wheel move downward.

20
1800 SRM 1135 Brake System Air Removal

4. Install the drive wheels. Remove the lift truck lift truck 10 times in each direction. This pro-
from the blocks. Operate the lift truck in the cedure causes the brake shoes to wear a small
FORWARD and REVERSE directions. Stop the amount and fit the brake drum better.

Brake System Air Removal

There are two commonly used methods to remove air USING BRAKE PEDAL PRESSURE
from the brake system. The preferred method is us-
ing a pressure bleed system. The other method is by NOTE: Adjust the service brakes before the air is re-
applying pressure using the brake pedal. moved from the brake system.

1. Fill the brake fluid reservoir with brake fluid.

USING PRESSURE BLEED SYSTEM
2. Place one end of a rubber hose on the bleeder
NOTE: Adjust the service brakes before the air is re-
screw of the wheel cylinder furthest from the
moved from the brake system.
master cylinder. Place the other end of the hose
1. Fill the brake fluid reservoir with brake fluid. into a clear container of brake fluid.

2. Place one end of a rubber hose on the bleeder NOTE: Check the level of the brake fluid in the reser-
screw of each wheel cylinder. Place the other end voir for the master cylinder during the procedure.
of each hose into a clear container of brake fluid. Make sure to obtain the brake fluid at the correct
level.
3. Connect a pressure bleeder to the brake fluid
reservoir. 3. Loosen the bleeder screw at the wheel cylinder
one turn so that the air can be removed from the
4. Loosen the bleeder screws at the wheel cylinders brake system. Slowly push the brake pedal and
one turn. hold it at the end of its stroke. Close the bleeder
screw.
NOTE: While applying air pressure to the pressure
bleeder, check the level of the brake fluid in the reser- 4. Repeat the procedures in Step 1 through Step 3
voir for the master cylinder. Make sure to obtain the until there are no air bubbles in the container.
brake fluid at the correct level to avoid forcing more
air into the brake system. 5. Repeat the procedures in Step 1 through Step 4
for the remaining wheel cylinder.
5. Apply 34.5 kPa (5 psi) of air pressure to the pres-
sure bleeder, forcing fluid through the lines un- 6. Check the level of the brake fluid in the reservoir
til all air is removed from the system. Close the for the master cylinder. Fill the brake fluid reser-
bleeder screws. voir to the correct level.

6. Check the level of the brake fluid in the reservoir

for the master cylinder. Fill the brake fluid reser-
voir to the correct level.

21
Brake Pedal Adjustment 1800 SRM 1135

Brake Pedal Adjustment

NOTE: Measurements are made with the floor mats 2. Depress arm V until it stops. Verify gap S be-
removed. tween arm V and tab W is 3.0 to 3.5 mm (0.11
to 0.13 in.). If it is not, then Tab W may require
1. Adjust the height (dimension R) of the inch- bending to obtain the proper gap of S.
ing/brake pedal to 31 ±0.4 mm (1.22 ±0.01 in.).
Use the upstop bolt to change the pedal height.
Tighten the nut while keeping the upstop bolt
fixed. See Figure 19.

1. INCH/BRAKE PEDAL 5. SENSOR MOUNT

2. UPSTOP BOLT 6. BRAKE POSITION SENSOR
3. NUT 7. BUMPER
4. PEDAL PAD

Figure 19. Brake Pedal Adjustment

22
1800 SRM 1135 Free Pedal Adjustment

Free Pedal Adjustment

After the brake pedal adjustment is completed, see
Brake Pedal Adjustment, perform the following pro-
cedure for the free pedal adjustment.

1. Loosen nut and screw it away from clevis See

Figure 20.

2. Turn push rod counterclockwise, as viewed from

the top of the push rod, until push rod can be
moved from side to side.

3. Turn push rod clockwise until it just begins to no

longer be moved from side to side.

4. Turn push rod counterclockwise 1.5 to 1.75 turns.

5. Tighten nut to 17 to 23 N•m (13 to 17 lbf ft).

6. Verify the free pedal is 10 to 12 mm (0.39 to

0.47 in.). See Figure 19.

1. COTTER PIN 5. PUSH ROD

2. WELDMENT 6. NUT
3. PIN 7. CLEVIS
4. MASTER
CYLINDER

Figure 20. Free Pedal Adjustment

23
Torque Specifications 1800 SRM 1135

Torque Specifications
Back Plate to Axle Mount Capscrews Wheel Nuts
S2.0-3.5FT (S40-70FT, S55FTS) [F187] and S2.0-3.5FT (S40-70FT, S55FTS) [F187]
H2.0-3.5FT (H40-70FT) [L177] 340 to 380 N•m (251 to 280 lbf ft)
255 to 306 N•m (188 to 226 lbf ft)
H2.0-3.5FT (H40-70FT) [L177]
S30FT, S35FT, S40FTS (E010) and H1.6FT, 450 to 500 N•m (332 to 369 lbf ft)
H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) [F001] S30FT, S35FT, S40FTS (E010) and H1.6FT,
152 to 167 N•m (112 to 123 lbf ft) H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) [F001]
Wheel Cylinder Capscrews 155 to 175 N•m (115 to 130 lbf ft)
18 to 26 N•m (13 to 19 lbf ft)

Axle Shaft Capscrews

S2.0-3.5FT (S40-70FT, S55FTS) [F187]
90 to 99 N•m (66 to 73 lbf ft)

H2.0-3.5FT (H40-70FT) [L177]

90 to 108 N•m (66 to 80 lbf ft)

S30FT, S35FT, S40FTS (E010) and H1.6FT,

H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) [F001]
52 to 62 N•m (39 to 46 lbf ft)

24
 TECHNICAL PUBLICATIONS

1800 SRM 1135 5/05 (12/04) Printed in U.S.A.