Hyster C098 (E120XL3) Forklift Service Repair Manual

SERVICE REPAIR E80XL3 E100XL3 E120XL3 E100XL3S [C098]

1800 SRM 338

Description and Operation

General This section has a description and the repair procedures for the parts of the hydraulic brake system. These parts include the brake booster, master cylinder, and brake shoe assemblies.

Description and Operation The master cylinder is actuated by a brake booster on S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005) lift trucks. The brake booster is a hydraulic valve actuated by the brake pedal. The brake booster uses the oil that flows from the steering control unit to multiply the force of the brake pedal. The system allows braking without hydraulic pressure at the brake booster.

Lift trucks of the E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) series have a different master cylinder that is not actuated by a brake booster.

BRAKE BOOSTER AND MASTER CYLINDER These parts are for the S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005) models. See Figure 1. The operation of the parts is described in Figure 2.

excess fluid from the system can return to the reservoir. The check valve keeps a very small amount of pressure in the brake system. The pressure helps to keep the system effectively sealed.

SERVICE BRAKE ASSEMBLY A service brake assembly is installed at each end of the housing for the drive axle. See Figure 4. Each service brake assembly has a single wheel cylinder at the top of each back plate. The support plate has an anchor for each shoe. When the wheel cylinder is actuated by fluid pressure from the master cylinder, the shoes touch the drum. The primary shoe starts to turn with the drum. This action pushes the secondary shoe tight against the drum and the anchor.

This servo action increases the force applied to the brake drums. When the lift truck is traveling in reverse, the primary shoe is pushed against the anchor and the drum by the secondary shoe.

MASTER CYLINDER This master cylinder is for the E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) models.

See Figure 3. The master cylinder has a housing and a piston assembly. The housing has two ports between the bore for the piston and the reservoir for the fluid. The compensator port in front of the piston is open when the piston is fully retracted.

The compensator port lets fluid move to or from the brake system when the temperature changes.

Another port keeps fluid in the cavity around the piston. The piston moves in the housing when the operator pushes the brake pedal. A small movement of the piston closes the compensator port. Hydraulic pressure actuates the wheel cylinders as the piston pushes fluid through the check valve. A return spring pushes the piston back to the stop plate when the pedal is released. Fluid can flow through passages in the piston and past the primary cup as the piston returns. Fluid flows across the piston to prevent a vacuum while fluid returns through the check valve. When the piston passes the compensator port,

NOTE: BRAKE BOOSTER AND MASTER CYLINDER FOR LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) SHOWN. 1.

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BRAKE BOOSTER INLET FROM STEERING CONTROL UNIT OUTLET TO HYDRAULIC TANK MASTER CYLINDER INLET FROM RESERVOIR OUTLET TO WHEEL CYLINDERS

Figure 1. Brake Booster and Master Cylinder

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Description and Operation

Figure 2. Brake Booster and Master Cylinder Operation

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1800 SRM 338

1800 SRM 338

Description and Operation Legend for Figure 2

NOTE: BRAKE BOOSTER AND MASTER CYLINDER FOR LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) SHOWN. A. BRAKES NOT APPLIED Hydraulic oil flows from the steering control unit to the inlet of the brake valve. The hydraulic oil flows freely between the plunger and the piston and returns to the hydraulic tank from the outlet.

B. BRAKES APPLIED When the brakes are applied and the engine is not running, the plunger pushes against the piston. The piston and piston rod push against the piston in the master cylinder to actuate the brakes.

When the engine is running, there is hydraulic oil flowing through the brake valve.

The movement of the plunger makes a restriction in the flow of oil between the plunger and the piston. The hydraulic pressure behind the piston increases and pushes on the piston and piston rod to move the piston in the master cylinder. The oil pressure behind the piston decreases the effort at the brake pedal to apply the brakes. As the piston for the master cylinder moves, brake fluid flows from the outlet to the wheel cylinders. The relief valve gives a 2300 kPa (332 psi) limit to the hydraulic pressure in the brake valve.

1. BRAKE VALVE (BOOSTER) 2. INLET 3. PLUNGER

4. PISTON (BRAKE VALVE) 5. PISTON ROD 6. OUTLET TO HYDRAULIC TANK

7. MASTER CYLINDER 8. PISTON (MASTER CYLINDER) 9. OUTLET TO WHEEL CYLINDERS

10. INLET FROM BRAKE RESERVOIR 11. RELIEF VALVE

NOTE: MASTER CYLINDER FOR LIFT TRUCK MODELS E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) SHOWN. 1.

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FILLER PLUG GASKET HOUSING PUSH ROD BOOT

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INTAKE PORT COMPENSATOR PORT LOCK WIRE PISTON STOP PLATE PISTON ASSEMBLY

11. PRIMARY CUP 12. RETURN SPRING 13. CHECK VALVE

Figure 3. Master Cylinder

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Description and Operation

1800 SRM 338 the shoes apart when the hand lever pulls the cables. On units with a powershift transmission and a MONOTROL® pedal, the hand lever also actuates a switch. The switch de-energizes the circuit for the MONOTROL pedal and the forward and reverse solenoids when the parking brake is applied. The action of the switch puts the transmission in NEUTRAL and makes the Start circuit complete.

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WHEEL CYLINDER BACK PLATE RETURN SPRING - GREEN ADJUSTER LINKS ADJUSTER SPRING LEVER ADJUSTER SCREW WHEEL (RIGHT-HAND THREAD) 7. ADJUSTER SCREW NUT 8. FRONT BRAKE SHOE 9. RETURN SPRING - BLACK Figure 4. Service Brakes (Left Side Shown) The automatic adjusting linkage turns the adjuster screw wheel to adjust the clearance between the brake shoes and the brake drum. The secondary shoe and the links move with the drum during a stop when the truck is traveling in reverse. The links permit the adjuster spring lever to rotate the adjuster screw wheel. The adjuster screw wheel can only turn when there is clearance between the lining and the brake drum. The adjuster screw wheel can be turned manually through a slot in the back plate.

PARKING BRAKE The parking brake uses the service brake shoes. See Figure 5 and Figure 6. Additional linkage pushes

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1. HAND LEVER 2. SWITCH 3. TERMINALS, NORMALLY CLOSED (NC) CIRCUIT 4. TERMINALS, NORMALLY OPEN (NO) CIRCUIT 5. LINK 6. CABLES TO BRAKE SHOES Figure 5. Parking Brake Arrangement for Lift Truck Models S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005)

1800 SRM 338

Description and Operation For adjustment procedures for seat brake used on E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/ E098) lift trucks, go to the section Seat Brake Assembly in this manual. For adjustment procedures for seat brake used on E3.50-5.50XL (E70-120XL, E70120XL 3 (C098) lift trucks, see the section Frame 100 SRM 284.

1. PARKING BRAKE LEVER 2. APPLIED POSITION

3. RELEASED POSITION 4. SWITCH LEVER 5. SWITCH

Figure 6. Parking Brake Arrangement for Lift Truck Models E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)

SEAT BRAKE Lift truck models E3.50-5.50XL (E70-120XL, E70120XL 3 (C098) and E3.50-5.50XL, E4.50XLS (E70120Z, E100ZS) (D098/E098) covered in this manual may be equipped with an optional seat brake that is attached to the traction motor and is actuated automatically when the operator leaves seat. See Figure 7. When correctly adjusted, this brake will hold lift truck with a capacity load on a 15% grade [a slope that increases 1.5 m increase in 10 m (1.5 ft increase in 10 ft)]. Make sure service brakes operate correctly before checking operation of seat brake. If brake does not hold lift truck on grade, seat brake must be adjusted by authorized service personnel.

NOTE: TRACTION MOTOR AND SEAT BRAKE FOR LIFT TRUCK MODELS E3.50-5.50XL, E4.50XLS (E70120Z, E100ZS) (D098/E098) SHOWN. 1. GUIDE PIPE CONNECTION 2. ELECTRICAL CONNECTION 3. SEAT BRAKE Figure 7. Traction Motor and Seat Brake Assembly

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Brake Shoe Assemblies Repair

1800 SRM 338

Brake Shoe Assemblies Repair 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 approved for brake dust or follow the cleaning procedure 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 linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used.

1. Tilt mast back and put blocks under outer mast weldment. Tilt mast forward to raise tires from floor.

WARNING Completely remove the air from the tires, on lift trucks equipped with pneumatic tires, before removing them from the lift truck. Air pressure in the tires can cause the tire and wheel parts to explode, causing serious injury or death.

2. The wheels, hub, and brake drum can be removed as an assembly. See Figure 4 and Figure 8. Make sure to remove air pressure from tires on lift trucks equipped with pneumatic tires, before you remove wheels from hub.

3. Remove capscrews that hold axle shaft to hub.

Remove axle shaft.

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4. Remove lock nut, lock plate, and bearing adjustment nut from axle housing. Remove outer bearing cone. Remove wheels, hub, and brake drum as an assembly. Remove inner seals and bearing cone from hub.

WARNING When the brake shoes are removed, do not create dust in the air. See the Clean and Inspect procedures in this section.

5. To loosen brake shoes, turn adjuster screw. Disconnect anchor link and actuator link. Remove adjuster spring lever.

6. Use spring pliers to remove shoe return springs.

7. Remove three spring clips.

CAUTION The adjuster screw assemblies are not the same. Make sure that each assembly has identification for installation on the correct side of the axle.

8. Remove brake shoes from wheel cylinder rods.

Remove adjuster screw spring. Remove adjuster screw assembly.

9. Remove parking brake cable from lever. Remove lever from primary shoe.

10. Disconnect and put cap on the line to the wheel cylinder. Remove support flange and backplate.

Remove two capscrews that hold wheel cylinder to backplate. Remove cable clamp and pull cable through backplate.

1800 SRM 338

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Brake Shoe Assemblies Repair

BACKPLATE SUPPORT FLANGE CAPSCREW AND LOCKWASHER CAPSCREW AND LOCKWASHER WHEEL CYLINDER ASSEMBLY SPRING AND RETAINER ASSEMBLY PISTON CUP PISTON PUSH ROD FITTING BOOT ANCHOR PIN SHOE AND LINING ASSEMBLY SHOE GUIDE SPRING PIN SHOE GUIDE SPRING CLIP

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RETURN SPRING - BLACK RETURN SPRING - GREEN ADJUSTER SCREW SPRING ADJUSTER SCREW WHEEL ADJUSTER SCREW NUT ADJUSTER SCREW GUIDE AUTOMATIC ADJUSTER SPRING LEVER ACTUATOR LINK ANCHOR END LINK LINK PIVOT SHOE ADJUSTER SLOT PLUG PARKING BRAKE LEVER SPRING CLIP PARKING BRAKE CONNECTING LINK SPECIAL FITTING

Figure 8. Brake Assembly (Right Side Shown)

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Brake Shoe Assemblies Repair

CLEAN AND INSPECT 1. Cleaning Procedures:

CAUTION Do not use an oil solvent to clean the wheel cylinder. Use a solvent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid or on the brake linings. a. Do not release brake lining dust from brake linings into air when brake drum is removed. b. Use a solvent approved for cleaning of brake parts to wet the brake lining dust. Follow instructions and cautions of manufacturer for use of solvent. If a solvent spray is used, do not create dust with spray. c. When dust is wet, clean parts. Put any cloth or towels in a plastic bag or an airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on plastic bag or airtight container. d. Any cleaning cloths that will be washed must be cleaned so fibers are not released into the air.

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. e. Clean all metal parts except linings and wheel cylinder with solvent.

2. Inspection procedures: NOTE: The procedures in Step a and Step b do not apply to seat brake used on E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) lift truck models. a. Check bore of wheel cylinder for holes or scratches. Replace wheel cylinder if there is any damage. b. Check return springs for damage. Inspect backplate for wear where brake shoes touch backplate.

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1800 SRM 338 c. Inspect brake shoes for cracks or damage. If linings or shoes are worn or damaged, replace brake shoes. It is recommended that brake shoes be replaced in complete sets.

NOTE: The procedure in Step d does not apply to seat brake used on E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) lift truck models. d. Check adjuster screw wheel for wear. Make sure adjuster screw turns. Check for bent or broken adjuster links.

NOTE: Service Brakes only: If brake drums require turning, do not remove more than 1.5 mm (0.060 in.) from the diameter. The maximum inside diameter of the brake drum, including wear, is 319.25 mm (12.57 in.). If the brake drum is larger than this, replace brake drum. e. Inspect brake drums for cracks or damage.

Use sandpaper on surface for brake shoes.

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For the seat brake used on E3.505.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) lift truck models, inspect brake drums for cracks or damage.

Replace drums if there are cracks or damage.

ASSEMBLE AND INSTALL WARNING The brake shoes on both wheels must be replaced if any shoe is damaged. The brake performance on both ends of an axle must be equal or the lift truck can be difficult to steer when the brakes are applied.

1. Install wheel cylinder on backplate. Push parking cable through backplate and fasten clamp.

See Figure 4 and Figure 8.

2. Install backplate and support plate. Install tapered dowels, capscrews, and nuts. Use the sequence shown in Figure 9 and tighten nuts to 54 to 81 N•m (40 to 60 lbf ft). Use the same sequence and tighten nuts 108 to 122 N•m (80 to 90 lbf ft). Using a hand torque wrench, verify that nuts are between 95 to 122 N•m (70 to 90 lbf ft).

1800 SRM 338

Brake Shoe Assemblies Repair

CAUTION The shoe return springs are not the same. Always install the black spring on the left-hand brake shoe.

6. Correctly install shoe return springs. Connect cable for parking brake to lever.

WARNING

Figure 9. Support Plate Tightening Sequence 3. Connect brake line to fitting on wheel cylinder.

4. Install link pivot on rear shoe. Install parking brake lever on front shoe. Install anchor pins in support flange so they engage brake shoes.

5. Lubricate shoe pads of backplate with molybdenum grease. Put shoes on backplate and install holddown pins and clips. Engage connecting link with parking brake lever. See Figure 10.

The threads of the adjuster wheel are not the same for each side. If the adjuster assemblies are installed on the wrong side, the brake shoe clearance will increase each time the brakes are applied. The adjuster wheel for the right brake has left-hand threads. The adjuster wheel for the left brake has right-hand threads.

7. Lubricate adjuster screw with Never-SeezeÂŽ.

Turn adjuster screw in so brake shoes retract.

Install adjuster between shoes. Align adjuster screw wheel with slot in backplate. Install adjuster spring with long hook toward adjuster screw wheel. Install adjuster spring lever and two links.

8. Install brake drum and adjust brake shoes until they touch brake drum. Rotate brake drum so brake shoes are correctly aligned within brake drum. Carefully remove brake drum so brake shoes do not move.

CAUTION If there is too much clearance, the automatic adjusters will not operate. If the clearance is too small, the automatic adjuster cannot turn the adjuster wheel to increase the clearance and the adjuster wheel will not turn until the brake shoes wear. If the adjuster wheel does not move for a long operating period, the adjuster link can wear a spot on the adjuster wheel so that it will not turn correctly.

1. PARKING BRAKE CONNECTING LINK 2. PARKING BRAKE LEVER Figure 10. Parking Brake Linkage (Right Side Shown)

9. The automatic adjuster lever must be set at 1.5 to 3.0 mm (0.06 to 0.12 in.) above the centerline of the adjuster screw wheel. See Figure 11. Use the tool to make sure automatic adjustment lever is in correct position. Bend link away from hub as necessary to adjust automatic adjustment lever.

Correct adjustment of lever is necessary for correct operation of automatic adjustment mechanism.

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Brake Shoe Assemblies Repair

1800 SRM 338

10. Use the following procedures to install hub and brake drum for lift truck models H3.50-5.00XL (H70-110XL) (F005/G005) (see Figure 12): a. Use new oil seals. Install inner seal, bearing cups, and outer seal in hub. Install inner bearing cone on spindle. Lubricate inner bearing with grease. b. If the brake drum was removed, assemble brake drum, hub, and wheel. Tighten nuts for brake drum to 285 N•m (210 lbf ft) on units with dual wheels. Tighten nuts for wheels to 610 to 680 N•m (450 to 500 lbf ft) on all units.

CAUTION Do not damage the seals when you install the hub assembly. c. Install hub and wheel on spindle. Lubricate outer bearing cone with 80W-90 oil for gears.

Install outer bearing cone and adjustment nut. d. Tighten adjustment nut to 203 N•m (150 lbf ft) while you rotate hub. Loosen nut until hub rotates freely. The torque must be less than 27 N•m (20 lbf ft). Tighten nut to 34 N•m (25 lbf ft) or to first alignment position after 34 N•m (25 lbf ft). Install lockwasher to hold nut. Install lock nut. Tighten lock nut to 135 N•m (100 lbf ft).

Legend for Figure 11 A. REFERENCE B. BEND 1.

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ACTUATOR LINK AUTOMATIC ADJUSTMENT LEVER ADJUSTER SCREW GUIDE ADJUSTER SCREW WHEEL ADJUSTER SCREW WHEEL CENTERLINE BACKPLATE TOOL

Figure 11. Brake Adjustment (Right Side Shown)

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1800 SRM 338

Brake Shoe Assemblies Repair

A. FOR H3.50-5.00XL (H70-110XL) (F005/G005) MODELS B. FOR S3.50-5.50XL (S70-120XL) (D004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) MODELS 1.

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AXLE SHAFT HUB BRAKE DRUM LOCK NUT LOCK PLATE ADJUSTMENT NUT

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AXLE SPINDLE BEARING ASSEMBLY OIL SEAL O-RING WHEEL BRACKET

Figure 12. Drive Axle and Brake Assembly

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Brake Shoe Assemblies Repair

1800 SRM 338 until hub rotates freely. The torque must be less than 27 N•m (20 lbf ft). Tighten nut to 34 N•m (25 lbf ft) or to first alignment position after 34 N•m (25 lbf ft). Install lockwasher to hold nut. Install lock nut. Tighten lock nut to 135 N•m (100 lbf ft).

CAUTION When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation.

Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 350 hours. e. Apply sealant (Hyster Part Number 264159) to flange of axle shaft. Install axle shaft.

Tighten capscrews to 225 N•m (165 lbf ft).

11. Use the following procedures to install hub and brake drum for lift truck models (see Figure 12) S3.50-5.00XL (S70-110XL) (D004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098): a. Use new oil seals. Install inner seal, bearing cups, and outer seal in hub. Install inner bearing cone on spindle. Lubricate inner bearing with grease. b. If brake drum was removed, install brake drum on hub. Install several nuts on studs for wheel. c. Install hub assembly on spindle. Lubricate outer bearing cone with 80W-90 oil for gears.

Install outer bearing cone and adjustment nut. d. Tighten adjustment nut to 203 N•m (150 lbf ft) while you rotate hub. Loosen nut

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CAUTION Do not damage the seals when you install the hub assembly. e. Install wheels. Tighten nuts for wheels to 610 to 680 N•m (450 to 500 lbf ft). f.

Apply sealant (Hyster Part Number 264159) to flange of axle shaft. Install axle shaft.

Tighten capscrews to 225 N•m (165 lbf ft).

CAUTION When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation.

Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 350 hours for lift truck models E3.50-5.50XL (E70-120XL) (C098), S3.50-5.50XL (S70-120XL) (D004), and H3.50-5.00XL (F005/G005) and 500 hours for lift truck models E3.50-5.50XL (E70-120XL 3) (C098), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) 12. Remove air from brake system and adjust brakes. See Brake System Air Removal and Brake Shoes Adjustment in this section.

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Master Cylinder Repair

Master Cylinder Repair MASTER CYLINDER FOR LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) NOTE: Replace the brake booster seal (Figure 17) when you repair or replace the master cylinder.

Remove 1. Disconnect brake line at master cylinder. Cover end of brake line. Disconnect wires at brake switch. Disconnect hose from reservoir. Put plug in end of hose. See Figure 13.

2. Remove capscrews that hold master cylinder to brake valve.

Disassemble WARNING The piston has a compressed spring behind it.

Remove the piston carefully.

1. Remove retaining ring from end of master cylinder. Carefully remove piston and spring from bore. See Figure 14.

CAUTION DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or the brake linings.

Use a solvent approved for cleaning of brake parts. Do not put oil or grease in the brake fluid or on the linings.

2. Remove seals from piston.

Assemble NOTE: Lubricate parts of master cylinder with clean brake fluid.

1. Install seal support washer on piston. Install seals on piston. Make sure cup washer is installed as shown in Figure 14. Carefully install spring and piston assembly in master cylinder.

Do not damage seals.

2. Install retaining ring for piston.

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BRAKE BOOSTER INLET FROM STEERING CONTROL UNIT OUTLET TO HYDRAULIC TANK MASTER CYLINDER INLET FROM RESERVOIR OUTLET TO WHEEL CYLINDERS

Figure 13. Brake Booster and Master Cylinder for Lift Truck Models S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005)

Install 1. Put master cylinder in position on brake booster and install capscrews for master cylinder. See Figure 13.

2. Connect brake lines and wires. Connect hose to brake fluid reservoir. Fill reservoir and remove air from brake system as described in Brake System Air Removal in this section.

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Master Cylinder Repair

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HOUSING RETAINING RING SEAL PISTON SPRING

CUP WASHER SEAL SUPPORT WASHER CHECK VALVE SPRING FITTING

Figure 14. Master Cylinder

MASTER CYLINDER FOR LIFT TRUCK MODELS E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) Remove and Disassemble 1. Remove floor plate. Disconnect brake line at master cylinder. Put caps on brake line and port in cylinder. See Figure 15.

2. Remove return spring for pedal. Disconnect rod end at pedal.

3. Remove capscrews that hold master cylinder to frame. Remove master cylinder.

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4. Remove boot and push rod as an assembly. Drain fluid in reservoir.

5. Put master cylinder in a vise that has soft jaws.

Make sure piston is at upper end of housing.

Use a screwdriver to hold piston against return spring. See Figure 16.

WARNING The piston has a compressed spring behind it.

Carefully remove the piston so you can control the spring and prevent an injury.

1800 SRM 338

Master Cylinder Repair goggles or a face shield to prevent injury to the eyes.

CAUTION When the piston is removed or installed, make sure the cylinder bore and piston is not scratched or damaged.

6. Remove lock wire and piston stop plate. Carefully remove piston from cylinder.

7. Remove spring and check valve.

Clean and Inspect

CAUTION DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or the brake linings.

Use a solvent approved for cleaning of brake parts. Do not put oil or grease in the brake fluid or on the linings.

1. Clean all parts of master cylinder. Use compressed air to dry parts. Keep oil and grease off parts and out of brake fluid.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective

2. Inspect bore of master cylinder and machined surfaces of piston. Replace a master cylinder that has a damaged bore or piston.

NOTE: MASTER CYLINDER FOR LIFT TRUCK MODELS E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) SHOWN. 1.

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ROD END JAM NUT PUSH ROD BOOT LOCK WIRE

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PISTON STOP PLATE PISTON ASSEMBLY PRIMARY CUP RETURN SPRING CHECK VALVE

11. BODY 12. GASKET 13. FILLER PLUG

Figure 15. Master Cylinder

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Brake Booster Repair

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Assemble and Install 1. Lubricate all parts with clean brake fluid.

2. Use a repair kit (Hyster Part No. 54977A). Install parts in the order shown in Figure 15. Use a screwdriver to hold piston in housing. See Figure 16. Make sure lock ring is correctly installed before you release piston.

3. Insert push rod into piston. Install boot over flange on housing.

4. Install master cylinder on frame. Connect rod end and return spring at brake pedal.

5. Install brake line on master cylinder. See Brake System Air Removal in this section to remove air from brake system and Brake Shoes Adjustment to adjust brake shoes.

6. Install floor plate.

1. PISTON 2. MASTER CYLINDER Figure 16. Piston Removal

Brake Booster Repair REMOVE

WARNING

1. Disconnect brake pedal from brake booster at push rod. See Figure 13.

The retainer has a compressed spring behind it. Carefully remove the retainer so you can control the spring and prevent an injury.

2. Disconnect hydraulic lines at brake booster. Put caps on open lines.

4. Remove retainer from housing.

3. Disconnect brake lines and wires at master cylinder. Disconnect hose from reservoir at master cylinder. Put plug in end of hose.

4. Remove capscrews that hold brake booster to bracket. Remove brake booster and master cylinder as an assembly.

DISASSEMBLE 1. Remove master cylinder from brake booster. See Figure 17.

2. Remove dust cover and push rod.

3. Remove retaining ring and washer for plunger.

Remove plunger from retainer.

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5. Remove piston, spring, and piston rod from housing.

6. Remove seals and O-rings from the parts of the brake booster.

7. If necessary, remove parts of relief valve from housing.

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

1800 SRM 338

Brake Booster Repair

Clean parts of brake booster with solvent. Check surface of machined parts for wear and damage.

ASSEMBLE

1. Assemble parts for relief valve. Make sure all parts are in their original positions. See Figure 17.

2. Install seals for piston rod, plunger, and piston.

NOTE: Use new parts from the repair kit (Hyster Part No. 375653). Lubricate parts with hydraulic oil during assembly. Make sure parts are clean.

CAUTION Do not let brake fluid touch any of the parts of the brake booster. The brake fluid can damage the seals in the brake booster.

3. Install piston rod, piston, and spring in housing.

Install retainer and O-ring in housing. Tighten retainer to 210 to 290 N•m (155 to 215 lbf ft).

4. Install plunger in retainer. Install washer and retaining ring.

5. Install dust cover and push rod.

NOTE: BRAKE BOOSTER FOR LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) SHOWN. 1.

2.

3.

4.

5.

6.

7.

PUSH ROD DUST COVER RETAINING RING WASHER RETAINER PLUNGER SEAL

8.

9.

10.

11.

12.

13.

14.

PISTON PISTON ROD SLEEVE O-RING SCREW RELIEF PISTON SPRING

15.

16.

17.

18.

19.

20.

GUIDE SHIM PLUG SNAP RING SPRING HOUSING

Figure 17. Brake Booster

17

Brake Pedal Adjustment

1800 SRM 338

INSTALL NOTE: See Figure 18 for lift trucks H3.50-5.00XL (H70-110XL) (F005/G005) with manual transmission.

See the section Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 SRM 397 for lift trucks S3.50-5.50XL (S70-120XL) (D004) .

1. Install brake booster on bracket.

2. Connect hydraulic lines to brake booster. Connect brake lines and wires to master cylinder.

Connect hose from reservoir to master cylinder.

3. Connect push rod to crank and brake pedal. Install pin for push rod.

4. Remove air from brake system and adjust brake linkage as described in Brake System Air Removal and Brake Shoes Adjustment in this section.

Brake System Air Removal NOTE: The E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) models do not have a special fitting at the master cylinder. Loosen nut on tube at master cylinder to remove air that you cannot remove at the wheel cylinders.

The air must be removed from the brake fluid. Fill reservoir for master cylinder with brake fluid. Always remove air from master cylinder first, then

wheel cylinders. Put one end of a rubber hose on special fitting at master cylinder or wheel cylinders.

Put other end of hose in a container with brake fluid.

Loosen special fitting. Push slowly on brake pedal.

Close special fitting. Repeat the procedure until no air bubbles are seen in container. Check fluid level in reservoir. Keep reservoir full of brake fluid during these procedures.

Brake Pedal Adjustment BRAKE PEDAL FOR LIFT TRUCK MODELS H3.50-5.00XL (H70-110XL) (F005/G005) WITH MANUAL TRANSMISSION AND E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) NOTE: The brake adjustment procedures for lift truck models H3.50-5.00XL (H70-110XL) (F005/G005), with powershift transmissions are in the section Powershift Transmission, Repairs 1300 SRM 337. For lift truck models S3.50-5.50XL (S70-120XL) (D004) see the section Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 SRM 397 for brake pedal adjustment procedures.

1. Make the adjustments when the key switch is in the OFF position and the engine is not running.

Use the stop screw to adjust the height of the brake pedal: • H3.50-5.00XL (H70-110XL) (F005/G005) 111 mm (4.38 in.) (Figure 18) • E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-

18

120Z, E100ZS) (D098/E098)81 mm (3.19 in.)

(Figure 19) Tighten nut on stop screw.

2. Adjust push rod for clearance between end of push rod and plunger (brake booster) or piston (master cylinder). Rotate push rod to make the adjustment. Set clearance as follows: • H3.50-5.00XL (H70-110XL) (F005/G005): Rotate push rod until it just touches plunger in brake booster. Rotate push rod 2.12 turns in the opposite direction to get the correct clearance. The correct clearance lets the pedal move down 9.5 mm (0.37 in.) before the push rod touches the plunger. Tighten jam nut against push rod.

• E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098): Adjust push rod so pedal moves down 1 to 4 mm (0.04 to 0.16 in.) before the push rod touches the piston. Tighten jam nut against push rod.

1800 SRM 338

Brake Pedal Adjustment Legend for Figure 18 1.

2.

3.

4.

BRAKE PEDAL PEDAL PAD FLOOR PLATE STOP SCREW

5.

6.

7.

8.

PUSH ROD PLUNGER BRAKE BOOSTER JAM NUT

Figure 18. Brake Pedal Adjustment H3.50-5.00XL (H70-110XL) (F005/G005)

1. BRAKE PEDAL 2. MASTER CYLINDER 3. PUSH ROD

4. JAM NUT 5. ROD END 6. FLOOR PLATE

7. STOP SCREW 8. RETURN SPRING

Figure 19. Brake Pedal Adjustment E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)

19

Parking Brake Adjustment

1800 SRM 338

Brake Shoes Adjustment The brake shoes are automatically adjusted when the brakes are applied while the truck travels in reverse.

Use the procedure that follows to manually adjust the brakes after you make repairs.

screw wheel in opposite direction. Turn adjuster screw wheel 25 teeth (or clicks) for the necessary clearance between brake shoes and drum. Rotate drive wheel to check for clearance.

1. Put lift truck on blocks so drive wheels do not touch ground. See the section Periodic Maintenance for your unit for the correct procedures.

Make sure blocks do not prevent access to backplates of brakes.

6. Repeat Step 3, Step 4, and Step 5 at other brake assembly. Install plugs in backplates.

2. Remove plugs in slots in backplates [26, Figure 8].

3. Use a tool for brake adjustment in slot nearest teeth of adjuster screw wheel [19, Figure 8].

Push up on teeth and turn adjuster screw wheel until brake shoes touch brake drum.

4. Put a small screwdriver through slot in backplate. Move automatic adjustment lever [2, Figure 11] away from adjuster screw wheel.

7. Remove lift truck from blocks. Drive lift truck in FORWARD and REVERSE. Use brakes to stop ten times in each direction.

NOTE: If the automatic brake adjusters adjust the brake shoes too much or too little, refer to Assembly and Installation in this section for the brake shoes.

If the brake shoes are too tight (too much adjustment), adjust position of automatic adjustment lever to 1.5 mm (0.06 in.) above centerline of adjuster screw wheel. If brake shoes are too loose (not enough adjustment), adjust position of automatic adjustment lever to 3.0 mm (0.12 in.) above centerline of adjuster screw wheel.

5. Turn adjuster screw wheel with tool for brake adjustment. Push down on teeth to turn adjuster

Parking Brake Adjustment PARKING BRAKE ADJUSTMENT, LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) Turn knob on parking brake lever to adjust parking brake. The brake must hold the lift truck with a capacity load on a 15% grade [a slope that increases 1.5 m in 10 m (1.5 ft increase in 10 ft)].

Lift trucks with a powershift transmission and a MONOTROL pedal have a switch on the inside of

20

the cowl. See Figure 20. A link on the parking brake lever operates the switch. The switch closes the circuit for starting the engine and opens the circuit for the MONOTROL control system. Make sure that the link moves up far enough to actuate the switch when the parking brake is applied. The normally closed (NC) circuit (Figure 20) of the switch must be open when the parking brake is applied.

The normally open (NO) circuit (Figure 20) must be closed so you can start the engine. Bend link as necessary or replace link if link does not correctly actuate switch.

1800 SRM 338

Parking Brake Adjustment Turn knob on parking brake lever to adjust parking brake. See Figure 21. The brake must hold the lift truck with a capacity load on a 15% grade [a slope that increases 1.5 m in 10 m (1.5 ft increase in 10 ft)].

The parking brake switch is actuated by the parking brake lever. When the lever is released (OFF), the switch is closed, energizing the traction circuit.

When the parking brake is applied, the switch is open and the traction circuit will not operate.

Check the adjustment of the parking brake switch when the lever is released. In this position, the switch lever must be 1 to 3 mm (0.04 to 0.12 in.) past the applied position.

1. HAND LEVER 2. SWITCH 3. TERMINALS, NORMALLY CLOSED (NC) CIRCUIT 4. TERMINALS, NORMALLY OPEN (NO) CIRCUIT 5. LINK 6. CABLES TO BRAKE SHOES Figure 20. Parking Brake Arrangement, Lift Truck Models S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005)

PARKING BRAKE LEVER AND SWITCH ADJUSTMENT E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) NOTE: See the section Frame 100 SRM 284 for lift truck models E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and Frame 100 SRM 1200 for lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) for the adjustment procedure for the seat brake.

1.

2.

3.

4.

5.

PARKING BRAKE LEVER APPLIED POSITION RELEASED POSITION SWITCH LEVER SWITCH Figure 21. Parking Brake E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098] and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

21

Seat Brake Assembly

1800 SRM 338

Seat Brake Assembly REMOVE NOTE: The procedures in this section apply only to lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) NOTE: Remove the battery from the lift truck before removing the seat brake. See the Operating Manual or the section Periodic Maintenance 8000 SRM 1201 for the procedures.

1. Loosen brake drum capscrew. Pull manual release lever up to release the compression spring.

Remove capscrew, washer, and lockwasher from brake drum. Remove brake drum from brake assembly. Remove spacer from motor shaft.

2. Put manual release lever down. Disconnect guide pipe and brake cable. Disconnect electrical connections. See Figure 7 and Figure 22.

3. Loosen the compression spring. Remove pin securing clevis and stud to brake assembly and traction motor. Remove brake assembly from traction motor.

4. Remove two capscrews from seat brake mounting bracket. Remove seat brake mounting bracket from traction motor.

5. Remove two rod end pins from seat brake mounting bracket to disconnect the solenoid.

CLEAN AND INSPECT Follow the Clean and Inspect procedures in the Brake Shoe Assemblies Repair section in this SRM.

INSTALL 1. Install and connect the solenoid to seat brake mounting bracket using two rod end pins.

2. Install seat brake to mounting bracket and traction motor with two capscrews.

3. Install pins to secure clevis and stud to brake assembly and traction motor. Tighten nuts on compression spring.

4. Connect the electrical connections, brake cable, and guide pipe.

5. Install spacer on motor shaft. Install lockwasher, washer, and capscrew into brake drum and install brake drum onto brake assembly. Tighten brake drum capscrew.

Legend for Figure 22 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

22

CAPSCREW BRACKET MOUNTING BRACKET FOR TRACTION MOTOR NUT WASHER DISC SPRING MANUAL RELEASE LEVER PIN ROD END PIN WIRE STOP BRAKE CABLE CONTROLLER LOCKWASHER GUIDE PIPE

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

CABLE LINK COMPRESSION SPRING CUP STUD SPACER BRAKE ASSEMBLY BRAKE DRUM COTTER PIN MOUNTING PLATE CLEVIS SWITCH SOLENOID GUIDE PIPE FITTING

1800 SRM 338

Seat Brake Assembly

Figure 22. Seat Brake Assembly

23

Seat Brake Assembly

ADJUSTMENTS Solenoid Adjustment NOTE: The solenoid is energized when the brake is released and de-energized when the brake is applied.

1. With the brake fully assembled and the solenoid de-energized, adjust the adjusting nut so the compression spring plus cup is 70 mm (2.75 in.) in length. Tighten Locknut. See Figure 24.

NOTE: The stroke is the amount the plunger protrudes from the solenoid body when it is de-energized.

2. Loosen locknut. Screw the plunger in or out of the clevis to adjust plunger stroke to 4 mm (0.016 in.). Tighten locknut. See Figure 24.

3. Raise the handle to energize the solenoid which will release the seat brake and check for drag by rotating the brake drum by hand.

4. If the brake drags while the solenoid is de-energize tighten locknut to increase the plunger stroke by 1/2 a turn and repeat Step 3 and Step 4 until the brake does not drag.

5. Tighten the clevis lock nut.

NOTE: The solenoid is correctly adjusted when the brake fully releases with the minimum possible solenoid stroke.

24

1800 SRM 338 NOTE: After the solenoid is adjusted, verify there is a minimum 7.0 mm (.028 in.) clearance between the jam nut on the thumb wheel and the inside of the solenoid housing when the solenoid is de-energized (brake applied). See Figure 23.

Traction cutoff Switch Adjustment 1. Mount switch to bracket leaving both screws loose enough to rotate the switch.

2. Mount the bracket and switch to the brake assembly and apply loctite part number 251099 to the screws and install washers and nuts as shown in Figure 23.

3. Using the Powered Solenoid, adjust the switch by rotating it so that a full solenoid compression the switch is actuated, switch should "click", allowing for a 0.5 mm (0.019 in.) feeler gauge to be placed between the metal leaf and the switch housing. Once the correct position is determined the mounting screws should be tightened to 0.45 to 0.56 N•m (4 to 5 lbf in).

4. Once switch is correctly adjusted the manual release handle will need to be readjusted to ensure that the minimum 0.5 mm (0.019 in.) clearance is maintained between the leaf and the switch housing.

1800 SRM 338

1.

2.

3.

4.

5.

Seat Brake Assembly

6.

7.

8.

9.

10.

TRACTION SWITCH CAPSCREWS SOLENOID JAM NUT THUMB WHEEL

BRACKET LEAF SCREW WASHER NUT

Figure 23. Traction Cutoff Switch Adjustment

Cable Adjustment

2. Move the handle to the DOWN position.

NOTE: The Solenoid and Traction Cutoff Switch adjustment must be completed before adjusting the release cable.

3. Pull the handle back into the UP position, and check for drag by rotating the brake drum by hand.

NOTE: When handle is in the UP position, brake is released. When handle is in the DOWN position, brake is applied.

NOTE: The solenoid must NOT be energized when performing this procedure.

4. If the brake drags while the handle is in the UP position, lower the handle, loosen the wire stop, pull cable through, and retighten the wire stop. Repeat Step 3 and Step 4 until the brake no longer drags. Lower the handle to the DOWN position.

NOTE: When the handle is in the UP position, the air gap between the leaf and the switch housing must be 0.5 mm (0.019 in.) minimum.

5. Adjust handle by tightening nut to 0.85 N•m (7.5 lbf in) so that the washers clamp onto the handle but allows handle to pivot easily.

1. With brake fully assembled, and the handle in the UP position. Pull the cable tight through the wire stop. Insert excess cable into the handle.

See Figure 24.

25

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