Hyster C098 (E5.50XL Europe) Forklift Service Repair Manual

SERVICE REPAIR E3.50XL E4.00XL E4.50XL E5.50XL E4.50XLS [C098]

100 SRM 284

Description

General This section has a description and the service procedures for the parts of the frame. These parts include the frame, counterweight assembly, overhead guard, hydraulic tank, access panels, and label positions. See Figure 1. The procedure for removing the traction motor is also described in this section.

Description The frame is a single weldment. The frame has mounts for the counterweight, overhead guard, tilt cylinders, steering axle, and drive axle assembly. See Figure 1. The hydraulic tank is a plastic tank mounted in the right side of the frame on all of the XL series of lift trucks except the E3.50-5.50XL (E70-120XL, E70-120XL 3) series. On the E3.50-5.50XL (E70-120XL, E70-120XL 3) models, the hydraulic tank is part of the lift truck frame and is a welded steel unit. The lift trucks must have a hood over the battery, or a covered battery if a hood

is not installed. The floor plates can be removed for access to the hydraulic systems. A panel in the bottom of the battery compartment can be removed for access to the traction motor and the hydraulic pump motor. On the E3.50-5.50XL (E70-120XL, E70-120XL 3) models, this panel also gives access to the power steering pump motor. The SCR (silicon controlled rectifier) electronic controller and contactors are in the counterweight. A panel in the counterweight can be removed for access to the SCR controller and contactors.

NOTE: E1.75XL (E35XL) UNIT SHOWN. 1. OVERHEAD GUARD 2. COUNTERWEIGHT 3. STEERING AXLE AND WHEELS 4. PARKING BRAKE LEVER

5.

6.

7.

8.

9.

FRAME DRIVE AXLE AND WHEELS UPRIGHT FORKS CARRIAGE

10. LOAD BACKREST EXTENSION 11. ACCESS PANEL TO SCR ELECTRONIC CONTROLLER

Figure 1. Lift Truck Parts

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Description The frames for the lift trucks are similar in design, but are different sizes for each XL series. The J1.25-1.75XL (E25-35XL) models with pneumatic tires have fenders welded to the frame because of the wider drive tires.

The E2.00-3.00XL (E40-60XL) lift trucks have frames made in four different configurations. The lift truck with the long (842 mm battery compartment) frame has a larger battery compartment than the lift truck with the short (695 mm battery compartment) frame. Some lift trucks have additional counterweight metal added to the frame in front of the steering axle because of differences in some battery weights. The remainder of the frame parts are the same.

The J2.00-3.00XL (J40-60XL) models are made with two sizes of frames. A short frame (842 mm battery compartment) is available for the J2.00-2.50XL (J40-50XL) models. A long frame (1010 mm battery compartment) is available for all of the J2.00-3.00XL (J40-60XL) models. The size of the battery compartment and battery size specifications are shown in Table 1, Table 2, andTable 3.

The E3.50-5.50XL (E70-120XL, E70-120XL 3) models are made with two sizes of frames. A short frame (1018 mm battery compartment) is available for the E3.50-4.00XL (E70-80XL) and the E5.00XLS (E100XLS) models. A long frame (1183 mm battery compartment) is available for the E5.00-5.50XL (E100-120XL, E70-120XL 3) models. The size of the battery compartment and battery size specifications are shown in Table 1, Table 2, Table 3, and Table 4.

The lift trucks are equipped with adjustable spacers in the battery compartment. See Figure 2. Add

2

100 SRM 284 or remove shims from under the front spacer bar to control the movement of the battery in the forward and backward directions. Install an equal number of shims at each capscrew. Install the additional shims under the nuts of the capscrews (outside battery compartment). The spacers on each side of the battery can be adjusted to control the movement of the battery from side to side. Access to the nuts for the spacers for the sides of the battery is under the frame near the steer tires on all units. Tighten all capscrews. It can be necessary to install the side spacers facing the opposite direction for some batteries. If the spacers cannot be adjusted for a battery that is specified for this lift truck, see your Hyster lift truck dealer for the correct spacers.

NOTE: Maximum tolerances are +0 and 13 mm (+0 and 0.5 in.) for the size of the battery compartment.

The battery specification chart shows the maximum size tolerances that will permit a battery to still fit into a battery compartment.

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use spacers to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction.

The weight of the battery is a large part of the counterweight system on an electric lift truck. Make sure that the battery is within the weight limits indicated on the nameplate. Each model of lift truck has a cast-iron counterweight that provides the additional weight necessary for the indicated capacity. A slot in the overhead guard permits removal of the battery without removing the overhead guard.

100 SRM 284

Description Table 1. Battery Specifications (Battery without Cover)

Model

Minimum Compartment Size Length × Width

E1.25XL (E25XL)

Battery Size Min./Max.

Weight

Length

Width

Min.

Max.

694 × 909 mm (27.3 × 35.8 in.)

654 to 692 mm (25.8 to 27.2 in.)

784 to 885 mm (30.9 to 34.8 in.)

794 kg (1749 lb)

1132 kg (2493 lb)

E1.50XL (E30XL)

694 × 909 mm (27.3 × 35.8 in.)

654 to 692 mm (25.8 to 27.2 in.)

784 to 885 mm (30.9 to 34.8 in.)

839 kg (1848 lb)

1132 kg (2493 lb)

E1.75XL (E35XL)

694 × 909 mm (27.3 × 35.8 in.)

654 to 692 mm (25.8 to 27.2 in.)

784 to 885 mm (30.9 to 34.8 in.)

917 kg (2020 lb)

1132 kg (2493 lb)

E2.00-2.50XL (E40-50XL)

694 × 987 mm (27.3 × 38.9 in.)

681 to 692 mm (26.8 to 27.2 in.)

978 to 983 mm (38.5 to 38.7 in.)

1045 kg (2302 lb)

1450 kg (3195 lb)

E2.00-3.00XL (E40-60XL)

841 × 987 mm (33.1 × 38.9 in.)

800 to 838 mm (31.5 to 32.9 in.)

978 to 983 mm (38.5 to 38.7 in.)

1315 kg (2896 lb)

1750 kg (3855 lb)

E3.50-4.00XL (E70-80XL)

993 × 1146 mm (39.3 × 45.1 in.)

950 to 1117 mm (37.4 to 43.9 in.)

950 to 990 mm (37.4 to 38.9 in.)

1542 kg (3396 lb)

2400 kg (5286 lb)

E5.00XL (E100XLS)

993 × 1146 mm (39.3 × 45.1 in.)

950 to 1117 mm (37.4 to 43.9 in.)

950 to 990 mm (37.4 to 38.9 in.)

1633 kg (3597 lb)

2400 kg (5286 lb)

E5.00XL (E100XL)

1153 × 1146 mm (45.9 × 45.1 in.)

950 to 1117 mm (37.4 to 43.9 in.)

1115 to 1150 mm (43.9 to 45.3 in.)

1814 kg (3996 lb)

2700 kg (5947 lb)

E5.50XL (E120XL)

1153 × 1146 mm (45.9 × 45.1 in.)

950 to 1117 mm (37.4 to 43.9 in.)

1115 to 1150 mm (43.9 to 45.3 in.)

1919 kg (4227 lb)

2700 kg (5947 lb)

J2.00-2.50XL (J40-50XL)

842 × 987 mm (33.1 × 38.9 in.)

800 to 838 mm (31.5 to 32.9 in.)

978 to 983 mm (38.5 to 38.7 in.)

1315 kg (2896 lb)

1750 kg (3855 lb)

J2.00-3.00XL (J40-60XL)

1010 × 987 mm (39.8 × 38.9 in.)

968 to 991 mm (38.1 to 39.0 in.)

978 to 983 mm (38.5 to 38.7 in.)

1550 kg (3417 lb)

2060 kg (4537 lb)

585 mm (23.0 in.) = maximum height for batteries without a cover used in lift trucks with a hood.

NOTE: Maximum tolerances are +0 and 13 mm (+0 and 0.5 in.) for the size of the battery compartment.

The battery specification chart shows the maximum size tolerances that will permit the battery to still fit into a battery compartment.

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use the spacers designed by Hyster Company to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction.

3

Description

100 SRM 284 Table 2. Battery Specifications (Battery with Flat Cover)

Model

Minimum Compartment Size Length × Width

E1.25XL (E25XL)

Battery Size Min./Max.

Weight

Length

Width

Min.

Max.

694 × 909 mm (27.3 × 35.8 in.)

654 to 692 mm (25.8 to 27.2 in.)

784 to 907 mm (30.9 to 35.7 in.)

794 kg (1749 lb)

1285 kg (2830 lb)

E1.50XL (E30XL)

694 × 909 mm (27.3 × 35.8 in.)

654 to 692 mm (25.8 to 27.2 in.)

784 to 907 mm (30.9 to 35.7 in.)

839 kg (1848 lb)

1285 kg (2830 lb)

E1.75XL (E35XL)

694 × 909 mm (27.3 × 35.8 in.)

654 to 692 mm (25.8 to 27.2 in.)

784 to 907 mm (30.9 to 35.7 in.)

917 kg (2020 lb)

1285 kg (2830 lb)

E2.00-2.50XL (E40-50XL) 36/48V

694 × 987 mm (27.3 × 38.9 in.)

681 to 691 mm (26.8 to 27.2 in.)

978 to 983 mm (38.5 to 38.7 in.)

1045 kg (2300 lb)

1450 kg (3197 lb)

E2.00-3.00XL (E40-60XL) 36/48V

841 × 987 mm (33.1 × 38.9 in.)

800 to 838 mm (31.5 to 32.9 in.)

978 to 983 mm (38.5 to 38.7 in.)

1315 kg (2900 lb)

1750 kg (3855 lb)

E2.00-2.50XL (E40-50XL) 72/80V

694 × 1037 mm (27.3 × 40.8 in.)

681 to 691 mm (27.0 to 27.2 in.)

1029 to 1034 mm (40.5 to 40.7 in.)

935 kg (2059 lb)

1270 kg (2797 lb)

E2.00-3.00XL (E40-60XL) 72/80V

841 × 1037 mm (33.1 × 40.8 in.)

833 to 838 mm (32.8 to 32.9 in.)

1029 to 1034 mm (40.5 to 40.7 in.)

1420 kg (3128 lb)

1690 kg (3722 lb)

E3.50-4.00XL (E70-80XL)

993 × 1146 mm (39.3 × 45.1 in.)

950 to 990 mm (37.4 to 39.0 in.)

950 to 1143 mm (37.4 to 45.0 in.)

1542 kg (3396 lb)

2400 kg (5286 lb)

E5.00XLS (E100XLS)

993 × 1146 mm (39.3 × 45.1 in.)

950 to 990 mm (37.4 to 39.0 in.)

950 to 1143 mm (37.4 to 45.0 in.)

1633 kg (3597 lb)

2400 kg (5286 lb)

E5.00XL (E100XL)

1153 × 1146 mm (45.9 × 45.1 in.)

1115 to 1150 mm (43.9 to 45.3 in.)

950 to 1143 mm (37.4 to 45.0 in.)

1814 kg (3996 lb)

2700 kg (5947 lb)

E5.50XL (E120XL)

1153 × 1146 mm (45.9 × 45.1 in.)

1115 to 1150 mm (43.9 to 45.3 in.)

950 to 1143 mm (37.4 to 45.0 in.)

1919 kg (4227 lb)

2700 kg (5947 lb)

J2.00-2.50XL (J40-50XL) 36/48V

841 × 987 mm (33.1 × 38.9 in.)

800 to 838 mm (31.5 to 32.9 in.)

978 to 983 mm (38.5 to 38.7 in.)

1315 kg (2900 lb)

1750 kg (3855 lb)

617 mm (24.3 in.) = maximum height for batteries with a flat cover used in lift trucks without a hood.

NOTE: Maximum tolerances are +0 and 13 mm (+0 and 0.5 in.) for the size of the battery compartment.

The battery specification chart shows the maximum size tolerances that will permit the battery to still fit into a battery compartment.

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use the spacers designed by Hyster Company to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction.

4

100 SRM 284

Description

Table 2. Battery Specifications (Battery with Flat Cover) (Continued) Minimum Compartment Size Length × Width

Model

Battery Size Min./Max.

Weight

Length

Width

Min.

Max.

J2.00-3.00XL (J40-60XL) 36/48V

1009 × 987 mm (39.7 × 38.9 in.)

968 to 991 mm (38.1 to 39.0 in.)

978 to 983 mm (38.5 to 38.7 in.)

1550 kg (3414 lb)

2060 kg (4537 lb)

J2.00-2.50XL (J40-50XL) 72/80V

841 × 1037 mm (33.1 × 40.8 in.)

833 to 838 mm (32.8 to 32.9 in.)

1029 to 1034 mm (40.5 to 40.7 in.)

1420 kg (3128 lb)

1690 kg (3722 lb)

J2.00-3.00XL (J40-60XL) 72/80V

1009 × 1037 mm (39.7 × 40.8 in.)

1001 to 1006 mm (39.4 to 39.6 in.)

1029 to 1034 mm (40.5 to 40.7 in.)

1600 kg (3524 lb)

1850 kg (4075 lb)

617 mm (24.3 in.) = maximum height for batteries with a flat cover used in lift trucks without a hood.

NOTE: Maximum tolerances are +0 and 13 mm (+0 and 0.5 in.) for the size of the battery compartment.

The battery specification chart shows the maximum size tolerances that will permit the battery to still fit into a battery compartment.

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use the spacers designed by Hyster Company to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction.

5

Description

100 SRM 284 Table 3. Battery Specifications (Battery with Dome Cover)

Model

Minimum Compartment Size Length × Width

E1.25XL (E25XL)

Battery Size Min./Max.

Weight

Length

Width

Min.

Max.

694 × 909 mm (27.3 × 35.8 in.)

686 to 691 mm (27.0 to 27.2 in.)

890 to 895 mm (35.0 to 35.2 in.)

794 kg (1750 lb)

1285 kg (2830 lb)

E1.50XL (E30XL)

694 × 909 mm (27.3 × 35.8 in.)

686 to 691 mm (27.0 to 27.2 in.)

890 to 895 mm (35.0 to 35.2 in.)

839 kg (1850 lb)

1285 kg (2830 lb)

E1.75XL (E35XL)

694 × 909 mm (27.3 × 35.8 in.)

686 to 691 mm (27.0 to 27.2 in.)

890 to 895 mm (35.0 to 35.2 in.)

917 kg (2020 lb)

1285 kg (2830 lb)

E2.00-2.50XL (E40-50XL)

694 × 1037 mm (27.3 × 40.8 in.)

686 to 691 mm (27.0 to 27.2 in.)

1029 to 1034 mm (40.5 to 40.7 in.)

935 kg (2059 lb)

1270 kg (2797 lb)

E2.50-3.00XL (E50-60XL)

841 × 1037 mm (33.1 × 40.8 in.)

833 to 838 mm (32.8 to 33.0 in.)

1029 to 1034 mm (40.5 to 40.7 in.)

1420 kg (3128 lb)

1690 kg (3722 lb)

J2.00-2.50XL (J40-50XL)

841 × 1037 mm (33.1 × 40.8 in.)

833 to 838 mm (32.8 to 32.9 in.)

1029 to 1034 mm (40.5 to 40.7 in.)

1420 kg (3128 lb)

1690 kg (3722 lb)

J2.00-3.00XL (J40-60XL)

1009 × 1037 mm (39.7 × 40.8 in.)

1001 to 1006 mm (39.4 to 39.6 in.)

1029 to 1034 mm (40.5 to 40.7 in.)

1600 kg (3524 lb)

1850 kg (4075 lb)

612 mm (24.1 in.) = maximum height for batteries with a dome cover used in lift trucks without a hood.

NOTE: Maximum tolerances are +0 and 13 mm (+0 and 0.5 in.) for the size of the battery compartment.

The battery specification chart shows the maximum size tolerances that will permit the battery to still fit into a battery compartment.

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use the spacers designed by Hyster Company to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction.

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100 SRM 284

Description Table 4. Battery Specifications*

Model

VOLTS

Minimum Compartment Size Length Ă— Width

Battery Length

Weight

Min./Max

Min.

Max.

E3.50-4.00XL (E70-80XL 3)

36

841 x 987 mm (33.1 x 38.9 in.)

950 to 990 mm (37.4 to 39.0 in.)

1542 kg (3400 lb)

2400 kg (5292 lb)

E5.00XL (E100XL 3S)

36

841 x 987 mm (33.1 x 38.9 in.)

950 to 990 mm (37.4 to 39.0 in.)

1633 kg (3600 lb)

2400 kg (5292 lb)

E5.00XL (E100XL 3)

36

694 x 10376 mm (27.3 x 40.8 in.)

1115 to 1150 mm (43.9 to 45.3 in.)

1814 kg (4000 lb)

2700 kg (5954 lb)

E5.50XL (E120XL 3)

36

993 x 1146 mm (39.3 x 45.1 in.)

1115 to 1150 mm (43.9 to 45.3 in.)

1919 kg (4231 lb)

2700 kg (5954 lb)

E3.50-4.00XL (E70-80XL 3)

48

841 x 987 mm (33.1 x 38.9 in.)

950 to 990 mm (37.4 to 39.0 in.)

1542 kg (3400 lb)

2400 kg (5292 lb)

E5.00XL (E100XL 3S)

48

841 x 987 mm (33.1 to 38.9 in.)

950 to 990 mm (37.4 to 39.0 in.)

1633 kg (3600 lb)

2400 kg (5292 lb)

E5.00XL (E100XL 3)

48

694 x 1037 mm (27.3 x 40.8 in.)

1115 to 1150 mm (43.9 to 45.3 in.)

1814 kg (4000 lb)

2700 kg (5954 lb)

E5.50XL (E120XL 3)

48

993 x 1146 mm (39.3 x 45.1 in.)

1115 to 1150 mm (43.9 to 45.3 in.)

1919 kg (4231 lb)

2700 kg (5954 lb)

*BATTERY WIDTH Batteries without cover: 950 to 1117 mm (37.4 to 44.0 in.)

Batteries with cover: 950 to 1143 mm (37.4 to 45.0 in.)

NOTE: Maximum tolerances are +0 and -13 mm (+0 and -0.5 in.) for the size of the battery compartment. The battery specification chart shows the maximum size tolerances that will permit the battery to still fit into a battery compartment.

7

Overhead Guard Repair

100 SRM 284

A. FRONT SPACER 1. BATTERY COMPARTMENT 2. BATTERY 3. BULKHEAD

4. SPACER BAR 5. SHIM 6. STORE ADDITIONAL SHIMS IN FRONT OF BULKHEAD Figure 2. Battery Compartment Shims

Overhead Guard Repair REMOVE WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.

1. Remove battery as described in the section Periodic Maintenance for your lift truck.

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2. Access to capscrews that hold rear supports of overhead guard to counterweight is from the battery compartment. Remove capscrews.

3. Remove two capscrews that hold each front support of overhead guard to cowl. Disconnect any electric wires from under cowl that go through supports of overhead guard. When overhead guard is lifted from the frame, make sure these

100 SRM 284

Overhead Guard Repair

electric wires move through the holes in the frame so they are not damaged.

4. Use lifting device or another person to help lift overhead guard from lift truck.

INSTALL

in cowl. Install four capscrews, washers, and nuts that hold front supports to cowl. Tighten capscrews to correct torque. Install capscrews and washers that hold rear supports to counterweight. Tighten capscrews to correct torque. The correct torque values are shown in Figure 3. Install battery.

Put overhead guard on lift truck. Install any electric wires from overhead guard supports through holes

Torque Values Model

Overhead Guard

Counterweight

Front

Rear

Upper

Lower

E1.25-3.00XL (E/J25-60XL)

86 N•m (64 lbf ft)

435 N•m (320 lbf ft)

435 N•m (320 lbf ft)

66 N•m (49 lbf ft)

E3.50-5.50XL (E70-120XL)

86 N•m (64 lbf ft)

86 N•m (64 lbf ft)

270 N•m (200 lbf ft)

66 N•m (49 lbf ft)

A. E/J1.25-3.00XL (E/J25-60XL)

B. E3.50-5.50XL (E70-120XL)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

OVERHEAD GUARD (OHG) COUNTERWEIGHT (CWT) FRAME CAPSCREWS (4) OHG-FRONT CAPSCREWS (2) OHG-REAR

CAPSCREWS CAPSCREWS CAPSCREWS CAPSCREWS CAPSCREWS

(2) CWT-UPPER (2) CWT-LOWER (2) OHG-UPPER (2) CWT-UPPER (2) CWT-LOWER

Figure 3. Frame, Overhead Guard, and Counterweight

9

Battery Restraint and Seat Assembly Repair

100 SRM 284

Battery Restraint and Seat Assembly Repair A battery restraint system is installed as a safety device. The function of the battery restraint system, when correctly locked in the down position, is to hold the battery in the battery compartment if an accident causes the lift truck to tip over. The battery restraint is a steel plate that is connected to the frame with a hinge. A sliding latch mechanism locks the battery restraint in the down position for operation. A knob near the hinge unlocks the battery restraint from the frame so the battery restraint can be raised to the up position for access to the battery. The battery restraint is also the support for the seat. A spring brace holds the seat and battery restraint in the up position. The operator must hold the seat assembly with one hand. Use the other hand on the knob to release the spring brace and lower the seat and battery restraint assembly to the operating position. Make sure that the battery restraint is correctly locked to the frame for operation of the lift truck.

An additional battery retention bar is used on models E3.50-5.50XL (E70-120XL, E70-120XL 3) where batteries can be longer. This bar has a hinge fastened to the counterweight and is part of the hood mechanism on lift truck with hoods. The bar is also installed on lift trucks without hoods.

Spacers are used inside the battery compartment to prevent horizontal movement of the battery.

WARNING The battery restraint and its latch mechanisms must operate correctly before a lift truck is operated. Make sure the battery has a cover if the lift truck does not have a hood.

To operate correctly, the battery restraint plate must be locked in the down position. On E3.50-5.50XL (E70-120XL, E70-120XL 3) units, the battery retention bar (and hood) must be lowered first; then the battery restraint plate is locked in the down position over the bar. The battery must have spacers to prevent movement in any one horizontal direction of 13 mm (0.5 in.) maximum. See Figure 4. Use the knob near the hinge to release the battery restraint plate. Use the handle on the restraint plate to raise

10

the plate and seat. A spring brace will hold the assembly in the up position. If installed, raise the hood.

Make sure that the battery cannot move more than a total of 13 mm (0.5 in.) in any one horizontal direction. Make sure the correct spacers are installed to prevent the movement. See your Hyster lift truck dealer to replace damaged or missing spacers. If a smaller battery of the correct weight (see nameplate) is installed and the spacers cannot prevent movement, your Hyster lift truck dealer has larger spacers. Push the seat and the battery restraint down until the latch locks. Make sure battery restraint is locked securely. Lift on battery restraint to make sure it is latched and will not move.

SEAT BRAKE ASSEMBLY E/J1.25-3.00XL (E/J25-60XL), ADJUST 1. Put a weight in the seat to release the seat brake. Measure dimensions X and Y. Add or remove shims under the clamp so dimension Y is 6 to 9 mm (0.23 to 0.35 in.) greater than dimension X. See Figure 5.

2. Adjust setscrew at top of lever so bottom of lever is 65 mm (2.5 in.) from front plate of battery compartment.

3. Turn spring adjustment so length is dimension J. Dimension J:

E/J1.25-1.75XL (E25-35XL)

E/J2.00-3.00XL (E/J40-60XL)

Standard Seat 63 mm (2.46 in.)

Suspension Seat 74 mm (2.91 in.)

Standard Seat 107 mm (4.13 in.)

Suspension Seat 118 mm (4.65 in.)

4. Adjust length of rod to remove clearance in lever and spring. Make sure adjustment does not apply brake.

100 SRM 284

Battery Restraint and Seat Assembly Repair Legend for Figure 4 1.

2.

3.

4.

5.

6.

7.

SEAT BATTERY RESTRAINT PLATE KNOB FOR LATCH MECHANISM HINGE LATCH SPRING BRACE BATTERY RETENTION BAR E3.50-5.50XL (E70-120XL, E70-120XL 3) ONLY

5. Raise seat to up position and make sure the jam nuts do not hit bearing. Test operation of seat brake to make sure seat brake is actuated correctly. Make sure measurements for linkage adjustments are correctly done. If seat brake does not correctly actuate brake after adjustments have been made, make additional adjustments to length of rod.

6. The seat can be removed from the battery restraint plate by removing four bolts. The battery restraint plate is removed from the frame by removing the hinge pin that holds the assembly to the frame.

Figure 4. Battery Restraint and Seat Assembly

11

Battery Restraint and Seat Assembly Repair

1.

2.

3.

4.

CLAMP LEVER SPRING ADJUSTMENT BEARING

100 SRM 284

5. FRONT PLATE BATTERY COMPARTMENT 6. ROD ADJUSTMENT 7. LEVER 8. SPRING

9.

10.

11.

12.

JAM NUTS BRAKE SWITCH MOTOR BRAKE ASSEMBLY

*THE LATEST LIFT TRUCKS EQUIPPED WITH A SEAT BRAKE NO LONGER HAVE A SWITCH LOCATED IN THE SEAT. THE BRAKE SWITCH IS ATTACHED TO THE FRONT PLATE OF THE BATTERY COMPARTMENT. ALSO, THE POWER STEERING TIMER HAS BEEN REPLACED WITH A FILTER. LIFT TRUCKS THAT ARE NOT EQUIPPED WITH A SEAT BRAKE WILL STILL HAVE A SWITCH LOCATED IN THE SEAT TO ACTIVATE THE POWER STEERING CIRCUIT. THESE UNITS WILL CONTINUE TO USE A POWER STEERING TIMER. Figure 5. Seat Brake Assembly E/J1.25-3.00XL (E/J25-60XL)

SEAT BRAKE ASSEMBLY E3.50-5.50XL (E70-120XL), ADJUST

NOTE: This adjustment can be made with the spring assembly removed from the lift truck.

1. Put a weight in the seat to release seat brake.

Measure dimension X and Y. Add or remove shims under clamp so dimension Y is equal to dimension X within ±3 mm (0.12 in.). Use equal number shims under each clamp. See Figure 6.

3. Adjust spring adjustment so length is dimension J.

2. Adjust setscrew at top of lever so bottom of lever equals dimension L from front plate of battery compartment.

12

4. On 280 mm (11 in.) diameter motor: Adjust lever to a level position using nut. On 330 mm (13 in.) diameter motor: Adjust lever to 25 ±2 mm (1 ±0.08 in.) using nut. Lock nut with jam nut. Make sure this adjustment does not apply the brake. See Table 5.

100 SRM 284

Battery Restraint and Seat Assembly Repair Table 5. Seat Brake Adjustment

Motor Dia.

280 mm (11 in.)

330 mm (13 in.)

Dimension

Seat Type

J

Standard

80 mm (3.2 in.)*

Suspension

75 mm (2.9 in.)

Standard

85 mm (3.3 in.)**

Suspension

80 mm (3.2 in.)

K

L

173 mm (6.7 in.)

65 mm (2.5 in.)

165 mm (6.5 in.)

55 mm (2.1 in.)

* 90 mm (3.5 in.), ** 80 mm (3.2 in.) on early models.

5. Adjust spring to dimension K. Lock nut with jam nut. This adjustment can be made with spring assembly removed from lift truck.

6. Adjust position of rod end so brake will start to apply when brake lever is raised 3 mm (0.12 in.) or less. Rotate brake drum by hand to feel brake start to apply.

7. Test operation of seat brake to make sure seat brake is actuated correctly. Make sure linkage is adjusted to correct measurements. If seat brake does not correctly actuate brake after adjustments have been made, adjust length of rod again and make sure dimension is correct.

8. The seat can be removed from the battery restraint plate. Remove four bolts. The battery restraint plate can be removed from the frame.

Remove hinge pin that holds assembly to frame.

Figure 6. Seat Brake Assembly E3.50-5.50XL (E70-120XL, E70-120XL 3)

13

Counterweight Repair

100 SRM 284

Legend for Figure 6 1.

2.

3.

4.

5.

6.

7.

8.

9.

CLAMP LEVER SPRING ADJUSTMENT BEARING FRONT PLATE BATTERY COMPARTMENT SPRING ASSEMBLY MOTOR LEVER MOTOR LEVER SPRING

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

JAM NUT JAM NUT ADJUSTMENT NUT ADJUSTMENT NUT JAM NUT SETSCREW MOTOR 280 mm (11 in.)

MOTOR 330 mm (13 in.)

BRAKE SEAT

Counterweight Repair If the lift truck must be put on blocks for maintenance and repair, see Periodic Maintenance 8000 SRM 291 section How to Put a Lift Truck on Blocks.

Table 6. Counterweights (Continued) Model (mm)*

Weight

E4.50XLS (E100XLS) 1018 mm

1747 kg (3850 lb)

The counterweight is very heavy. Make sure that the crane and lifting devices have enough lifting capacity to safely lift the counterweight.

The weights of the counterweights are shown in Table 6.

E5.50XL (E120XL) 1183 mm

1747 kg (3850 lb)

The counterweight normally is not removed for most repairs. Replacement of some large parts of the SCR electronic controller is easier when the counterweight is removed. The counterweight is fastened to the frame with four capscrews. The weights for the counterweights are in Table 6.

WARNING

Table 6. Counterweights Model (mm)*

Weight

E/J1.25XL (E25XL)

300 kg (661 lb)

E/J1.50XL (E30XL)

506 kg (1116 lb)

E/J1.75XL (E35XL)

678 kg (1495 lb)

E2.00XL (E40XL) 695 mm

562 kg (1239 lb)

E2.00XL (E40XL) 842 mm

373 kg (822 lb)

E2.50XL (E50XL) 694 mm

975 kg (2150 lb)

E2.50XL (E50XL) 842 mm

660 kg (1455 lb)

E3.00XL (E60XL) 842 mm

975 kg (2150 lb)

E3.50XL (E70XL) 1018 mm

700 kg (1545 lb)

E4.00XL (E80XL) 1018 mm

1134 kg (2500 lb)

E4.50XL (E100XL) 1183 mm

1134 kg (2500 lb)

*mm dimensions are battery compartment sizes.

14

J2.00XL (J40XL) All

373 kg (822 lb)

J2.50XL (J50XL) 842 mm

373 kg (822 lb)

J2.50XL (J50XL) 1010 mm

373 kg (822 lb)

J3.00XL (J60XL) 1010 mm

373 kg (822 lb)

*mm dimensions are battery compartment sizes.

REMOVE 1. Remove battery. See the Periodic Maintenance 8000 SRM 291 section of this manual under How to Change the Battery.

2. Remove overhead guard as described in the paragraphs under Overhead Guard Repair, Remove.

3. Install lifting eyebolts in holes that are used to fasten overhead guard to counterweight on E/J1.25-3.00XL (E/J25-60XL) models. The E3.50-5.50XL (E70-120XL, E70-120XL 3) models have a hole on top of the counterweight for a single eye bolt. Attach chain or sling to eyebolts.

Use crane to hold the weight of the counterweight. See Figure 3 and Figure 7.

4. From inside the battery compartment, remove two capscrews that hold counterweight to frame.

Remove two capscrews from tow pin area of counterweight. Use crane to lift counterweight away from frame. Make sure you do not damage the electronic controls.

100 SRM 284

Traction Motor Repair

INSTALL NOTE: The access panel to the electronic controller can be removed from the counterweight to make checks and adjustments on the controller. Make sure lugs are correctly engaged when access panel is installed again or panel will fall from counterweight during operation.

1. Use crane to lift counterweight into position.

Make sure you do not damage electronic controller. Install two upper capscrews from inside battery compartment that hold counterweight to frame. Install two lower capscrews in tow pin area of counterweight. Tighten capscrews to correct torque. The correct torque values for capscrews are shown in Figure 3.

NOTE: E5.50XL (E120XL, E70-120XL, E70-120XL 3) MODEL SHOWN. 1. LIFTING EYEBOLT 2. CAPSCREWS

3. TOW PIN

Figure 7. Lift Counterweight

2. Disconnect sling or chain. Remove eyebolts from counterweight.

3. Install overhead guard as described in the paragraphs for the Overhead Guard Repair, Install.

4. Install battery. See Periodic Maintenance 8000 SRM 291 section How to Change the Battery.

Traction Motor Repair REMOVE This procedure will show the removal of the traction motor through the battery compartment. Some lift trucks have a seat brake that actuates the brake on the armature shaft of the traction motor. See Figure 8. The seat brake linkage must be disconnected at the front of the traction motor before the motor is removed.

NOTE: The traction motor can also be removed from under the lift truck with the use of a floor jack, but is more difficult. The lift truck must be on blocks with clearance for the jack and traction motor if the traction motor is removed from under the lift truck. The hydraulic lines from the hydraulic tank must also be disconnected if the traction motor is removed from under the lift truck.

2. Disconnect seat brake linkage. Disconnect hydraulic line to main control valve so motor mount can be disconnected. Put caps on open hydraulic fittings.

3. Disconnect power cables from traction motor.

Make an identification of which cable is connected to each terminal.

4. Put lift truck on blocks for easier access to bottom bolts between traction motor and speed reducer.

Remove bolts between speed reducer and motor.

5. Install sling to hold traction motor. See Figure 9.

Use wood block and board under sling as shown in the illustration to control traction motor during removal and installation. Use crane to hold weight of traction motor. See Figure 10.

1. Remove battery. Remove floor plates and access panel in bottom of battery compartment.

15

Traction Motor Repair

100 SRM 284

1. SLING 2. USE WOOD BLOCK AND BOARD UNDER SLING FOR A LEVER 3. TRACTION MOTOR Figure 9. Sling Installation to Lift Traction Motor A. TRACTION MOTOR B. TRACTION MOTOR WITH OPTIONAL SEAT BRAKE Figure 8. Traction Motor NOTE: The traction motors are in different configurations for different applications of the lift trucks. Traction motors weigh approximately 90 to 140 kg (200 to 310 lb). Make sure the sling cannot slide and permit traction motor to fall.

6. Remove motor mount that holds traction motor to frame. Pull traction motor from speed reducer.

7. Use crane to move traction motor to a space to make repairs.

Figure 10. Use Crane to Lift Traction Motor

16

100 SRM 284

Hydraulic Tank Repair

INSTALL 1. Install sling to lift traction motor. Use wood block and board under sling as shown in Figure 9 to control traction motor during installation.

2. Lower traction motor into position in lift truck.

Align traction motor with speed reducer. See Figure 11.

3. Use board or prybar as necessary to push traction motor into speed reducer.

4. Align bolt holes in speed reducer and motor housing. Install bolts that hold traction motor to speed reducer. Tighten bolts to 38 N•m (28 lbf ft).

5. Remove sling and install traction motor mount.

6. Connect inlet hydraulic line to main control valve. Install power cables.

1. SLING 2. BOARD

3. WOOD BLOCK

Figure 11. Align Traction Motor with Speed Reducer

Hydraulic Tank Repair INSPECT Make a visual inspection of all sides of the tank. Inspect welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

E/J1.25-3.00XL (E/J25-60XL) The hydraulic tank is plastic and is normally replaced if it is damaged.

The traction motor must be removed before the hydraulic tank can be replaced. A bracket on the front plate of the battery compartment holds the hydraulic tank in position. The hydraulic tank must be drained through one of the hydraulic supply hoses. Disconnect hydraulic hoses from hydraulic tank when it must be replaced.

E3.50-5.50XL (E70-120XL, E70-120XL 3) The hydraulic tank is part of the frame weldment and cannot be removed from the lift truck. See Figure 12.

Repairs for leaks in the hydraulic tank can require special procedures described in the next paragraphs.

1. HYDRAULIC TANK 2. OUTER FRAME

3. INNER FRAME 4. SUCTION PIPE

Figure 12. Hydraulic Tank E3.50-5.50XL (E70-120XL, E70-120XL 3) Models

17

Hydraulic Tank Repair

100 SRM 284

SMALL LEAKS, REPAIR

Steam Method

Use the following procedure to seal small leaks:

Use the following procedure to clean the tank with steam:

1. Use steam to clean area around leak. Remove all paint and dirt around leak.

WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

2. Apply Loctite® 290 to leak. Follow instructions of manufacturer.

LARGE LEAKS, REPAIR 1. Use one of the procedures described under Clean in this section to clean and prepare the tank for repairs.

2. Use acceptable welding practices to repair tank.

See the American National Standard Safety In Welding and Cutting ANSI Z 49.1 - 1973.

CLEAN WARNING Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside of a building, make sure there is enough ventilation. See the following manuals for additional information: • Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, A6.0-65 • Safety In Welding and Cutting, American National Standard, ANSI Z 49.1 - 1973 When cleaning tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control the pressure of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between nozzle and tank. Connect ground wire to tank to prevent static electricity.

18

1. Remove all parts from tank. Install drain plug.

2. Fill tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water.

3. Mix solution in tank using air pressure. Make sure all surfaces on inside of tank are flushed with solution. Drain tank.

4. Put steam into tank until tank does not have odors and metal is hot. Steam vapors must come from all openings.

5. Flush inside of tank with boiling water. Make sure all loose material is removed from inside of tank.

6. Make inspection of inside of tank. If it is not clean, repeat Step 4 and Step 5 and make another inspection. When making inspections, use a light that is approved for locations with flammable vapors.

7. Put plugs in all openings in tank. Wait 15 minutes, then remove inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.

Chemical Solution Method If the tank cannot be cleaned with steam, use the following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer.

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 goggles or a face shield to prevent injury to the eyes.

2. Fill tank with cleaning solution. Use compressed air to mix solution in tank.

100 SRM 284

Painting Instructions

3. Drain tank. Flush inside of tank with hot (boiling) water. Make sure all cleaning compound is removed.

4. Make an inspection of inside of tank. If tank is not clean, repeat Step 1 through Step 3. Make another inspection of tank. When making inspections, use a light that is approved for locations with flammable vapors.

5. Check tank for flammable vapors using a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.

ADDITIONAL PREPARATIONS FOR REPAIR If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices For Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, A6.0-65. If these gases are not available, another method using water can be used as follows: 1. Fill tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent.

2. Use acceptable welding practices to repair tank.

See the American National Standard "Safety in Welding and Cutting," ANSI Z 49.1 - 1973.

Painting Instructions WARNING Always use solvents and paints in an area with ventilation. Do not use solvents or paints near heat, fire, or electrical equipment that can make sparks. Follow the manufacturer’s instructions and Cautions.

1. Remove all dirt from surface to be painted. Clean area to be painted. Use a solvent for painted surfaces to remove grease and oil before sanding. Do not use solvent on new paint. Make sure all oil and grease is removed.

2. Use sandpaper to remove top surface of paint and rust from metal. All metal surfaces where paint is completely removed must be painted. Use a primer. Apply primer before applying final coat of paint.

3. Protect all surfaces that will not be painted. See the list of items in Figure 13.

CAUTION Do not paint the pads, plastic covers or knobs, cables, labels, and information plates or controls. Paint can make some assemblies not operate correctly.

4. Paint surfaces. Use correct paint from your dealer for Hyster lift trucks. Follow directions on container. The correct arrangement of colors is shown in the note in Figure 13.

WARNING Make sure all labels are installed after painting is complete. Safety labels are installed on the lift truck to give information about possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

5. Check that all safety labels are installed in correct locations on lift truck. New labels are available from your dealer for Hyster lift trucks.

19

Painting Instructions

100 SRM 284

NOTE: USE COLORS APPROVED BY HYSTER. DO NOT PAINT THE FOLLOWING ITEMS: PEDAL PADS, LEVER KNOBS, INSTRUMENTS, STEERING WHEEL, SEAT ASSEMBLY AND SEAT RAILS, INFORMATION CASE AND COVER, TIRES, MAST CHAINS AND HOSES, ALL LABELS AND INFORMATION PLATES, BATTERY CONNECTOR, PARKING BRAKE HANDLE, KEY SWITCH, CYLINDER RODS, ALL PLASTIC COVERS, AND STEERING COLUMN COVER. NOTE: LIGHT AREAS = YELLOW, DARK AREAS = BLACK, AND FORKS = RED. Figure 13. Color Arrangement

20

100 SRM 284

Safety Label Replacement

Safety Label Replacement If the labels or information plates are missing or have damage, they must be replaced. See Figure 14, Figure 15, Figure 16, and Figure 17.

WARNING Labels that have WARNINGS or CAUTIONS must be replaced if they are damaged. If an upright of a different size or an accessory carriage is installed, the capacity rating can change. Changes in the kind of drive tires can change the capacity rating. See a HYSTER Dealer for a replacement nameplate. The nameplate information is a safety item and must be correct for the equipment and configuration of the lift truck.

NOTE: The nameplate is installed using rivets. The old rivets must be removed before installing a new nameplate.

1. Make sure surface is dry and has no oil or grease.

Do not use solvent on new paint. Clean surface of old paint using a cleaning solvent.

2. Remove paper from back of label. Do not touch adhesive surface.

3. Carefully hold label in correct position above surface. The label cannot be moved after it touches the surface. Put label on surface. Make sure all air is removed from under label and corners and edges are tight.

21

Safety Label Replacement

100 SRM 284

NOTE: INSTALL NEW LABEL IN SAME LOCATION AS ORIGINAL. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

MODEL LABEL MAST WARNING LABEL PARKBRAKE WARNING LABEL HYSTER LABEL FORWARD/REVERSE LABEL OPERATOR WARNING LABEL LIFTING EYE LABEL BATTERY DISCONNECT LABEL LIFT/TILT LABEL PINCH POINT LABEL AUXILIARY FUNCTION LABEL

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

XLX LABEL CORROSION LABEL TIPOVER WARNING LABEL BATTERY SPACER LABEL NO RIDERS LABEL SLIP RESISTANT TREAD MAST WARNING LABEL HYSTER LABEL EE/ES LABEL OPERATOR RESTRAINT LABEL

Figure 14. Label Positions E/J2.00-3.00XL (E40-60XL) Models

22

100 SRM 284

Safety Label Replacement

NOTE: INSTALL NEW LABEL IN SAME LOCATION AS ORIGINAL. 1. OPERATOR WARNING LABEL 2. TIPOVER WARNING/OPERATOR RESTRAINT LABEL 3. NO RIDERS LABEL 4. LIFT/TILT LABEL 5. IMPACT RATING (US) PLATE 6. BATTERY SPACER LABEL 7. PARKBRAKE WARNING LABEL 8. MAST WARNING LABEL 9. MAST WARNING LABEL 10. HYSTER LABEL 11. FORWARD/REVERSE LABEL

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

AUXILIARY FUNCTIONS LABEL MODEL LABEL BATTERY DISCONNECT LABEL XL2 LABEL HYSTER LABEL PINCH POINT LABEL CORROSION LABEL FREEZER LABEL EE LABEL ES LABEL LIFTING EYE LABEL

Figure 15. Label Positions E/J1.25-1.75XL (E25-35XL) Models

23

Safety Label Replacement

100 SRM 284

NOTE: INSTALL NEW LABEL IN SAME LOCATION AS ORIGINAL. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

MODEL LABEL MAST WARNING LABEL HYSTER LABEL OPERATORS WARNING LABEL CORROSION/FREEZER LABEL NO RIDERS LABEL BATTERY DISCONNECT LABEL EE/ES LABEL PARKBRAKE WARNING LABEL PINCH POINT LABEL LIFT/TILT LABEL

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

AUXILIARY LABEL FORWARD/REVERSE LABEL TIPOVER WARNING LABEL BATTERY SPACER LABEL OPERATOR RESTRAINT LABEL MAST WARNING LABEL XL2 LABEL XLX LABEL HYSTER LABEL GUARD LABEL SLIP RESISTANT TREAD

Figure 16. Label Positions E3.50-5.50XL (E70-120XL) Models

24

100 SRM 284

Safety Label Replacement

Figure 17. Label Positions, E3.50-5.50XL (E70-120XL 3)

25

Safety Label Replacement

100 SRM 284 Legend for Figure 17

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

26

PARKING BRAKE WARNING LABEL MAST WARNING LABEL CAPACITY PLATE FORWARD/REVERSE LABEL NOTICE TO USER LABEL UL LABEL PINCH POINT LABEL HYSTER LABEL OVERHEAD GUARD LABEL OPERATOR WARNING LABEL OPERATOR RESTRAINT LABEL

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

LIFT/TILT LABEL NO RIDERS LABEL BATTERY RESTRAINT LABEL UL INSPECTION PLATE BATTERY SPACER LABEL OPTION LABEL EE/ES LABEL MODEL LABEL PATENT LABEL BATTERY DISCONNECT LABEL AUXILIARY CONTROLS

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.

2.

3.

4.

5.

6.

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

1

Description and Operation

Figure 2. Brake Booster and Master Cylinder Operation

2

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.

2.

3.

4.

5.

FILLER PLUG GASKET HOUSING PUSH ROD BOOT

6.

7.

8.

9.

10.

INTAKE PORT COMPENSATOR PORT LOCK WIRE PISTON STOP PLATE PISTON ASSEMBLY

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

Figure 3. Master Cylinder

3

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.

1.

2.

3.

4.

5.

6.

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

4

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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