service repair manual

1. SERVICE REPAIR
E80XL3 E100XL3 E120XL3 E100XL3S [C098]

2. 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,
E70-120XL3) (C098) and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098) series have a dif-
ferent 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.
MASTER CYLINDER
This master cylinder is for the E3.50-5.50XL
(E70-120XL, E70-120XL3) (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 pas-
sages in the piston and past the primary cup as the
piston returns. Fluid flows across the piston to pre-
vent a vacuum while fluid returns through the check
valve. When the piston passes the compensator port,
excess fluid from the system can return to the reser-
voir. 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 sec-
ondary 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 re-
verse, the primary shoe is pushed against the anchor
and the drum by the secondary shoe.
NOTE: BRAKE BOOSTER AND MASTER CYLIN-
DER FOR LIFT TRUCK MODELS S3.50-5.50XL
(S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL)
(F005/G005) SHOWN.
1. BRAKE BOOSTER
2. INLET FROM STEERING CONTROL UNIT
3. OUTLET TO HYDRAULIC TANK
4. MASTER CYLINDER
5. INLET FROM RESERVOIR
6. OUTLET TO WHEEL CYLINDERS
Figure 1. Brake Booster and Master Cylinder
1

3. Description and Operation 1800 SRM 338
Figure 2. Brake Booster and Master Cylinder Operation
2

4. 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, E70-120XL3) (C098) AND
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) SHOWN.
1. FILLER PLUG
2. GASKET
3. HOUSING
4. PUSH ROD
5. BOOT
6. INTAKE PORT
7. COMPENSATOR PORT
8. LOCK WIRE
9. PISTON STOP PLATE
10. PISTON ASSEMBLY
11. PRIMARY CUP
12. RETURN SPRING
13. CHECK VALVE
Figure 3. Master Cylinder
3

5. Description and Operation 1800 SRM 338
1. WHEEL CYLINDER
2. BACK PLATE
3. RETURN SPRING - GREEN
4. ADJUSTER LINKS
5. ADJUSTER SPRING LEVER
6. 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
the shoes apart when the hand lever pulls the ca-
bles. 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 NEU-
TRAL and makes the Start circuit complete.
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)
4

6. 1800 SRM 338 Description and Operation
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,
E70-120XL3) (C098) and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098)
SEAT BRAKE
Lift truck models E3.50-5.50XL (E70-120XL, E70-
120XL3 (C098) and E3.50-5.50XL, E4.50XLS (E70-
120Z, 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 au-
tomatically when the operator leaves seat. See Fig-
ure 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.
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 Assem-
bly in this manual. For adjustment procedures for
seat brake used on E3.50-5.50XL (E70-120XL, E70-
120XL3 (C098) lift trucks, see the section Frame 100
SRM 284.
NOTE: TRACTION MOTOR AND SEAT BRAKE FOR
LIFT TRUCK MODELS E3.50-5.50XL, E4.50XLS (E70-
120Z, E100ZS) (D098/E098) SHOWN.
1. GUIDE PIPE CONNECTION
2. ELECTRICAL CONNECTION
3. SEAT BRAKE
Figure 7. Traction Motor and Seat Brake
Assembly
5

7. 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 cloth-
ing 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, be-
fore 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 re-
moved as an assembly. See Figure 4 and Fig-
ure 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.
4. Remove lock nut, lock plate, and bearing adjust-
ment nut from axle housing. Remove outer bear-
ing 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 cre-
ate dust in the air. See the Clean and Inspect
procedures in this section.
5. To loosen brake shoes, turn adjuster screw. Dis-
connect 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 iden-
tification 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.
6

8. 1800 SRM 338 Brake Shoe Assemblies Repair
1. BACKPLATE
2. SUPPORT FLANGE
3. CAPSCREW AND LOCKWASHER
4. CAPSCREW AND LOCKWASHER
5. WHEEL CYLINDER ASSEMBLY
6. SPRING AND RETAINER ASSEMBLY
7. PISTON CUP
8. PISTON
9. PUSH ROD
10. FITTING
11. BOOT
12. ANCHOR PIN
13. SHOE AND LINING ASSEMBLY
14. SHOE GUIDE SPRING PIN
15. SHOE GUIDE SPRING CLIP
16. RETURN SPRING - BLACK
17. RETURN SPRING - GREEN
18. ADJUSTER SCREW SPRING
19. ADJUSTER SCREW WHEEL
20. ADJUSTER SCREW NUT
21. ADJUSTER SCREW GUIDE
22. AUTOMATIC ADJUSTER SPRING LEVER
23. ACTUATOR LINK
24. ANCHOR END LINK
25. LINK PIVOT
26. SHOE ADJUSTER SLOT PLUG
27. PARKING BRAKE LEVER
28. SPRING CLIP
29. PARKING BRAKE CONNECTING LINK
30. SPECIAL FITTING
Figure 8. Brake Assembly (Right Side Shown)
7

9. Brake Shoe Assemblies Repair 1800 SRM 338
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 in-
structions 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 con-
tainer while they are still wet. Put a DAN-
GEROUS 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 recom-
mendations 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.
c. Inspect brake shoes for cracks or damage. If
linings or shoes are worn or damaged, re-
place 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 re-
quire turning, do not remove more than 1.5 mm
(0.060 in.) from the diameter. The maximum in-
side 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.
(1) For the seat brake used on E3.50-
5.50XL, 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 re-
placed if any shoe is damaged. The brake per-
formance 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 park-
ing cable through backplate and fasten clamp.
See Figure 4 and Figure 8.
2. Install backplate and support plate. Install ta-
pered dowels, capscrews, and nuts. Use the se-
quence 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, ver-
ify that nuts are between 95 to 122 N•m (70 to
90 lbf ft).
8

10. 1800 SRM 338 Brake Shoe Assemblies Repair
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 molybde-
num grease. Put shoes on backplate and install
holddown pins and clips. Engage connecting link
with parking brake lever. See Figure 10.
1. PARKING BRAKE CONNECTING LINK
2. PARKING BRAKE LEVER
Figure 10. Parking Brake Linkage (Right Side
Shown)
CAUTION
The shoe return springs are not the same. Al-
ways install the black spring on the left-hand
brake shoe.
6. Correctly install shoe return springs. Connect
cable for parking brake to lever.
WARNING
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 ad-
juster wheel for the left brake has right-hand
threads.
7. Lubricate adjuster screw with Never-Seeze®.
Turn adjuster screw in so brake shoes retract.
Install adjuster between shoes. Align adjuster
screw wheel with slot in backplate. Install ad-
juster 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.
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 cor-
rect operation of automatic adjustment mecha-
nism.
9

11. 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, bear-
ing cups, and outer seal in hub. Install in-
ner 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 lock-
washer 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. ACTUATOR LINK
2. AUTOMATIC ADJUSTMENT LEVER
3. ADJUSTER SCREW GUIDE
4. ADJUSTER SCREW WHEEL
5. ADJUSTER SCREW WHEEL CENTERLINE
6. BACKPLATE
7. TOOL
Figure 11. Brake Adjustment (Right Side
Shown)
10

12. 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, E70-120XL3) (C098), AND E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098) MODELS
1. AXLE SHAFT
2. HUB
3. BRAKE DRUM
4. LOCK NUT
5. LOCK PLATE
6. ADJUSTMENT NUT
7. AXLE SPINDLE
8. BEARING ASSEMBLY
9. OIL SEAL
10. O-RING
11. WHEEL
12. BRACKET
Figure 12. Drive Axle and Brake Assembly
11

13. Brake Shoe Assemblies Repair 1800 SRM 338
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 Fig-
ure 12) S3.50-5.00XL (S70-110XL) (D004),
E3.50-5.50XL (E70-120XL, E70-120XL3)
(C098), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098):
a. Use new oil seals. Install inner seal, bear-
ing cups, and outer seal in hub. Install in-
ner 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
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 lock-
washer to hold nut. Install lock nut. Tighten
lock nut to 135 N•m (100 lbf ft).
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
(E70-120XL3) (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.
12

14. 1800 SRM 338 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.
1. BRAKE BOOSTER
2. INLET FROM STEERING CONTROL UNIT
3. OUTLET TO HYDRAULIC TANK
4. MASTER CYLINDER
5. INLET FROM RESERVOIR
6. 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)
Disassemble
WARNING
The piston has a compressed spring behind it.
Remove the piston carefully.
1. Remove retaining ring from end of master cylin-
der. 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 in-
stalled as shown in Figure 14. Carefully install
spring and piston assembly in master cylinder.
Do not damage seals.
2. Install retaining ring for piston.
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 Sys-
tem Air Removal in this section.
13

15. Master Cylinder Repair 1800 SRM 338
1. HOUSING
2. RETAINING RING
3. SEAL
4. PISTON
5. SPRING
6. CUP WASHER
7. SEAL SUPPORT WASHER
8. CHECK VALVE
9. SPRING
10. FITTING
Figure 14. Master Cylinder
MASTER CYLINDER FOR LIFT TRUCK
MODELS E3.50-5.50XL (E70-120XL,
E70-120XL3) (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.
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.
14

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17. 1800 SRM 338 Master Cylinder Repair
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. Care-
fully remove piston from cylinder.
7. Remove spring and check valve.
Clean and Inspect
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.
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 com-
pressed air to dry parts. Keep oil and grease off
parts and out of brake fluid.
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, E70-120XL3) (C098) AND
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) SHOWN.
1. ROD END
2. JAM NUT
3. PUSH ROD
4. BOOT
5. LOCK WIRE
6. PISTON STOP PLATE
7. PISTON ASSEMBLY
8. PRIMARY CUP
9. RETURN SPRING
10. CHECK VALVE
11. BODY
12. GASKET
13. FILLER PLUG
Figure 15. Master Cylinder
15

18. Brake Booster Repair 1800 SRM 338
Assemble and Install
1. Lubricate all parts with clean brake fluid.
2. Use a repair kit (Hyster Part No. 54977A). In-
stall parts in the order shown in Figure 15. Use
a screwdriver to hold piston in housing. See Fig-
ure 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
1. Disconnect brake pedal from brake booster at
push rod. See Figure 13.
2. Disconnect hydraulic lines at brake booster. Put
caps on open lines.
3. Disconnect brake lines and wires at master cylin-
der. 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.
WARNING
The retainer has a compressed spring behind
it. Carefully remove the retainer so you can
control the spring and prevent an injury.
4. Remove retainer from housing.
5. Remove piston, spring, and piston rod from hous-
ing.
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 recom-
mendations of the manufacturer.
16

19. 1800 SRM 338 Brake Booster Repair
Clean parts of brake booster with solvent. Check sur-
face of machined parts for wear and damage.
ASSEMBLE
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.
1. Assemble parts for relief valve. Make sure all
parts are in their original positions. See Fig-
ure 17.
2. Install seals for piston rod, plunger, and piston.
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. PUSH ROD
2. DUST COVER
3. RETAINING RING
4. WASHER
5. RETAINER
6. PLUNGER
7. SEAL
8. PISTON
9. PISTON ROD
10. SLEEVE
11. O-RING
12. SCREW
13. RELIEF PISTON
14. SPRING
15. GUIDE
16. SHIM
17. PLUG
18. SNAP RING
19. SPRING
20. HOUSING
Figure 17. Brake Booster
17

20. Brake Pedal Adjustment 1800 SRM 338
INSTALL
NOTE: See Figure 18 for lift trucks H3.50-5.00XL
(H70-110XL) (F005/G005) with manual trans-
mission. See the section Single-Speed Pow-
ershift 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. Con-
nect brake lines and wires to master cylinder.
Connect hose from reservoir to master cylinder.
3. Connect push rod to crank and brake pedal. In-
stall pin for push rod.
4. Remove air from brake system and adjust brake
linkage as described in Brake System Air Re-
moval and Brake Shoes Adjustment in this sec-
tion.
Brake System Air Removal
NOTE: The E3.50-5.50XL (E70-120XL, E70-120XL3)
(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. Al-
ways 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, E70-120XL3)
(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, E70-120XL3)
(C098) and E3.50-5.50XL, E4.50XLS (E70-
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, E70-120XL3)
(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.
18

21. 1800 SRM 338 Brake Pedal Adjustment
Figure 18. Brake Pedal Adjustment
H3.50-5.00XL (H70-110XL) (F005/G005)
Legend for Figure 18
1. BRAKE PEDAL
2. PEDAL PAD
3. FLOOR PLATE
4. STOP SCREW
5. PUSH ROD
6. PLUNGER
7. BRAKE BOOSTER
8. JAM NUT
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, E70-120XL3) (C098) and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098)
19