Hyster S70XL-S120XLS (S3.50-S5.50XL) Forklift Repair Service Manual 2005 (P/N 897120)

• 34-page PDF of the ©2006 Hyster factory brake-system service section for H3.50-5.00XL (H70-110XL) [F005/G005], 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]; Hyster P/N 897120; section 1800 SRM 338.
• Covers service-brake shoe assembly removal, disassembly, cleaning, inspection, reassembly, and installation, including wheel cylinders, backplates, support plates, parking-brake linkage, automatic adjusters, hubs, bearings, and brake drums.
• Separates the hydraulic brake-booster/master-cylinder system used on D004 and F005/G005 trucks from the non-booster master-cylinder arrangement used on C098 and D098/E098 models, with model-specific repair procedures for both designs.
• Includes brake-system air removal, brake-pedal and shoe adjustment, parking-brake lever and switch setup, MONOTROL transmission-interlock operation, brake-booster relief-valve checking, and a multi-page problem/cause/action troubleshooting chart.
• Details the optional traction-motor-mounted seat brake on D098/E098 trucks, including removal and installation, solenoid adjustment, traction cutoff switch setup, and release-cable adjustment; C098 seat-brake adjustment is directed to Frame 100 SRM 284.
• Provides 24 numbered factory figures, including Brake Booster and Master Cylinder Operation, Brake Assembly, Support Plate Tightening Sequence, Drive Axle and Brake Assembly, Seat Brake Assembly, and Traction Cutoff Switch Adjustment.

Brake System Component Walkthrough

The opening section explains how the hydraulic service brake works before moving into repair. On S3.50-5.50XL and H3.50-5.00XL trucks, oil flowing from the steering control unit feeds a pedal-actuated brake booster that reduces pedal effort. Its plunger can still actuate the master cylinder when booster pressure is unavailable. The electric C098 and D098/E098 trucks use a different master cylinder without the booster. The service-brake discussion follows fluid pressure to the wheel cylinders and explains primary- and secondary-shoe servo action, reverse-stop automatic adjustment, and the relationship between shoe clearance and adjuster operation.

The brake shoe chapter covers far more than lining replacement. It identifies the drive-axle wheel, hub, drum, bearing, wheel-cylinder, backplate, and support-plate work required to reach the brake assembly, then covers cleaning, inspection, reassembly, and final adjustment. Factory inspection content addresses wheel-cylinder bore condition, return springs, shoe contact areas, adjuster links, brake-drum damage, and drum machining limits. Hub and bearing installation procedures are separated where the H, S, and electric chassis use different arrangements.

Separate master-cylinder repair sections cover the booster-mounted cylinder on D004 and F005/G005 trucks and the frame-mounted cylinder on C098 and D098/E098 models. For the electric-truck cylinder, the manual identifies Hyster master-cylinder repair kit P/N 54977A. Brake-booster repair covers removal, disassembly, seal and O-ring inspection, reassembly with Hyster repair kit P/N 375653, installation, and the factory relief-valve check.

Hydraulic Service and Adjustment Specifications

Air-removal procedures address the different master-cylinder fittings used across the model groups. Brake-pedal coverage includes pedal height and pushrod clearance for H3.50-5.00XL trucks with manual transmission and for the covered electric models. Pedal adjustment for H3.50-5.00XL powershift trucks is referenced to Powershift Transmission, Repairs 1300 SRM 337, while S3.50-5.50XL adjustment is referenced to Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 SRM 397 rather than duplicated here.

Parking-brake coverage explains how the hand lever applies the service-brake shoes. On powershift trucks with a MONOTROL pedal, the lever switch interrupts the MONOTROL and direction-solenoid circuits, places the transmission in neutral, and completes the start circuit. Electric-truck coverage follows the parking-brake switch through the traction cutoff function and includes lever and switch adjustment plus the loaded grade-holding check.

The optional seat-brake chapter applies specifically to E3.50-5.50XL and E4.50XLS D098/E098 trucks. It covers removal from the traction motor, bracket and brake-drum removal and installation, solenoid compression and stroke adjustment, traction cutoff switch positioning, and manual release-cable adjustment. The troubleshooting chart then connects braking complaints with likely causes and repair actions for weak braking, one or both brakes failing to release, excessive noise, unequal braking, and parking-brake hold or release problems.

Specification content includes the staged support-plate tightening sequence, component torque data, hub and bearing adjustment, brake-drum inspection limits, pedal and pushrod settings, booster relief pressure, automatic-adjuster geometry, and seat-brake solenoid, switch, and cable settings. These values stay tied to the affected model and assembly instead of being presented as a generic brake specification list.

The manual flags two easy-to-miss assembly traps. The right- and left-side adjuster assemblies use opposite threads, so swapping them causes shoe clearance to increase each time the brakes are applied; the black and green shoe return springs also have fixed positions. It separately warns that brake fluid damages brake-booster seals and that oil or grease must be kept out of the brake fluid and off the linings.

Brake-lining dust must be controlled, the truck must be securely blocked, wheel and hub assemblies require proper lifting support, and the battery must be isolated before electric-model seat-brake work. Follow the publication's warnings and model-specific references before beginning physical repair.