Hyster S70XL-S120XLS (S3.50-S5.50XL) Forklift Repair Service Manual 2005
Hyster Models Covered & Key Technical Specifications
Models: H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), E3.50-5.50XL (E70-120XL, E70-120XL3), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
Sub-models / Variants: H70-110XL, S70-120XL, E70-120XL, E70-120XL3, E70-120Z, E100ZS
Model Years: 2006
Serial Numbers: F005, G005, D004, C098, D098, E098
Technical Data:
- Master cylinder piston release: 2300 kPa (332 psi) relief valve limit
- Seat brake holding capacity: 15% grade with capacity load
- Wheel nut torque check: 350 hours (varies by model)
- Backplate tightening torque: 54 to 81 Nm (40 to 60 lbf ft) initial, 108 to 122 Nm (80 to 90 lbf ft) final
Hyster Manual Features & Content Preview
- Official 2006 Hyster OEM factory reference covering hydraulic, parking, and seat brake systems for H3.50-5.00XL, S3.50-5.50XL, and E3.50-5.50XL lift trucks
- Publication P/N 897120, 1800 SRM 338
- Contains 8 exploded-view diagrams and 3 specific torque-sequence charts for brake assembly
Brake System Component Walkthrough
This publication documents the removal, installation, and operation of Hyster hydraulic brake components. Detailed sections review the brake booster and master cylinder, mapping out the relationship between the steering control unit, hydraulic pressure relief, and wheel cylinder actuation. It clearly separates models with booster-actuated systems from those using standard master cylinder configurations. This gives technicians the exact context needed to understand primary and secondary shoe functions within the service brake assembly.
Additional chapters cover parking and seat brake maintenance. The manual breaks down the interaction between the MONOTROL pedal, transmission interlock switches, and the parking brake hand lever. You will also find seat brake adjustment routines for various traction motor configurations, including essential solenoid stroke requirements and cutoff switch clearances. Because working on industrial lift truck brakes involves high-pressure hydraulic lines and heavy assemblies, personnel must adhere to strict shop safety protocols and verify all procedures before performing physical service.
Hydraulic Service and Adjustment Specifications
The documentation provides the hard technical data necessary for proper system reassembly. For example, it outlines support plate tightening sequences in specific stages, up to final torque verifications of 95 to 122 Nm (70 to 90 lbf ft). Mechanics can verify factory-set relief valve pressures in the brake valve, which are rated at 2300 kPa (332 psi). Brake pedal movement is also defined with precise tolerances. For the E3.50-5.50XL models, the guide specifies a 1 to 4 mm pedal travel before piston contact. Having this exact factory data on hand helps eliminate guesswork and ensures reliable component installation on the shop floor.
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