Hyster C024 (S155XL2) Forklift Service Repair Manual 2

SERVICE REPAIR S135XL S155XL S155XL2 [C024]

100 SRM 449

Description

General This section has the description and repair procedures for the frame and connected parts. Included in this section are the frame, counterweight, hood, hydraulic and fuel tanks, radiator, and exhaust system. Also included are the instructions for removal and installation of the engine.

Description The frame is a one-piece weldment and has mounts for the counterweight, upright, overhead guard, engine and transmission, axles, and other parts. See Figure 1.

1. HOOD 2. FLOOR PLATE 3. OVERHEAD GUARD

4. COUNTERWEIGHT 5. FRAME Figure 1. Frame and Connected Parts

1

Counterweight Repair

100 SRM 449

Counterweight Repair REMOVE WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies causes large changes in the center of gravity: upright, drive axle, engine and transmission, and the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: a. Before removing the upright and drive axle, put blocks under the counterweight so that the lift truck cannot fall backward. b. Before removing the counterweight, put blocks under the upright assembly so that the lift truck cannot fall forward.

If the engine will not run, close the fuel valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit. Permit the pressure in the fuel system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

2. Use the following procedure to remove the LPG tank: a. Removable LPG tanks can be removed and replaced indoors only if the lift truck is at least 8 m (25 ft) from any open flame or ignition source.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one piece units.

Do not operate the lift truck if the capscrews for the counterweight are not installed. When the capscrew is removed, the counterweight can fall from the lift truck.

WARNING Make sure any lifting devices have the correct capacity for the parts being moved. See Figure 2.

1. If the lift truck has an LPG fuel system, remove the LPG tank and bracket so that the counterweight can be removed. See Figure 2.

WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (25 ft) from any open flame, motor vehicles, electrical equipment, or ignition source.

Close the fuel valve on the LPG tank before any part of the engine fuel system is disconnected.

Run the engine until the fuel in the system is used and the engine stops.

2

Weight of Counterweights S6.00XL (S135XL) 2873 to 2953 kg (6335 to 6511 lb) 1. LIFT TRUCK FRAME 2. COUNTERWEIGHT 3. GRILL 4. CAPSCREW

S7.00XL (S155XL) 3330 to 3420 kg (7343 to 7541 lb) 5. ACCESS DOOR 6. TRANSITION PLATE 7. HOOD

Figure 2. Counterweight

100 SRM 449

Hood Repair

b. Move the lift truck to the area where tanks are changed. c. Turn the tank fuel valve clockwise until the valve is completely closed. d. Run the engine until it stops, then turn the key switch to the OFF position. e. Disconnect the quick disconnect fitting.

lifting eye. Remove the two vertical capscrews and the capscrew behind the tow pin that hold the counterweight to the frame.

5. Lift the counterweight from the frame. Put the counterweight in a position so that it has stability and will not fall.

INSTALL

Release the LPG tank latch and remove the tank from the bracket.

1. Connect a lifting device to the lifting eye on the counterweight. Lift the counterweight into position on the frame. See Figure 2.

3. Open the access door between the counterweight and the hood. Remove the LPG tank and tank bracket if the unit has the LPG fuel system.

2. Install the capscrews for the counterweight.

Tighten the capscrews to 655 N•m (485 lbf ft).

f.

4. Install a lifting eye in the hole in the top of the counterweight. Connect a lifting device to the

3. Close the access door. Install the LPG tank on LPG units.

Hood Repair REMOVE 1. Remove the capscrews that fasten the transition plate. Do NOT remove the plate. See Figure 2.

2. Open the access door, reach under the transition plate, and remove the radiator overflow hose from the two J clamps.

3. Raise the hood and disconnect the gas assist cylinder at the hood. Remove the hood, transition plate, and access door.

INSTALL 1. Install the hood, transition plate, and access door in position on the lift truck. Install the capscrews for the transition plate. Connect the gas assist cylinder to the hood. Align the hood for the latch on the front cover. Tighten the capscrews for the transition plate.

2. Install the overflow hose in the J clamps. Close the access door.

WARNING The hood, hood latch, and latch striker must be correctly adjusted for the correct operation of the operator restraint system.

3. Use the following procedure to adjust the hood latch (see Figure 3): a. Install the floor plates and tighten the capscrews. b. Install the latch striker in the highest slot position on the rear floor plate. Check that the latch striker is in the center of the jaws of the hood latch. c. Close the hood to the fully-closed position.

The hood latch has two positions. The hood is fully closed after two clicks of the latch. d. Loosen the capscrews for the latch striker just enough to let the striker move. Push the hood down until the hood just touches the rubber bumpers on the frame. Make sure the latch striker is still in the center of the hood latch. Tighten the capscrews for the latch striker. e. Check the operation of the hood latch. Have an operator sit in the seat. Make sure the hood is fully closed (two clicks). Also check that the hood touches the rubber bumpers.

If necessary, repeat Step d.

3

Hood Repair

100 SRM 449

A. GAS/DIESEL ARRANGEMENT

B. LPG ARRANGEMENT

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

LATCH STRIKER HOOD LATCH LATCH LEVER SEAT SEAT BELT LATCH HIP RESTRAINT

SEAT RAIL FLOOR PLATE HOOD GAS CYLINDER HINGE

Figure 3. Hood and Seat Latches Check

4

100 SRM 449

Operator Restraint System Repair

Overhead Guard Repair REMOVE

capscrews that hold the overhead guard to the cowl.

Lift the overhead guard from the lift truck.

WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.

Changes that are made by welding or by drilling holes that are too big in the wrong location, can reduce the strength of the overhead guard. See the instructions for Changes to the Overhead Guard in the Periodic Maintenance section included with this lift truck.

Connect a lifting device to the top of the overhead guard. If installed, remove the overhead exhaust and LPG fuel line clamps. If installed, disconnect the light wiring harness. Remove the capscrews that hold the overhead guard to the frame. Remove the

INSTALL 1. Connect a lifting device to the top of the overhead guard. Put the overhead guard in position on the lift truck.

2. Install the capscrews at the rear of the overhead guard. Install the capscrews that hold the overhead guard to the cowl. Tighten the rear and top front capscrews to 90 N•m (67 lbf ft). Tighten the front capscrews under the cowl to 165 N•m (122 lbf ft).

3. If removed, install the overhead exhaust and LPG fuel line. Connect the light wiring harness.

Operator Restraint System Repair The seat belt, hip restraint brackets, seat and mounting, hood, latches, and floor plates are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition.

A seat belt that is damaged worn or does not operate properly will not give protection when it is needed.

The end of the belt must fasten correctly in the latch.

The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 4.

AUTOMATIC LOCKING RETRACTOR (ALR)

The following seat belt operation checks must be performed: • With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. if the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly.

• With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly.

If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly.

• With the hood in the open position, make sure the seat belt will not pull from the retractor assembly.

If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly.

NOTE: Lift trucks produced before November 2005 are equipped with the ALR type seat belts.

The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced. See Figure 4.

EMERGENCY LOCKING RETRACTOR (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt.

When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat.

Make sure the seat rails and latch striker are not loose. See Figure 3. The seat rails must lock tightly in position, but move freely when unlocked. The seat rails must be correctly fastened to the mount surface.

If the mount surface is the hood, the hood must be

5

Fuel and Hydraulic Tanks Repair

100 SRM 449

fastened to the floor plate with the latch. The floor plate must be fastened to the lift truck frame. Try to lift the hood to make sure it is fastened correctly and will not move.

Adjust the hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or replaced. See the Hood Repair section for more details.

1. FORWARD/BACKWARD ADJUSTMENT 2. SWIVEL ADJUSTMENT 3. OPERATOR WEIGHT ADJUSTMENT

4. SEAT POSITION ADJUSTMENT (SEAT RAIL) 5. SET BELT

Figure 4. Operator Restraint System (Swivel Seat Shown)

Fuel and Hydraulic Tanks Repair INSPECT

WARNING

Make a visual inspection of all sides of the tank. Inspect the 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.

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

SMALL LEAKS, REPAIR

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

Use the following procedure to repair small leaks: 1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.

6

2. Apply LoctiteÂŽ 290 to the leak. Follow the instructions of the manufacturer.

LARGE LEAKS, REPAIR

2. Use acceptable welding practices to repair the tank. See the American National Standard Safety In Welding and Cutting AWS Z 49.1 1999.

100 SRM 449

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 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, American Welding Society, F4.1 - 1999. • Safety In Welding and Cutting, American National Standard, AWS Z 49.1 - 1999.

When cleaning the 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 the nozzle and the tank.

Connect a ground wire to the tank to prevent static electricity.

Steam Method of Cleaning Use the following procedure to clean the tank with steam: 1. Remove all the parts from the tank. Install the drain plug.

2. Fill the 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 the solution in the tank using air pressure.

Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank.

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

5. Flush the inside of the tank with boiling water.

Make sure all the loose material is removed from the inside of the tank.

Fuel and Hydraulic Tanks Repair 6. Make an inspection of the inside of the 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 the openings in the tank. Wait 15 minutes, then remove the 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 of Cleaning 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.

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

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

4. Make an inspection of the inside of the tank.

If the tank is not clean, repeat Step 1 through Step 3. Make another inspection of the tank.

When making inspections, use a light that is approved for locations with flammable vapors.

5. Check the tank for flammable vapors using special indicator for gas vapors. If the amount of flammable vapors is not below 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, F4.1 - 1999. If these gases are not available, another method using water can be used as follows: 1. Fill the 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.

7

Exhaust System Repair

100 SRM 449

2. Use acceptable welding practices to repair the tank. See the American National Standard

Safety In Welding and Cutting AWS Z 49.1 1999.

Radiator Repair REMOVE

INSTALL

NOTE: To make radiator removal easier, remove the counterweight as described in Counterweight Repair, Remove.

NOTE: The installation of the radiator is easier if the counterweight is removed. See Counterweight Repair, Remove in this section.

1. Open the access door between the hood and the counterweight. Remove the cover plate over the radiator. If installed, remove the LPG tank and bracket.

1. Tip the radiator forward over the engine as you install the radiator in the lift truck. Move the exhaust pipe for clearance to the radiator flange.

2. Drain the coolant from the radiator. Remove the radiator hoses. Disconnect the oil lines at the radiator. Put caps on the open lines.

3. Remove the remote fill assembly and radiator hoses to the engine. Disconnect the hose to the auxiliary coolant reservoir.

4. Remove the hood and transition plate as described in Hood Repair, Remove. Remove the fan shroud and fan. Loosen the exhaust band clamp on the gasoline and LPG units. Remove the engine water outlet on diesel units.

2. Install the capscrews that fasten the radiator. Install the muffler and inlet exhaust pipe at the muffler.

3. Install the engine water outlet on diesel units.

Tighten the exhaust band clamp on gasoline or LPG units. Install the fan and fan shroud. Install the hood and transition plate as described in the Hood Repair, Install section.

4. Connect the hose to the auxiliary coolant reservoir. Install the remote fill assembly and radiator hoses to the engine. Make sure the hose clamp screws have an access at the wheel wells.

5. Remove the muffler and inlet exhaust pipe to the muffler. Remove the capscrews that fasten the radiator. Move the exhaust pipe for clearance of the radiator flange.

5. Connect the oil lines at the radiator. Install the cover plate over the radiator and fill the radiator with the coolant specified in the table in the Periodic Maintenance 8000 SRM 393.

6. Tip the radiator forward over the engine as you lift and remove the radiator.

6. If removed, install the counterweight as described in the Counterweight Repair, Install section. If the LPG tank and bracket were removed, install them.

Exhaust System Repair MUFFLER

3. Remove the clamp from the muffler outlet and remove the muffler.

Remove 1. Remove the grill by removing the retaining plate at the top of the grill. See Figure 5, Figure 6, and Figure 7.

2. Disconnect the exhaust pipes and remove the clamps.

8

Install 1. On overhead exhaust units, install the counterweight exhaust pipe on the muffler, but do NOT tighten. See Figure 5, Figure 6, and Figure 7.

100 SRM 449

Exhaust System Repair

Figure 5. Exhaust System

9

Exhaust System Repair

100 SRM 449 Legend for Figure 5

1.

2.

3.

4.

5.

COUNTERWEIGHT GM-V6 ENGINE PERKINS ENGINE MUFFLER CLAMP

6.

7.

8.

9.

EXHAUST PIPE CROSSOVER PIPE TAIL PIPE BAND CLAMP

A. GAS/LPG COUNTERWEIGHT EXHAUST EPA COMPLIANT B. GAS/LPG COUNTERWEIGHT EXHAUST NON-EPA COMPLIANT 1.

2.

3.

4.

5.

6.

UPPER EXHAUST PIPE TAIL PIPE COUNTERWEIGHT MUFFLER GASKET LOWER EXHAUST PIPE

7.

8.

9.

10.

11.

RAW GAS CHECK PORT OXYGEN SENSOR PORT CROSSOVER PIPE FLEX PIPE CLAMP

Figure 6. Exhaust System EPA Compliant Engine

10

100 SRM 449

Exhaust System Repair

A. DIESEL COUNTERWEIGHT EXHAUST EPA COMPLIANT B. GAS/LPG/DIESEL OVERHEAD EXHAUST 1.

2.

3.

4.

5.

UPPER EXHAUST PIPE TAIL PIPE COUNTERWEIGHT MUFFLER CLAMP

6.

7.

8.

9.

10.

FLEX PIPE LOWER EXHAUST PIPE OVERHEAD TAIL PIPE OUTER SHIELD INNER SHIELD

Figure 7. Exhaust System, Diesel EPA Compliant

11

Engine Repair

100 SRM 449

2. Install the muffler and, on units with the overhead exhaust, rotate the muffler so the outlet is at the top. Install the other exhaust pipes and tighten the clamps. Rotate the counterweight

exhaust pipe so that it points straight back and down at a 45 angle.

3. Install the grill and align the end of the counterweight exhaust pipe so that it is between the grill bars.

Engine Repair REMOVE

d. Remove the pedal bracket.

NOTE: The lift truck can have a powershift or a manual transmission. The powershift transmission and the torque converter are attached to the engine. The engine and powershift transmission are normally removed as a unit. The manual transmission is attached to the drive axle housing. This engine is removed without removing the manual transmission.

e. On units without the MONOTROLÂŽ pedal, disconnect the direction control linkage at the transmission.

1. Put the lift truck on blocks. See the Operating Manual or the Periodic Maintenance 8000 SRM 393 for the correct procedures to put the lift truck on blocks. Remove the overhead guard, hood, transition plate, and access door. See the Hood Repair, Remove section for more details.

Remove the floor plates.

2. Disconnect the cables at the battery. Remove the battery, air cleaner inlet duct, and battery tray.

Disconnect the brake fluid reservoir and engine crankcase breather lines.

3. Remove the fan and fan shroud. Disconnect the exhaust pipe at the exhaust headers.

4. Disconnect the fuel lines at the engine. Disconnect the throttle linkage at the engine. Disconnect the wires and wiring harnesses at the engine and powershift transmission.

5. Disconnect the oil lines at the hydraulic pumps.

Drain the hydraulic tank and put plugs in the open ports. Disconnect the oil cooler lines from the powershift transmission.

6. Powershift transmission. procedure:

Do the following

a. Disconnect the linkage between the transmission and the pedals at the transmission. b. Disconnect the hydraulic lines to the brake booster. c. Disconnect the brake line at the booster. Disconnect the electrical wiring.

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f.

Disconnect the drive line at the universal joint.

7. Manual transmission. Do the following procedure: a. Disconnect the drive line at the universal joint near the clutch. b. Disconnect the hydraulic and brake lines.

Disconnect the push rod to the brake booster.

Disconnect the electrical wiring.

WARNING Do NOT leave the clutch pedal free in the up position with the over-center spring installed.

The spring is under tension and can cause an injury. Fasten the clutch pedal so that it cannot move down, remove the spring or carefully move the pedal to the down position to remove the tension. c. Remove the brake booster. Disconnect the clutch push rod from the clutch cover.

8. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 450 kg (1000 lb). Remove the four motor mount bolts.

Raise the engine from the frame. Be careful of the hydraulic pump. Make sure that all wires and hoses are disconnected. Put the engine in a position so that it has stability and will not fall.

9. Remove the powershift transmission from the engine as described in the Two-Speed Powershift Transmission, Troubleshooting and Repairs 1300 SRM 325. On units with the manual transmission, remove the oil clutch housing and clutch cover from the engine.

100 SRM 449

Engine Repair

INSTALL

hold the engine mounts to the mount plate to 65 N•m (48 lbf ft).

1. Install the engine mounts on the engine as follows (see Figure 8):

b. PERKINS: Apply a sealant to the threads of the capscrews and tighten the capscrews that hold the engine mounts to the fan end of the engine to 65 N•m (48 lbf ft).

a. GM V-6: Tighten the capscrews that hold the engine mount to the fan end of the engine to 30 N•m (22 lbf ft). Tighten the bolts that

A. B. C. D.

FRONT MOUNTS PERKINS, POWERSHIFT GM-V6, POWERSHIFT ONLY PERKINS, GM-V6 MANUAL ONLY

E. REAR MOUNTS F. PERKINS G. GM-V6

1. ENGINE OR TRANSMISSION MOUNT 2. ENGINE, TRANSMISSION, OR CLUTCH HOUSING 3. MOUNT PLATE

4.

5.

6.

7.

BOLT WASHER RUBBER MOUNT FRAME MOUNT WELDMENT

Figure 8. Engine Mounts

13

Engine Repair

100 SRM 449 e. Connect the linkage between the transmission and the pedals at the transmission.

CAUTION Apply a sealant (Hyster Part Number 264159) to the flange of the flywheel housing. Make sure the torque converter or clutch is installed correctly and engaged with the oil pump. If the parts are not engaged, the oil pump or torque converter will be damaged.

2. If removed, install the torque converter and powershift transmission on the engine as described in the Two-Speed Powershift Transmission, Troubleshooting and Repairs 1300 SRM 325.

If removed, install the oil clutch housing and cover on the engine.

3. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 450 kg (1000 lb). Install the engine in the unit. Be careful of the hydraulic pump. Make sure that all wires and hoses are not damaged. Install the four motor mount bolts. Connect all hoses and wiring. Make sure the clamp screws for the radiator hoses are aligned for access from the wheel wells.

4. Install the bolts for the engine mounts. See Figure 5. Tighten the bolts to 120 N•m (89 lbf ft).

5. Powershift transmission: procedure:

do the following

a. Connect the drive line at the universal joint. b. On units without the MONOTROL pedal, connect the direction control linkage at the transmission. c. Install the pedal bracket. Connect the brake line at the booster. d. Connect the hydraulic lines to the brake booster.

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f.

Connect the oil cooler lines for the transmission.

6. Manual transmission: do the following procedure: a. Install the brake booster. Connect the clutch push rod to the clutch cover. b. Connect the hydraulic and brake lines. Connect the push rod to the brake booster. c. Connect the drive line at the universal joint near the clutch.

7. Connect the oil lines at the hydraulic pumps. Fill the hydraulic tank with the oil specified in the Periodic Maintenance 8000 SRM 393.

8. Connect the fuel lines at the engine. Connect the throttle linkage at the engine.

9. Connect the exhaust pipe at the exhaust header.

Install the fan and fan shroud.

10. Connect the engine crankcase breather and the brake fluid reservoir lines. Install the battery tray, air cleaner inlet duct, and battery. Connect the cables at the battery.

11. Install the floor plates. Install the overhead guard and the hood, transition plate, and access door. See Hood Repair, Install in this section.

Remove the blocks that support the lift truck using the reverse of the installation procedure in the section Periodic Maintenance 8000 SRM 393 or in the Operating Manual.

12. Check all of the fluid levels and fill as necessary.

Remove the air from the brake system.

100 SRM 449

Throttle Pedal Adjustment

Throttle Pedal Adjustment PERKINS 1104C-44(RE) DIESEL ENGINE NOTE: The procedures below are for lift trucks equipped with the Perkins 1104C-44(RE) Diesel Engine. If your lift truck has either a gas or LPG engine, see the section LPG Fuel System 900 SRM 348 for the procedures to adjust the throttle linkage.

1. Adjust the cable adjustment nuts to allow for a 3.0 mm (0.12 in.) maximum of free play on the throttle cable length. See Figure 9. Secure cable length by tightening cable lock nuts.

2. Set pedal stop to 35 ±2 mm (1.40 ±0.08 in.). Secure in place with pedal stop jam nuts.

NOTE: THE MONOTROL PEDAL IS SHOWN. THE ADJUSTMENT PROCEDURES FOR THE ACCELERATOR PEDAL ARE THE SAME. 1.

2.

3.

4.

MONOTROL PEDAL DIESEL INJECTOR PUMP CABLE ADJUSTMENT NUTS CABLE LOCK NUTS

5.

6.

7.

8.

PEDAL STOP JAM NUTS PEDAL STOP UP POSITION PEDAL STOP CAPSCREW

Figure 9. MONOTROL and Accelerator Pedal Adjustment

15

Safety Labels

100 SRM 449

3. With the pedal against the stop, adjust the throttle cable to ensure that the diesel injector pump is at full power (the injection pump lever is touching the lever stop in Figure 10).

4. Release the throttle pedal and adjust the up position pedal stop until the tension is removed from the cable when the injection pump lever is returned to the idle position. Tighten up position pedal stop with capscrew. See Figure 9.

NOTE: DIESEL INJECTOR PUMP IS SHOWN IN THE IDLE POSITION. 1. INJECTION PUMP LEVER 2. LEVER STOP Figure 10. Diesel Injector Pump

Safety Labels WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped and the nameplate must show the new capacity rating. Contact your dealer for Hyster lift trucks for a replacement nameplate.

If a label must be replaced, use the following procedure to install a new label (see Figure 11):

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using

16

cleaning solvents, always follow the recommendations of the manufacturer.

1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint with a cleaning solvent.

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

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

100 SRM 449

Safety Labels

A. GASOLINE/LPG

B. DIESEL

1.

2.

3.

4.

5.

6.

11. CASE, OPERATING MANUAL 12. REPLACE OPERATING MANUAL LABEL (NOT REQUIRED FOR ENGLISH SPEAKING COUNTRIES) 13. FLAMMABLE LP GAS 14. LABEL, LP TANK IDENTIFIER (U.S. AND CANADA ONLY) 15. PARKING BRAKE WARNING 16. NO RIDERS 17. OPERATOR WARNING 18. ANTIFREEZE 19. MAST WARNING

7.

8.

9.

10.

FAN WARNING (ON SHROUD) INSPECTION PLATE, UL HOIST/TILT AUXILIARY FUNCTIONS IMPACT RATING PLATE NAMEPLATE (INFORMATION MUST BE COMPLETE) OPERATOR RESTRAINT (FOR EQUIPPED UNITS) OR TIPOVER WARNING (FOR OTHER UNITS) PATENT LABEL (INSIDE COWL, RIGHT) SAFETY TREAD (LEFT AND RIGHT) MODEL LABEL (2)

Figure 11. Label Positions

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1600 SRM 451

Description

General This section has the description and repair procedures for the steering axle. For information on the steering control unit, see the section Steering Control Unit 1600 SRM 54 .

Description The steering axle assembly includes an axle frame, steering cylinder, tie rods, and two spindle and hub assemblies. See Figure 1. The steering axle is articulated and is connected to the frame with center pivot mounts. The large rubber pivot mounts permit the

steering axle to move in the lift truck frame when the lift truck travels over rough surfaces. The S7.00XL (S155XL, S155XLS, S155XL 2) (B024, C024), also has a large rubber block at the top center of the steering axle to cushion vertical shocks.

A. LATER MODELS 1.

2.

3.

4.

5.

6.

7.

8.

AXLE FRAME STEERING CYLINDER SPINDLE BEARING ASSEMBLY (CUP AND CONE) WEAR SLEEVE SEAL SHIMS TIE ROD

9.

10.

11.

12.

13.

14.

15.

PIN SNAP RING BEARING CAP RUBBER MOUNT DUST COVER GREASE CAP PIN

Figure 1. Steering Axle

1

Steering Axle Assembly Repair The end caps of the steering cylinder are also the mounts for the cylinder and are held to the axle by capscrews. The ends of the piston rod extend from both ends of the cylinder. A single piston and the seal are at the center of the piston rod. Oil pressure on one side of the piston moves the piston in the bore.

The piston pushes an equal amount of oil from the opposite side of the cylinder. The oil returns to the steering control unit.

When the piston in the steering cylinder reaches the end of the stroke, a relief valve controls the oil pressure. The relief valve for the steering system is in the

1600 SRM 451 manifold block that is installed on the steering control unit. Each spindle turns on two tapered roller bearings in the axle frame. The preload on the bearings is controlled by shims at the lower bearing cap.

The tie rods that connect the spindle arms to the cylinder do not have an adjustment.

The wheel hubs rotate on two tapered roller bearings and are held on the spindles by a castle nut.

The bearing preload of the wheel hubs is adjusted by the castle nut. The grease seals protect the bearings from dirt and water. Wear sleeves prevent the seals from causing wear on the hub.

Steering Axle Assembly Repair REMOVE WARNING Put the lift truck on blocks. Follow the procedures for raising the lift truck that are in the Operating Manual or the Periodic Maintenance 8000 SRM 393 for this lift truck. The surface must be solid, even, and level. Make sure the blocks are solid, one-piece units. Make sure the lifting devices used during repairs can lift the weight of the parts as given in the procedures.

The steering axle can be removed without removing the counterweight. See Figure 1.

1. Make sure the wheels are set for straight travel.

Put blocks under the frame in front of the steer wheels and under the counterweight so that the steering axle can be removed. The top of the axle frame must have clearance under the counterweight so that the steering axle can be removed.

2. Disconnect the hydraulic lines at the steering cylinder. Install caps on the cylinder and put plugs in the hydraulic lines. The caps prevent the spindles from turning when the axle is removed from under the lift truck.

3. Slide a floor jack or the forks of another lift truck under the steering axle. Make sure the lifting device has a capacity of 475 kg (1045 lb). Raise the lifting device until it holds the weight of the axle assembly. Remove the four capscrews and

2

washers that fasten the two brackets under the rubber mounts. Remove the brackets and slowly lower the axle assembly onto the tires. Carefully roll the axle assembly from under the lift truck.

INSTALL NOTE: The S7.00XL (S155XL, S155XLS, S155XL 2) (B024, C024), has an additional rubber mount on the top of the steering axle between the axle and lift truck frame. See Figure 1.

1. Apply a lubricant that is approved for use with rubber (tire lubricant) to the rubber mounts and the lift truck frame at the mount positions. Do NOT use a petroleum base oil. The lubricant is used where the rubber mounts fit onto the steering axle and into the lift truck frame brackets.

2. Install the rubber mount on the axle with the heavier section of mount at the top and the PART NUMBER facing away from the axle frame. Install the rubber block in the center pocket at the top of the axle on S7.00XL (S155XL, S155XLS, S155XL 2) (B024, C024) units.

3. Use a floor jack or another lift truck to put the steering axle into the position in the frame.

Make sure the rubber mounts fit inside the frame brackets for the mounts. If necessary, lower the weight of the lift truck onto the axle to make sure the rubber mounts fit completely in the frame brackets.

1600 SRM 451

Wheels and Hubs Repair

4. Install the bottom plates for the rubber mounts.

Tighten the four capscrews for the brackets to 250 to 275 N•m (185 to 203 lbf ft).

5. Remove the plugs and caps and connect the hydraulic lines to the steering cylinder.

6. Operate the steering system to remove the air from the system. Turn the steering wheel several times from one stop to the other stop. Check for hydraulic leaks.

Wheels and Hubs Repair REMOVE AND DISASSEMBLE

ASSEMBLE AND INSTALL

NOTE: The wheels and hubs can be removed without removing the steering axle.

1. If the wheel bearings must be replaced, use a press and the correct tool to install the new bearing cups in the hub. See Figure 1. Install a new wear sleeve in the wheel hub. Install the grease seal on the spindle. Fill the bearing cones and lubricate seal surfaces with grease. Make sure the bearings are filled with grease. Install the bearing cone on the spindle.

1. Put the axle or lift truck on blocks so that the wheels are just raised from the floor. See Figure 1. See the Operating Manual or the Periodic Maintenance 8000 SRM 393 to put the rear of the lift truck on blocks. Remove the grease cap at the center of the wheel. Remove the cotter pin and the castle nut. Remove the bearing cone. Slide the hub from the spindle.

Remove the inner bearing cone and the seal from the spindle.

2. If the wheel bearings must be replaced, use a brass drift to remove the bearing cup and the wear sleeve.

3. Repeat the procedure for the other wheel.

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

CAUTION Do not damage the seals during installation.

2. Carefully slide the wheel and hub onto the spindle. Install the outer bearing cone.

3. Install the washer and castle nut. Tighten the castle nut to 200 N•m (150 lbf ft) while rotating the wheel and hub. Loosen the nut to less than 27 N•m (20 lbf ft). Tighten the nut to 34 N•m (25 lbf ft). Tighten the castle nut until the cotter pin can be installed. Install the cotter pin. Bend one end of the cotter pin over the spindle and cut it flush with the end of the spindle. Bend the other end of the cotter pin and cut it. Install the grease cap at the center of the wheel.

4. Repeat the procedure for the other wheel.

Clean all parts with solvent. Make sure the bearings are clean.

3

Spindles, Bearings, and Tie Rods Repair

1600 SRM 451

Spindles, Bearings, and Tie Rods Repair REMOVE CAUTION Do not hit the threads or the nut of the tie rod.

1. Early Production Models. If the tie rod must be replaced, remove the cotter pin and castle nut.

To loosen the stud, hold a large hammer behind the spindle arm of the spindle. Hit the side of the spindle arm with another large hammer. The shock of the hammer from hitting the spindle arm will normally loosen the tapered stud. If the stud does not loosen, use a tie rod end puller to remove the stud.

Later Production Models. Remove the snap ring from the retainer pin in each tie rod shown in Figure 1. Remove the pin.

NOTE: The spindle and tie rod can be removed as a unit. Disconnect the tie rod at the retaining pin inside the dust cover. (Use a hammer and a drift to push the pins) for the tie rods upward.

2. Remove the grease cap at the top of the spindle.

Remove the capscrews from the bearing cap. Remove the bearing cap and shims. If necessary, remove the bearing cup from the bearing cap as shown in Figure 2.

3. Tilt the spindle and lift the spindle from the axle.

If the bearing must be replaced, remove the bearing and seals from the spindle. If the wear sleeve and the bearing cup must be replaced, remove them from the axle frame.

4. Repeat the procedure for the other spindle and tie rod.

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

Clean all parts except the ends of the tie rods in solvent. Make sure the bearings are clean.

4

1. PRY BAR 2. BEARING CUP

3. BEARING CAP 4. O-RING

Figure 2. Bearing Cup Removal

ASSEMBLE AND INSTALL 1. Install new seals on the spindle. Lubricate the seals with grease. See Figure 1.

2. Fill the bearings with wheel bearing grease.

Make sure the bearings are filled with grease. If necessary, press the new bearing cups into the steering axle frame and bearing cap. Install the wear sleeve in the steering axle frame. Install the seals and bearing cones on the spindle.

3. Install the spindle in the steering axle. Install the bearing cap without the O-ring shown in Figure 2. Tighten the capscrews evenly until all the clearance is removed from the spindle so that it cannot move vertically. Measure the clearance between the bearing cap and the axle to find the

1600 SRM 451

Steering Cylinder Repair

correct shim thickness for preload. Remove the bearing cap. Install shims to decrease the clearance to 0.00 to 0.13 mm (0.000 to 0.005 in.). This clearance is necessary to give a bearing preload when the cap is tightened. Install the O-ring on the bearing cap. Install the bearing cap and capscrews. Tighten the capscrews evenly to 52 N•m (38 lbf ft).

NOTE: The spindle bearings must have zero clearance. Install shims so that the clearance decreases to 0.00 to 0.13 mm (0.000 to 0.005 in.). This clearance is necessary for the bearing preload.

4. Install the tie rod to the spindle arm or steering cylinder. Install the dust cover over the tie rod.

If removed, tighten the castle nut. Tighten the castle nut to 160 N•m (118 lbf ft) so that the cotter pin can be installed.

5. Install the grease cap on the top of the steering axle. Use a sealant between the grease cap and the steering axle.

6. Repeat the procedure for the other spindle and tie rod.

7. (Tie rods with grease fittings) Lubricate the spindles at the grease fitting in each bearing cap. Use the grease specified in the Periodic Maintenance Schedule of the Operating Manual or the Periodic Maintenance 8000 SRM 393.

Steering Cylinder Repair REMOVE AND DISASSEMBLE NOTE: The end caps of the steering cylinder are held in the shell by the cylinder mount capscrews. See Figure 3. To prevent oil leaks at the end caps, hold the caps on the shell during removal.

1. Disconnect the hydraulic lines at the steering cylinder. Install end caps in the fittings on the cylinder and put fittings on the hydraulic lines.

2. Loosen the clamps on both dust covers on the ends of the steering cylinder rod. Slide the dust covers from the cylinder rod.

3. Remove the snap ring from the retainer pin in each end of the rod shown in Figure 1. Remove the pin.

4. Remove the capscrews and washers that fasten the steering cylinder to the axle frame. Hold the end caps on the shell and remove the steering cylinder.

5. Hold the end of the steering cylinder over a drain pan. Remove the cap for the hydraulic fitting from each end cap. Push the rod toward the end of the shell that is over the drain pan. Oil drains from the cylinder. Repeat the procedure for the other end.

the center of the shell during removal. Remove the end cap from the rod. Remove the other end cap from the shell. Remove all seals, wipers, and O-rings.

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

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.

1. Clean all parts in solvent. Use compressed air to dry the parts.

2. Inspect the piston rod for grooves or damage. Remove small scratches with fine (400 grit) emery cloth. Inspect the cylinder bore for damage. Inspect the mounts for cracks.

6. Carefully slide one end cap from the shell. Carefully pull the rod from the shell. Keep the rod in

5

Steering Cylinder Repair

1600 SRM 451

ASSEMBLE AND INSTALL 1. Put the O-rings, seals, and wipers in warm hydraulic oil. Install the O-rings, seals, and wipers in the correct positions shown in Figure 3.

CAUTION Do not damage the following items during installation: O-rings, seals, or wipers.

2. Lubricate the O-rings, seals, and wipers with O-ring lubricant and carefully install one end cap on the rod.

3. Carefully slide the rod into the shell. Keep the rod in the center of the shell during installation.

Carefully slide the end cap into the shell. Carefully install the other end cap on the rod and shell. Put caps on the hydraulic fittings of the end caps.

1.

2.

3.

4.

SHELL END CAP PISTON ROD PISTON SEAL

4. Hold the end caps and install the steering cylinder on the axle frame using the capscrews and washers. Make sure the end caps are fully engaged with the shell. Tighten the capscrews to 225 N•m (166 lbf ft).

5. Align the tie rods at each end of the rod. See Figure 1. Install the pins and snap rings. Slide the dust covers over the rod so that the edge of each dust cover is against the shoulder of the rod.

Tighten the clamps at the edge of the dust cover.

6. Remove the plugs and caps and connect the hydraulic lines to the steering cylinder. Start the engine and operate the steering system to remove the air from the cylinder and the system.

Turn the steering wheel several times from one stop to the other. Check for leaks.

NOTE: The tie rods do not have an adjustment.

5.

6.

7.

8.

O-RING BACKUP RING ROD SEAL WIPER SEAL

Figure 3. Steering Cylinder

6

2100 SRM 103

Tilt Cylinder Repair

General This section has a description and the repair procedures for several different types of tilt cylinders. The

number and the design of the parts can be different, but the operation of the tilt cylinders is the same.

Description The tilt cylinders [Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6] are used to move the mast forward and backward. To extend the cylinder rod (tilt forward), oil enters the tilt cylinder port behind the piston. The oil pressure pushes the cylinder

rod out of the cylinder. Oil in front of the piston returns to the hydraulic tank. To retract the cylinder rod (tilt backward), the oil enters the port in front of the piston. The oil pressure pushes the cylinder rod into the tilt cylinder. The oil behind the piston returns to the hydraulic tank.

Tilt Cylinder Repair REMOVE WARNING Before removing the tilt cylinder(s), tilt the mast forward. Use a chain to hold the mast to the frame and prevent the mast from moving forward.

1. Disconnect the hydraulic lines at the tilt cylinder.

Install caps on the hydraulic lines and ports.

WARNING Do not push the anchor pins out of the rod end with your fingers. Do not permit the tilt cylinders to drop and cause damage.

2. Remove the retainers for the anchor pins. Push the anchor pins out of the rod end with a tool.

3. Use a lifting device to move large tilt cylinders.

Remove the anchor pins from the frame anchors.

Remove the tilt cylinder from the frame.

DISASSEMBLE 1. Put the tilt cylinder in a vise with soft jaws. Remove the rod end from the rod.

2. Remove the retainer from the tilt cylinder. Remove the rod and piston from the cylinder.

3. Disassemble the tilt cylinder as necessary. See Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

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.

Clean all parts in solvent and dry with compressed air.

ASSEMBLE Tilt Cylinders With O-Ring or Single-Lip Seals NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: During 1980 and 1981, a change was made in the tilt cylinders used in most lift trucks. The O-ring seal between the retainer and the cylinder shell was moved from above the threads to the area below the threads. A backup ring was added to increase the strength of the O-ring. The assembly of the tilt cylinders is the same, but caution must be used so that the O-ring seal is not damaged by the threads.

1

Tilt Cylinder Repair

2100 SRM 103

1. Install the O-ring inside the piston bore. See Figure 1. Install the piston on the piston rod. Make sure the O-ring is not damaged. Tighten the nut on the piston rod to the specifications given in Torque Specifications.

2. Install the O-ring, seal ring, and guide ring on the piston. The seal ring may be heated to ease installation. Polyurethane rings (brown) will return to shape; Teflon rings (yellow) should be re-sized by using a spring compressor.

3. If used, install the O-ring and the backup ring in the groove of the outer retainer. Install the

1.

2.

3.

4.

5.

6.

7.

PISTON ROD PISTON RING O-RING O-RING PISTON GUIDE RING NUT

rod seal (O-ring and sealing lip facing toward the piston) and wiper seal in the inner retainer.

4. Install the retainer on the piston rod. Install the piston and rod assembly and the retainer in the cylinder. If used, install the O-ring on the retainer. Tighten the retainer to specifications given in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the piston rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

8.

9.

10.

11.

12.

13.

14.

CYLINDER SHELL O-RING BACKUP RING RETAINER SEAL RING WIPER RING SPACER (SOME MODELS)

Figure 1. Tilt Cylinders With O-Ring or Single-Lip Seals

2

2100 SRM 103

Tilt Cylinder Repair

Tilt Cylinders for XM and XMS Models NOTE: The following procedure is for these models: • S/H/E/2.00-3.00XM (S/H/E/40-65XM) • J2.00-3.00XM (J40-60XM, J40-60XM 2) (A216) • J2.00-3.00XM (J40-65Z) (A416) • E1.50-2.00XM (E25-35Z, 40ZS) (E114) • J1.60-2.00XMT (J30-40XM) • H/S/E1.25-1.75XM, H/S/E2.00XMS (S/H/E2535XM, S/H/E40XMS)

1. Install the piston seal and O-ring(s) onto the piston. See Figure 2 and Figure 3. Install the piston onto the cylinder rod. Make sure the piston seal is not damaged. Tighten the nut on the piston rod to the value shown in Torque Specifications.

2. Install a new wiper and rod seal. Install the O-ring and backup ring onto the retainer.

3. Install the retainer assembly onto the rod.

NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

4. Install the piston and rod assembly into the cylinder. Tighten the retainer to the value shown in Torque Specifications.

NOTE: If a new piston was not installed, the piston rod nut must be retightened to the value shown in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

1.

2.

3.

4.

CYLINDER SHELL NUT PISTON O-RING

5.

6.

7.

8.

SEAL RING PISTON ROD O-RING BACKUP RING

9. SEAL RING 10. RETAINER 11. WIPER RING

Figure 2. Tilt Cylinders for S/H/E/2.00-3.20XM (S/H/E/40-65XM), J2.00-3.00XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z) (A416/B416), and E2.00-3.20XM (E45-65Z) (G108)

3

Tilt Cylinder Repair

1.

2.

3.

4.

5.

CYLINDER SHELL RETAINER ROD WIPER RING ROD SEAL

2100 SRM 103

6.

7.

8.

9.

10.

BACKUP RING O-RING NUT PISTON PISTON SEAL

Figure 3. Tilt Cylinders for H/S/E/J1.25-1.75XM, XMS, XMT (H/S/E/J25-40XM, XMS, XMT) and E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114)

Tilt Cylinders for XL, XLS, and XL 3 Models NOTE: The following procedure is for these models: (E70-120XL, • E3.50-5.50XL, E3.50-5.50XL 3 E70-120XL 3) (C098) • E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: If a new piston was not installed, the piston rod nut must be retightened to the value shown in Torque Specifications.

1. Install the guide ring, piston seal and O-ring onto the piston. See Figure 4. Install the piston onto the cylinder rod. Make sure the piston seal is not

4

damaged. Tighten the nut on the piston rod to the value shown in Torque Specifications.

2. Install a new wiper and rod seal. Install o-ring and backup ring onto retainer.

3. Install retainer assembly onto piston rod.

4. Install O-ring and shims onto piston rod.

5. Install the piston and rod assembly into the cylinder. Tighten the retainer to the value shown in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

2100 SRM 103

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

O-RING BACKUP RING CAP/RETAINER ROD SEAL ROD WIPER SHIM [3.0 mm (0.120 in.)]

SHIM [1.5 mm (0.060 in.)]

NUT LOCKWASHER ROD END

Tilt Cylinder Repair

11.

12.

13.

14.

15.

16.

17.

18.

19.

BUSHING ANCHOR PIN ANCHOR RETAINER CAPSCREW ROD PISTON PISTON SEAL GUIDE RING FITTING

Figure 4. Tilt Cylinders for E3.50-5.50XL, E3.50-5.50XL 3 (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) Models

5

Tilt Cylinder Repair

2100 SRM 103

Tilt Cylinders for H700-800A and Early Model H700-920B NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

1. Install the thrust plate on the rod. Install the backup ring and O-ring on the rod. Install the piston on the rod. Install the piston rings and seals on the piston. See Figure 5.

2. Install the lock nut on the rod. Tighten the lock nut until the thrust plate is tight against the rod.

Install the pin in the lock nut and rod if necessary, drill a hole in the rod for the pin. Install the snap ring to hold the pin in position.

1.

2.

3.

4.

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CYLINDER SHELL SNAP RING LOCK NUT DOWEL PISTON RING O-RING SEAL RING

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9.

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11.

12.

13.

14.

PISTON RING PISTON THRUST PLATE O-RING BACKUP RING PISTON ROD O-RING

3. Install the piston and rod assembly in the shell.

Install the seals on the retainer. Install the retainer in the shell.

4. Install the lock ring in the shell, but do not tighten it. Install the capscrews in the lock ring.

Turn the lock ring until it is even with the end of the shell. Install the pipe plug in the lock ring and tighten the plug to 34 to 48 N•m (25 to 35 lbf ft). Tighten the capscrews in the lock ring to 14 to 20 N•m (10 to 15 lbf ft).

5. Install the rod end on the rod. Tighten the capscrews on the rod end to 610 N•m (450 lbf ft).

15.

16.

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20.

21.

BACKUP RING RETAINER SEAL RING WIPER RING RETAINER RING PLUG CAPSCREW

Figure 5. Tilt Cylinders for H700-800A, Early Model H700-920B

6

2100 SRM 103

Tilt Cylinder Repair

INSTALL 1. Use a lifting device to move large tilt cylinders.

Put the cylinder in the lift truck. Install the anchor pin in the frame. Install the retainer pin or cotter pin.

2. Install the anchor pin at the mast mount. Install the retainer pin or cotter pin for the anchor pin.

Tighten the capscrews for the retainer pins.

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.

Tilt Cylinders Using Chevron Packing NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: The following procedure is for the H360-650C (early model). See Figure 6.

3. Connect the hydraulic lines to the tilt cylinder.

4. Operate the tilt cylinders. Check for correct operation and leakage. Adjust the tilt cylinders as described in Tilt Cylinder Leak Check and

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5.

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CYLINDER SHELL NUT PISTON HEAD O-RING NYLON RING PACKING NYLON RING

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14.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

PISTON HALF (FLAT) PISTON ROD O-RING BACKUP RING RETAINER O-RING BACKUP RING

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19.

BUSHING PACKING RETAINER RING SETSCREW WIPER RING

Figure 6. Tilt Cylinders With Chevron Packing (Early Model H360-650C)

7

Tilt Cylinder Repair

2100 SRM 103

Install STEP 1.

Install the O-ring and the backup ring on the bushing. Install the packing in the bushing. The end of the packing must extend 3 mm (0.125 in.) beyond the end of the bushing.

1.

2.

3.

4.

O-RING BACKUP RING PACKING BUSHING

STEP 2.

Install the O-ring and the backup ring on the retainer. Use your hand to push the bushing into the retainer. Make sure the O-ring is not damaged during installation. Install the retainer and bushing assembly on the cylinder rod.

1. O-RING 2. BACKUP RING 3. BUSHING STEP 3.

Install the flat piston half on the cylinder rod. Put the O-ring on the rod halfway between the threads and the piston half.

1. PACKING 2. PISTON HALF

8

2100 SRM 103

Tilt Cylinder Repair

STEP 4.

Install the piston half with the packing on the cylinder rod. Make sure the O-ring fits into the piston groove when the piston half is installed. Install the piston rod nut. Tighten to the specifications given in Torque Specifications.

1. O-RING 2. PISTON HALF 3. PISTON HALF WITH PACKING STEP 5.

Push the piston into the cylinder bore. Push the retainer into the bore. Make sure the O-ring is not damaged.

1. CYLINDER ROD 2. PISTON AND PACKING 3. ROD NUT

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