SERVICE REPAIR S135FT S155FT [E024]
8000 SRM 1320
Capacities
Lift Truck Lifting Capacity Model
Weight
S6.0FT (S135FT)
6123 kg (13,500 lb)
S7.0FT (S155FT)
7030 kg (15,500 lb)
H6.0FT (H135FT)
6123 kg (13,500 lb)
H7.0FT (H155FT)
7030 kg (15,500 lb)
NOTE: Load center at 600 mm (24 in.).
Counterweight Weights Model
Weight
S6.0FT, S7.0FT (S135FT, S155FT)
2779 kg (6127 lb)
H6.0FT (H135FT)
2622 kg (5780 lb)
H7.0FT (H155FT)
3135 kg (6911 lb)
Tire Sizes Truck
Drive Tires
Steer Tires
S6.0FT, S7.0FT (S135FT, S155FT)
28 × 12 × 22
22 × 8 × 16
H6.0FT, H7.0FT (H135FT, H155FT)
8.25 × 15
8.25 × 15
Capacities Table 1. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Item
Quantity
Specifications
Fuel Capacity Gas
65.8 liter (17.4 gal)
87 Octane
LPG
38.6 liter (10.2 gal) Empty 19.0 kg (41 lb) Full 38.2 kg (84.51 lb)
LPG-HD 5, HD 10
Diesel
65.8 liter (17.4 gal)
Diesel No. 2
1
Capacities
8000 SRM 1320
Table 1. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models (Continued) Item
Quantity
Specifications
Engine Oil GM 4.3L
4.7 liter (5.0 qt)
7 C ( 20 F) and below SAE 5W-20 16 C (60 F) and below SAE 5W-30 18 C (0 F) and above SAE 10W-30 API SL ILSAC GF3 SAE J2362
Cummins 4.5L Diesel
13.0 liter (13.7 qt)
0 C (32 F) and below SAE 0W-30 25 to 20 C ( 13 to 68 F) SAE 5W-30 20 to 20 C ( 4 to 68 F) SAE 10W-30 15 C (5 F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4
Cummins QSB 3.3L Diesel
7.5 liter (8.0 qt)
0 C (32 F) and below SAE 0W-30 25 to 20 C ( 13 to 68 F) SAE 5W-30 20 to 20 C ( 4 to 68 F) SAE 10W-30 15 C (5 F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4
2
8000 SRM 1320
Capacities
Table 1. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models (Continued) Item
Quantity
Specifications
Cooling System GM 4.3L
15.1 liter (15.9 qt)
CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. 50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Cummins 4.5L Diesel
13.5 liter (14.2 qt)
CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. 50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Cummins QSB 3.3L Diesel
10.4 liter (11.0 qt)
CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. 50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Hydraulic Tank Oil Capacity All Trucks
64 liter (68 qt) Initial Fill 60.5 liter (64 qt) Drain and Fill
CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Hyster dealer.
ISO VG-46 Hydraulic Oil 15 C (5 F) and above
3
Capacities
8000 SRM 1320
Table 1. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models (Continued) Item
Quantity
Specifications
Basic Powershift Transmission (2-Speed)
24 liter (25.4 qt)
John Deere JDM J20C
DuraMatchâ„¢ (3-Speed)
24 liter (25.2 qt)
John Deere JDM J20C
Drive Axle Housing Arm Oil Right Chamber
8.8 liter (9.3 qt)
John Deere JDM J20C
Drive Axle Housing Arm Oil Left Chamber
8.8 liter (9.3 qt)
John Deere JDM J20C
Right Wheel Hub Oil
1.6 liter (1.7 qt)
John Deere JDM J20C
Left Wheel Hub Oil
1.6 liter (1.7 qt)
John Deere JDM J20C
Transmission Oil Capacity
Wet Brake Drive Axle Oil Capacities
Brake Oil (Master Cylinder) All Lift Truck Models
0.35 liter (0.74 pt)
WARNING DO NOT use DOT fluid; only use Dexron III oil from sealed container to prevent possible damage to the brake system. Failure to observe the above Warning could result in death or serious injury. Dexron III From Sealed Container Wet Brake Center Section Oil All Lift Truck Models
4
4.2 liter (4.4 qt)
John Deere JDM J20C
8000 SRM 1320
Capacities
Table 2. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Item
Quantity
Specifications
Fuel Capacity Gas
74.8 liter (19.7 gal)
87 Octane
LPG
38.6 liter (10.2 gal) Empty 19.0 kg (41 lb) Full 38.2 kg (84.51 lb)
LPG-HD 5, HD 10
Diesel
74.8 liter (19.7 gal)
Diesel No. 2
Engine Oil GM 4.3L
4.7 liter (5.0 qt)
7 C ( 20 F) and below SAE 5W-20 16 C (60 F) and below SAE 5W-30 18 C (0 F) and above SAE 10W-30 API SL ILSAC GF3 SAE J2362
Cummins 4.5L Diesel
13.0 liter (13.7 qt)
0 C (32 F) and below SAE 0W-30 25 to 20 C ( 13 to 68 F) SAE 5W-30 20 to 20 C ( 4 to 68 F) SAE 10W-30 15 C (5 F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4
Cummins QSB 3.3L Diesel
7.5 liter (8.0 qt)
0 C (32 F) and below SAE 0W-30 25 to 20 C ( 13 to 68 F) SAE 5W-30 20 to 20 C ( 4 to 68 F) SAE 10W-30 15 C (5 F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4
5
Capacities
8000 SRM 1320
Table 2. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models (Continued) Item
Quantity
Specifications
Cooling System GM 4.3L
15.1 liter (15.9 qt)
CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. 50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Cummins 4.5L Diesel
13.5 liter (14.2 qt)
CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. 50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Cummins QSB 3.3L Diesel
10.4 liter (11.0 qt)
CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. 50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Hydraulic Tank Oil Capacity All Trucks
75 liter (79 qt) Initial Fill 71.7 liter (75.7 qt) Drain and Fill
CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Hyster dealer.
ISO VG-46 Hydraulic Oil 15 C (5 F) and above Transmission Oil Level
6
Basic Powershift Transmission (2-Speed)
24 liter (25.4 qt)
John Deere JDM J20C
DuraMatch™ (3-Speed)
24 liter (25.4 qt)
John Deere JDM J20C
8000 SRM 1320
Electrical System
Table 2. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models (Continued) Item
Quantity
Specifications
7.8 liter (8.25 qt)
John Deere JDM J20C
7.8 liter (8.25 qt)
John Deere JDM J20C
Right Wheel Hub Oil
N/A
N/A
Left Wheel Hub Oil
N/A
N/A
Wet Brake Drive Axle Oil Capacities Drive Axle Housing Arm Oil Right Chamber Drive Axle Housing Arm Oil Left Chamber
Brake Oil (Master Cylinder) All Lift Truck Models
0.35 liter (0.74 pt)
WARNING DO NOT use DOT fluid; only use Dexron III oil from sealed container to prevent possible damage to the brake system. Failure to observe the above Warning could result in death or serious injury. Dexron III From Sealed Container Wet Brake Center Section Oil All Lift Truck Models
4.6 liter (4.9 qt)
John Deere JDM J20C
Electrical System Table 3. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Item
GM 4.3L
Cummins 4.5L and QSB 3.3L Diesel
Battery
12-volt, negative ground
12-volt, negative ground
Spark Plugs
AC 41-993
N/A
Spark Plug Gap
1.5 mm (0.059 in.)
N/A
Gas
Not Adjustable
N/A
LPG
Not Adjustable
N/A
Diesel
N/A
Not Adjustable
Ignition Timing
7
Electrical System
8000 SRM 1320
GM 4.3L Alternator Output (14 Volts)
G and LPG
GS and LPS
Idle
50 amps @ 750 rpm
38 amps @ 750 rpm
Governed Speed
65 amps @ 2400 rpm
45 amps @ 2400 rpm
Cummins 4.5L (Diesel) Alternator Output (13.5 Volts)
D
DS
Low Idle
54 amps @ 800 rpm
28 amps @ 800 rpm
Governed Speed
95 amps @ 2225 rpm
45 amps @ 2225 rpm
Cummins QSB 3.3L (Diesel) Alternator Output (13.5 Volts)
D
DS
Low Idle
30 amps @ 800 rpm
N/A
Governed Speed
95 amps @ 2230 rpm
N/A
Table 4. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Item
GM 4.3L
Cummins 4.5L
Battery
12-volt, negative ground
12-volt, negative ground
Spark Plugs
AC 41-993
N/A
Spark Plug Gap
1.5 mm (0.059 in.)
N/A
Gas
Not Adjustable
N/A
LPG
Not Adjustable
N/A
Diesel
N/A
0.90 mm (0.035 in.)
Ignition Timing:
GM 4.3L Alternator Output (14 Volts)
G and LPG
GS and LPS
Idle
50 amps @ 750 rpm
38 amps @ 750 rpm
Governed Speed
65 amps @ 2400 rpm
45 amps @ 2400 rpm
Cummins 4.5L (Diesel) Alternator Output (13.5 Volts)
D
DS
Low Idle
54 amps @ 800 rpm
32 amps @ 800 rpm
High Idle
95 amps @ 2225 rpm
45 amps @ 2225 rpm
Cummins QSB 3.3L (Diesel)
8
Alternator Output (13.5 Volts)
D
DS
Low Idle
30 amps @ 800 rpm
20 amps @ 800 rpm
Governed Speed
95 amps @ 2230 rpm
45 amps @ 2230 rpm
8000 SRM 1320
Transmission Oil Pressures
Transmission Oil Pressures 3-Speed Transmission All Pressures at 2000 rpm and Oil at 50 to 65 C (120 to 150 F) Port 1 Transmission Pump
Port 2
Port 3
Port 4
Port 5
Port 6
Port 7
Port 8
Low and High Pressure
Reverse Clutch (R1 and R2)
Forward Low Clutch (F1 and F2)
Forward High Clutch (F3)
Torque Converter
Lubrication
First Test Port (F1 and R1)
Second Test Port (F2, F3 and R2)
1793 to 2068 kPa (260 to 300 psi)
1793 to 2068 kPa (260 to 300 psi)
1793 to 2068 kPa (260 to 300 psi)
758 kPa (110 psi)
69 to 276 kPa (10 to 40 psi)
1793 to 2068 kPa (260 to 300 psi)
1793 to 2068 kPa (260 to 300 psi)
1793 to 2068* kPa (260 to 300 psi)
*Relief Pressure
9
Hydraulic System Relief Pressures
8000 SRM 1320
2-Speed Transmission All Pressures at 2000 rpm and Oil at 50 to 65 C (120 to 150 F) Port 1 Transmission Pump
Port 2
Port 3
Port 4
Port 5
Port 6
Port 7
Port 8
Low and High Pressure
Reverse Clutch (R1 and R2)
Forward Low Clutch (F1)
Forward High Clutch (F2)
Torque Converter
Lubrication
First Test Port (F1 and R1)
Second Test Port (F2, and R2)
1793 to 2068 kPa (260 to 300 psi)
1793 to 2068 kPa (260 to 300 psi)
1793 to 2068 kPa (260 to 300 psi)
758 kPa (110 psi)
69 to 276 kPa (10 to 40 psi)
1793 to 2068 kPa (260 to 300 psi)
1793 to 2068 kPa (260 to 300 psi)
1793 to 2068* kPa (260 to 300 psi)
*Relief Pressure
Hydraulic System Relief Pressures
10
Item
Specification
Oil Temperature
50 to 65 C (122 to 149 F)
Primary Relief Valve Pressure (High Idle)
22.1 ±0.48 MPa (3205 ± 70 psi)
Secondary Relief Valve Pressure (High Idle)
15.51 ±0.48 MPa (2250 ±70 psi)
8000 SRM 1320
Stall Speeds (in RPM ±100 rpm)
Steering System Table 5. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Item
Quantity
Oil Temperature
50 to 65 C (122 to 149 F)
Steering Relief Pressure at 800 rpms
12.4 ±0.3 MPa (1798 ±43.5 psi)
Steering Cylinder Stroke (Each Side)
210.8 mm (8.3 in.)
Inside Steering Tire Angle
80.3
Number of Turns to Lock
4.07
Turning Radius (±50 mm NO LOAD)
Outside
Inside
All Trucks
2585
107
Table 6. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Item
Quantity
Oil Temperature
55 to 65 C (131 to 149 F)
Steering Relief Pressure at 800 rpms
12.4 ±0.3 MPa (1798 ±43.5 psi)
Steering Cylinder Stroke (Each Side)
224.0 mm (8.3 in.)
Inside Steering Tire Angle
74.5
Number of Turns to Lock
3.50
Turning Radius (±76 mm NO LOAD)
Outside
Inside
H6.0FT (H135FT)
3319
293
H7.0FT (H155FT)
3376
293
Stall Speeds (in RPM ±100 rpm) GM 4.3L GAS S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) Transmission
New Engine
Broken-In Engine (30 hrs)
Basic Powershift
2160
2210
DuraMatch™
N/A*
N/A*
*DuraMatch™ transmission has torque limiting feature.
11
Stall Speeds (in RPM ±100 rpm)
8000 SRM 1320
GM 4.3L LPG S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) Transmission
New Engine
Broken-In Engine (30 hrs)
Basic Powershift
2070
2170
DuraMatch™
N/A*
N/A*
*DuraMatch™ transmission has torque limiting feature.
GM 4.3L GAS H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Transmission
New Engine
Broken-In Engine (30 hrs)
Basic Powershift
2160
2210
DuraMatch™
N/A*
N/A*
*DuraMatch™ transmission has torque limiting feature.
GM 4.3L LPG H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Transmission
New Engine
Broken-In Engine (30 hrs)
Basic Powershift
2070
2170
DuraMatch™
N/A*
N/A*
*DuraMatch™ transmission has torque limiting feature.
CUMMINS 4.5L DIESEL S6.0FT, S7.0FT, (S135FT,S155FT) (D024) Transmission
New Engine
Broken-In Engine (30 hrs)
Basic Powershift
1900
2050
DuraMatch™
N/A*
N/A*
*DuraMatch™ transmission has torque limiting feature.
12
8000 SRM 1320
Stall Speeds (in RPM ±100 rpm)
CUMMINS QSB 3.3L DIESEL S6.0FT, S7.0FT, (S135FT,S155FT) (E024) Transmission
New Engine
Broken-In Engine (30 hrs)
Basic Powershift
1935
1950
DuraMatch™
N/A*
N/A*
*DuraMatch™ transmission has torque limiting feature.
CUMMINS 4.5L DIESEL H6.0FT, H7.0FT (H135FT, H155FT) (H006) Transmission
New Engine
Broken-In Engine (30 hrs)
Basic Powershift
1900
2050
DuraMatch™
N/A*
N/A*
*DuraMatch™ transmission has torque limiting feature.
CUMMINS QSB 3.3L DIESEL H6.0FT, H7.0FT (H135FT, H155FT) (J006) Transmission
New Engine
Broken-In Engine (30 hrs)
Basic Powershift
1935
1950
DuraMatch™
N/A*
N/A*
*DuraMatch™ transmission has torque limiting feature.
13
Mast Speeds
8000 SRM 1320
Mast Speeds NOTE: Lift speed is measured in meters/sec (inch/ sec) at governed engine RPM with full open valve and 65 C (149 F) oil temperature.
Plus or minus 10% acceptable lifting or lowering.
Lowering speed is measured in meters/sec (inch/sec) with full open valve and 65 C (149 F) oil temperature. Table 7. Lift Truck Models S6.0FT(S135FT) (D024, E024)
Engine
GM 4.3L
Mast
Lowering M/Sec (Inch/Sec)
Lifting M/Sec (Inch/Sec)
No Load
Rated Load
No Load
Rated Load
2-Stage LFL
0.53 (21.0)
0.58 (23.0)
0.54 (21.0)
0.53 (21.0)
3-Stage FFL
0.41 (16.0)
0.53 (21.0)
0.52 (20.0)
0.51 (20.0)
Table 8. Lift Truck Models S7.0FT (S155FT) (D024, E024)
Engine
GM 4.3L
Mast
Lowering M/Sec (Inch/Sec)
Lifting M/Sec (Inch/Sec)
No Load
Rated Load
No Load
Rated Load
2-Stage LFL
0.53 (21.0)
0.58 (23.0)
0.54 (21.0)
0.53 (21.0)
3-Stage FFL
0.41 (16.0)
0.55 (22.0)
0.52 (20.0)
0.51 (20.0)
Table 9. Lift Truck Models S6.0FT(S135FT) (D024, E024)
Engine
Cummins 4.5L and QSB 3.3L
Mast
Lowering M/Sec (Inch/Sec)
Lifting M/Sec (Inch/Sec)
No Load
Rated Load
No Load
Rated Load
2-Stage LFL
0.53 (21.0)
0.58 (23.0)
0.50 (20.0)
0.49 (19.0)
3-Stage FFL
0.41 (16.0)
0.53 (21.0)
0.48 (19.0)
0.47 (19.0)
Table 10. Lift Truck Models S7.0FT (S155FT) (D024, E024)
Engine
Cummins 4.5L and QSB 3.3L
14
Mast
Lowering M/Sec (Inch/Sec)
Lifting M/Sec (Inch/Sec)
No Load
Rated Load
No Load
Rated Load
2-Stage LFL
0.53 (21.0)
0.58 (23.0)
0.46 (18.0)
0.45 (18.0)
3-Stage FFL
0.41 (16.0)
0.55 (22.0)
0.44 (17.0)
0.43 (17.0)
8000 SRM 1320
Mast Speeds Table 11. Lift Truck Models H6.0FT (H135FT) (H006, J006)
Engine
GM 4.3L
Mast
Lowering M/Sec (Inch/Sec)
Lifting M/Sec (Inch/Sec)
No Load
Rated Load
No Load
Rated Load
2-Stage LFL
0.53 (21.0)
0.58 (23.0)
0.54 (21.0)
0.53 (21.0)
3-Stage FFL
0.41 (16.0)
0.53 (21.0)
0.52 (20.0)
0.51 (20.0)
Table 12. Lift Truck Models H7.0FT (H155FT) (H006, J006)
Engine
GM 4.3L
Mast
Lowering M/Sec (Inch/Sec)
Lifting M/Sec (Inch/Sec)
No Load
Rated Load
No Load
Rated Load
2-Stage LFL
0.53 (21.0)
0.58 (23.0)
0.54 (21.0)
0.53 (21.0)
3-Stage FFL
0.41 (16.0)
0.55 (22.0)
0.52 (20.0)
0.51 (20.0)
Table 13. Lift Truck Models H6.0FT (H135FT) (H006, J006)
Engine
Cummins 4.5L
Mast
Lowering M/Sec (Inch/Sec)
Lifting M/Sec (Inch/Sec)
No Load
Rated Load
No Load
Rated Load
2-Stage LFL
0.53 (21.0)
0.58 (23.0)
0.50 (20.0)
0.49 (19.0)
3-Stage FFL
0.41 (16.0)
0.53 (21.0)
0.48 (19.0)
0.47 (19.0)
Table 14. Lift Truck Models H7.0FT (H155FT) (H006, J006)
Engine
Cummins 4.5L
Mast
Lowering M/Sec (Inch/Sec)
Lifting M/Sec (Inch/Sec)
No Load
Rated Load
No Load
Rated Load
2-Stage LFL
0.53 (21.0)
0.58 (23.0)
0.46 (18.0)
0.45 (18.0)
3-Stage FFL
0.41 (16.0)
0.55 (22.0)
0.44 (17.0)
0.43 (17.0)
15
Front End Equipment - Mast Creep
8000 SRM 1320
Tilt Angles Lift truck should be on level ground and in unloaded condition. Table 15. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Mast Type
Forward
2-Stage FFL, 3-Stage FFL, 3-Stage LFL
6
+1 ,
0.5
6
+0 ,
0.5
2-Stage LFL
6
+1 ,
0.5
10
+0 ,
0.5
Tolerance
Back
Tolerance
Table 16. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Mast Type
Forward
2-Stage FFL, 3-Stage FFL, 3-Stage LFL
5
+1 ,
0.5
6
+0 ,
0.5
2-Stage LFL
5
+1 ,
0.5
10
+0 ,
0.5
Tolerance
Back
Tolerance
Front End Equipment - Mast Creep MAST CREEP Measure with rated load at 2.5 m (8.0 ft) high and with the lift, tilt, and auxiliary control levers in neutral position. NOTE: Mast should be 90 vertical prior to test. Table 17. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Hydraulic Oil Temperature
16
Maximum Vertical Creep at Carriage
Maximum Tilt Creep Mast Angle
Cylinder Stroke
C
F
mm/Min
in./Min
/Min
mm/Min
in./Min
20
68
2.2
0.086
0.11
1.24
0.054
30
86
3.3
0.130
0.16
1.80
0.071
40
104
6.3
0.247
0.31
3.50
0.137
50
122
10.0
0.394
0.50
5.62
0.221
60
140
14.6
0.575
0.73
8.20
0.323
8000 SRM 1320
Engine Specifications
Table 18. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Hydraulic Oil Temperature
Maximum Tilt Creep
Maximum Vertical Creep at Carriage
Mast Angle
Cylinder Stroke
C
F
mm/Min
in./Min
/Min
mm/Min
in./Min
20
68
2.2
0.086
0.11
1.30
0.051
30
86
3.3
0.130
0.16
1.90
0.075
40
104
6.3
0.247
0.31
3.67
0.145
50
122
10.0
0.394
0.50
5.92
0.233
60
140
14.6
0.575
0.73
8.65
0.341
Engine Specifications Item
GM 4.3L
No. of Cylinders
6
Firing Order
1-6-5-4-3-2
Bore
101.6 mm (3.9 in.)
Stroke
88.4 mm (3.48 in.)
Displacement
4.3 liter (262.4 in. 3 )
Horsepower (Gasoline)
100 @ 2400 rpm
Horsepower (LPG)
93 @ 2400 rpm
Engine Timing
Timing is controlled by the Electronic Control Module (ECM) Compression Ratio
Gas
9.4:1
LPG
9.4:1
Oil Pressure
207-380 ± 30 kPa (30-55 ± 4.4 psi) @ 2000 rpm 80 C (176 F) Valve Clearance
Intake
Not Adjustable
Exhaust
Not Adjustable
Idle Speed - Gas
750 ±25 rpm
Idle Speed - LPG
750 ±25 rpm
Governed Speed High Idle (No Load)
2400 ±25 rpm
17
Engine Specifications
8000 SRM 1320
Item
GM 4.3L Thermostat Range
STARTS TO OPEN
82 ±1.5 C (180 ±35 F)
FULL OPEN
128 ±1.5 C (260 ±35 F)
Cooling System Pressure
103 kPa (15 psi)
Item
Cummins 4.5L Diesel
No. of Cylinders
4
Firing Order
1-3-4-2
Bore and Stroke
102 mm × 138 mm (4.01 in. × 5.43 in.)
Displacement
4506 cc
Compression Ratio
17.6:1
Horsepower/rpm
78 @ 2050 rpm
Oil Pressure @ 80 C (176 F)
at low idle 69 kPa (10 psi) @ 800 rpm at high idle 207 kPa (30 psi) @ 2250 rpm Valve Clearance
Intake
0.254 mm (0.010 in.) (COLD)
Exhaust
0.508 mm (0.020 in.) (COLD)
Idle Speed (Cold Engine)
770 ±50 rpm
Idle Speed (Hot Engine)
800 ±50 rpm
Governed Speed High Idle (No Load)
2250 ±50 rpm
Thermostat Range STARTS TO OPEN
82 C (180 F)
FULL OPEN
95 C (203 F)
Cooling System Pressure
103 kPa (15 psi)
Item
Cummins QSB 3.3L Diesel
No. of Cylinders Firing Order Bore and Stroke Displacement Compression Ratio Horsepower/rpm (basic transmission)
18
4 1-3-4-2 95 mm × 115 mm (3.74 in. × 4.53 in.) 3261 cc 17.3:1 80 @ 2200 rpm
8000 SRM 1320
Torque Specifications
Item
Cummins QSB 3.3L Diesel
Horsepower/rpm (Duramatch transmission)
99 @ 2200 rpm
Oil Pressure
49 kPa (7 psi)
Valve Clearance Intake
0.35 mm (0.014 in.)
Exhaust
0.50 mm (0.02 in.)
Idle Speed
800 ±25 rpm
Governed Speed High Idle (No Load)
2230 ±25 rpm
Thermostat Range START TO OPEN
82 C (180 F)
FULL OPEN
95 C (203 F)
Cooling System Pressure
103 kPa (15 psi)
Torque Specifications FRAME
STEERING SYSTEM
Overhead Guard Mount Capscrews 66 N•m (49 lbf ft)
Hub Nut (Slotted Nut), Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) 203 N•m (150 lbf ft) initial 35 N•m (26 lbf in) final
Cowl-to-Overhead Guard Legs 66 N•m (49 lbf ft) Counterweight Capscrews 1020 N•m (750 lbf ft)
MAST, LIFT TRUCK MODELS S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Mast Mounting Capscrews Mast to Drive Axle 320 N•m (236 lbf ft) Tilt/Cylinder Adjust 90 N•m (66 lbf ft) Pivot Pin Retainer 68 N•m (50 lbf ft)
MAST, LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Mast Mounting Capscrews Mast to Drive Axle 755 to 830 N•m (557 to 612 lbf ft) Tilt/Cylinder Adjust 90 to 99 N•m (66 to 73 lbf ft) Pivot Pin Retainer 68 N•m (50 lbf ft)
Hub Nut (Slotted Nut), Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) 203 N•m (150 lbf ft) initial 34 N•m (25 lbf in) final Steering Axle Mounting Bolts and Nuts, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) 250 to 275 N•m (184 to 203 lbf ft) Steering Axle Mounting Bolts and Nuts, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) 270 N•m (199 lbf ft) Spindle Bearing Cap Capscrew, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) 52 N•m (38 lbf ft)
19
Torque Specifications Spindle Bearing Cap Capscrew, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) 47 N•m (35 lbf ft) Steering Cylinder Mounting Bolts 225 N•m (166 lbf ft)
TRANSMISSION Transmission Mounting Bracket to Differential Housing Capscrew 225 to 255 N•m (166 to 188 lbf ft) Torque Converter Housing to Transmission Case Capscrews 38 N•m (28 lbf ft) Torque Converter Access Bolts 55 N•m (41 lbf ft) Drive Shaft to Output Yoke Capscrews 55 to 63 N•m (41 to 47 lbf ft) Control Valve Mounting Capscrews 20 to 25 N•m (15 to 18 lbf ft) Engine Mounting Bracket to Frame Bolts 320 N•m (236 lbf ft)
ENGINE - GM 4.3L Alternator Pulley 61 N•m (45 lbf ft) Balance Shaft Gear Capscrew 20 N•m (177 lbf in) Plus 35 Degrees Balance Shaft Retainer Capscrews 12 N•m (106 lbf in) Camshaft Retainer Screws 12 N•m (106 lbf in) Camshaft Sprocket Capscrews 28 N•m (21 lbf ft)
8000 SRM 1320 Coolant Pump to Engine Block 41 N•m (30 lbf ft) Cooling Fan to Pulley 24 N•m (212 lbf in) Cylinder Head See the section GM Engines, 4.3 Liter V-6 600 SRM 1251 for torque value and tightening sequence to use. Distributor Mount Capscrew 25 N•m (18 lbf ft) Exhaust Manifold 15 N•m (133 lbf in) - first step 30 N•m (22 lbf ft) - second step Flywheel 100 N•m (74 lbf ft) Flywheel Housing 48 N•m (35 lbf ft) Inlet Manifold to Cylinder Head 3 N•m (27 lbf in) - first step 12 N•m (106 lbf ft) - second step 15 N•m (133 lbf in) - third step (final) Main Bearing Cap 105 N•m (77 lbf ft) Motor Mount to Engine 31 N•m (23 lbf ft) Oil Pump Cover 12 N•m (106 lbf in) Oil Pump to Crankcase 90 N•m (66 lbf ft) Oil Pressure Switch 27 N•m (20 lbf ft) Oil Screen Support to Crankcase 50 N•m (37 lbf ft)
Camshaft Sprocket Nut 25 N•m (18 lbf ft)
Oil Pan to Crankcase Capscrews 25 N•m (18 lbf ft) Nuts 25 N•m (18 lbf ft)
Chain Control Block for Hydraulic Pump Drive 19 N•m (168 lbf in) with Adhesive Sealant
Rear Oil Seal Retainer Screws and Nut 15 N•m (133 lbf in)
Connecting Rod Cap 27 N•m (240 lbf in) After this step, tighten nuts an additional 70 degrees.
Rocker Arm Cover 12 N•m (106 lbf in)
20
Rocker Arm Nuts 25 N•m (18 lbf ft)
8000 SRM 1320
Torque Specifications
Rocker Arm Studs 47 N•m (35 lbf ft)
Vibration Damper 95 N•m (70 lbf ft)
Rocker Arm Bolts 30 N•m (22 lbf ft)
ENGINE - CUMMINS 4.5L AND QSB 3.3L DIESEL
Thermostat Housing 25 N•m (18 lbf ft)
For torque instructions for the Cummins 4.5L and QSB 3.3L diesel engine, contact your local Hyster dealer or see Hyster Hypass Online.
Timing Cover 12 N•m (106 lbf in) Valve Lifter Retainer Capscrews 16 N•m (142 lbf in)
21
1800 SRM 1247
General
General DRY BRAKE SYSTEM
WET BRAKE SYSTEM
NOTE: The dry brake system is used only on lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005).
NOTE: The wet brake system is used on all lift truck models covered in this SRM. The wet brake system in this section includes the following parts: master cylinder and parking brake system. See Figure 2 and Figure 3.
This section has service procedures for the dry brake system. The dry brake system includes the following parts: master cylinder and parking brake system (see Figure 1) and brake shoes and wheel cylinders (see Figure 4).
NOTE: LIFT TRUCK MODEL S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) SHOWN. 1. 2. 3. 4. 5.
1. 2. 3. 4. 5. 6. 7.
PARK BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB PARK BRAKE CABLES INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER BRAKE ASSEMBLY BRAKE POSITION SENSOR (RIGHT-HAND SIDE) Figure 1. Dry Brake System
6. 7. 8. 9. 10. 11.
PARK BRAKE HANDLE ASSEMBLY INCH/BRAKE PEDAL BOOSTER ASSEMBLY PARK BRAKE LEVERS PLANETARY CARRIER HOUSING (LEFT-HAND SIDE SHOWN) WET DISC BRAKE HOUSING PARK BRAKE CABLES ADJUSTMENT KNOB BRAKE POSITION SENSOR (LEFT-HAND SIDE SHOWN) MASTER CYLINDER CYLINDER BLOCK
Figure 2. Wet Brake System for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
1
Service Brakes Repair (Dry Brake)
1800 SRM 1247
The wet disc brakes are a component of the wet brake drive axle. The brake discs are located inside the planetary carrier housing at each end of the drive axle. See Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1246 for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1318 for lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) or Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1344 for lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) for the removal, assembly and installation procedures.
NOTE: LIFT TRUCK MODEL S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) SHOWN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
PARK BRAKE HANDLE ASSEMBLY INCH/BRAKE PEDAL BOOSTER ASSEMBLY ADJUSTMENT KNOB PLANETARY CARRIER HOUSING (LEFT-HAND SIDE SHOWN) WET DISC BRAKE HOUSING PARK BRAKE CABLES BRAKE POSITION SENSOR MASTER CYLINDER CYLINDER BLOCK PARK BRAKE LEVERS
Figure 3. Wet Brake System for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
Service Brakes Repair (Dry Brake) NOTE: The procedures in this section apply on to lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
2
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) equipped with the dry brake system.
1800 SRM 1247
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 brake linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. 1. See the procedure How to Put Lift Truck on Blocks in the section Periodic Maintenance 8000 SRM 1248 or the Operating Manual. Start the engine and tilt the mast fully backward. Put blocks under the mast. Tilt the mast forward until the wheels just touch the floor. Stop the engine. Put blocks under the frame of the lift truck. 2. Remove the capscrews that hold the axle shaft to the hub. Remove the axle shaft.
Service Brakes Repair (Dry Brake) screwdriver to push the adjuster actuator away from the adjuster wheel. Use a brake adjustment tool or a screwdriver to turn the adjuster wheel to loosen the brake shoes. Remove the hub and drum assembly. Do not damage the grease seal when removing the hub. NOTE: During disassembly, note the arrangement of parts to aid in re-assemble of the brake system. 5. Remove the primary, secondary return springs and tension spring with spring pliers and remove the anchor pin from the primary brake shoe. See Figure 4. 6. Remove the pressure springs that hold the brake shoes to the backing plate. 7. Disconnect the parking brake cable from park brake lever. See Figure 4.
WARNING When the brake shoes are removed, do not create dust in the air. See the Clean procedure in this section. 8. Remove brake shoes. 9. Remove the auto adjuster assembly from the backing plate. See Figure 5.
3. Bend the lock plate tab and remove the nut, lockplate, washer and bearing cone.
10. Disconnect the brake line from the wheel cylinder. Remove wheel cylinder from backing plate. See Figure 5.
4. Put grease on the floor so that the wheel assembly will slide easily from the axle tube. Pull the wheel assembly from the lift truck. If the wheel assembly cannot be removed easily, use a small
11. If damaged, remove the backing plate from the axle housing. Discard the eight mounting lock bolts.
3
Service Brakes Repair (Dry Brake)
1. 2. 3. 4. 5. 6. 7. 8.
RETAINER SECONDARY RETURN SPRING SECONDARY BRAKE SHOE PRESSURE SPRING AUTO ADJUSTER LINK ADJUSTER WHEEL AUTO ADJUSTMENT ASSEMBLY PARKING BRAKE CABLE
1800 SRM 1247
9. 10. 11. 12. 13. 14. 15. 16.
TENSION SPRING PRIMARY BRAKE SHOE PARK BRAKE LEVER STRUT PRIMARY RETURN SPRING ANCHOR PIN BACKING PLATE WHEEL CYLINDER
Figure 4. Brake Assembly (Left-Hand Shown)
4
1800 SRM 1247
Service Brakes Repair (Dry Brake) damage and leaks in the seals of a brake system. Small amounts of water in the brake system can cause reduced braking if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water. DO NOT use unfiltered shop air to blow out brake components. Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the safety instructions of the solvent manufacturer.
CAUTION Do not permit brake cleaning fluid to contact the master cylinder or wheel cylinder. Brake cleaning fluid will cause damage and leaks in seals of the brake system. 1. Do not release brake lining dust from the brake linings into the air when the brake drum is removed.
CAUTION Do not permit oil or grease on the brake linings. Use a brake cleaning fluid as necessary to clean linings that will not be replaced. 1. 2. 3. 4.
WHEEL CYLINDER CAPSCREWS AUTO ADJUSTER CAPSCREW ADJUSTER WHEEL ACCESS PLUGS BRAKE LINE
Figure 5. Auto Adjuster and Wheel Cylinder Mount Location
CLEAN WARNING DO NOT use an oil solvent to clean the brake linings, use a solvent approved for cleaning of brake parts. Do not permit oil or grease on the brake linings, the brakes will not operate correctly if oil, grease, or brake cleaning fluid is on the brake linings. Oil and grease will cause
2. Use a solvent approved for cleaning of brake parts to wet the brake lining dust. Follow the instructions and cautions of the manufacturer for the use of the solvent. If a solvent spray is used, spray at a distance so that the dust is not released into the air. 3. When the brake lining dust is wet, clean the parts. Put any cloth or towels in a plastic bag or an airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on the plastic bag or airtight container. 4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air.
5
Service Brakes Repair (Dry Brake)
INSPECT WARNING Small amounts of water in the brake system can cause reduced braking if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water. DO NOT use unfiltered shop air to blow out brake components. Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the safety instructions of the solvent manufacturer.
CAUTION Do not permit brake cleaning fluid to contact the master cylinder or wheel cylinder. Brake cleaning fluid will cause damage and leaks in seals of the brake system. 1. Inspect the bore of the wheel cylinder for holes or scratches. Replace the wheel cylinder assembly if there is any damage. 2. Inspect wheel cylinder parts for dirt or water. Clean any dirt or water present in the wheel cylinder parts using a lint free cloth. 3. Inspect the primary, secondary and tension springs for wear and damage. Inspect the back plate for wear where the brake shoes touch the back plate. Remove any grooves or replace a worn or damaged back plate. 4. Inspect the park brake lever and strut. If damaged, replace primary and secondary brake shoe assembly.
WARNING The brake shoes on both wheels must be replaced if any shoe is damaged. The brake performance on both ends of an axle must be equal, or the lift truck can be difficult to steer when the brakes are applied.
6
1800 SRM 1247 5. Inspect the brake shoes for cracks or damage. If the linings or shoes are worn or damaged, replace the brake shoes. Maximum wear is to within 1 mm (0.039 in.) of contact with the rivets, or the metal shoe on bonded linings. Brake shoes must be replaced in complete sets. Inspect the brake drums for cracks or damage. Replace any damaged parts. 6. Inspect the brake drum for deep grooves or other damage. NOTE: If grooves must be removed from the brake drums, do not grind more than 1.5 mm (0.060 in.) from the internal diameter of the brake drum. The maximum limit of the internal diameter of the brake drum is 317.5 mm (12.4 in.). If the internal diameter is larger than the limit, replace the brake drum. 7. The teeth of the adjuster wheels must not be worn. The adjuster wheel must turn freely. Check the adjuster links for damage. See Figure 4 and Figure 5. Replace the auto adjuster assembly if there is any damage. 8. Make sure the parking brake cables are in good condition. Replace parking brake cables if worn or damaged. 9. Check the grease seals and the surfaces of the seals for wear or damage. Replace damaged seals.
ASSEMBLE AND INSTALL 1. If removed, install backing plate using eight new lock bolts to the axle housing using tightening sequence, see Figure 6. Tighten bolts to 340 to 375 N•m (251 to 277 lbf ft). NOTE: Replace wheel cylinder if there is any damage or it is not working properly. 2. Install the wheel cylinder on the backing plate and tighten capscrews to 20 to 25 N•m (15 to 19 lbf ft). Connect the brake line to the wheel cylinder. See Figure 5.
1800 SRM 1247
Service Brakes Repair (Dry Brake)
NOTE: Replace auto adjuster assembly if there is any damage or it is not working properly.
7. Install pressure springs to hold the brake shoes to the backing plate.
3. Install the auto adjuster assembly on the backing plate between the two brake shoes and tighten capscrew to 120 to 140 N•m (89 to 103 lbf ft). See Figure 4 and Figure 5.
8. Install the primary and secondary return springs, and tension spring to the brake shoe. See Figure 4.
4. Lubricate the backing plate with small amount of lithium grease where the brake shoes touch.
9. Coat threads of the adjuster wheels with antiseize compound. Turn the adjuster wheels so that the adjuster assembly is in its shortest position. This action permits the brake drum to be easily installed over the brake shoes. NOTE: Seal and bearings are to be installed flush with the hub. Seal is to be installed with no grease or oil on outside surface. 10. Clean the bearings and lubricate them with wheel bearing grease. Install the bearings and seals in the wheel hub. Install the assembly on the axle housing. See Figure 7 and Figure 8. NOTE: To prevent damage to the inner oil seal when installing the hub, the hub and drum assembly can be temporarily fastened to the wheel. Align the height of the axle housing with hub bearings. Put grease under the wheel and slide the wheel toward the axle housing. Install the outer bearing and nut.
Figure 6. Backing Plate to Axle Housing Tightening sequence NOTE: The park brake lever and strut are a component of the primary brake shoe. If damaged, replace primary and secondary brake shoe assembly. 5. Install the primary and secondary brake shoes on the push rod of wheel cylinder and auto adjuster link. See Figure 4.
11. Install the washer, lock plate and wheel adjustment nut. See Figure 9. To align the bearing rollers, tighten the wheel adjustment nut to 28 to 32 N•m (21 to 24 lbf ft) and rotate the hub 2 revolutions in both directions. To seat the wheel bearings, tighten the wheel adjustment nut to 400 to 480 N•m (295 to 354 lbf ft). Back off the wheel adjustment nut to zero end play. Preload the wheel bearings by tightening the wheel adjustment nut to 28 to 32 N•m (21 to 24 lbf ft). Rotate the hub 3 complete revolutions in both directions. Verify the wheel adjustment nut torque is 28 to 32 N•m (21 to 24 lbf ft) and that the torque stabilizes at that specification.
6. Connect the parking brake cable to park brake lever.
7
Service Brakes Repair (Dry Brake)
1. INNER SEAL 2. OUTER SEAL 3. BRAKE DRUM
1800 SRM 1247
4. INNER BEARING 5. OUTER BEARING Figure 7. Grease Seals and Bearing Locations
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
8
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. NOTE: If the brake shoes were not replaced, loosen the two adjuster wheels equally, approximately 20 teeth.
1800 SRM 1247
Service Brakes Repair (Dry Brake) 13. Install the drive wheels. Remove the lift truck from the blocks. Operate the lift truck in the FORWARD and REVERSE directions. Stop the lift truck 10 times in each direction. This procedure causes the brake shoes to wear a small amount and fit the brake drum better.
Figure 8. Inner Grease Seal Installation
1. ADJUSTER LEVER 2. ADJUSTER WHEEL 3. ADJUSTER LINK Figure 10. Auto Adjuster Assembly
1. 2. 3. 4. 5.
AXLE SHAFT WHEEL ADJUSTMENT NUT LOCK PLATE WASHER HUB
14. Coat the flange of the axle shaft with liquid sealant, Hyster Part Number 264159. Install the axle shaft and capscrews. Tighten the capscrews in the sequence shown in Figure 11 to 90 to 99 N•m (66 to 73 lbf ft).
Figure 9. Wheel Adjustment 12. To manually adjust the brakes, it is necessary to turn the adjuster wheels. See Figure 4. Remove the two access plugs in the adjustment slots located on the back side of the backing plate. Place an adjuster tool and screwdriver through the slot in the backing plate. See Figure 5. Push the adjuster lever away from the adjuster wheel, in the direction indicated in Figure 10 and turn the adjuster wheel until the brake shoe just touches the brake drum. Use the adjuster tool to loosen the adjuster wheel approximately 20 teeth. Adjust the brake shoe for the other adjuster wheel using the same method. See Figure 10. Make sure to install the access plugs after the adjustment is complete. See Figure 5.
Figure 11. Axle Shaft Tightening Sequence
9
Parking Brake Repair
1800 SRM 1247
ADJUST
pedal must not touch the floor plate. Move the lift truck in REVERSE and push on the brake pedal to permit adjusting mechanism to operate. Repeat this operation several times.
1. Remove the air from the brake hydraulic system. See Brake System Air Removal. 2. Install the wheel on the hub. Tighten the wheel nuts to 610 to 680 N•m (450 to 502 lbf ft). 3. Start the engine and tilt the mast backward to remove the blocks. Push on the brake pedal. The
4. The service brakes must be adjusted before the parking brake can be adjusted. See Figure 13 and the following paragraphs in this section for the correct adjustment of the parking brake.
Parking Brake Repair REMOVE AND DISASSEMBLE NOTE: For removal and disassembly procedures for a dry brake system use Step 1 through Step 5. For the wet brake system use Step 1 through Step 4 and Step 6. If the handle assembly for the parking brake must be removed from the cowl, use the following procedure. For dry brake system see Figure 13 and for wet brake system see Figure 14 and Figure 15. 1. Block the front and rear side of the wheels to make sure the lift truck cannot move. Release the parking brake handle assembly. 2. Remove the four capscrews that fasten the bracket for the parking brake to the cowl. Remove the bracket and parking brake handle assembly. 3. Loosen the jam nuts that fasten the threaded ends of the parking brake cables to the parking brake handle assembly. 4. Turn the adjustment knob counterclockwise until the parking brake cables are loosened. Disconnect the cables from the equalizer links. 5. The service brake assembly must be removed before the parking brake cable can be removed from the back plate of the service brake. See Figure 12. A snap ring holds the sheath of the parking brake cable in the back plate of the service brake. Remove the snap ring and remove the parking brake cable from the back plate. See Figure 12.
10
1. 2. 3. 4. 5.
PARKING BRAKE CABLE SHEATH SNAP RING SERVICE BRAKE ASSEMBLY BACK PLATE
Figure 12. Parking Brake Cable Removal for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Dry Brake System 6. The cotter pin, clevis pin, and cable clamps must be removed from the parking brake levers before the parking brake cables can be removed. See Figure 14 and Figure 15.
1800 SRM 1247
Parking Brake Repair
Figure 13. Parking Brake Lever Adjustment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Dry Brake System 11
Parking Brake Repair
1800 SRM 1247 Legend for Figure 13
A. RIGHT HAND SIDE
B. LEFT HAND SIDE
1. 2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12. 13. 14.
PARKING BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB PARKING BRAKE CABLES INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER BRAKE ASSEMBLY BRAKE POSITION SENSOR
ADJUSTMENT SLOT (UNDERNEATH SPRING) EQUALIZER LINK NUT CAPSCREW PARKING BRAKE BRACKET JAM NUTS PARKING BRAKE CABLE BRACKET
Legend for Figure 14 A. 1. 2. 3. 4. 5. 6. 7.
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005)
PARKING BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB EQUALIZER LINKS PARKING BRAKE CABLES NUT CAPSCREW BRAKE POSITION SENSOR (RIGHT SIDE SHOWN) 8. ADJUSTMENT SLOT (UNDERNEATH SPRING)
12
B. S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) 9. 10. 11. 12. 13. 14. 15. 16. 17.
INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER CLEVIS PIN COTTER PIN PARKING BRAKE LEVER CABLE CLAMPS PARKING BRAKE BRACKET JAM NUTS PARKING BRAKE CABLE BRACKET
1800 SRM 1247
Parking Brake Repair
Figure 14. Parking Brake Lever Adjustment for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 120FT) (N005, P005) With Wet Brake System 13
Parking Brake Repair
1800 SRM 1247
Figure 15. Parking Brake Lever Adjustment for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) (Wet Brake System)
14
1800 SRM 1247
Parking Brake Repair Legend for Figure 15
A. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
B. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
1. 2. 3. 4. 5. 6. 7. 8.
9. 10. 11. 12. 13. 14. 15.
PARKING BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB EQUALIZER LINKS PARKING BRAKE CABLES NUT CAPSCREW BRAKE POSITION SENSOR ADJUSTMENT SLOT (UNDERNEATH SPRING)
ASSEMBLE AND INSTALL NOTE: For assemble and install procedures for a dry brake system use Step 1, Step 3, Step 4, Step 6 and Step 7. For the wet brake system use Step 2, Step 3, and Step 5 through Step 7. If the lever assembly for the parking brake was removed from the cowl, use the following procedure for installation:
INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER CLEVIS PIN COTTER PIN PARKING BRAKE LEVER CABLE CLAMPS/MOUNTING BRACKET JAM NUTS in the parking brake handle assembly and not pulling on the equalizer links with the parking brake handle assembly in the released position. See Figure 14 and Figure 15.
6. Install the round ends of the parking brake cables in their slots in the equalizer link. Tighten the upper jam nuts to hold the sheaths of the parking brake cables in the parking brake cable bracket.
1. The parking brake cables must be installed in the back plate before the service brake is installed. See Figure 12. A snap ring holds the sheath of the parking brake cable in the back plate of the service brake. Install the parking brake cable in the back plate and install the snap ring that holds the sheath of the parking brake cable in the back plate. See Figure 12.
7. Use the four capscrews, washers, and nuts and fasten the bracket to the inside of the cowl. Tighten park brake cable clamps on frame and axle.
2. The parking brake cables must be installed on the parking brake levers located on the wet brake drive axle and the cables loosely clamped to the frame and axle in the correct position before connecting cables to the equalizer links located on the parking brake handle assembly. See Figure 14 and Figure 15.
Make sure the service brakes are adjusted and the operation of the automatic adjuster mechanism is correct before the parking brake cables are adjusted.
3. Make sure the parking brake handle is in the released position. Turn the adjustment knob until the equalizer link is adjusted to the bottom of the adjustment slot. For Dry Brake system, see Figure 13. For Wet Brake system, see Figure 14 and Figure 15. 4. Adjust the jam nuts on the ends of the cable assemblies so that the threads of the cable sheaths extend 23 to 26 mm (0.90 to 1.02 in.) above their support plate in the lever assembly. See Figure 13. 5. Adjust the jam nuts on the ends of the parking cables so that the threads of the cable are level
ADJUST Dry Brake System
Wet Brake System Make sure the park brake levers are adjusted before the parking brake cables are adjusted. See Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1246 for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1318 for lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) or Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 SRM 1344 for lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) for park brake lever adjustment procedures.
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Master Cylinder Repair
1800 SRM 1247
Lift Trucks With a MONOTROLÂŽ Pedal or Forward Reverse Lever The switch energizes the seat warning circuit when hand lever is released. This switch puts the transmission in NEUTRAL by de-energizing the direction solenoid. There is also a switch on the left-hand side of bracket. This switch prevents engine from starting unless parking brake is applied.
CAUTION On lift trucks equipped with the wet brake system, check the dash display to verify the transmission oil is at operating temperature, 49 to 66 C (120 to 150 F) before adjusting the parking brake adjustment knob. 1. To adjust the parking brake, turn the adjustment knob to raise the equalized link and tighten the parking brake cables shown in Figure 13, Figure 14 and Figure 15. Do not tighten the adjustment so that the brake is applied when the lever is released. The lever for the parking brake has a lock. Use your thumb or finger to release the lock on the lever when the parking brake is released.
NOTE: Before doing Step 2 and Step 3, make sure the parking brake is correctly adjusted. The parking brake is correctly adjusted when it takes 125 N (28 lbf) force (6 clicks) to fully apply the parking brake for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and 200 N (45 lbf) force (6 clicks) to fully apply the parking brake for lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006). 2. For new brakes, test the operation of the parking brake. The lift truck, with a capacity load, must not move when parking brake is applied on a 7.5 percent grade [a slope that increases .75 m in 10 m (9 in. in 10 ft)]. 3. For burnished brakes, test the operation of the parking brake. The lift truck, with a capacity load, must not move when parking brake is applied on a 15 percent grade [a slope that increases 1.5 m in 10 m (1.5 ft in 10 ft)].
Master Cylinder Repair REMOVE NOTE: The removal procedure in this section is the same for both dry and wet brake systems. 1. Remove the floor plate, kick plate, and seal plate from the lift truck for access to the master cylinder and booster assembly. 2. Remove master cylinder hoses and brake pressure transducer: a. For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, S100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005), remove and tag the brake
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booster supply and return hoses from the master cylinder and booster assembly. Plug hoses to prevent hoses from draining. Disconnect the connector at the brake pressure transducer, and remove brake pressure transducer. See Figure 16. b. For lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024), remove and tag the accumulator to booster hose, the booster and accumulator supply hose, the brake hose, and booster return hose. Plug hoses to prevent hoses from draining. Disconnect the connector at the brake pressure transducer, and remove brake pressure transducer. See Figure 17.
1800 SRM 1247
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
CAPSCREW BRAKE OIL RESERVOIR CLAMP UPPER BRAKE OIL SUPPLY HOSE CYLINDRICAL BLOCK MOUNT LOWER BRAKE OIL SUPPLY HOSE INSERT FITTING FOR BOOSTER RETURN HOSE BRAKE HOSE
Master Cylinder Repair
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
BRAKE PRESSURE TRANSDUCER BOOSTER SUPPLY HOSE BOOSTER ASSEMBLY MOUNTING BOLT MANIFOLD MOUNT BRACKET COTTER PIN ROD END PIN MASTER CYLINDER NIPPLE
Figure 16. Master Cylinder and Reservoir Assembly, Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
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