SERVICE REPAIR H45XM H50XM H55XM H60XM H65XM [H177]
100 SRM 505
Operator Module Repair
General WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. • Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.
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. See the Operating Manual or Periodic Maintenance 8000 SRM 707. This section has the description of the frame and some connected parts. See Figure 1. Procedures for the removal and installation of the counterweight, hood, overhead guard, and engine (including the transmission) are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.
Description The frame is one weldment and includes the hydraulic tank and the fuel tank for gasoline or diesel fuel. There is a counterweight for each capacity of lift truck. The counterweights are similar, but are different weights. The muffler is fastened to the frame inside the counterweight.
An operator module is installed on the frame with rubber mounts. The overhead guard, steering controls, instrument panel, hood, and seat are installed on the operator module. The hood is connected to the operator module with hinges. Two gas-controlled springs give assistance when raising the hood and hold the hood in the open position. The floor plates and side covers can be removed for access to the engine, transmission, and other components.
Operator Module Repair REMOVE
INSTALL
1. Remove the hood and side covers. See Figure 1.
NOTE: If the overhead guard was removed from the operator module, tighten the rear leg mount capscrews to 53 N•m (39 lbf ft). On H2.00-3.20XM (H45-65XM) units, tighten the capscrews that fasten the module cowl side plate to the front legs to 66 N•m (49 lbf ft).
2. Remove the steering housing and instrument cluster from the cowl. Remove the capscrews that hold the parking brake lever to the cowl. 3. Remove the crossmember that is the mount for the hood. 4. Remove the nuts and bolts at the mounts for the operator module. 5. Connect a lifting device to the overhead guard. The overhead guard and module weigh approximately 385 kg (850 lb). Lift the operator module from the frame.
1. Connect a lifting device to the overhead guard. The overhead guard and module weigh approximately 385 kg (850 lb). Lift the operator module onto the frame. 2. Make sure the rubber mounts are installed in the frame. Install the large washer and nut on the
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Operator Module Repair
100 SRM 505
bottom of the mount. Tighten the nuts to 53 N•m (39 lbf ft).
4. Install the steering controls and the parking brake lever.
3. Install the crossmember for the hood and pedal mounts. Install the hood and side covers.
5. Install the floor plates.
1. 2. 3. 4. 5.
6. 7. 8. 9. 10.
OPERATOR MODULE FRAME HYDRAULIC TANK FUEL TANK STEERING AXLE MOUNT
DRIVE AXLE MOUNT CAPSCREW WASHER RUBBER MOUNT NUT
Figure 1. Frame and Operator Module
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100 SRM 505
Hood and Side Covers Repair
Hood and Side Covers Repair REMOVE NOTE: The combined weight of the hood and seat is approximately 45 kg (100 lb). Have a helper or use a lifting device to remove the hood and seat.
1. Raise the hood. Hold the hood so that it does not fall and disconnect the gas-controlled spring at the hood. See Figure 2. 2. Remove the rod end pins and pivot pins from the hood hinges. Remove the hood.
NOTE: H2.00-3.20XM (H45-65XM) SHOWN. S2.00-3.20XM (S40-65XM) SIMILAR. 1. 2. 3. 4. 5.
HOOD SEAT PAN ROD END PIN PIVOT PIN HOOD LATCH
6. 7. 8. 9. 10.
SIDE COVER GAS SPRING CLAMP SPRING CROSSMEMBER
11. LATCH STRIKER 12. PANEL 13. HOOD BUMPER
Figure 2. Hood and Side Covers
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Overhead Guard Repair
100 SRM 505
INSTALL 1. Install the hood in position on the lift truck. See Figure 2 and Figure 3. Install the pivot pins and rod end pins at the hood hinges. Connect the gascontrolled spring to the hood. Adjust the hood latch as follows:
WARNING
the latch striker is still in the center of the hood latch. Open the hood and tighten the capscrews for the latch. 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.
The hood, hood latch, and latch striker must be correctly adjusted for the correct operation of the operator restraint system. a. Install the hood latch in the lowest slot position on the frame of the hood. Tighten the capscrews so the hood latch can still move when the hood is closed. b. Install the latch striker. Check that the latch striker is in the center of the jaws of the hood latch when the hood closes. c. Carefully 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. Push the hood down until the hood just touches the rubber bumpers. Make sure
1. HOOD FRAME 2. HOOD LATCH
3. LATCH STRIKER
Figure 3. Hood Latch Check
Overhead Guard Repair REMOVE AND INSTALL 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 or in the wrong location, can reduce the strength of the overhead guard. See the instructions for Changes to the Overhead Guard in Periodic Maintenance 8000 SRM 707 section for your lift truck. 1. Connect a crane or lifting device to remove or install the overhead guard. Disconnect the air intake at the overhead guard leg. 2. Disconnect any wires between the frame and the overhead guard. When the overhead guard is lifted from the frame, make sure that any electrical wires are moved through the holes in the frame so that they are not damaged.
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3. There are two capscrews at each corner of the left-hand leg of the overhead guard. Remove and install the capscrews for the overhead guard as follows: a. Access to the bolts at the front of the overhead guard is under the dash panel. Remove the plastic box from the right-hand side of the dash panel. b. Access to the bolts at the rear of the overhead guard is under the rear fender wells. c. Tighten the rear leg mount capscrews to On H2.00-3.20XM 53 N•m (39 lbf ft). (H45-65XM) units, tighten the capscrews that fasten the module cowl side plate to the front legs to 66 N•m (49 lbf ft). NOTE: The air inlet for the air filter is installed in the left-hand leg of the overhead guard. Make sure the grill is installed with the louvers pointed downward.
100 SRM 505
Counterweight Repair
LED BACKUP AND BRAKE LIGHTS, REPLACE NOTE: Newer models of lift trucks are equipped with LED (Light Emitting Diode) backup and brake tail lights. These light assemblies are non-repairable and must be replaced as a complete unit. See the Parts Manual for replacement LED lights.
Remove 1. Disconnect negative terminal of battery and remove the key. 2. Disconnect the LED light from the chassis light harness. 3. Remove LED light assembly and harness from mounting bracket. See Figure 4. 4. If the LED mounting bracket must be removed from the overhead guard leg, remove the plug, screw and bracket from the overhead guard leg.
Install 1. If the mounting bracket was removed, install it onto the overhead guard leg. Insert the plug and screw to attach mounting bracket to overhead guard leg. See Figure 4. 2. Install the LED light assembly and harness on the mounting bracket. 3. Connect the LED light to the chassis light harness. 4. Connect the negative terminal of battery and close the hood.
A. LED ASSEMBLY WITH STANDARD EXHAUST B. LED ASSEMBLY WITH OVERHEAD EXHAUST 1. 2. 3. 4. 5.
LED LIGHT SCREW WASHER LOCK NUT MOUNTING BRACKET
6. 7. 8. 9.
GROMMET PLUG SCREW OVERHEAD GUARD LEG
Figure 4. LED Backup and Brake Lights Assembly
Counterweight Repair WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.
• Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward. 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. See the Operating Manual or Periodic Maintenance 8000 SRM 707 for your lift truck. The counterweight is held in position on the frame by two hooks that are part of the frame. One M24 × 3
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Counterweight Repair
100 SRM 505
capscrew holds the counterweight to the lower part of the frame.
d. Run the engine until it stops, then turn the key switch to the OFF position.
REMOVE
e. Disconnect the quick-disconnect fitting. f.
WARNING
Release the LPG tank latch and remove the tank from the bracket.
Do not operate the lift truck if the capscrew for the counterweight is not installed. When the capscrew is removed, the counterweight can fall from the lift truck.
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 (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source. Close the shutoff 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. If the engine will not run, close the shutoff 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. 1. If the lift truck has an LPG fuel system, use the following procedure to remove the LPG tank and bracket so that the counterweight can be removed: See Figure 5. Additional information on the LPG fuel system can be found in the following sections LPG Fuel System, GM 2.2L and 3.0L Engines 900 SRM 498, LPG Fuel System, Mazda M4-2.0G Engine 900 SRM 523, or Electronic Controlled LPG/Gasoline Fuel System, GM 3.0L and 4.3L EPA Compliant Engines 900 SRM 1088 a. LPG tanks can be removed and replaced indoors only if the lift truck is at least 8 m (26 ft) from any flame or ignition source. b. Move the lift truck to the area where tanks are changed. c. Turn the shutoff valve clockwise until the valve is completely closed.
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NOTE: H2.00-3.20XM (H45-65XM) SHOWN. S2.003.20XM (S40-65XM) SIMILAR. 1. 2. 3. 4.
SEAL SPACER COUNTERWEIGHT HOLE FOR EYEBOLT
5. EYEBOLT 6. TOW PIN 7. CAPSCREW
Figure 5. Counterweight 2. If an overhead exhaust is installed, remove it as shown in Figure 7.
WARNING The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough capacity to lift the weight. The approximate weights of the counterweight castings are shown in Table 1. 3. Install a lifting eye in the lifting hole of the counterweight. See Figure 5. Connect a crane to the lifting eye and raise the crane until it holds
100 SRM 505
Counterweight Repair
part of the weight of the counterweight. Remove the capscrew that holds the counterweight to the frame. Use the crane to lift the counterweight from the lift truck. Put the counterweight on the floor so that it has stability and will not fall over. Remove the spacers from the mounts.
a. Before the LPG tank is installed on the lift truck, make sure the tank has fuel in it. Check the operation of the fuel gauge. Look at the fuel gauge and move the tank. If the gauge needle does not move, a new tank must be installed.
Table 1. Weight of Counterweights Model
kg
lb
H2.00XM
1080 ±16
2380 ±35
H2.25XM (H45XM)
1231 ±18
2715 ±40
1354 ±20
2985 ±44
1406 ±21
3100 ±46
H2.50XM (H50XM) H50XM
1
2
1611 ±24
3550 ±53
H3.00XM (H60XM)
1
1800 ±27
3970 ±60
H3.00XM (H60XM)
2
1696 ±25
3740 ±55
1770 ±27
3900 ±60
H2.75XM (H55XM)
H3.20XM (H65XM)
NOTES: 1 1623 mm (63.9 in.) Wheelbase 2 1700 mm (67.0 in.) Wheelbase S2.00XM (S40XM)
1070 ±15
2360 ±33
S2.25XM (S45XM)
1233 ±19
2720 ±42
S2.50XM (S50XM)
1433 ±21
3160 ±46
S2.75XM (S55XM)
1640 ±25
3615 ±55
S2.75XM (S55XM)
1710 ±25
3770 ±55
S3.00XM (S60XM)
1855 ±28
4090 ±62
S3.20XM (S65XM)
2018 ±30
4450 ±66
INSTALL 1. Install the spacers on the mounts. See Figure 6. Use a crane to install the counterweight on the lift truck. When the counterweight is installed, make sure the hooks on the frame fully engage the counterweight so it is aligned with the parts of the frame. Use the spacers to obtain a gap of 8.5 to 11.5 mm (0.33 to 0.45 in.) between the counterweight and the overhead guard leg. Install and tighten the M24 × 3 capscrew to 555 N•m (409 lbf ft). 2. If the lift truck has an LPG fuel system, use the following procedure to install the bracket and LPG tank after the counterweight has been installed:
1. SPACER 2. RUBBER SEAL
3. CAPSCREW
Figure 6. Counterweight Installation
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Exhaust System Repair
100 SRM 505
b. Put the tank in the tank bracket. Make sure the tank is aligned with the alignment pin. c. Close the latch. d. Connect the quick-disconnect fitting to the shutoff valve on the tank. Use your hand to tighten the fitting. Do not open the shutoff valve until the quick-disconnect fitting is completely tightened. Turn the shutoff valve counterclockwise to open the valve.
e. Inspect the fuel system for leaks when the shutoff valve is open. Frost on the surface of the tank, valves, or fittings or a strong odor indicates leakage. 3. If the lift truck has an overhead exhaust, install it as shown in Figure 7.
Exhaust System Repair The muffler is installed inside the cavity of the counterweight. A short exhaust pipe sends the exhaust gases out of the lift truck through the grille in the counterweight.
counterweight to 38 N•m (28 lbf ft). Install the cover.
The lift truck can have an overhead exhaust system. The exhaust pipe is fastened to the top of the counterweight. See Figure 7.
MUFFLER, REPLACE The counterweight must be removed to install the muffler. When replacing parts of a standard exhaust system, see Figure 8. When replacing parts of the GM3.0L EPA Compliant Exhaust System, see Figure 9. When replacing parts of a low-emissions exhaust system, see Figure 10. When replacing parts of the Mazda 2.0L and 2.2L EPA Compliant Exhaust Systems, see Figure 11. When connecting the exhaust pipe to the engine, do the following: 1. Isuzu 4JB1 and 4JG2 Engines/Low-Emmissions Exhaust Systems: Install the adapter on the exhaust manifold. Tighten the nuts for the adapter to 40 N•m (30 lbf ft). Install the exhaust seal, spacer, and exhaust pipe. Install the springs and special capscrews. Tighten the special capscrews to 38 N•m (28 lbf ft). 2. GM 2.2L and 3.0L Engines: Install the exhaust seal and exhaust pipe. Install the spring, special capscrew, and lockwasher. Make sure the lockwasher is between the exhaust manifold and special capscrew. 3. On units with an overhead exhaust, tighten the capscrews that hold the overhead exhaust to the
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1. OVERHEAD EXHAUST
2. COVER 3. COUNTERWEIGHT
Figure 7. Overhead Exhaust
100 SRM 505
1. 2. 3. 4. 5. 6.
MUFFLER RUBBER MOUNT ISUZU C240 ARRANGEMENT ISUZU 4JB1, 4JG2 ARRANGEMENT GM 2.2L AND 3.0L ARRANGEMENT MAZDA M4-2.0G ARRANGEMENT
Exhaust System Repair
7. 8. 9. 10. 11. 12.
GASKET ADAPTER SEAL SPACER SPRING SPECIAL CAPSCREW
Figure 8. Exhaust System
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Exhaust System Repair
1. 2. 3. 4. 5.
100 SRM 505
MUFFLER COUNTERWEIGHT EXHAUST PIPE GASKET EXHAUST PIPE SEAL
6. 7. 8. 9.
SPRING SPECIAL SCREW OXYGEN SENSOR PORT RAW GAS CHECK PORT
Figure 9. Exhaust System, GM3.0L EPA Compliant
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100 SRM 505
1. 2. 3. 4. 5. 6. 7.
Exhaust System Repair
MUFFLER SPACER BRACKET CATALYTIC CONVERTER DIFFUSER CLAMP GASKET
8. 9. 10. 11. 12. 13. 14.
ADAPTER SEAL SPACER SPRING SPECIAL CAPSCREW PLUG (RAW GAS CHECK PORT) OXYGEN SENSOR
Figure 10. Exhaust System, Low Emissions (2.0L and 2.2L)
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Exhaust System Repair
Figure 11. EPA Compliant Exhaust System Mazda 2.0L and 2.2L
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100 SRM 505
100 SRM 505
Radiator and Cooling System Repair Legend for Figure 11
1. 2. 3. 4. 5. 6. 7. 8.
MUFFLER SPACER BRACKET CATALYTIC CONVERTER DIFFUSER CLAMP GASKET ADAPTER
9. 10. 11. 12. 13. 14. 15.
SEAL SPACER SPRING SPECIAL CAPSCREW PLUG (RAW GAS CHECK PORT) OXYGEN SENSOR OVERHEAD EXHAUST PIPE
Radiator and Cooling System Repair REMOVE WARNING DO NOT remove the radiator cap while it is hot. Hot coolant and steam can cause burns. Make sure the label is on the radiator cap. See Figure 16. 1. Use the drain valve and drain the coolant from the radiator. Remove the bottom radiator hose and drain the coolant from the engine. See Figure 12 and Figure 13. 2. Remove the capscrews that fasten the fan to the hub. Remove the capscrews that hold the fan shroud to the radiator. Remove both the fan and the fan shroud. 3. Disconnect the top coolant hose at the radiator. Disconnect the lines to the oil cooler in the side of the radiator. Put caps on the open lines and ports. Remove the capscrews that hold the radiator to the frame. Remove the radiator.
INSTALL 1. Install the radiator. See Figure 12 and Figure 13. Install the fan and fan shroud in position on the radiator. Install the capscrews that hold the fan shroud. Install the capscrews that fasten the fan to the hub. Tighten the capscrews to 26 N•m (19 lbf ft).
1. 2. 3. 4. 5.
RADIATOR RADIATOR CAP AUXILIARY COOLANT RESERVOIR SHROUD DRAIN VALVE Figure 12. Cooling System (Older)
2. Connect the upper coolant hoses at the radiator. Connect the lines for transmission oil to the oil cooler in the radiator.
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Radiator and Cooling System Repair
100 SRM 505
A. MAZDA 2.0L AND 2.2L ENGINES 1. RADIATOR 2. RADIATOR CAP
3. AUXILIARY COOLANT RESERVOIR Figure 13. Cooling System (Newer)
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4. SHROUD 5. DRAIN VALVE
100 SRM 505
Operator Restraint System Repair
Operator Restraint System Repair The seat belt, hip restraint, seat and mount, hood, and latch are all part of the operator restraint system. Each item must be checked to make sure it is fastened correctly, functions correctly, and is in good condition. See Figure 14. The end of the seat belt must fasten correctly in the latch. Make sure the seat belt pulls from the retractor assembly and retracts smoothly. The seat
1. 2. 3. 4. 5. 6.
LATCH STRIKER HOOD LATCH LATCH LEVER SEAT SEAT BELT LATCH HIP RESTRAINT
belt must be in good condition. A seat belt that is damaged or worn will not give protection when it is needed. Adjust the hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or replaced. See Hood and Side Covers Repair for the adjustment procedures.
7. 8. 9. 10. 11.
SEAT RAIL HOOD HINGE OPERATOR WEIGHT ADJUSTMENT FORWARD/BACKWARD ADJUSTMENT
Figure 14. Hood and Seat Check
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Engine Repair
100 SRM 505
Engine Repair REMOVE ENGINE ONLY WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. • Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward. 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. See the Operating Manual or the Periodic Maintenance section for your lift truck. The engine can be removed with or without the transmission. Follow this procedure to remove the engine without the transmission.
WARNING Always disconnect the cables at the battery before you make repairs to the engine. Disconnect the cable at the negative terminal first. 1. Remove the floor plates. Remove the hood and side covers. Remove the crossmember that is the hood mount. Remove the air filter and battery. Remove the radiator. 2. Disconnect the throttle linkage. Disconnect the exhaust system. 3. Disconnect the wires and wiring harnesses at the engine. Disconnect the fuel lines at the engine.
WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 340 kg (750 lb). 6. Remove the nuts and bolts from the engine mounts. Use the lifting device to carefully move the engine away from the torque converter. Make sure all hoses, wires, and cables are disconnected from the engine, then lift the engine from the frame.
REMOVE ENGINE AND TRANSMISSION The engine can be removed with or without the transmission. Follow this procedure to remove the engine with the transmission. 1. Remove the mast. See the section Mast, Repairs 4000 SRM 522. Put the lift truck on blocks so you have access under the lift truck. See the section Periodic Maintenance 8000 SRM 707. 2. Perform Step 1 through Step 3 from Remove Engine Only. 3. Remove the crossmember for the brake and throttle pedals. 4. Remove the hydraulic hose between the pump and the tank. Put a cap on the tank fitting. Remove the hydraulic filter and hoses. Remove the supply line to the main control valve. 5. Drain the oil from the axle housing. Remove the capscrews that hold the axle shafts to the hubs. Remove the axle shafts. Disconnect the brake lines and parking brake cables. Remove the capscrews that hold the transmission housing to the axle housing.
WARNING
4. Connect a lifting device to the engine. Put a block under the transmission housing as a support.
The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb).
5. Remove the capscrews that hold the torque converter housing to the flywheel housing. Remove the capscrews that hold the drive plate to the torque converter.
6. Connect a lifting device to the engine and transmission. Make sure the engine and transmission assembly can be raised at an angle so they will clear the frame. Remove the nuts and bolts from
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100 SRM 505
Engine Repair
the engine mounts. Use the lifting device to carefully lift the engine and transmission from the frame.
INSTALL ENGINE ONLY The engine can be installed with or without the transmission. Follow this procedure to install the engine without the transmission.
WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 340 kg (750 lb). 1. Make sure the torque converter is installed in the transmission and the drive plate is on the flywheel. Connect a lifting device to the engine. Lift the engine into the frame. Carefully align the drive plate with the transmission. See the section Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 SRM 501. Make sure the pilot on the torque converter is in the hole in the flywheel. Install the capscrews that hold the torque converter housing to the flywheel housing. Install the capscrews that hold the drive plate to the torque converter. 2. Install the nuts and bolts for the engine mounts. Install the parts of the mounts as shown in Figure 15. Use a maximum of three spacers to bring the engine mounts within 1.0 mm (0.04 in.) of a vertical position. Tighten the nuts to 66 N•m (49 lbf ft). 3. Install the radiator and connect the coolant hoses and the lines to the transmission. 4. Install the crossmember that is the hood mount. Connect the wires and wiring harnesses at the engine. Connect the fuel lines at the engine. 5. Connect the throttle linkage. Connect the exhaust system. Install the air filter assembly.
1. 2. 3. 4. 5.
BOLT ENGINE MOUNT FLAT WASHER SPACER CUP
6. 7. 8. 9. 10.
RUBBER MOUNT TUBE SPACER BUMPER LOCKWASHER NUT
Figure 15. Engine Mounts
6. Install the battery. Install the side covers and the hood. 7. Check all fluid levels as described in Periodic Maintenance 8000 SRM 707.
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Fuel and Hydraulic Tanks Repair
INSTALL ENGINE AND TRANSMISSION The engine can be installed with or without the transmission. Follow this procedure to install the engine with the transmission. 1. Put the lift truck on blocks so you have access under the lift truck. See the section Periodic Maintenance 8000 SRM 707.
WARNING The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb). 2. Apply a gasket sealant to the flange of the axle housing. Connect a lifting device to the engine and transmission. Lift the engine and transmission into the frame. Connect the transmission housing to the axle housing. Install a capscrew
100 SRM 505 in the "tight fit" hole first. This hole is on the side of the transmission with the dipstick, near the top. Install the remaining capscrews. Tighten the capscrews to 38 N•m (28 lbf ft). 3. Install the nuts and bolts for the engine mounts. Install the parts of the mounts as shown in Figure 15. Use a maximum of three spacers (4) to bring the engine mounts within 1.0 mm (0.04 in.) of a vertical position. Tighten the nuts to 66 N•m (49 lbf ft). 4. Install the hydraulic hose between the pump and the tank. Install the hydraulic filter and hoses. Connect the supply line to the main control valve. 5. Install the crossmember for the brake and throttle pedals. 6. Perform Step 3 through Step 7 from Install Engine Only.
Fuel and Hydraulic Tanks Repair INSPECT 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 by the American Welding Society, F4.1 - 1999. • Safety in Welding and Cutting, American National Standard, AWS Z 49.1 - 1999.
WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion. 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
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are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.
SMALL LEAKS, REPAIR 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. 2. Apply Loctite® 290 to the leak. Follow the instructions of the manufacturer.
LARGE LEAKS, REPAIR 1. Use one of the procedures described under Clean to clean and prepare the tank for repairs. 2. Contact your dealer for Hyster lift trucks for welding instructions. 3. 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 505
CLEAN WARNING
Fuel and Hydraulic Tanks Repair
Chemical Solution Method of Cleaning WARNING
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 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.
If the tank cannot be cleaned with steam, use the following procedure:
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.
1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkaline 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.
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.
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.
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.
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.
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.
ADDITIONAL PREPARATIONS FOR REPAIR
5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank. 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.
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. 2. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 1999.
19
Safety Labels
100 SRM 505
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 a new nameplate.
WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.
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If a new label must be installed, use the following procedure to install a new label (see Figure 16 or Figure 17): 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 505
Safety Labels
NOTE: SEE PARTS MANUAL FOR PART NUMBERS OF LABELS. 1. 2. 3. 4. 5. 6. 7.
WARNING, OPERATION NAMEPLATE WARNING FOR PARKING BRAKE NO ONE ON OR UNDER FORKS NO RIDERS TIPOVER WARNING MAST WARNING
8. 9. 10. 11. 12. 13. 14.
FAN WARNING RADIAL TIRE WARNING* ETHER WARNING* TWO-PIECE WHEEL WARNING FLAMMABLE LP-GAS* RADIATOR CAP WARNING OPTIONAL FIRE SAFETY RATING*
*NOT USED ON ALL UNITS Figure 16. Label Positions for H2.00-3.20XM (H45-65XM)
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Safety Labels
100 SRM 505
NOTE: SEE PARTS MANUAL FOR PART NUMBERS OF LABELS. 1. 2. 3. 4. 5. 6. 7. 8.
MAST WARNING NAMEPLATE TIPOVER WARNING OVERHEAD GUARD WARNING, OPERATION FAN WARNING RADIATOR CAP WARNING DUAL FUEL (IN ENGINE COMPARTMENT)*
9. 10. 11. 12. 13. 14. 15.
FLAMMABLE LP-GAS* OPTIONAL FIRE SAFETY RATING* NO RIDERS DRIVE TRAIN PROTECTION* NO ONE ON OR UNDER FORKS PINCH POINT WARNING WARNING FOR PARKING BRAKE
*NOT USED ON ALL UNITS Figure 17. Label Positions for S2.00-3.20XM (S40-65XM)
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1600 SRM 316
Description
General This section has the description and repair procedures for the steering axle. See the following sections for additional information on the parts of the steering system: Steering Housing and Control Unit and Hydraulic System.
Description The steering axle assembly includes an axle frame, steering cylinder, and two spindle and hub assemblies. See Figure 1. The steering axle is connected to the frame with center pivot mounts. The center pivot mounts on the axle frame are fastened to the lift truck frame with rubber mounts. The steering axle can make an articulated motion and gives the lift truck a smoother travel over rough surfaces. The end caps of the steering cylinder are also the mounts for the cylinder and are held to the shell by the mount capscrews. O-rings, seals, and wipers in the end caps are used to keep the oil inside the
1. SPINDLE AND HUB ASSEMBLY 2. AXLE FRAME 3. BRACKET
steering cylinder. 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 rod. Oil pressure on one side of the piston moves the piston in the bore. When the piston moves in the bore, it pushes an equal amount of oil from the opposite end of the cylinder. This oil returns to the steering control unit. When the piston reaches the end of the stroke, a relief valve controls the oil pressure so the components are not damaged. Tie rods connect the spindle arms to the cylinder.
4. RUBBER MOUNT 5. STEERING CYLINDER 6. NUT AND BOLT Figure 1. Steering Axle
1
Steering Axle Assembly Repair Each spindle turns on two tapered roller bearings. The spindle and bearings are held in the axle frame by a kingpin. The preload on the bearings is controlled by a threaded nut on the bottom of the kingpin.
1600 SRM 316 The wheel or hub rotates on two tapered roller bearings and is held on the spindle by a castle nut. The preload on the bearings in the hub is adjusted by the castle nut. A grease seal in the inner hub and a hub cap protect the bearings from dirt and water. A wear sleeve in the inner hub protects the hub from wear by the seal.
Steering Axle Assembly Repair REMOVE WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: drive axle, battery, or counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: 1. If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. 2. If the battery (electric lift trucks) or counterweight is removed, put blocks under the mast so the lift truck cannot fall forward. Put the lift truck on blocks on a solid, even, and level surface. Make sure the blocks of stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies. NOTE: The steering axle assembly without the wheels weighs approximately 115 kg (250 lb). The steering axle can be removed without removing the counterweight. If necessary, remove counterweight as described in the Frame section. 1. Make sure wheels are set for straight travel. Put lift truck on blocks so steering axle can be removed. The top of the axle frame must have clearance under the counterweight so the steering axle can be removed. See Figure 1.
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2. Disconnect hydraulic lines at steering cylinder. Install caps on cylinder and put plugs in hydraulic lines. The caps will prevent spindles from turning when axle is removed from under lift truck. 3. Slide a floor jack or forks of another lift truck under steering axle. Raise lifting device until it holds the weight of the axle assembly. Remove four capscrews and nuts that fasten two brackets under rubber mounts. Remove brackets and slowly lower axle assembly onto wheels. Carefully roll axle assembly from under lift truck.
INSTALL 1. Install rubber mounts on axle as follows (see Figure 1): a. E1.25-1.75XL (E25-35XL), J2.00-3.00XL (J40-60XL), H2.00-3.20XM (H40-65XM), J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), and J2.00-3.20XM (J40-65Z) (A416/B416): Make sure PART NO. on the mounts is right side up and facing away from axle frame. b. J1.25-1.75XL (Europe only): Make sure PART NO. on mounts is upside down and facing away from axle frame. 2. Apply a lubricant that is approved for use with rubber to rubber mount. The lubricant is used where the rubber mount fits into the frame brackets. 3. Use a floor jack or another lift truck to put steering axle into position in frame. Make sure rubber mounts fit inside frame brackets for mounts.
1600 SRM 316
Wheels and Hubs Repair
4. Install bottom brackets. Tighten four bracket capscrews and nuts to 88 N•m (65 lbf ft). 5. Remove plugs and caps and connect hydraulic lines to steering cylinder.
6. Operate steering system to remove air from system. Turn steering wheel several times from one stop to the other stop. Check for hydraulic leaks.
Wheels and Hubs Repair REMOVE AND DISASSEMBLE WARNING
2. If the wheel bearings must be replaced, use a brass drift to remove bearing cups and wear sleeve.
PUTTING THE LIFT TRUCK ON BLOCKS
3. Repeat procedure for other wheel.
The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: drive axle, battery, or counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: 1. If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. 2. If the battery (electric lift trucks) or counterweight is removed, put blocks under the mast so that the lift truck cannot fall forward.
CLEAN
Put the lift truck on blocks on a solid, even, and level surface. Make sure the blocks of stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies.
WARNING Completely deflate the tires before removing them from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire. 1. Put axle on blocks so tires are raised from floor. Remove grease cap. Remove cotter pin and castle nut. Remove outer bearing cone. Slide wheel from spindle. Remove inner bearing cone and seal from spindle. See Figure 2.
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. Clean all parts with solvent. Make sure bearings are clean.
ASSEMBLE AND INSTALL CAUTION Do not damage the seals during installation. 1. If wheel bearings must be replaced, use a press to install new bearing cups in wheel or hub. See Figure 2. Install new wear sleeve in wheel or hub. Install grease seal on spindle. Lubricate bearing cones with grease. Make sure bearings are filled with grease. Install bearing cone on spindle. 2. Carefully slide wheel or hub onto spindle. Install outer bearing cone. 3. Install castle nut. Tighten castle nut to 200 N•m (150 lbf ft) while wheel is rotated. Loosen nut to less than 27 N•m (20 lbf ft). Tighten nut to 34 N•m (25 lbf ft). If cotter pin cannot be installed with nut tightened to 34 N•m (25 lbf ft), tighten castle nut until cotter pin can be installed. Install cotter pin. 4. Repeat procedure for other wheel.
3
Wheels and Hubs Repair
1600 SRM 316
NOTE: H2.00-3.20XM (H40-65XM) SHOWN, OTHERS SIMILAR. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
AXLE FRAME WASHER BOLT BELLEVILLE WASHER RUBBER MOUNT BRACKET NUT STEERING CYLINDER PIN SNAP RING BUSHING TIE ROD GREASE FITTING CASTLE NUT SLEEVE
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
SEAL BEARING CONE BEARING CUP SPINDLE SPACER O-RING KINGPIN GROOVE PIN WEAR SLEEVE HUB* STUD* WHEEL NUT* COTTER PIN GREASE CAP
*PNEUMATIC TIRES ONLY Figure 2. Steering Axle
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1600 SRM 316
Spindles, Bearings, and Tie Rods Repair
Spindles, Bearings, and Tie Rods Repair REMOVE
(25 lbf ft), tighten castle nut until cotter pin can be installed. Install cotter pin.
WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: drive axle, battery, or counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: 1. If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. 2. If the battery (electric lift trucks) or counterweight is removed, put blocks under the mast so the lift truck cannot fall forward. Put the lift truck on blocks on a solid, even, and level surface. Verify the blocks of stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the parts and assemblies. NOTE: Dirt and corrosion can make the spacer difficult to remove from the steering axle frame. A machined space is made in the top of the spacer so that the spacer can be removed with a bearing puller. Remove wheel or hub from steering axle spindle. See Figure 3. Remove pin to disconnect tie rod from spindle. Remove cotter pin and castle nut from bottom of kingpin. Use a driver to remove kingpin. Remove sleeve and then spindle from axle. Use a driver to remove bearings and seals from spindle.
INSTALL 1. Use new bearings and seals. See Figure 2 and Figure 3. Apply grease to bearings and kingpin as they are installed in axle. Install bearings in spindle. Install seals in correct position. Align spindle in axle and install kingpin. Make sure new O-ring is installed at top of kingpin. Install sleeve on bottom of kingpin. Install castle nut and tighten it to 90 N•m (66 lbf ft). Loosen castle nut to less than 34 N•m (25 lbf ft). Tighten nut to 34 N•m (25 lbf ft). If cotter pin cannot be installed with nut tightened to 34 N•m
1. 2. 3. 4. 5. 6. 7.
O-RING KINGPIN GROOVE PIN SPACER SEAL BEARING CONE BEARING CUP
8. 9. 10. 11. 12. 13. 14.
SPINDLE SEAL WEAR SLEEVE CASTLE NUT COTTER PIN GREASE CAP SLEEVE
Figure 3. Spindle Assembly 2. Connect tie rods. Verify belleville washers are installed on both sides of bushings. 3. Install wheels or hubs. See the section Wheels and Hubs Repair for proper installation procedure. On H2.00-3.20XM (H40-65XM), J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z) (A416/B416) tighten wheel nuts to 237 to 305 N•m (175 to 225 lbf ft). On J1.25-1.75XL (J25-35XL) and J2.00-3.00XL (J40-60XL), tighten wheel nuts to 155 N•m (115 lbf ft).
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Steering Cylinder Repair
1600 SRM 316
Steering Cylinder Repair REMOVE AND DISASSEMBLE WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: drive axle, battery, or counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: 1. If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. 2. If the battery (electric lift trucks) or counterweight is removed, put blocks under the mast so the lift truck cannot fall forward.
1. ROD 2. WIPER 3. END CAP
Put the lift truck on blocks on a solid, even, and level surface. Make sure the blocks of stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Make sure the lifting devices used during repairs can lift the weight of the parts and assemblies. NOTE: The end caps of the steering cylinder are held in the shell by the cylinder mount capscrews. To prevent oil leaks at the caps, hold caps on shell during removal. 1. Disconnect hydraulic lines at steering cylinder. See Figure 4. Install caps in fittings on cylinders and put caps on hydraulic lines. 2. Remove snap rings from pins in tie rods. Remove pins.
4. O-RING 5. BACKUP RING 6. SHELL Figure 4. Steering Cylinder
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7. PISTON SEAL 8. ROD SEAL 9. QUADRANT RING
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