Hyster Forklift S70XM-120XM (E004, F004) service manual by www.heydownloads.com

ALTERNATOR WITH REGULATOR DELCO, MOTOROLA, AND LEECE-NEVILLE COVERS DELCO, MOTOROLA, AND LEECE-NEVILLE ALTERNATORS USED ON HYSTER LIFT TRUCKS

PART NO. 899784

2200 SRM 2

Alternator with Regulator

Table of Contents

1 1 3 3 3 4 5 5 8 8 8 9 10 11 11 13 14 14 15 16 16 16 16 17 18 18 18

This section is for the following models: Covers Delco, Motorola, and Leece-Neville alternators used on Hyster lift trucks

ÂŠ2003 HYSTER COMPANY

2200 SRM 2

Description

General CAUTION When using an arc welder, always disconnect the ground lead from the lift truck battery to prevent alternator or battery damage. Attach the welding ground clamp as close to the weld area as possible to prevent welding current from damaging the bearings. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors in the electrical system. • Do not disconnect an electric wire before the engine is stopped and the switches are OFF.

• Do not cause a short circuit by connecting the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected. • Make sure a battery is the correct voltage and polarity before it is connected. • Do not check for current flow by making a spark because the electronic components can be damaged. NOTE: Information on alternators manufactured outside the United States is in the SRM (Service Repair Manual) sections for lift trucks that use those alternators. This section has a description and the repair procedures for the alternator with a voltage regulator as part of the alternator.

Description NOTE: For this SRM section, the alternators are in two groups: Type A and Type B. The two types are very similar, but the Type A alternators have a set of three diodes (diode set) as well as the diode bridge. The Type B alternator has zener diodes as part of the diodes in the diode bridge. This alternator does not have a diode set, but does have an additional fan inside the rear housing. The basic operation of both types is very similar. The alternator generates an alternating current when the engine is running. The alternator is either ON or OFF. The alternator generates maximum current when it is ON and no current when it is OFF. The regulator switches the alternator between ON and OFF to get the average current needed to charge the battery. Alternator output is directly changed by engine speed and rotor field current. The alternating current is changed to a direct current by the diode bridge inside the alternator. The alternator has these parts (see Figure 1 and Figure 2): A stator A rotor A diode bridge A diode set (Type A only) Two end housings or frame halves A solid-state voltage regulator

NOTE: DELCO TYPE A SHOWN. 1. BRUSH ASSEMBLY 2. ROLLER BEARING 3. GREASE RESERVOIR 4. LIP SEAL

5. 6. 7. 8.

DIODE BRIDGE BALL BEARINGS FELT SEAL REGULATOR

Figure 1. Alternator Cross Section

Description

2200 SRM 2

Figure 2. Alternator Schematics

2200 SRM 2

Alternator Repair Legend for Figure 2

NOTE: LEECE-NEVILLE NOT AVAILABLE, SIMILAR TO THOSE SHOWN. A. DELCO TYPE A (SMALL CAPACITY LIFT TRUCKS) B. DELCO TYPE B

C. MOTOROLA TYPE A D. DELCO TYPE A (LARGE CAPACITY LIFT TRUCKS)

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14.

BATTERY KEY SWITCH FUSE RESISTOR INDICATOR LIGHT OR AMMETER VOLTAGE REGULATOR ROTOR FIELD

The direct current from the diodes of the diode bridge flows to the output or BAT terminal. A capacitor between the BAT terminal and the electrical ground removes any remaining alternating current from the direct current. The capacitor also protects the diodes from high voltages. The voltage is controlled by the amount of current flowing through the field winding in the alternator and the rpm of the rotor. The voltage regulator, inside the housing, contains a transistor, diodes, resistors, and capacitor. The voltage regulator cannot be repaired. NOTE: On some large capacity lift trucks, the alternator has an external voltage adjustment.

STATOR DIODE BRIDGE DIODE SET FIELD TERMINAL REGULATOR TERMINAL OUTPUT (BAT) TERMINAL VOLTAGE ADJUSTMENT

The voltage regulator controls the alternator to charge the battery. The voltage is set by the manufacturer and is not usually adjustable. Battery voltage decreases as the starting circuit and other circuits take energy from the battery. When the key switch is put in the IGN position, the voltage regulator is energized. A positive current flows to the field terminal (F or 1) on Type A alternators and (L) on Type B alternators. The battery sends a positive current to the regulator terminal (Type A R or 2) and the BAT terminal. The regulator senses a decrease in battery voltage and increases the alternator output to charge the battery.

Alternator Repair ALTERNATOR TYPE A Remove and Disassemble WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal. NOTE: Use Troubleshooting and General Check and Adjustment, Low Output Check (Type A or Type B), High Output Check (Type A or Type B), Brushes Circuit Check, Diodes Check, Diode Bridge Check, Rotor Field Winding Check, Stator Windings Check, and Voltage Regulator Check procedures of this SRM before starting any repair procedures. Make sure that repair or replacement of that part is necessary before removal, disassembly, or replacement of the part.

NOTE: There are some checks of the alternator that are done with the alternator on the engine. See General Check and Adjustment, Low Output Check (Type A or Type B), High Output Check (Type A or Type B), Brushes Circuit Check, Diodes Check, Diode Bridge Check, Rotor Field Winding Check, Stator Windings Check, and Voltage Regulator Check procedures of this SRM before starting any removal or repair procedures. NOTE: Many parts of the Leece-Neville alternator can be replaced without disassembling the alternator. See Figure 5. The alternator must be disassembled to replace only the diode bridge, filter capacitor, rotor, stator, or bearings. 1. Disconnect the battery ground cable. See Figure 3, Figure 4, and Figure 5. Install labels and disconnect the wires at the alternator. Loosen the alternator mount capscrews and remove the drive belt. Remove the capscrews that hold the alternator to the engine.

Alternator Repair

2200 SRM 2

2. On Leece-Neville alternators, remove the brushes, voltage regulator, or diode set. Install labels on all wires for correct connection during installation. 3. Put a mark on each housing and on the stator for correct alignment during assembly. Remove the bolts that hold the housings together. Separate the housings and stator. 4. Put the rotor in a vise that has soft jaws. Do not tighten the vise to cause rotor distortion. Use a socket wrench to remove the pulley nut. Remove the pulley, fan, collar, spacer, shield, or other parts between the fan and housing. Remove the front housing from the rotor. 5. Remove any nuts or screws that fasten parts inside to the rear housing. Then, remove the stator assembly from the rear housing so that the other parts can be removed. Remove the screws for the capacitor, diode bridge, diode set, brushes, and other parts as necessary. If the stator will be removed from the diode bridge, make sure the wires have tags for correct connection during assembly. 6. Mark the stator to show the position of the brushes and connector or diode bridge assembly. Use pliers as a heat sink to keep heat from the

diodes. Use a soldering iron to remove the stator leads from the diode assembly. 7. Remove the bearings from the housings only if they will be replaced.

Clean WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION Never use solvent on the parts of the alternator. NOTE: If necessary, use fine abrasive cloth to polish the slip rings. The abrasive cloth must be number 500 to 600. Remove all dust. Turn the rotor while polishing the slip rings. Use compressed air to remove dirt from the alternator. Clean the brushes and slip rings with a clean, dry cloth.

A. DELCO

B. MOTOROLA

1. GROUND TERMINAL 2. BATTERY TERMINAL (BAT OR +)

3. FIELD TERMINAL 4. REGULATOR TERMINAL

Figure 3. Type A Alternators, Rear Views

2200 SRM 2

Alternator Repair

Assemble

a. Install the brush and holder, voltage regulator, and diodes from the inside of the alternator. Make sure the insulator sleeves are on the screws for the brush holder. Install the capacitor.

1. For Delco (Type A) alternators, install a new bearing(s) in the housing as follows (see Figure 3, Figure 4, and Figure 5): a. Install a new plug and seal in the rear housing. Push the bearing from the outside of the housing until the top of the bearing is even with the outside of the housing. Hold the housing with the collar on the inside of the housing. Keep the lip of the seal away from the bearing. Lubricate the bearing area with non-conductive grease. b. Install a new bearing in the front housing. Fill one quarter of the grease reservoir with non-conductive grease. Move the grease so that it touches the bearing when the retainer plate is installed. c. Add the same type of grease to fill the area between the retainer plate and the bearing. Install the spacer, gasket, and retainer plate on the bearing. Fasten the retainer plate in position with the three screws and lockwashers. 2. For Motorola and Leece-Neville alternators, use a press to install the rear bearing on the rotor. Install the bearing and bearing retainer in the front housing. If used, install the spacer on the bearing.

CAUTION Hold the rotor in a vise that has soft jaws. Do not tighten the vise more than necessary. 3. Install the front housing on the rotor. If used, install the spacer or shield, shaft key, and washer. Install the fan, pulley, lockwasher, and nut. Tighten the nut to 54 to 81 Nâ&#x20AC;˘m (40 to 60 lbf ft).

CAUTION Be sure to install the insulators. Make sure the heat sink does not touch the housing. 4. Install the diode bridge and heat sink in the reverse order of disassembly. Make sure the insulators and washers are in the correct positions. Install the capacitor.

b. Install the stator in the rear housing. Connect the three wires from the stator to the diode bridge and fasten at the studs. Connect the wires from the diodes to the studs on the diode bridge. Install and tighten the three lockwashers and nuts. c. Install the brushes in the brush holders. To hold the brushes in position, put a pin through the hole in the brush holders. Apply a thin layer of oil to the lip of the seal for the bearing. 6. On Motorola alternators, install parts as follows: a. Install the diode bridge on the stator. Use pliers to keep the heat from the soldering iron away from the diodes. b. Install the capacitor, diode set, and terminal on the diode bridge. Align the marks made during removal and install the stator and bridge assembly in the rear housing. 7. Align the marks made during disassembly. Carefully install the stator and the rear housing over the rotor. Do not damage the seal while sliding the housing over the rotor shaft. Install the front housing. 8. Install the four screws to hold the alternator together. On Delco alternators, remove pin to release the brushes. 9. On Motorola alternators, install the brush holder and brushes. Make sure the washer is on the right-hand screw. Install the voltage regulator and tighten the screws. 10. On Leece-Neville alternators, install the brushes, voltage regulator, or diode set in the reverse order of removal.

Install 1. Install the alternator in the bracket on the engine and adjust the tension of the belt.

5. On Delco alternators, install parts as follows:

Alternator Repair

2200 SRM 2

2. Connect all wires and the connector according to the labels made during removal. Also see the schematic diagram for your alternator in Figure 2. Make sure all wires are connected correctly and all fasteners are tight. See Figure 3.

3. Check the indicator light or the ammeter to check the operation of the alternator. The indicator light for Type A alternators will only be ON if the battery is discharged.

Figure 4. Type A Alternators, Exploded Views

2200 SRM 2

Alternator Repair Legend for Figure 4

A. DELCO

B. MOTOROLA

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

NUT SCREW DIODE BRIDGE CAPACITOR BEARING SLIP RINGS TERMINAL PULLEY FAN RETAINER SPACER SHIELD GASKET

9. 10. 11. 12. 13. 14. 15. 16.

BOLT FAN ROTOR STATOR NEGATIVE DIODE BRIDGE POSITIVE DIODE BRIDGE FILTER CAPACITOR REAR HOUSING

INSULATOR PLUG AND BEARING BEARING SEAL BOLT HOUSING VOLTAGE REGULATOR LOCKWASHER BRUSH AND HOLDER BRUSH SPRING WASHER ROTOR STATOR DIODES

A. LEECE-NEVILLE 1. 2. 3. 4. 5. 6. 7. 8.

TERMINAL DIODE SET BRUSH AND SPRING BRUSH HOLDER VOLTAGE REGULATOR BEARING RETAINER BEARING FRONT HOUSING

Figure 5. Type A Alternator, Exploded View

Alternator Repair

ALTERNATOR TYPE B Remove and Disassemble WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

2200 SRM 2 4. Use a punch to remove the rivets or pins that fasten the cover. Remove the cover for access to the stator leads. Discard the cover. See Figure 7. 5. Cut the stator leads as close to the connectors as possible. Install labels on the leads for correct connection during assembly and remove the stator from the rear housing. 6. Use a punch to remove the three baffle pins and remove the baffle. See Figure 7.

NOTE: Use the Troubleshooting and General Check and Adjustment, Low Output Check (Type A or Type B), High Output Check (Type A or Type B), Brushes Circuit Check, Diodes Check, Diode Bridge Check, Rotor Field Winding Check, Stator Windings Check, and Voltage Regulator Check procedures of this SRM before starting any repair procedures. Make sure that repair or replacement of that part is necessary before removal, disassembly, or replacement of the part.

NOTE: Carefully make a note of the sequence of removal of parts in Step 7 and Step 8 for correct installation. Also make a note of all types of connections (crimp, soldered, or welded) as well as all mechanical fasteners.

8. Open the crimps or use a soldering iron and disconnect the connectors to separate the brush holder, voltage regulator, and diode bridge.

1. Disconnect the battery ground cable. See Figure 6, Figure 7, and Figure 8. Install labels and disconnect the wires at the alternator. Disconnect the wire connector. Loosen the alternator mount capscrews and remove the drive belt. Remove the capscrews that hold the alternator to the engine. 2. Put a mark on each housing and on the stator for correct alignment during assembly. Remove the bolts that hold the housings together. Separate the housings and stator. 3. Put the rotor in a vise that has soft jaws. Do not tighten the vise to cause rotor distortion. Use a socket wrench to remove the pulley nut. Remove the pulley, collar, fan, outside collar, front housing, and inside collar from the rotor. NOTE: The cover must be replaced if the parts will be removed from the stator. If necessary, remove the stator as described in Step 4 and Step 5.

7. Remove the three mount screws and "BAT" terminal nut. See Figure 8. Lift the brush holder, voltage regulator, and diode bridge from the housing.

9. If the bearing will be replaced in the rear housing, remove the bearing and retainer ring.

2200 SRM 2

Alternator Repair

A. DELCO 1. 2. 3. 4. 5. 6. 7.

NUT PULLEY COLLAR OUTSIDE FAN OUTSIDE COLLAR FRONT HOUSING INSIDE COLLAR

8. 9. 10. 11. 12. 13. 14.

STATOR ROTOR AND FAN BAFFLE SCREW DIODE BRIDGE BRUSHES AND HOLDER VOLTAGE REGULATOR

15. 16. 17. 18. 19. 20.

COVER REAR HOUSING BALL BEARING RETAINER RING TERMINAL SET BOLT

Figure 6. Type B Alternator, Exploded View

Assemble 1. If the bearing was removed from the rear housing, install a new retainer ring. See Figure 6.

CAUTION

4. Put a thin coating of silicon grease on the inside of the rear housing under the diode bridge. 5. Install the bridge, regulator, and brush holder assembly in the rear housing and install the screws as removed during disassembly.

The bearing is not completely installed until Step 11 is complete.

6. Install the baffle and use a punch to fasten the pins.

2. Install a new bearing by pushing on the new bearing outer race until the bearing hits the bottom in the rear housing.

7. Align the marks made during disassembly and install the stator in the rear housing. Use pliers on the connectors of the diode bridge to keep heat from the diodes. Use a soldering iron to connect the stator leads to the connectors.

3. Assemble the voltage regulator, diode bridge, and brush holder on a flat surface. Put crimps in the connectors or solder the connectors to fasten and connect the parts as originally assembled. Use a pin to hold the brushes in the brush holder.

Alternator Repair

2200 SRM 2 (0.075 to 0.087 in.) below the surface of the rear housing.

Install 1. Install the alternator in the bracket on the engine and adjust the tension of the belt. 2. Connect all wires and the connector according to the labels made during removal. Also see the schematic diagram for your alternator in Figure 2. Make sure all wires are connected correctly and all fasteners are tight. See Figure 7. 3. Check the indicator light or the ammeter to check the operation of the alternator. The indicator light can also be ON if the alternator output is too high on Type B alternators.

NOTE: TYPE B ONLY. 1. REAR HOUSING 2. COVER 3. COVER RIVETS OR PINS

4. BAFFLE PINS 5. BOLTS TO FASTEN HOUSINGS TOGETHER

Figure 7. Outside Rear Housing 8. Install a new cover using rivets or pins to fasten the cover to the rear housing. 9. If necessary, install the bearing in the front housing. Put the rotor in a vise with soft jaws and install the inner collar, front housing, outer collar, fan, collar pulley, and nut on the rotor. Tighten the nut to 54 to 108 Nâ&#x20AC;˘m (40 to 80 lbf ft). 10. Align the front and rear housings using the marks made during disassembly. Push on both the inner and outer races of the rear bearing to push the two housings and stator together. Install the three bolts that fasten the alternator together. 11. Push on both the inner and outer race of the rear bearing so that the outer race is 1.9 to 2.2 mm

NOTE: TYPE B ONLY. 1. REAR HOUSING 2. VOLTAGE REGULATOR 3. BRUSH HOLDER 4. DIODE BRIDGE 5. TERMINALS FOR STATOR LEADS

6. NUT ON "BAT" TERMINAL 7. MOUNT SCREWS 8. SOLDERED OR WELDED CONNECTOR 9. BRUSH PIN

Figure 8. Inside Rear Housing

2200 SRM 2

Low Output Check (Type A or Type B)

General Check and Adjustment There are no adjustments for the alternator or most regulators. One Delco alternator and the Leece-Neville alternator has a voltage adjustment. Always check the general condition of the complete system before doing a complete check on each part. Check the general condition of the following parts: (1) battery, (2) battery cables and connections, and (3) alternator and regulator wires and connectors. Also check the condition and tension of the fan belt for the alternator.

CAUTION NEVER operate the engine if the alternator output BAT terminal is not connected to the battery. Do not short-circuit or connect jumper wires to any of the alternator terminals unless told to by the procedures. Make sure polarity is correct before connecting a battery charger or another battery. Remove the battery cables and clean the terminals and cable connectors. Inspect the insulation on the wires. Make sure all the fasteners and connections are clean and tight. If necessary, use a water and soda solution to clean the top of the battery. Do NOT remove the cell caps or permit the water and soda solution to get in the battery.

WARNING Put the transmission in NEUTRAL. Apply the parking brake.

CAUTION Do not change the polarity of the circuits. Do not connect any wires in the circuits, except as described in these instructions. Never connect the wire from the terminal marked "BAT" to an open circuit. When connecting a charger or another battery, connect the positive terminals to the positive terminal of the battery. Then connect the negative terminal to a clean metal part of the engine. Disconnect the charger or other battery in the reverse order. Problems in the charging circuit are indicated by one or more of the following: â&#x20AC;˘ The starter motor turns slowly. The battery voltage is low because of low alternator output or a bad battery. â&#x20AC;˘ The specific gravity readings are low. Battery is not fully charged or is damaged. â&#x20AC;˘ The battery uses more than 30 ml (1 oz) of water per cell per month. The alternator output is too high. The two problems of the charging circuit are low output and high output. Low output causes a low battery and difficult starting. A high output causes heating of the battery and evaporation of water from the electrolyte. The following two checks will find out if the alternator, regulator, or wiring has a charging fault. The two checks will also find out if the charging system has a correct output. Do the following two checks before removal, disassembly, or replacement of alternator or regulator. NOTE: Information on alternators manufactured outside the United States is in the SRM (service repair manual) sections for lift trucks that use those alternators.

Low Output Check (Type A or Type B) CAUTION Do not connect the wire from the "BAT" terminal to the electrical ground.

2. Connect a voltmeter to the field terminal and the regulator terminal. Follow the procedure in Step 1 and check the readings.

NOTE: Make sure the wire from the voltmeter makes contact with each terminal on the alternator.

3. If there are no readings on the voltmeter during Step 1 and Step 2, check for an open circuit between each terminal and the battery.

1. Connect a voltmeter between the BAT terminal and the electrical ground. Turn the key switch to the ON position and check the reading.

4. If there are readings on the voltmeter during Step 1 and Step 2, disconnect the cable for the electrical ground on the battery.

Low Output Check (Type A or Type B) 5. Make connections to the Type A alternator as shown in Figure 9. Make connections to the Type B alternator as shown in Figure 10. 6. Connect the cable for the electrical ground on the battery.

2200 SRM 2 10. If the ammeter reading is within 10%, the alternator is in good condition. Check the starter or wires for problems. Some alternators on larger lift trucks have a voltage adjustment. See Figure 12. For alternators with the voltage adjustment, do Step a to set the voltage:

7. Connect a carbon pile across the terminals of the battery.

a. The voltage setting can be increased by changing the position of the adjustment plug. LO is the lowest voltage setting. 2 is medium low and 3 is the medium setting. The voltage setting is highest when HI is aligned with the arrow on the alternator. Change the setting as necessary.

8. Run the engine at 2000 to 2500 rpm. Adjust the carbon pile until the maximum charging rate is reached. 9. Read the value of the maximum charging rate shown on the alternator housing or in the section Capacities and Specifications for your lift truck. Read the ammeter. The reading on the ammeter must be within 10% of the maximum value.

NOTE: TYPE B ONLY. NOTE: TYPE A ONLY. 1. 2. 3. 4.

CARBON PILE BATTERY AMMETER STARTER

5. ALTERNATOR 6. BAT TERMINAL 7. FIELD TERMINAL

Figure 9. Alternator Output Check

1. 2. 3. 4.

BATTERY CARBON PILE VOLTMETER RESISTOR (35 OHM 5 WATT TO 500 OHM 1/2 WATT)

5. 6. 7. 8.

AMMETER ALTERNATOR BAT TERMINAL CONNECT TO L TERMINAL

Figure 10. Alternator Output Check

2200 SRM 2

High Output Check (Type A or Type B)

11. On Type A Delco alternators, do the following checks:

CAUTION Do not push the screwdriver into the hole for more than 25 mm (1 in.). a. If the output shown is not within 10%, put a screwdriver into the hole shown in Figure 11. b. Run the engine at 2000 to 2500 rpm. Adjust the carbon pile until the maximum charging rate is reached. c. If the output is within 10%, check the field winding. If the field winding is in good condition, replace the voltage regulator. d. If the output is not within 10%, check the wires to the brushes, diodes, diode bridge, field winding, and stator. e. Remove the screwdriver, ammeter, and variable resistor.

NOTE: DELCO TYPE A SHOWN. 1. HOLE 2. MAKE SURE SCREWDRIVER TOUCHES HOUSING AND METAL TAG. Figure 11. Electrical Ground on Field Winding

High Output Check (Type A or Type B) 1. Connect a voltmeter from the regulator terminal to the electrical ground. Check the reading on the voltmeter. See Figure 9 or Figure 10. 2. If there are no readings, check for an open circuit between the regulator terminal and the battery. 3. If there is a reading, connect a voltmeter between the BAT terminal and the electrical ground. 4. Increase the engine speed until the maximum voltage reading is reached. 5. If the voltage shown is more than 15.5 volts on a 12-volt system or 31 volts on a 24-volt system, disassemble the alternator and do the remainder of the checks. For alternators with the voltage adjustment, do the following:

a. Delco alternator. The voltage setting can be increased or decreased by changing the position of the adjustment plug. See Figure 12. LO is the lowest voltage setting. 2 is medium low and 3 is the medium setting. The voltage setting is highest when HI is aligned with the arrow on the alternator. Do not change the setting when engine is operating. Change the setting as necessary. b. Leece-Neville alternator. Remove the screw in the cover. See Figure 12. Start the engine. Connect a voltmeter across the battery terminals and use a screwdriver to adjust the voltage.

Brushes Circuit Check

2200 SRM 2

1. VOLTAGE ADJUSTMENT CAP SHOWN IN MEDIUM HIGH (3) POSITION.

2. DELCO TYPE A 3. LEECE-NEVILLE

Figure 12. Voltage Adjustment

Brushes Circuit Check DELCO ALTERNATORS 1. Use an ohmmeter that has a 1.5 volt cell. (Use the lowest range scale.) Connect the ohmmeter from the clip for the brushes to the metal housing. Make the test, then connect the ohmmeter leads in the reverse direction and test again. 2. If both readings are zero, either the wire or the clip for the brushes has a short circuit to ground, or the voltage regulator has damage. 3. The cause of the problem can also be a missing washer, a missing sleeve on a screw, or a damaged insulator. See Figure 13. Remove the screw

and inspect the insulator. If the insulator is in good condition, do Step 4, Step 5, and Step 6. 4. Connect the ohmmeter from the wire of the diodes to the housing. 5. If the reading is zero on the ohmmeter, either the wire to the diodes has a short circuit to ground, or the voltage regulator has damage. 6. The cause of the problem can be a missing washer, a missing sleeve on a screw, or a damaged insulator. Remove the screw and inspect the insulator. If the insulator is in good condition, replace the voltage regulator.

2200 SRM 2

Brushes Circuit Check

MOTOROLA ALTERNATORS 1. Use an ohmmeter or a 12-volt test lamp to check the brushes as shown in Figure 13. 2. For correct operation, there must be continuity between A to B and C to D. There must be no continuity from A to D or from C to B. See Figure 13. If there is continuity, the brushes are connected to the wrong terminal.

A. DELCO

B. MOTOROLA

1. 2. 3. 4.

5. DIODES 6. INSULATOR WASHERS 7. OHMMETER

BRUSH HOLDER CAPACITOR DIODE BRIDGE NUTS

Figure 13. Brushes Circuit Check

Diode Bridge Check

2200 SRM 2

Diodes Check Use an ohmmeter with a 1.5 volt cell. Use the lowest range scale. Connect one lead of tester to the common connector, and one lead to one of the three diode connections. Make the test, then reverse the tester

leads and make the same test. If both readings are the same reading, replace the diodes. A good diode will show one high reading, and one low reading. See Figure 14.

A. DELCO TYPE A

B. MOTOROLA

1. OHMMETER 2. COMMON FOR DIODE SET

3. DIODE SET CONNECTIONS Figure 14. Diodes Check

Diode Bridge Check DELCO AND LEECE-NEVILLE ALTERNATORS CAUTION Do not use a 120-volt test lamp to check the diode bridge. Use a 12-volt tester to prevent diode damage. To check the diode bridge, connect the ohmmeter to one heat sink and each of the three diodes in turn.

Check the readings, then connect the leads in the reverse direction. If both readings are the same, replace the diode. Repeat the test for the other heat sink checking in both directions. See Figure 15.

MOTOROLA ALTERNATORS Remove the wires for the diode set from the terminals A, B, and C. Use an ohmmeter, diode tester, or 12-volt test lamp to check between points A, B, and C, and points D and E. Good diodes indicate continuity in only one direction. If any parts are bad, replace the diode bridge assembly. See Figure 14.

2200 SRM 2

Rotor Field Winding Check

A. DELCO TYPE A

B. DELCO TYPE B

C. LEECE-NEVILLE

1. BRUSH HOLDER 2. HEAT SINK

3. VOLTAGE REGULATOR 4. DIODE

5. OHMMETER

Figure 15. Diode Bridge Check

Rotor Field Winding Check Connect an ohmmeter to each slip ring and check for open circuits. If the reading is high (infinity), the winding has an open circuit. To check the resistance of the field, connect the ohmmeter to the two slip rings. The correct reading is 4.0 to 4.5 ohms. If the reading is less than specified, there is a short circuit in the windings. If the reading is more than specified, there is excessive resistance in the windings. NOTE: Make sure the needle in the ohmmeter always returns to zero correctly. The readings will change when the temperature of the winding changes. To check the electrical ground, connect the ohmmeter between either slip ring and the electrical ground as shown in Figure 16. Replace the rotor if the reading is less than infinity. Figure 16. Rotor Coil Checks

Troubleshooting

2200 SRM 2

Stator Windings Check To check the stator windings for electrical ground, connect an ohmmeter as shown in Figure 17. There must be no continuity between any of the stator terminals and the metal housing. To check the stator for open circuits, connect the ohmmeter or test lamp between each pair of wires to the stator as shown in Figure 17. If the test lamp does not illuminate or the meter reading is high, the windings have an open circuit.

Figure 17. Stator Checks

Voltage Regulator Check Use a voltage regulator test device. Do not use an ohmmeter. If the voltage regulator has damage, replace the voltage regulator.

Troubleshooting PROBLEM Battery is charged above normal.

Battery uses more water than normal.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Alternator is not charging correctly.

Repair or install new parts.

Electrical ground in wire to brush or clip.

Repair or install new parts.

High resistance in the circuit.

Repair or install new parts.

Battery is charging more than normal.

Replace voltage regulator.

Alternator has damage in the field windings, diodes, diode bridge, or stator.

Install new parts.

Battery has damage or is too old.

Replace battery.

2200 SRM 2

PROBLEM There is no charge from the alternator.

There is no charge from the alternator. The indicator light or ammeter indicates a discharged condition when the rpm is high and the load is high.

Ammeter or the indicator light indicates a discharged condition at all speeds.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

The brushes are worn or damaged.

Install new brushes.

Weak springs for brushes. Brushes or brush holders do not move freely.

Install new parts.

Dirt on the slip rings.

Clean or install new parts.

There is an electrical ground in the field winding.

Replace rotor or alternator.

Drive belt is not tight or is broken.

Adjust or replace drive belt.

There is a short circuit in the diodes.

Install new parts.

There is an electrical ground at the end of the windings.

Replace rotor or alternator.

The voltage regulator has damage.

Replace voltage regulator.

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

BRAKE SYSTEM S3.50-5.50XM (S70-120XM) [E004, F004]

PART NO. 1510466

1800 SRM 985

Brake System

Table of Contents

1 1 1 1 1 2 2 2 5 5 8 8 8 8 8 8 8 10 10 10 12 12 12 13 13 14 14

This section is for the following models: S3.50-5.50XM (S70-120XM) [E004, F004]

1800 SRM 985

Description and Operation

General This section contains a description and repair procedures for parts of the hydraulic brake system. These parts include the brake booster, master cylinder, and brake shoe assemblies.

Description and Operation The brake pedal is connected to the push rod for the brake booster. The brake booster helps increase the force on the master cylinder by using vacuum from the engine. The piston in the master cylinder forces oil to the wheel cylinders to apply the brakes. The system allows braking without vacuum from the engine.

links move with the drum during a stop when the truck is traveling in reverse. The links permit the adjuster spring lever to rotate the adjuster screw wheel. The adjuster screw wheel will only turn when there is clearance between the lining and brake drum. The adjuster screw wheel can be turned manually through a slot in the back plate.

BRAKE BOOSTER AND MASTER CYLINDER

PARKING BRAKE

The brake booster and master cylinder are assembled as a unit. The brake booster has a diaphragm that is actuated by engine vacuum. See Figure 1. The diaphragm along with the operatorâ&#x20AC;&#x2122;s effort pushes on the piston in the master cylinder. Hydraulic pressure actuates wheel cylinders as the piston pushes fluid through check valve. A return spring pushes piston back to the stop plate when pedal is released. Fluid can flow through passages in piston and past the primary cup as piston returns. Fluid flows across the piston to prevent a vacuum while fluid returns through the check valve. When piston passes the compensator port, excess fluid from brake system returns to the reservoir. The check valve keeps a very small amount of pressure in brake system. The reservoir for brake fluid has a sending unit for a low fluid level warning light.

The parking brake uses the service brake shoes. Additional linkage pushes brake shoes apart when the hand lever pulls the cables. A switch on the right-hand side of mounting bracket is actuated by the hand lever. On all units, the switch energizes the seat warning circuit when hand lever is released. On units with a MONOTROLÂŽ pedal, this switch puts the transmission in NEUTRAL by de-energizing the direction solenoids. On units with a MONOTROL pedal, there is also a switch on left-hand side of bracket. This switch prevents engine from starting unless parking brake is applied.

SERVICE BRAKE ASSEMBLY Service brake assemblies are installed at each end of the housing for the drive axle. Each service brake assembly has a single wheel cylinder at the top of each back plate. The support plate has an anchor for each shoe. When wheel cylinder is actuated by fluid pressure from the master cylinder, the shoes expand against the drum. The primary shoe starts to turn with the drum. This action pushes secondary shoe tight against drum and anchor. When lift truck is traveling in reverse, the primary shoe is pushed against anchor and drum by the secondary shoe. The automatic adjusting linkage turns adjuster screw wheel to adjust clearance between brake shoes and brake drum. The secondary shoe and

1. 2. 3. 4.

PUSH ROD BRAKE BOOSTER RESERVOIR MASTER CYLINDER

5. OUTLET TO WHEEL CYLINDERS 6. ENGINE VACUUM CONNECTION

Figure 1. Brake Booster and Master Cylinder

Brake Shoe Assemblies Repair

1800 SRM 985

Brake Shoe Assemblies Repair REMOVE AND DISASSEMBLE WARNING Brake linings can contain dangerous fibers. Breathing 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 cleaning procedure in this section. When 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 linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. 1. Tilt mast back and put blocks under outer mast weldment. Tilt mast forward to raise tires from floor. 2. Remove wheel nuts, then remove wheels. Put capscrews (16 mm) in threaded holes to push brake drums from hubs. See Figure 2. 3. Remove capscrews holding axle shaft to wheel hub. Remove axle shaft. 4. Remove lock nut, lockplate, and bearing adjustment nut from axle housing. Remove outer bearing cone. See Figure 2. 5. Remove hub from axle housing. Remove inner seals and bearing cone from hub.

WARNING When the brake shoes are removed, do not create dust in the air. See the cleaning procedures in this section. 6. Turn adjuster screw to loosen brake shoes. Disconnect linkage for automatic adjuster. See Figure 3. 7. Use spring pliers to remove shoe return springs. 8. Remove hold down springs.

CAUTION The adjuster screw assemblies are not the same. Make sure each assembly has identification for installation on the correct side of the axle. 9. Remove brake shoes from wheel cylinder rods. Remove adjuster screw spring. Remove adjuster screw assembly. See Figure 3. 10. Remove parking brake cable from parking brake lever. Remove lever from rear brake shoe. 11. Disconnect and put a cap on the line to the wheel cylinder. Remove backplate. Remove capscrews holding wheel cylinder to backplate. Remove cable clamp and pull cable through backplate.

CLEAN WARNING Brake linings can contain dangerous fibers. Breathing 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 cleaning procedure in this section. When 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 linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. 1. Do not release brake lining dust from brake linings into air when brake drums are removed. 2. Use a solvent approved for cleaning of brake parts to wet brake lining dust. Follow instructions and cautions of manufacturer for use of solvent. If a solvent spray is used, do not create dust with spray.

1800 SRM 985

Brake Shoe Assemblies Repair

CAUTION Do not use an oil solvent to clean wheel cylinder. Use a solvent approved for cleaning of brake parts. Do not permit oil or grease in brake fluid or on brake linings.

3. When dust is wet, clean brake parts. Put any cloth or towels in a plastic bag or airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on plastic bag or airtight container. 4. Any cleaning cloths that will be washed must be cleaned so fibers are not released into the air.

1. 2. 3. 4. 5. 6. 7. 8.

AXLE HOUSING AXLE MOUNT BRAKE ASSEMBLY (SHOES AND BACKPLATES) BRAKE DRUM SEAL BEARING CONE BEARING CUP WHEEL HUB

9. 10. 11. 12. 13. 14. 15.

ADJUSTMENT NUT LOCKWASHER LOCK NUT AXLE SHAFT TIRE AND WHEEL MOUNTING PIN DOWEL PIN

Figure 2. Brakes and Drive Axle Assembly

Brake Shoe Assemblies Repair

1800 SRM 985

NOTE: LEFT-HAND SIDE SHOWN. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

BACKING PLATE WHEEL CYLINDER ASSEMBLY REAR BRAKE SHOE ADJUSTER SCREW PARKING BRAKE LEVER SHOE RETURN SPRING SPRING AND LINK ASSEMBLY STRUT SHOE HOLDDOWN PIN SHOE HOLDDOWN CUP

11. 12. 13. 14. 15. 16. 17. 18. 19.

SHOE HOLDDOWN SPRING WASHER COTTER PIN BOLT BRAKE LINE SPRING LEVER FRONT BRAKE SHOE LINK

Figure 3. Service Brakes

1800 SRM 985

INSPECT WARNING

Brake Shoe Assemblies Repair to axle mounts. See Figure 2. Use sequence shown in Figure 4 and tighten capscrews to 340 to 375 Nâ&#x20AC;˘m (250 to 275 lbf ft).

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. 1. Clean all metal parts except brake linings and wheel cylinder with solvent. 2. Check bore of wheel cylinder for holes or scratches. Replace wheel cylinder if there is any damage. 3. Check return springs for damage. Inspect backplate for wear where brake shoes touch backplate.

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 lift truck can be difficult to steer when brakes are applied. 4. Inspect brake shoes for cracks or damage. If linings or shoes are worn or damaged, replace brake shoes. It is recommended that brake shoes be replaced in complete sets. 5. Check adjuster screw wheel for wear. Make sure adjuster screw turns. Check for bent or broken adjuster links. NOTE: If the brake drums require grinding, do not grind more than 1.5 mm (0.060 in.) from the diameter. The maximum inside diameter of the brake drum, including wear, is 319.5 mm (12.58 in.). If brake drum is larger than this, replace brake drum. 6. Inspect brake drums for cracks or damage. Use sandpaper to clean surface for brake shoes.

ASSEMBLE AND INSTALL

Figure 4. Backplate Installation 3. Connect brake line to fitting on wheel cylinder. 4. Install link pivot on front brake shoe. Install parking brake lever on rear brake shoe. Install anchor pins in the support flange so they engage brake shoes. 5. Lubricate the back plate with a small amount of grease where the brake shoes touch. Install the brake shoes on the anchor and engage the push rods of the wheel cylinder. Engage the parking brake lever in the slot in the parking brake cable as the brake shoes are installed on the back plate. 6. Put an anchor pin that holds the brake shoes through the back plate. Put a spring seat, spring, and retainer on the anchor pin. Push the retainer onto the anchor pin and rotate the retainer 90 degrees. Make sure the retainer is in the correct position. Install another retainer spring assembly. 7. Install the link, parking brake, and spring between the parking brake lever and the brake shoe. NOTE: The forward shoe return spring is marked with white paint.

1. Install wheel cylinder on backplate. Push parking brake cable through backplate and fasten clamp. See Figure 3.

8. Using the correct tools, install the return springs.

2. Use a sealant (Hyster Part No. 264159) between backplate and axle hanger. Install backplate

10. Connect cable for parking brake to lever.

9. Verify that the return springs are properly installed.

Brake Shoe Assemblies Repair

1800 SRM 985

WARNING The threads of the adjuster wheel are not the same for each side. If the adjuster assemblies are installed on the wrong side, the brake shoe clearance will increase each time the brakes are applied. The adjuster wheel for the right brake has left-hand threads. The adjuster wheel for the left brake has right-hand threads. 11. Lubricate adjuster screw with antiseize compound. Turn adjuster screw to retract brake shoes. Install adjuster between shoes. 12. Align adjuster screw wheel with slot in backplate. 13. Install adjuster spring with long hook toward adjuster screw wheel. 14. Install adjuster spring lever and two links.

CAUTION Do not damage the seals when you install the hub assembly. 15. Use new oil seals. Install inner seal, bearing cups, and outer seal in hub. Install inner bearing cone on spindle. Lubricate inner bearing with grease. See Figure 5 and Figure 6. 16. Install hub on spindle. See Figure 5 and Figure 6. Lubricate outer bearing cone with 80W-90 oil for gears. Install outer bearing cone and adjustment nut. 17. Tighten adjustment nut to 203 N•m (150 lbf ft) while rotating hub until hub does not turn. Loosen nut until hub rotates freely with NO end play. The torque must be less than 27 N•m (20 lbf ft). Tighten nut to 34 N•m (25 lbf ft) or to the first alignment position after 34 N•m (25 lbf ft). Install lockwasher to hold the nut. Install lock nut and tighten it to 135 N•m (100 lbf ft).

NOTE: LONG-WHEEL BASE HUB SHOWN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

AXLE HOUSING AXLE MOUNT BRAKE SYSTEM HUB ASSEMBLY AXLE SHAFT DURALOCK BOLTS OUTER SEAL OUTER BEARING BEARING CUP LOCK NUT WHEEL NUT

11. BRAKE HOSE 12. SERRATED BOLTS 13. AXLE SHAFT BOLTS 14. LOCKWASHER 15. LOCK NUT WHEEL BEARINGS 16. INNER BEARING 17. INNER SEAL

Figure 5. Brake Assembly 18. Install brake drum and adjust brake shoes as described in Brake Shoes Adjustment.

1800 SRM 985

Brake Shoe Assemblies Repair

A. SHORT WHEEL BASE HUB ASSEMBLY

B. LONG WHEEL BASE HUB ASSEMBLY

1. 2. 3. 4.

5. ROLLER BEARING CUP 6. BEARING CONE 7. INNER SEAL

HUB BRAKE DRUM SERRATED HUB BOLT OUTER SEAL

Figure 6. Hub Assembly 19. Apply sealant (Hyster Part No. 264159) to flange of axle shaft. Install axle shaft. See Figure 2. Tighten capscrews to 225 N•m (166 lbf ft). See Figure 7.

CAUTION When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 500 hours. 20. Install wheel. Tighten wheel nuts to 610 to 680 N•m (450 to 500 lbf ft). 21. Remove air from brake system and adjust brakes. See Brake Shoes Adjustment in this section.

Figure 7. Axle Shaft Tightening Sequence

Brake Booster and Master Cylinder

1800 SRM 985

Brake Booster and Master Cylinder REMOVE

ASSEMBLE

1. Disconnect push rod from inching crank. See Figure 8. Disconnect brake line at master cylinder. Cover end of brake line. Disconnect wires at reservoir.

NOTE: Lubricate parts of master cylinder with clean brake fluid.

2. Remove nuts that hold brake booster to mount. 3. Remove brake booster and master cylinder.

1. Install seals on piston. Install seat, check valve, and spring in bore. Install spring and piston. Install snap ring in bore. See Figure 9. 2. Install O-ring and master cylinder on brake booster.

DISASSEMBLE NOTE: Do not disassemble the brake booster. Repair parts are not available. 1. Remove nuts that hold master cylinder to brake booster. See Figure 9.

WARNING

INSTALL 1. Put master cylinder in position on brake booster and install nuts for master cylinder. Install brake booster on mount. 2. Install nuts for brake booster. Connect push rod to inching crank. See Figure 8.

There is a compressed spring behind the piston. To prevent possible injury, use care when removing the snap ring and piston.

3. Connect brake line at master cylinder. Connect wires at reservoir.

2. Remove snap ring from end of master cylinder. Carefully remove piston and spring from bore.

4. Fill reservoir and remove air from brake system as described in Brake System Air Removal in this section.

3. Remove seals from piston.

CLEAN AND INSPECT

5. Adjust brake linkage as described in Brake Pedal Adjustment.

BRAKE BOOSTER FILTER, REPLACE CAUTION DO NOT use an oil solvent to clean the master cylinder. Use a solvent approved for cleaning of brake parts. Inspect bore of master cylinder for holes or scratches. Replace master cylinder assembly if there is damage.

1. Remove the two clamps holding the old filter to the brake vacuum lines. Remove the brake booster filter. See Figure 9. 2. Install new filter onto brake vacuum lines. Install the two clamps to hold brake booster filter onto brake vacuum lines.

1800 SRM 985

Brake Booster and Master Cylinder

Figure 8. Brake System

Parking Brake Repair

1800 SRM 985 Legend for Figure 8

NOTE: DUAL-PEDAL OPTION SHOWN. A. BRAKE SYSTEM ARRANGEMENT

B. BRAKE LINES ARRANGEMENT

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

BRACKET BRAKE PEDAL INCHING PEDAL PEDAL PADS BUSHING CAPSCREW LOCKWASHER NUT MASTER CYLINDER AND BOOSTER PIN COTTER PIN LINK INCHING LINK WASHER ROD END PIN DISK SNAP RING

SWITCH SPACER CRANK BEARING SPRING SCREW HEX LINK ROD END WAVE SPRING BRAKE FLUID RESERVOIR BRAKE LINES MANIFOLD PRESSURE SWITCH FITTING HOSE CLAMP FILTER

Parking Brake Repair REMOVE AND DISASSEMBLE

ASSEMBLE AND INSTALL

If the lever assembly for the parking brake must be removed from the cowl, use the following procedure (see Parking Brake Lever Adjustment):

If the lever assembly for the parking brake was removed from the cowl, use the following procedure for installation (see Figure 10):

1. Place blocks under tires to make sure lift truck cannot move. Push the release button to release the parking brake lever.

1. Make sure parking brake lever is in the released position. Turn adjustment knob until parking brake link is adjusted to the bottom of adjustment slot.

2. Remove the two nuts that fasten the parking brake to the mounting bracket on the cowl. Remove the brake lever assembly. 3. Loosen the jam nuts that fasten the threaded ends of the brake cables to the brake lever assembly.

2. Place parking brake assembly between mounting bracket on the inside of the cowl. Align mounting holes on lever assembly with holes on mounting bracket. Insert the two capscrews to secure parking brake assembly to mounting bracket and cowl.

4. Turn adjuster knob counterclockwise until brake cables are loosened. Disconnect cables from the parking brake link.

3. Install parking brake cable to parking brake lever assembly by loosening grip and moving yoke to lowest position.

5. The service brake assembly must be removed before the parking brake cable can be removed from the backplate of the service brake. The sheath of the parking brake cable is threaded into the backplate of the service brake.

4. Check to ensure nut on parking cable end is at the center in the screw range. 5. Adjust guide to a distance of 12 mm (0.47 in.) from the body guide. See dimension H in Figure 10. 6. Install parking brake cable to yoke and guide.

1800 SRM 985

Parking Brake Repair

7. Turn lever grip clockwise three times and pull up yoke. Confirm that lever does not return by pulling lever. 8. Tighten the two bolts which fasten the guide and tension the cables. Adjust guide to a distance

1. 2. 3. 4. 5. 6. 7. 8. 9.

BRAKE BOOSTER SNAP RING SEAL PISTON SPRING CHECK VALVE SEAT O-RING MASTER CYLINDER

of 14 to 15 mm (0.55 to 0.59 in.) from the body guide. See dimension H in Figure 10. 9. Turn lever grip as needed to adjust it so that parking brake will hold lift truck when applied.

10. 11. 12. 13. 14. 15. 16. 17. 18.

GROMMET RESERVOIR CAP PIN VACUUM FITTING VACUUM LINES CLAMPS BRAKE BOOSTER FILTER VACUUM LINE FITTING

Figure 9. Brake Booster and Master Cylinder

Parking Brake Adjustment

1800 SRM 985

Brake System Air Removal Air must be removed from the brake fluid. Fill the reservoir for the master cylinder with brake fluid. Always remove air from master cylinder first, then from wheel cylinders. Put one end of a rubber hose on the special fitting at the master cylinder or wheel cylinders. Put the other end of the hose in a container

with brake fluid. Loosen the special fitting. Push slowly on the brake pedal. Close the special fitting. Repeat the procedure until no air bubbles are seen in the container. Check the fluid level in the reservoir. Keep the reservoir full of brake fluid during these procedures.

Brake Pedal Adjustment The adjustment for the brake/inching pedal is in the section Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 SRM 397.

Parking Brake Adjustment Make sure the service brakes are adjusted and the operation of the automatic adjuster mechanism is correct before the parking brake is adjusted. 1. Turn adjustment knob to raise the parking brake link and tighten parking brake cables. Turn adjustment knob until parking brakes are fully applied when lever is used to apply parking brake. See Figure 10. 2. Test the operation of the parking brake. The lift truck with a capacity load must not move when the parking brake is applied on a 15% grade, [a slope that increases 1.5 m in 10 m (1.5 ft in 10 ft)]. See Figure 11. 3. Check the operation of the switches on the parking brake. Legend for Figure 10 NOTE: THE LETTER H IN FIGURE ABOVE REPRESENTS THE GUIDE MOVEMENT RANGE. SEE SECTION PARKING BRAKE REPAIR FOR H DIMENSIONS. 1. GRIP 2. ADJUSTMENT SLOT 3. YOKE ASSEMBLY 4. GUIDE PLATE 5. ADJUSTMENT KNOB 6. PARKING BRAKE CABLES

7. 8. 9. 10. 11.

NUTS COWL EQUALIZER LINK MICROSWITCH PARKING BRAKE LEVER 12. RELEASE BUTTON 13. NUT 14. BRACKET Figure 10. Parking Brake Lever Adjustment

Parking Brake Switch Test (MONOTROLÂŽ Pedal Only)

1800 SRM 985

Figure 11. Defining a 15% Grade

Parking Brake Not Applied Switch Test The "Parking Brake Not Applied" switch is located in the operator seat. This switch actuates an audible buzzer on the instrument cluster. When the operator leaves the seat for more than 2 seconds

without applying the parking brake, the buzzer will be on continuously for 10 seconds. The buzzer operates whether key switch is ON or OFF.

Parking Brake Switch Test (MONOTROLÂŽ Pedal Only) When the parking brake assembly and cables have been adjusted, the parking brake switches must be tested for correct operation.

WARNING If brake switches are not adjusted correctly, the engine can be started with the parking brake released. The purpose of the left-hand switch is to prevent the starter motor from being energized when parking brake is not applied. The right-hand switch de-energizes the direction solenoids to put the transmission in NEUTRAL when the parking brake is applied. 1. Put lift truck on blocks so the drive wheels do not touch the ground or any other object. Put blocks at both sides of steering tires to prevent movement of lift truck. 2. Release parking brake. The right-hand, two-circuit microswitch closes the electric circuit for the MONOTROL pedal (energize the solenoids for the powershift transmission). The left-hand switch de-energizes the starting circuit.

4. Apply parking brake with the parking brake lever. The right-hand, two-circuit microswitch opens the MONOTROL circuit (de-energize the solenoids for the transmission). The starting circuit is energized by the ignition switch through the left-hand switch. 5. Turn ignition switch to START position. The starter operates when the parking brake switch operates correctly. Turn ignition switch to OFF position. 6. Check the wires for the parking brake switches if the conditions from the results of Step 2 through Step 5 are not correct. 7. Apply parking brake and start the engine. Push parking brake lever toward the released position, but do not push release button. The parking brake will stay in the ON position and locked. 8. The transmission must be in NEUTRAL any time the parking brake lever is applied. If results of the test are not correct, check for wear and damage. Make repairs as necessary and repeat Step 1 through Step 7.

3. Turn the ignition switch to the START position. If parking brake switch operates correctly, the starter will not energize. Turn ignition switch to OFF position.

Troubleshooting

1800 SRM 985

Brake Shoes Adjustment The brake shoes are automatically adjusted when the brakes are applied while the truck travels in REVERSE. Use the procedure described below to manually adjust the brakes after you make repairs. 1. Put lift truck on blocks so drive wheels do not touch the ground. See the section Periodic Maintenance 8000 SRM 987 for the correct procedures. Make sure the blocks do not prevent access to backplates of brakes. 2. Remove plugs in slots in backplates. See Figure 3. NOTE: If the automatic brake adjusters adjust the brake shoes too much or too little, refer to Remove and Disassemble in this section for the brake shoes. 3. Use a tool for brake adjustment in the slot nearest the teeth of the adjuster screw wheel. Push

up on the teeth and turn adjuster screw wheel until brake shoes touch brake drum. 4. Insert a small screwdriver through slot in back plate in order to move automatic adjustment lever away from adjuster screw wheel. 5. Turn adjuster screw wheel with brake adjustment tool. Push down on teeth to turn adjuster screw wheel in opposite direction. Turn adjuster screw wheel one revolution for the necessary clearance between brake shoes and drum. Rotate drive wheel to check for clearance. 6. Repeat Step 3, Step 4, and Step 5 at other brake assembly. Install plugs in backplates. 7. Remove lift truck from blocks. Drive lift truck in FORWARD and REVERSE. Use brakes to stop 10 times in each direction.

Troubleshooting PROBLEM Brakes do not stop the lift truck correctly.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Air is in the brake system.

Remove air from brake system.

Mount for the brake booster or the brake booster is loose.

Tighten capscrews.

Brake shoes are worn or damaged.

Install new brake shoes.

Brake linings are too hard.

Install new brake shoes.

Brake drum is cracked.

Install new brake drum.

Backplate is damaged.

Install new backplate.

A wheel cylinder is leaking or does not operate correctly.

Repair or install a new wheel cylinder.

Brake linings do not fit the brake drums.

Install new brake shoes.

Master cylinder is damaged.

Repair or install a new master cylinder.

Water or oil is on the brake linings.

Clean linings or install new brake shoes.

Brake booster is damaged.

Install a new brake booster.

1800 SRM 985

Troubleshooting

PROBLEM One brake does not release.

Brakes make too much noise.

Brakes equally.

not

operate

Both brakes do not release.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Brake shoe is damaged.

Install new brake shoes.

Return spring is damaged.

Install a new spring.

Brake lines have a restriction.

Install new brake lines.

Parking brake cable is damaged or needs adjustment.

Adjust or install new brake cable(s).

Wheel cylinder is damaged.

Repair or install a new wheel cylinder.

Backplate is worn or damaged.

Install a new backplate.

Oil, water, or brake fluid is on the linings.

Clean linings or install new brake shoes.

Brake linings or brake shoes are worn or damaged.

Install new brake shoes.

Brake drum is damaged.

Install a new brake drum.

Oil or brake fluid is on the linings.

Clean linings or install new brake shoes.

Brake linings are worn or hard.

Install new brake shoes.

Wheel cylinder is leaking.

Repair or install a new wheel cylinder.

Brake shoes are not correctly installed.

Install brake shoes.

Backplate or brake shoes are damaged.

Install new parts.

Brake drum is not round.

Repair or install a new brake drum.

Brake shoes are adjusted too tight.

Adjust brake shoes correctly.

Parking brake is not released.

Adjust parking brake.

Parking brake cables need adjustment.

Adjust parking brake.

There is not enough clearance for the push rod.

Adjust brake linkage.

Troubleshooting

PROBLEM Both brakes do not release. (Cont.)

Parking brake will not hold the lift truck.

Parking brake will not release.

1800 SRM 985

POSSIBLE CAUSE

PROCEDURE OR ACTION

Master cylinder is damaged.

Repair or install a new master cylinder.

Brake shoes are adjusted too tightly.

Adjust brake shoes.

Oil, water, or brake fluid is on the linings.

Clean linings or install new brake shoes.

Parking brake cables need adjustment.

Adjust parking brake.

Parking brake cable is damaged.

Install new cable(s).

Parking brake lever is adjusted too tightly.

Adjust parking brake.

Parking brake cables are damaged.

Install new cable(s).

CAPACITIES AND SPECIFICATIONS S3.50-5.50XM (S70-120XM) [E004, F004]

PART NO. 1510478

8000 SRM 988

Capacities and Specifications

Table of Contents

TABLE OF CONTENTS Tire Sizes ............................................................................................................................................................ Hydraulic System............................................................................................................................................... Electrical System ............................................................................................................................................... Engine Specifications......................................................................................................................................... Capacities ........................................................................................................................................................... Lift Truck Weights ............................................................................................................................................. Transmission Pressures (Single-Speed Powershift)......................................................................................... Mast Speeds ....................................................................................................................................................... Torque Specifications ......................................................................................................................................... Frame ............................................................................................................................................................. Engine - GM V-6 ............................................................................................................................................ Engine - Perkins ............................................................................................................................................ Transmission.................................................................................................................................................. Drive Axle ...................................................................................................................................................... Steering System............................................................................................................................................. Brake System................................................................................................................................................. Hydraulic System .......................................................................................................................................... Main Control Valve........................................................................................................................................ Tilt Cylinders ................................................................................................................................................. Lift Cylinders ................................................................................................................................................. Mast................................................................................................................................................................

1 1 1 2 2 3 4 5 6 6 6 6 6 6 6 7 7 7 7 7 7

This section is for the following models: S3.50-5.50XM (S70-120XM) [E004, F004]

ÂŠ2005 HYSTER COMPANY

8000 SRM 988

Electrical System

Tire Sizes Model

Steering

Drive

S3.50 (S70XM)

18 × 6 × 12.1

22 × 9 × 16

S4.00 (S80XM)

18 × 7 × 12.1

22 × 9 × 16

S4.50-5.50XM (S100-120XM)

18 × 8 × 12.1

22 × 12 × 16

Hydraulic System Item

Specification

Hydraulic System Capacity

39.3 liter (10.4 gal)

Hydraulic Tank Capacity (Total Tank Capacity)

35.5 liter (9.4 gal)

Relief Pressures* Main Control Valve Lift Circuit

22.0 MPa (3200 psi)

Tilt and Auxiliary Circuit

15.5 MPa (2250 psi)

Steering Circuit

10.7 MPa (1550 psi)

Hydraulic Pump** Capacity

89 liter/min (23.5 gal/min)

Priority Flow

None

*Oil temperature 50 to 100 C (120 to 210 F) and engine speed at 2500 rpm. **Oil temperature 80 to 100 C (176 to 210 F) and engine speed at 2550 rpm.

Electrical System Alternator Output GM V-6

Perkins

38 Amps @ 650 rpm (Hot) 62 Amps @ 2200 rpm (Hot) 42 Amps @ 650 rpm (Hot) 62 Amps @ 2500 rpm (Hot) All Models - 12 Volt, Negative Ground

Capacities

8000 SRM 988

Engine Specifications Item

GM V-6 4.3

Perkins 1004-4

1-6-5-4-3-2

1-3-4-2

Bore

102.00 mm (4.00 in.)

103.00 mm (4.055 in.)

Stroke

88.40 mm (3.50 in.)

127.00 mm (5.00 in.)

Number of Cylinders Firing Order

4.3 liter (262.4 in. )

4.0 liter (244.0 in. 3 )

9.3:1

18.5:1

675 to 725 rpm

725 to 775 rpm

2400 to 2500 rpm

2450 to 2550 rpm

Broken in Engine

1810 (Gas) 1735 (LPG) +300/-50 rpm

2050 rpm ±50 rpm

New Engine

1710 (Gas) 1635 (LPG) +300/-50 rpm

1950 rpm ±50 rpm

0 BTDC at 650 rpm

2 BTDC (Static)

207 to 380 kPa (30 to 55 psi)

280 kPa (41 psi)

Intake

Not adjustable

0.20 mm (0.008 in.) Cold

Exhaust

Not adjustable

0.45 mm (0.018 in.) Cold

Displacement Compression Ratio Idle Speed Governor Speed Stall Speed

Timing Oil Pressure (Minimum) Valve Clearance

Capacities Item

Quantity

Engine Oil GM V-6

4.7 liter (5.0 qt)

Perkins 1004-4

8.0 liter (8.5 qt)

Cooling System

18.9 liter (20.0 qt)

Hydraulic Tank (Total Tank Capacity)

35.5 liter (9.4 gal)

Transmission

15.1 liter (16.0 qt)

Differential Fuel Tank Brake Fluid

5.7 liter (6.0 qt) 34.0 liter (9.1 gal) 0.2 liter (0.5 pt)

8000 SRM 988

Lift Truck Weights

Lift Truck Weights Unit

S3.50XM (S70XM)

5,515

11,937

S4.00XM (S80XM)

5,780

12,742

S4.00XM BCS (S80XM BCS)

5,995

13,217

S4.50XM (S100XM)

6,768

14,920

S4.50XM BCS (S100XM BCS)

7,245

15,973

S5.50XM (S120XM)

7,433

16,387

S5.50XMS (S120XMS)

7,527

16,589

S5.50XMSPRS (S120XMSPRS)

7,820

17,241

NOTE: Lift trucks equipped with overhead guard, mast, carriage, load backrest, forks, and LPG engine. NOTE: S3.50-4.00XM (S70-80XM) and S4.00XM BCS (S80XM BCS) have 3099 mm (122 in.) two-stage LFL mast. S4.50-5.50XM (S100-120XM), S4.50XM BCS (S100XM BCS), S5.50XMS (S120XMS), and S5.50XMSPRS (S120XMSPRS) have 2845 mm (112 in.) two-stage LFL mast.

Transmission Pressures (Single-Speed Powershift)

8000 SRM 988

Transmission Pressures (Single-Speed Powershift) Port No.

Transmission Pressures*

System Pressure

1170 to 1380** kPa (170 to 200 psi) **Relief pressure 1379 kPa (200 psi)

Forward Clutch

895 to 1035 kPa (130 to 150 psi)

Reverse Clutch

895 to 1035 kPa (130 to 150 psi)

Torque Converter

655 to 760 kPa (95 to 110 psi)

Lubrication Pressure

35 to 105 kPa (5 to 15 psi)

Modulator Pressure

Pressure Variation

*Oil temperature at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm. NOTE: The difference between Forward and Reverse clutch pressure must not be more than: â&#x20AC;˘ Manufacturing limit 48 kPa (7 psi) â&#x20AC;˘ Service limit 70 kPa (10 psi)

8000 SRM 988

Mast Speeds

Mast Speeds Two-Stage Full Free-Lift Mast Unit

Lifting No Load

Lowering Rated Load

No Load

Rated Load

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

S3.50-4.00XM (S70-80XM)

0.60

118

0.56

111

0.36

0.50

S4.50XM (S100XM)

0.51

101

0.48

0.32

0.45

S5.50XM (S120XM)

0.51

101

0.44

0.32

0.47

Two-Stage Limited Free-Lift Mast Unit

Lifting No Load

Lowering Rated Load

No Load

Rated Load

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

S3.50-4.00XM (S70-80XM)

0.68

134

0.62

123

0.47

0.55

108

S4.50-5.50XM (S100-120XM)

0.55

108

0.53

105

0.42

0.51

100

Three-Stage Full Free-Lift Unit

Lifting No Load

Lowering Rated Load

No Load

Rated Load

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

S3.50-4.00XM (S70-80XM)

0.63

124

0.58

114

0.44

0.53

105

S4.50XM (S100XM)

0.52

102

0.51

100

0.39

0.47

S5.50XM (S120XM)

0.52

102

0.45

0.39

0.47

Torque Specifications

8000 SRM 988

Torque Specifications FRAME

TRANSMISSION

Counterweight Capscrew 1022 N•m (755 lbf ft)

Transmission Cover Capscrews 40 N•m (30 lbf ft)

ENGINE - GM V-6

Oil Pump Capscrews 40 N•m (30 lbf ft)

Intake Manifold Capscrews 47 N•m (35 lbf ft) Valve Cover Capscrews 10 N•m (7 lbf ft) Exhaust Manifold Capscrews 35 N•m (25 lbf ft) Center Port 25 N•m (20 lbf ft) Outer Ports 50 N•m (35 lbf ft) Camshaft Sprocket Capscrews 25 N•m (20 lbf ft) Vibration Damper Capscrew 81 N•m (60 lbf ft) Main Bearing Cap Capscrews 70 N•m (50 lbf ft) Connecting Rods 45 N•m (35 lbf ft) Flywheel Capscrews 80 N•m (60 lbf ft) Flywheel Housing Capscrews 50 N•m (40 lbf ft) Engine Mount to Engine Capscrews 30 N•m (25 lbf ft) Engine Mount to Mount Plate Bolts 65 N•m (50 lbf ft) Engine Mount to Flywheel Housing Capscrews 165 N•m (120 lbf ft) Engine Mount Bolts 120 N•m (90 lbf ft)

ENGINE - PERKINS Engine Mount to Engine Capscrews 65 N•m (50 lbf ft) Engine Mount Bolts 120 N•m (90 lbf ft)

Torque Converter Housing Capscrews 40 N•m (30 lbf ft) Control Valve Capscrews 20 N•m (15 lbf ft) Differential Case Capscrews 140 N•m (105 lbf ft) Ring Gear Capscrews 140 N•m (105 lbf ft) Output Gear Nut 750 N•m (550 lbf ft) Torque Converter Drive Plate Capscrews 45 N•m (35 lbf ft) Differential Bearing Caps 225 N•m (166 lbf ft)

DRIVE AXLE Brake Assembly to Axle Nuts 340 to 375 N•m (251 to 277 lbf ft) Axle Mount to Frame 320 to 350 N•m (235 to 258 lbf ft) Axle Shaft Flange Capscrews 225 to 250 N•m (166 to 184 lbf ft) Axle Housing to Transmission Capscrews 65 N•m (48 lbf ft) Hub Adjustment Nut 205 N•m (151 lbf ft) Initial 35 N•m (26 lbf ft) Final Wheel Nuts 610 to 680 N•m (450 to 502 lbf ft)

STEERING SYSTEM Axle Mount Capscrews 90 N•m (66 lbf ft)

8000 SRM 988 Bearing Cap for Spindle 45 N•m (35 lbf ft) Tie Rod Castle Nut 175 N•m (129 lbf ft) Steering Cylinder Capscrews 225 N•m (166 lbf ft) Wheel Bearing Adjustment Nut 200 N•m (148 lbf ft) Initial 35 N•m (26 lbf ft) Final

BRAKE SYSTEM Back Plate Capscrews 340 N•m (251 lbf ft)

HYDRAULIC SYSTEM Capscrews for Special Blocks for Pump Drive Chain 20 N•m (15 lbf ft)

MAIN CONTROL VALVE Through Bolt Nuts (5/16 in.) 20 N•m (15 lbf ft) Through Bolts Nuts (3/8 in.) 45 N•m (35 lbf ft)

Torque Specifications

TILT CYLINDERS Piston Nut 400 to 440 N•m (295 to 325 lbf ft) Retainer 400 to 500 N•m (295 to 370 lbf ft) Rod End Lock Capscrews 90 N•m (66 lbf ft) Anchor Pin Retainer Capscrews 77 N•m (57 lbf ft)

LIFT CYLINDERS Main Lift Cylinder Retainer Cap 340 to 410 N•m (251 to 302 lbf ft) Free-Lift Cylinder Retainer Cap 400 to 475 N•m (295 to 350 lbf ft) Free-Lift Cylinder Mount Capscrews 121 N•m (89 lbf ft)

MAST Pivot Pin Capscrews 320 N•m (236 lbf ft) Sideshift Carriage Lower Hook Capscrews 78 N•m (58 lbf ft) Side Roller Mount Capscrews 90 N•m (66 lbf ft)

&22/,1* 6<67(0 INTERNAL COMBUSTION ENGINE POWERED UNITS

PART NO. 897934

700 SRM 626

Cooling System

Table of Contents

1 2 2 2 2 3 3 3 3 3 4 4 4 4 4 4 5 6

This section is for the following models: Internal Combustion Engine Powered Units

700 SRM 626

General

General This section has the description and the checks for some parts of the cooling system. Prodecures for cleaning the radiator and troubleshooting are also included in this section.

The cooling system has the following parts: radiator, auxiliary coolant reservoir, water pump, thermostat, fan, and fan shroud. See Figure 1.

1. 2. 3. 4.

5. 6. 7. 8.

AUXILIARY COOLANT RESERVOIR RADIATOR CAP RADIATOR RADIATOR DRAIN VALVE

TOP RADIATOR HOSE FAN SHROUD BOTTOM RADIATOR HOSE PORTS FOR TRANSMISSION OIL COOLER

Figure 1. Typical Radiator Arrangement

Description

700 SRM 626

Description The purpose of the cooling system is to control the operating temperature of the engine (and in some units, the transmission, brakes, and hydraulic system). A centrifugal water pump circulates coolant through passages in the engine block and the radiator. A thermostat is installed in the water outlet fitting on the engine. As the coolant flows through the radiator, the fan moves air through the radiator to help cool the system. The coolant is a mixture of water and antifreeze. The antifreeze prevents the coolant from freezing in cold weather, and thereby preventing damage to the engine and radiator. The antifreeze also prevents rust and lubricates the water pump.

RADIATOR The radiator is the heat exchanger for the cooling system. The fan causes air to flow through the radiator and reduces the temperature of the coolant. The auxiliary coolant reservoir is connected to the radiator by a hose. As the engine gets hot, the coolant expands. During expansion, coolant moves from the radiator to the reservoir. When the engine stops, the coolant becomes cool and contracts. The coolant in the reservoir flows back into the radiator. In this way, the radiator is kept filled with coolant during normal operation.

by another spring. The vacuum valve opens to relieve the vacuum created when the coolant temperature decreases. In certain conditions this vacuum can cause the radiator or top hose to collapse.

THERMOSTAT The thermostat is a device that controls coolant flow by opening and closing to regulate coolant temperature. The thermostat uses a wax pellet to control its operation. The wax pellet expands when it is heated and contracts when it is cold. When heated, the wax pellet pushes on the piston, causing the valve in the thermostat to open. As the wax pellet cools, it contracts and lets a spring close the valve. When the engine is first started and the coolant is cold, the thermostat remains closed. During this time the coolant circulates through the engine, letting it warm quickly. As the engine becomes warm the thermostat opens, letting coolant circulate through the radiator. The opening and closing of the thermostat helps keep the coolant within the operating limits of the system. The same thermostat is used for summer and winter seasons. Do not operate the engine without a thermostat. The engine will take longer to get warm and may run improperly. See Figure 2.

On units with a powershift transmission, an oil cooler is built into the radiator. Oil from the transmission flows through coils in the radiator tank to help control the oil temperature.

RADIATOR CAP The radiator cap is a pressure-vent type that lets the pressure in the cooling system increase to 103 kPa (15 psi). The pressure in the system prevents vapor from forming in the coolant flowing to the water pump. This action maintains the efficiency of the water pump and the performance of the cooling system. The increase in pressure also raises the boiling point of the coolant mixture to approximately 125 C (257 F) at sea level. The radiator cap has a pressure valve and a vacuum valve. The pressure valve is held against its seat by a spring. The pressure valve opens when the pressure in the cooling system exceeds 103 kPa (15 psi). The vacuum valve is held against its seat

1. 2. 3. 4.

PISTON VALVE SEAT SPRING DIAPHRAGM

5. 6. 7. 8.

WAX PELLET FRAME FLANGE VENT HOLE

Figure 2. Typical Thermostat

700 SRM 626

Cooling System Checks

WATER PUMP

FAN AND FAN SHROUD

The centrifugal-type water pump is installed at the front of the engine block. The inlet for the pump is connected to the bottom of the radiator by a hose. From the pump, coolant passes through the passages in the engine block to the top of the radiator. The thermostat controls the flow of coolant through the engine and radiator.

The fan is used to provide airflow through the radiator at all engine speeds. The fan is a pusher-type or puller-type and can be installed on the water pump or on a separate hub. The fan is driven by a drive belt from the engine crankshaft. The fan shroud ensures the air flow from the fan goes through the core of the radiator.

Cooling System Checks RADIATOR

2. Mix solution of water with 33% antifreeze. Heat solution to 14 C (57 F) above temperature on thermostat.

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

3. Hold thermostat with wire and put it in solution. Stir solution. If operating correctly, thermostat will open.

NOTE: The Repair procedures for the radiator are in the Frame section of the Service Manual.

4. Remove thermostat and put in same solution at â&#x2C6;&#x2019;12 C (10 F) below temperature on thermostat. Valve must close completely.

To check for water flow restrictions in the radiator, run the engine until it is warm. Shut the engine OFF and feel the radiator. The temperature must be even across the radiator. (The radiator will be hotter near the top radiator hose.) Cold spots on the radiator indicate restrictions. If the radiator has leaks, have it repaired by trained personnel.

THERMOSTAT WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

CAUTION DO NOT operate the engine without a thermostat. The engine and cooling system can be damaged. NOTE: Repair procedures for the thermostat are in the Engine section of the Service Manual. 1. Remove thermostat from cooling system. Figure 3.

See

1. 2. 3. 4.

FAN SPACER HUB/PULLEY WATER PUMP

5. THERMOSTAT 6. THERMOSTAT HOUSING

Figure 3. Cooling System Components Typical Arrangement

Radiator Cleaning

700 SRM 626

WATER PUMP

FAN AND FAN SHROUD

WARNING

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. NOTE: Repair procedures for the water pump are in the Engine section of the Service Manual. Run the engine until it is warm. Check the operation of the water pump by holding the top radiator hose. If the pump is operating, there will be pressure surges in the hose. See Figure 3.

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING DO NOT try to repair a damaged fan. If a fan has a bent blade or is cracked, install a new fan. A damaged fan can break during use and cause damage or serious injury. NOTE: Repair procedures for the fan and shroud are in the Frame section of the Service Manual.

EXHAUST LEAKS WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. To check for exhaust leaks into the cooling system, use a kit for this purpose. Follow the manufacturerâ&#x20AC;&#x2122;s instructions when doing the test.

1. When installing fan, make sure correct spacers are installed and mounting capscrews are tight. See Figure 1 and Figure 3. 2. When installing fan shroud, make sure correct seals are on shroud. Before tightening capscrews, make sure clearance around circumference of fan is even with shroud. Also make sure 1/3 to 1/2 of cross-section of fan blade extends into fan shroud. 3. Make sure WARNING labels are installed on shroud.

Radiator Cleaning DRAIN WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 1. Let coolant cool to room temperature. Put drain pan under radiator. Remove radiator cap. See Figure 1.

2. Open drain valve or remove bottom radiator hose. Remove drain plug from engine block to drain engine.

CLEAN CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 1. Drain cooling system. Fill cooling system with clean water. 2. Install radiator cap. Run engine until top radiator hose is hot. Stop engine and let engine cool.

700 SRM 626 3. Drain water from radiator. If water is dirty, fill system with water and repeat procedure until water is clean.

CAUTION Follow the manufacturer’s instructions when using a chemical radiator cleaner. 4. If water does not clean system, use chemical radiator cleaner.

CAUTION Follow the manufacturer’s instructions when using special equipment to reverse clean the radiator. NOTE: On lift truck models S3.50-5.50XM (S70-120XM) (E004), the cooling system may be equipped with an optional radiator screen.

Radiator Cleaning NOTE: Units with a Mazda engine must use a boronfree type of antifreeze. 2. Fill cooling system with mixture of 50% water and 50% ethylene glycol antifreeze. Install radiator cap. The 50/50 mixture will protect the cooling system to −37 C (−35 F). 3. Use same coolant mixture to fill auxiliary coolant reservoir to FULL mark. See Figure 4. 4. Start and run engine until thermostat opens. (Top radiator hose will be warm.) 5. Check coolant level at auxiliary coolant reservoir. Add coolant as necessary to keep level between FULL and ADD marks.

5. If radiator or cooling system is very dirty or has restriction, use reverse cleaning method. This method uses air pressure to force water through radiator in opposite direction of normal flow.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 6. Check radiator fins. Clean exterior of radiator with compressed air or water as needed.

FILL 1. Install drain plug in engine block. Close drain valve or install bottom radiator hose as needed.

1. 2. 3. 4. 5.

ADD MARK FULL MARK AUXILIARY COOLANT RESERVOIR FILL CAP RADIATOR CAP

WARNING Do not use an alcohol or methanol-base antifreeze. They are flammable and can cause personal injury or damage to the lift truck.

Figure 4. Auxiliary Coolant Reservoir

Troubleshooting

700 SRM 626

Troubleshooting PROBLEM Coolant leaks.

The engine is too hot during operation.

Exhaust leaks into coolant.

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is a leak in the radiator.

Repair radiator.

There is a leak in a radiator hose or coolant hose.

Install new hoses.

There is a leak from a plug or sensor in the engine block.

Check sensors and plugs, and repair leaks.

Water pump leaks.

Install new water pump.

Thermostat housing leaks.

Install new thermostat housing. Check for correct installation of thermostat.

Cylinder head gasket is damaged.

Install new head gasket.

Cylinder head is cracked.

Install new cylinder head.

Engine block is cracked.

Install new cylinder block.

There is not enough coolant in the cooling system.

Check coolant level in radiator and coolant recovery bottle. Add coolant to correct level.

The radiator is dirty.

Drain and clean radiator. Clean radiator fins with low pressure air or water in reverse direction of normal air flow. Be careful not to bend fins. Refill with clean coolant.

The drive belt for water pump is not adjusted correctly, worn, or broken.

Check water pump drive belt. Adjust or install new belt as required.

The thermostat is wrong heat range or does not operate correctly.

Check heat range. Install new thermostat.

The cooling system has restrictions.

Drain and back-flush engine and radiator. Refill with clean coolant.

The water pump is worn or damaged.

Install new water pump.

The exhaust system has restrictions.

Check exhaust system. Remove restrictions.

Ignition timing is not correct.

Check and adjust timing.

Head gasket(s) leaks.

Install new gasket(s).

Cylinder head is damaged.

Install new cylinder head.

DIAGRAMS S3.50-5.50XM (S70-120XM) [E004, F004]

PART NO. 1510481

8000 SRM 989

Diagrams

Table of Contents

1 2 2 5 7 9 13 17 21 24 26 28 32 36 40 42 46 48 51 53 55 59 63 67 67

This section is for the following models: S3.50-5.50XM (S70-120XM) [E004, F004]

ÂŠ2007 HYSTER COMPANY

8000 SRM 989

General

General This service repair manual contains electrical, hydraulic, and transmission diagrams for S3.50-5.50XM (S70120XM) model lift trucks.