S40XL S50XL S60XL [A187]
SERVICE REPAIR
General
Thissectionhasadescriptionandtherepairproceduresforseveraldifferenttypesoftiltcylinders.The
numberandthedesignofthepartscanbedifferent, buttheoperationofthetiltcylindersisthesame.
Description
Thetiltcylinders(Figure2,Figure3,Figure4,and Figure5)areusedtomovethemastforwardand backward.Toextendthecylinderrod(tiltforward), oilentersthetiltcylinderportbehindthepiston.The oilpressurepushesthecylinderrodoutofthecylinder.Oilinfrontofthepistonreturnstothehydraulic
REMOVE
WARNING
Beforeremovingthetiltcylinder(s),tiltthe mastforward.Useachaintoholdthemastto theframe,andpreventthemastfrommoving forward.
1. Disconnectthehydrauliclinesatthetiltcylinder. Installcapsonthehydrauliclinesandports.
WARNING
Donotpushtheanchorpinsoutoftherodend withyourfingers.Donotpermitthetiltcylinderstodropandcausedamage.
2. Removetheretainersfortheanchorpins.Push theanchorpinsoutoftherodendwithatool.
3. Usealiftingdevicetomovelargetiltcylinders. Removetheanchorpinsfromtheframeanchors. Removethetiltcylinderfromtheframe.
DISASSEMBLE
1. Putthetiltcylinderinavisewithsoftjaws.Removetherodendfromtherod.
2. Removetheretainerfromthetiltcylinder.Removetherodandpistonfromthecylinder.
3. Disassemblethetiltcylinderasnecessary.See Figure2,Figure3,Figure4,andFigure5.
tank.Toretractthecylinderrod(tiltbackward),the oilenterstheportinfrontofthepiston.Theoilpressurepushesthecylinderrodintothetiltcylinder. Theoilbehindthepistonreturnstothehydraulic tank.
CLEAN
WARNING
Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer ’srecommendedsafetyprocedures.
Compressedaircanmoveparticlessothatthey causeinjurytotheuserortootherpersonnel. Makesurethatthepathofthecompressedair isawayfromallpersonnel.Wearprotective gogglesorafaceshieldtopreventinjurytothe eyes.
Cleanallpartsinsolventanddrywithcompressed air.
ASSEMBLE
TiltCylindersWithO-RingorSingle-Lip Seals
NOTE: AlwaysusenewsealsandO-rings.Makesure allpartsareclean.Lubricateallpartswithclean hydraulicoil.
NOTE: During1980and1981,achangewasmadein thetiltcylindersusedinmostlifttrucks.TheO-ring sealbetweentheretainerandthecylindershellwas movedfromabovethethreadstotheareabelowthe threads.Aback-upringwasaddedtoincreasethe strengthoftheO-ring.Theassemblyofthetiltcylindersisthesame,butcautionmustbeusedsothatthe O-ringsealisnotdamagedbythethreads.
2100SRM103 TiltCylinderRepair
TiltCylinderRepair
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1. InstalltheO-ringinsidethepistonbore.SeeFigure1.Installthepistononthepistonrod.Make suretheO-ringisnotdamaged.Tightenthenut onthepistonrodtothespecificationsgivenin TorqueSpecifications.
2. InstalltheO-ring,sealring,andguideringon thepiston.Thesealringmustbeheatedbefore installation.Afterheating,itmustbepushed intoitsgrooveusingaringcompressor.Letthe sealringcoolandreturntoitsnormalshape.
3. Ifused,installtheO-ringandtheback-upringin thegrooveoftheouterretainer.Installtherod
seal(O-ringtowardthepiston)andwipersealin theinnerretainer.
4. Installtheretaineronthepistonrod.Install thepistonandrodassemblyandtheretainerin thecylinder.Ifused,installtheO-ringonthe retainer.Tightentheretainertospecifications giveninTorqueSpecifications.
NOTE: Afterassemblyiscomplete,installtherod endonthepistonrod.Tightenthecapscrewonthe rodendasspecifiedin Mast sectionforyourspecific lifttruck.
TiltCylinderRepair 2100SRM103
1.PISTONROD 2.PISTONRING 3.O-RING 4.O-RING 5.PISTON 6.GUIDERING 7.NUT 8.CYLINDERSHELL 9.O-RING 10.BACK-UPRING 11.RETAINER 12.SEALRING 13.WIPERRING 14.SPACER(SOMEMODELS)
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Figure1.TiltCylinderswithO-RingorSingleLipSeals
TiltCylindersforXMandXMSModels
NOTE: Thefollowingprocedureisforthese models:S/H/E/J2.00-3.00XM(S/H/E/J40-65XM) J1.60-2.00XMT(J30-40XM)H/S/E1.25-1.75XM, H/S/E2.00XMS(S/H/E25-35XM,S/H/E40XMS).
NOTE: AlwaysusenewsealsandO-rings.Makesure allpartsareclean.Lubricateallpartswithclean hydraulicoil.
1. InstallthepistonsealandO-ring(s)ontothepiston.SeeFigure2andFigure3.Installthepiston ontothecylinderrod.Makesurethepistonseal isnotdamaged.Tightenthenutonthepiston rodtothevalueshowninTorqueSpecifications.
2. Installanewwiperandrodseal.Installthe O-ringandback-upringontotheretainer.
3. Installtheretainerassemblyontotherod.
4. Installthepistonandrodassemblyintothecylinder.Tightentheretainertothevalueshownin TorqueSpecifications.
NOTE: Afterassemblyiscomplete,installtherod endonthecylinderrod.Tightenthecapscrewonthe rodendasspecifiedin Mast sectionforyourspecific lifttruck.
2100SRM103 TiltCylinderRepair
1.CYLINDERSHELL 2.NUT 3.PISTON 4.O-RING 5.SEALRING 6.PISTONROD 7.O-RING 8.BACK-UPRING 9.SEALRING 10.RETAINER 11.WIPERRING
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Figure2.TiltCylindersforS/H/E/J2.00-3.20XM(S/H/E/J40-65XM)
TiltCylindersforH700-800AandEarly ModelH700-920B
NOTE: AlwaysusenewsealsandO-rings.Makesure allpartsareclean.Lubricateallpartswithclean hydraulicoil.
1. Installthethrustplateontherod.Installthe back-upringandO-ringontherod.Installthe pistonontherod.Installthepistonringsand sealsonthepiston.SeeFigure4.
2. Installthelocknutontherod.Tightenthelock nutuntilthethrustplateistightagainsttherod. Installthepininthelocknutandrodifnecessary,drillaholeintherodforthepin.Install thesnapringtoholdthepininposition.
3. Installthepistonandrodassemblyintheshell. Installthesealsontheretainer.Installtheretainerintheshell.
4. Installthelockringintheshell,butdonot tightenit.Installthecapscrewsinthelockring. Turnthelockringuntilitisevenwiththeend oftheshell.Installthepipepluginthelock ringandtightentheplugto34to48N•m(25to 35lbfft).Tightenthecapscrewsinthelockring to14to20N•m(10to15lbfft).
5. Installtherodendontherod.Tightenthecapscrewsontherodendto610N•m(450lbfft).
TiltCylinderRepair 2100SRM103 1.CYLINDERSHELL 2.RETAINER 3.ROD 4.WIPERRING 5.RODSEAL 6.BACK-UPRING 7.O-RING 8.NUT 9.PISTON 10.PISTONSEAL
Figure3.TiltCylindersforH/S/E/J1.25-1.75XM,XMS,XMT(H/S/E/J25-40XM,XMS,XMT)
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INSTALL
1. Usealiftingdevicetomovelargetiltcylinders. Putthecylinderinthelifttruck.Installtheanchorpinintheframe.Installtheretainerpinor cotterpin.
2. Installtheanchorpinatthemastmount.Install theretainerpinorcotterpinfortheanchorpin. Tightenthecapscrewsfortheretainerpins.
3. Connectthehydrauliclinestothetiltcylinder.
4. Operatethetiltcylinders.Checkforcorrectoperationandleakage.Adjustthetiltcylinders asdescribedinTiltCylinderLeakCheckand TiltCylinderStrokeandMastTiltAngleAdjustment.
2100SRM103 TiltCylinderRepair 1.CYLINDERSHELL 2.SNAPRING 3.LOCKNUT 4.DOWEL 5.PISTONRING 6.O-RING 7.SEALRING 8.PISTONRING 9.PISTON 10.THRUSTPLATE 11.O-RING 12.BACK-UPRING 13.PISTONROD 14.O-RING 15.BACK-UPRING 16.RETAINER 17.SEALRING 18.WIPERRING 19.RETAINERRING 20.PLUG 21.CAPSCREW
Figure4.TiltCylindersforH700-800A,EarlyModelH700-920B
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TiltCylindersUsingChevronPacking
NOTE: AlwaysusenewsealsandO-rings.Make sureallpartsareclean.Lubricateallpartswith cleanhydraulicoil.
NOTE: ThefollowingprocedureisfortheH360-650C (earlymodel).SeeFigure5.
NOTE: Afterassemblyiscomplete,installtherod endonthecylinderrod.Tightenthecapscrewonthe rodendasspecifiedin Mast sectionforyourspecific lifttruck.
TiltCylinderRepair 2100SRM103
1.CYLINDERSHELL 2.NUT 3.PISTONHEAD 4.O-RING 5.NYLONRING 6.PACKING 7.NYLONRING 8.PISTONHALF(FLAT) 9.PISTONROD 10.O-RING 11.BACK-UPRING 12.RETAINER 13.O-RING 14.BACK-UPRING 15.BUSHING 16.PACKING 17.RETAINERRING 18.SETSCREW 19.WIPERRING
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Figure5.TiltCylinderswithChevronPacking(EarlyModelH360-650C)
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Install STEP1.
InstalltheO-ringandtheback-upringonthebushing.Installthepackinginthebushing.Theendof thepackingmustextend3mm(0.125in.)beyondthe endofthebushing.
STEP2.
InstalltheO-ringandtheback-upringonthe retainer.Useyourhandtopushthebushinginto theretainer.MakesuretheO-ringisnotdamaged duringinstallation.Installtheretainerandbushing assemblyonthecylinderrod.
STEP3.
Installtheflatpistonhalfonthecylinderrod.Put theO-ringontherodhalfwaybetweenthethreads andthepistonhalf.
2100SRM103 TiltCylinderRepair
1.O-RING
2.BACK-UPRING
3.PACKING
4.BUSHING
1.O-RING
2.BACK-UPRING
3.BUSHING
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1.PACKING2.PISTONHALF
STEP4.
Installthepistonhalfwiththepackingonthecylinderrod.MakesuretheO-ringfitsintothepiston groovewhenthepistonhalfisinstalled.Installthe pistonrodnut.Tightentothespecificationsgivenin TorqueSpecifications.
STEP5.
Pushthepistonintothecylinderbore.Pushtheretainerintothebore.MakesuretheO-ringisnotdamaged.
TiltCylinderRepair 2100SRM103
1.O-RING 2.PISTONHALF 3.PISTONHALF WITHPACKING
1.CYLINDERROD 2.PISTONAND PACKING 8
3.RODNUT
STEP6.
Installanewwipersealintheretainer.Turntheretainerintothecylindershelluntilthethreadshave started.Pushthepistoninandoutseveraltimesto makesurethealignmentiscorrect.
STEP7.
Tightentheretainertothespecificationsgivenin TorqueSpecifications.Tightenthesetscrew.
TiltCylinderLeakCheck
WARNING
Neverallowanyoneunderaraisedcarriage. Donotputanypartofyourbodyinorthrough theliftmechanismunlessallpartsofthemast arecompletelyloweredandtheengineis STOPPED.
Donottrytofindhydraulicleaksbyputting yourhandonhydrauliccomponentsunder pressure.Hydraulicoilcanbeinjectedinto thebodybythepressure.
1. Putacapacityloadontheforks.Useasafety chaintoholdtheloadtothecarriage.Raisethe loadapproximately2.5m(8ft).Putthemastin averticalposition.
2. Measurethedistancethattherodfortiltcylinderextendsfromtheshell.Checkthedistance therodmovesinfiveortenminutes.Multiply
therateinTable1bythetimeofthetestand comparethenumbers.
3. Ifthetiltrateisgreaterthanthespecifications, lowerthemastandremovetheloadfromthe forks.Installavalvebetweentheportatthe frontofthetiltcylinderandthehydraulicline. Puttheloadontheforksagain.Closethevalve. Tiltthemastforwardjustpasttheverticalposition.Ifthemastcontinuestotiltslowlyforward, thesealsonthepistonareleaking.
4. Ifthemastdoesnotmove,openthegatevalve andcheckthemovementagain.Ifthemast movesforwardwhenthegatevalveisopen, checkforleaksinthehydrauliclinesandfittings.Ifnoleaksarefound,themaincontrol valvecanbewornordamaged.Removetheload fromtheforkswhenthechecksarecomplete.
2100SRM103 TiltCylinderLeakCheck
1.WIPERSEAL2.RETAINER
1.RETAINER2.SETSCREW
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Table1.MovementRates(Maximum)forTiltCylinders
TiltCylinderStrokeandMastTiltAngleAdjustment
Adjustthetiltcylindersasdescribedinthesectionforthe Mast
TorqueSpecifications
PISTONRODNUT
E1.25-1.75XL(E25-35XL) 163to190N•m(120to140lbfft)
J1.60-2.00XMT(J30-40XM) 163to190N•m(120to140lbfft)
E2.00-3.00XL(E40-60XL) 320to400N•m(236to295lbfft)
E/J2.00-3.20XM(E/J40-65XM) 150N•m(110lbfft)
E20-30B 244to271N•m(180to200lbfft)
E30-60B,E30-60AC 407to475N•m(300to350lbfft)
E3.50-5.50XL(E70-120XL) 400to440N•m(295to325lbfft)
TorqueSpecifications 2100SRM103
HYDRAULICOILTEMPERATURE/MAST TILTRATE 20 C(68 F) 60 C(140 F) LIFTTRUCKMODEL mm/min in./min mm/min in./min A1.00-1.50XL(A20-30XL) 1.3 0.05 9.1 0.50 E1.25-5.50XL,XM(E25-120XL) 0.8 0.03 5.0 0.20 J1.60-2.00XMT(J30-40XM) 0.8 0.03 5.0 0.20 E/J2.00-3.20XM(E/J40-65XM) 0.8 0.03 5.0 0.20 H1.25-1.75XL(H25-35XL) 0.8 0.03 5.0 0.20 S/H/E1.50-1.75XM,S/H/E2.00XMS (S/H/E25-35XM,S/H/E40XMS) 0.8 0.03 5.0 0.20 H2.00-3.00XL(H40-60XL) 1.1 0.04 7.3 0.30 S/H2.00-3.20XM(S/H40-65XM) 1.0 0.04 6.8 0.30 H3.50-7.00XL(H70-155XL) 1.3 0.05 8.9 0.34 H8.00-16.00XL(H165-360XL) 1.8 0.07 11.7 0.05 H8.00-16.00XM(H170-360HD) 1.8 0.07 11.7 0.05 H20.00-32.00F(H440-700F/FS) 1.3 0.05 3.8 0.15 H36.00-48.00C(H800-1050C) 1.3 0.05 3.8 0.15 J2.00-3.00XL(J40-60XL) 0.8 0.03 5.0 0.20 J25-35A,B 1.3 0.05 3.8 0.15 S1.25-5.50XL(S25-120XL) 0.8 0.03 5.0 0.20 S6.00-7.00XL(S135-155XL) 1.2 0.05 8.2 0.32
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