Hyster E114 (E1.50XM Europe) Forklift Service Repair Manual

General

Thissectionhasadescriptionandtherepairproceduresforseveraldifferenttypesoftiltcylinders.The

numberandthedesignofthepartscanbedifferent, buttheoperationofthetiltcylindersisthesame.

Description

Thetiltcylinders[Figure1,Figure2,Figure3,Figure4,Figure5,andFigure6]areusedtomovethe mastforwardandbackward.Toextendthecylinder rod(tiltforward),oilentersthetiltcylinderportbehindthepiston.Theoilpressurepushesthecylinder

rodoutofthecylinder.Oilinfrontofthepistonreturnstothehydraulictank.Toretractthecylinder rod(tiltbackward),theoilenterstheportinfrontof thepiston.Theoilpressurepushesthecylinderrod intothetiltcylinder.Theoilbehindthepistonreturnstothehydraulictank.

TiltCylinderRepair

REMOVE

WARNING

Beforeremovingthetiltcylinder(s),tiltthe mastforward.Useachaintoholdthemastto theframeandpreventthemastfrommoving 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,Figure5,andFigure6.

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.Abackupringwasaddedtoincreasethe strengthoftheO-ring.Theassemblyofthetiltcylindersisthesame,butcautionmustbeusedsothatthe O-ringsealisnotdamagedbythethreads.

1. InstalltheO-ringinsidethepistonbore.SeeFigure1.Installthepistononthepistonrod.Make suretheO-ringisnotdamaged.Tightenthenut onthepistonrodtothespecificationsgivenin TorqueSpecifications.

2. InstalltheO-ring,sealring,andguideringon thepiston.Thesealringmaybeheatedtoease installation.Polyurethanerings(brown)willreturntoshape;Teflonrings(yellow)shouldbe re-sizedbyusingaspringcompressor.

3. Ifused,installtheO-ringandthebackupring inthegrooveoftheouterretainer.Installthe

rodseal(O-ringandsealinglipfacingtowardthe piston)andwipersealintheinnerretainer.

4. Installtheretaineronthepistonrod.Install thepistonandrodassemblyandtheretainerin thecylinder.Ifused,installtheO-ringonthe retainer.Tightentheretainertospecifications giveninTorqueSpecifications.

NOTE: Afterassemblyiscomplete,installtherodend onthepistonrod.Tightenthecapscrewontherod endasspecifiedin Mast sectionforyourspecificlift truck.

Figure1.TiltCylindersWithO-RingorSingle-LipSeals

TiltCylindersforXMandXMSModels

NOTE: Thefollowingprocedureisforthesemodels:

• S/H/E/2.00-3.00XM(S/H/E/40-65XM)

• J2.00-3.00XM(J40-60XM,J40-60XM 2)(A216)

• J2.00-3.00XM(J40-65Z)(A416)

• E1.50-2.00XM(E25-35Z,40ZS)(E114)

• J1.60-2.00XMT(J30-40XM)

• H/S/E1.25-1.75XM,H/S/E2.00XMS(S/H/E2535XM,S/H/E40XMS)

NOTE: AlwaysusenewsealsandO-rings.Makesure allpartsareclean.Lubricateallpartswithclean hydraulicoil.

NOTE: Ifanewpistonwasnotinstalled,thepiston rodnutmustberetightenedtothevalueshownin TorqueSpecifications.

1. InstallthepistonsealandO-ring(s)ontothepiston.SeeFigure2andFigure3.Installthepiston ontothecylinderrod.Makesurethepistonseal isnotdamaged.Tightenthenutonthepiston rodtothevalueshowninTorqueSpecifications.

2. Installanewwiperandrodseal.Installthe O-ringandbackupringontotheretainer.

3. Installtheretainerassemblyontotherod.

4. Installthepistonandrodassemblyintothecylinder.Tightentheretainertothevalueshownin TorqueSpecifications.

NOTE: Afterassemblyiscomplete,installtherodend onthecylinderrod.Tightenthecapscrewontherod endasspecifiedin Mast sectionforyourspecificlift truck.

Figure2.TiltCylindersforS/H/E/2.00-3.20XM(S/H/E/40-65XM),J2.00-3.00XM(J40-60XM, J40-60XM 2)(A216),J2.00-3.20XM(J40-65Z)(A416/B416),andE2.00-3.20XM(E45-65Z)(G108)

Figure3.TiltCylindersforH/S/E/J1.25-1.75XM,XMS,XMT(H/S/E/J25-40XM,XMS,XMT)and E1.50-2.00XM(E25-35Z,40ZS)(E114/F114)

TiltCylindersforXL,XLS,andXL 3 Models

NOTE: Thefollowingprocedureisforthesemodels:

• E3.50-5.50XL,E3.50-5.50XL 3 (E70-120XL, E70-120XL 3)(C098)

• E3.50-5.50XL,E4.50XLS(E70-120Z,E100ZS) (D098/E098)

NOTE: AlwaysusenewsealsandO-rings.Makesure allpartsareclean.Lubricateallpartswithclean hydraulicoil.

NOTE: Ifanewpistonwasnotinstalled,thepiston rodnutmustberetightenedtothevalueshownin TorqueSpecifications.

1. Installtheguidering,pistonsealandO-ringonto thepiston.SeeFigure4.Installthepistononto thecylinderrod.Makesurethepistonsealisnot

damaged.Tightenthenutonthepistonrodto thevalueshowninTorqueSpecifications.

2. Installanewwiperandrodseal.Installo-ring andbackupringontoretainer.

3. Installretainerassemblyontopistonrod.

4. InstallO-ringandshimsontopistonrod.

5. Installthepistonandrodassemblyintothecylinder.Tightentheretainertothevalueshownin TorqueSpecifications.

NOTE: Afterassemblyiscomplete,installtherodend onthecylinderrod.Tightenthecapscrewontherod endasspecifiedin Mast sectionforyourspecificlift truck.

Figure4.TiltCylindersforE3.50-5.50XL,E3.50-5.50XL 3 (E70-120XL,E70-120XL 3)(C098)and E3.50-5.50XL,E4.50XLS(E70-120Z,E100ZS)(D098/E098)Models

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TiltCylindersforH700-800AandEarly ModelH700-920B

NOTE: AlwaysusenewsealsandO-rings.Makesure allpartsareclean.Lubricateallpartswithclean hydraulicoil.

1. Installthethrustplateontherod.Installthe backupringandO-ringontherod.Installthe pistonontherod.Installthepistonringsand sealsonthepiston.SeeFigure5.

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).

Figure5.TiltCylindersforH700-800A,EarlyModelH700-920B

INSTALL

1. Usealiftingdevicetomovelargetiltcylinders. Putthecylinderinthelifttruck.Installtheanchorpinintheframe.Installtheretainerpinor cotterpin.

2. Installtheanchorpinatthemastmount.Install theretainerpinorcotterpinfortheanchorpin. Tightenthecapscrewsfortheretainerpins.

3. Connectthehydrauliclinestothetiltcylinder.

4. Operatethetiltcylinders.Checkforcorrectoperationandleakage.Adjustthetiltcylinders asdescribedinTiltCylinderLeakCheckand

TiltCylinderStrokeandMastTiltAngleAdjustment.

TiltCylindersUsingChevronPacking

NOTE: AlwaysusenewsealsandO-rings.Makesure allpartsareclean.Lubricateallpartswithclean hydraulicoil.

NOTE: ThefollowingprocedureisfortheH360-650C (earlymodel).SeeFigure6.

NOTE: Afterassemblyiscomplete,installtherodend onthecylinderrod.Tightenthecapscrewontherod endasspecifiedin Mast sectionforyourspecificlift truck.

Figure6.TiltCylindersWithChevronPacking(EarlyModelH360-650C)

Install

STEP1.

InstalltheO-ringandthebackupringonthebushing.Installthepackinginthebushing.Theendof thepackingmustextend3mm(0.125in.)beyondthe endofthebushing.

STEP2.

InstalltheO-ringandthebackupringontheretainer.Useyourhandtopushthebushinginto theretainer.MakesuretheO-ringisnotdamaged duringinstallation.Installtheretainerandbushing assemblyonthecylinderrod.

1.O-RING

2.BACKUPRING

3.PACKING

4.BUSHING

STEP3.

Installtheflatpistonhalfonthecylinderrod.Put theO-ringontherodhalfwaybetweenthethreads andthepistonhalf.

1.O-RING

2.BACKUPRING

3.BUSHING

1.PACKING

2.PISTONHALF

STEP4.

Installthepistonhalfwiththepackingonthecylinderrod.MakesuretheO-ringfitsintothepiston groovewhenthepistonhalfisinstalled.Installthe pistonrodnut.Tightentothespecificationsgivenin TorqueSpecifications.

STEP5.

Pushthepistonintothecylinderbore.Pushtheretainerintothebore.MakesuretheO-ringisnotdamaged.

2.PISTONHALF

3.PISTONHALFWITHPACKING

2.PISTONANDPACKING

3.RODNUT

1.O-RING

1.CYLINDERROD

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 therodmovesin fiveortenminutes.Multiply therateinTable1bythetimeofthetestand comparethenumbers.

3. Ifthetiltrate isgreaterthanthespecifications, lowerthemast andremovetheloadfromthe forks.Installagatevalvebetweentheportatthe frontofthetiltcylinderandthehydraulicline. Puttheloadontheforksagain.Closethegate valve.Tiltthemastforwardjustpasttheverticalposition.Ifthemastcontinuestotiltslowly forward,the sealsonthepistonareleaking.

1.WIPERSEAL 2.RETAINER

1.RETAINER 2.SETSCREW