Hyster C117 (H800-1050C) Service Manual – PDF DOWNLOAD

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

PART NO. 897934

700 SRM 626

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

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.

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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

1

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

2

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4.

PISTON VALVE SEAT SPRING DIAPHRAGM

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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 −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.

Figure 3. Cooling System Components Typical Arrangement

See

FAN SPACER HUB/PULLEY WATER PUMP

5. THERMOSTAT 6. THERMOSTAT HOUSING

1.

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4.

3

Radiator Cleaning

700 SRM 626

WATER PUMP

FAN AND FAN SHROUD

WARNING

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 manufacturer’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.

4

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.

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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

5

Troubleshooting

700 SRM 626

Troubleshooting PROBLEM Coolant leaks.

The engine is too hot during operation.

Exhaust leaks into coolant.

6

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.

TECHNICAL PUBLICATIONS 700 SRM 626

11/01 (9/00)(9/96) Printed in U.S.A.

7,/7 &</,1'(56 ALL MODELS EXCEPT H3.50-5.50XM (H70-120XM)

PART NO. 910102

2100 SRM 103

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

2100 SRM 103

Tilt Cylinder Repair

General This section has a description and the repair procedures for several different types of tilt cylinders. The

number and the design of the parts can be different, but the operation of the tilt cylinders is the same.

Description The tilt cylinders ( Figure 2, Figure 3, Figure 4, and Figure 5 ) are used to move the mast forward and backward. To extend the cylinder rod (tilt forward), oil enters the tilt cylinder port behind the piston. The oil pressure pushes the cylinder rod out of the cylinder. Oil in front of the piston returns to the hydraulic

tank. To retract the cylinder rod (tilt backward), the oil enters the port in front of the piston. The oil pressure pushes the cylinder rod into the tilt cylinder.

The oil behind the piston returns to the hydraulic tank.

Tilt Cylinder Repair REMOVE WARNING Before removing the tilt cylinder(s), tilt the mast forward. Use a chain to hold the mast to the frame, and prevent the mast from moving forward.

1. Disconnect the hydraulic lines at the tilt cylinder.

Install caps on the hydraulic lines and ports.

WARNING Do not push the anchor pins out of the rod end with your fingers. Do not permit the tilt cylinders to drop and cause damage.

2. Remove the retainers for the anchor pins. Push the anchor pins out of the rod end with a tool.

3. Use a lifting device to move large tilt cylinders.

Remove the anchor pins from the frame anchors.

Remove the tilt cylinder from the frame.

DISASSEMBLE 1. Put the tilt cylinder in a vise with soft jaws. Remove the rod end from the rod.

2. Remove the retainer from the tilt cylinder. Remove the rod and piston from the cylinder.

3. Disassemble the tilt cylinder as necessary. See Figure 2, Figure 3, Figure 4, and Figure 5.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

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.

Clean all parts in solvent and dry with compressed air.

ASSEMBLE Tilt Cylinders With O-Ring or Single-Lip Seals NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: During 1980 and 1981, a change was made in the tilt cylinders used in most lift trucks. The O-ring seal between the retainer and the cylinder shell was moved from above the threads to the area below the threads. A back-up ring was added to increase the strength of the O-ring. The assembly of the tilt cylinders is the same, but caution must be used so that the O-ring seal is not damaged by the threads.

1

Tilt Cylinder Repair

2100 SRM 103

1. Install the O-ring inside the piston bore. See Figure 1. Install the piston on the piston rod. Make sure the O-ring is not damaged. Tighten the nut on the piston rod to the specifications given in Torque Specifications.

2. Install the O-ring, seal ring, and guide ring on the piston. The seal ring must be heated before installation. After heating, it must be pushed into its groove using a ring compressor. Let the seal ring cool and return to its normal shape.

3. If used, install the O-ring and the back-up ring in the groove of the outer retainer. Install the rod

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PISTON ROD PISTON RING O-RING O-RING PISTON

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10.

seal (O-ring toward the piston) and wiper seal in the inner retainer.

4. Install the retainer on the piston rod. Install the piston and rod assembly and the retainer in the cylinder. If used, install the O-ring on the retainer. Tighten the retainer to specifications given in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the piston rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

GUIDE RING NUT CYLINDER SHELL O-RING BACK-UP RING

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RETAINER SEAL RING WIPER RING SPACER (SOME MODELS)

Figure 1. Tilt Cylinders with O-Ring or Single Lip Seals

2

2100 SRM 103

Tilt Cylinder Repair

Tilt Cylinders for XM and XMS Models NOTE: The following procedure is for these 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: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

1. Install the piston seal and O-ring(s) onto the piston. See Figure 2 and Figure 3. Install the piston onto the cylinder rod. Make sure the piston seal is not damaged. Tighten the nut on the piston rod to the value shown in Torque Specifications.

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CYLINDER SHELL NUT PISTON O-RING

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SEAL RING PISTON ROD O-RING BACK-UP RING

2. Install a new wiper and rod seal. Install the O-ring and back-up ring onto the retainer.

3. Install the retainer assembly onto the rod.

4. Install the piston and rod assembly into the cylinder. Tighten the retainer to the value shown in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

9. SEAL RING 10. RETAINER 11. WIPER RING

Figure 2. Tilt Cylinders for S/H/E/J2.00-3.20XM (S/H/E/J40-65XM)

3

Tilt Cylinder Repair

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CYLINDER SHELL RETAINER ROD WIPER RING

2100 SRM 103

5.

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8.

ROD SEAL BACK-UP RING O-RING NUT

9. PISTON 10. PISTON SEAL

Figure 3. Tilt Cylinders for H/S/E/J1.25-1.75XM, XMS, XMT (H/S/E/J25-40XM, XMS, XMT)

Tilt Cylinders for H700-800A and Early Model H700-920B NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

1. Install the thrust plate on the rod. Install the back-up ring and O-ring on the rod. Install the piston on the rod. Install the piston rings and seals on the piston. See Figure 4.

2. Install the lock nut on the rod. Tighten the lock nut until the thrust plate is tight against the rod.

Install the pin in the lock nut and rod if necessary, drill a hole in the rod for the pin. Install the snap ring to hold the pin in position.

4

3. Install the piston and rod assembly in the shell.

Install the seals on the retainer. Install the retainer in the shell.

4. Install the lock ring in the shell, but do not tighten it. Install the capscrews in the lock ring.

Turn the lock ring until it is even with the end of the shell. Install the pipe plug in the lock ring and tighten the plug to 34 to 48 N•m (25 to 35 lbf ft). Tighten the capscrews in the lock ring to 14 to 20 N•m (10 to 15 lbf ft).

5. Install the rod end on the rod. Tighten the capscrews on the rod end to 610 N•m (450 lbf ft).

2100 SRM 103

1.

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5.

6.

7.

Tilt Cylinder Repair

CYLINDER SHELL SNAP RING LOCK NUT DOWEL PISTON RING O-RING SEAL RING

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PISTON RING PISTON THRUST PLATE O-RING BACK-UP RING PISTON ROD O-RING

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BACK-UP RING RETAINER SEAL RING WIPER RING RETAINER RING PLUG CAPSCREW

Figure 4. Tilt Cylinders for H700-800A, Early Model H700-920B

INSTALL

3. Connect the hydraulic lines to the tilt cylinder.

1. Use a lifting device to move large tilt cylinders.

Put the cylinder in the lift truck. Install the anchor pin in the frame. Install the retainer pin or cotter pin.

4. Operate the tilt cylinders. Check for correct operation and leakage. Adjust the tilt cylinders as described in Tilt Cylinder Leak Check and Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.

2. Install the anchor pin at the mast mount. Install the retainer pin or cotter pin for the anchor pin.

Tighten the capscrews for the retainer pins.

5

Tilt Cylinder Repair

2100 SRM 103

Tilt Cylinders Using Chevron Packing NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

NOTE: The following procedure is for the H360-650C (early model). See Figure 5.

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CYLINDER SHELL NUT PISTON HEAD O-RING NYLON RING PACKING NYLON RING

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PISTON HALF (FLAT) PISTON ROD O-RING BACK-UP RING RETAINER O-RING BACK-UP RING

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BUSHING PACKING RETAINER RING SETSCREW WIPER RING

Figure 5. Tilt Cylinders with Chevron Packing (Early Model H360-650C)

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2100 SRM 103

Tilt Cylinder Repair

Install STEP 1.

Install the O-ring and the back-up ring on the bushing. Install the packing in the bushing. The end of the packing must extend 3 mm (0.125 in.) beyond the end of the bushing.

1. O-RING 2. BACK-UP RING

3. PACKING 4. BUSHING

1. O-RING 2. BACK-UP RING

3. BUSHING

1. PACKING

2. PISTON HALF

STEP 2.

Install the O-ring and the back-up ring on the retainer. Use your hand to push the bushing into the retainer. Make sure the O-ring is not damaged during installation. Install the retainer and bushing assembly on the cylinder rod.

STEP 3.

Install the flat piston half on the cylinder rod. Put the O-ring on the rod halfway between the threads and the piston half.

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Tilt Cylinder Repair

2100 SRM 103

STEP 4.

Install the piston half with the packing on the cylinder rod. Make sure the O-ring fits into the piston groove when the piston half is installed. Install the piston rod nut. Tighten to the specifications given in Torque Specifications.

1. O-RING 2. PISTON HALF

3. PISTON HALF WITH PACKING

1. CYLINDER ROD 2. PISTON AND PACKING

3. ROD NUT

STEP 5.

Push the piston into the cylinder bore. Push the retainer into the bore. Make sure the O-ring is not damaged.

8

2100 SRM 103

Tilt Cylinder Leak Check

STEP 6.

Install a new wiper seal in the retainer. Turn the retainer into the cylinder shell until the threads have started. Push the piston in and out several times to make sure the alignment is correct.

1. WIPER SEAL

2. RETAINER

1. RETAINER

2. SETSCREW

STEP 7.

Tighten the retainer to the specifications given in Torque Specifications. Tighten the setscrew.

Tilt Cylinder Leak Check WARNING Never allow anyone under a raised carriage.

Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Do not try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure.

1. Put a capacity load on the forks. Use a safety chain to hold the load to the carriage. Raise the load approximately 2.5 m (8 ft). Put the mast in a vertical position.

2. Measure the distance that the rod for tilt cylinder extends from the shell. Check the distance the rod moves in five or ten minutes. Multiply

the rate in Table 1 by the time of the test and compare the numbers.

3. If the tilt rate is greater than the specifications, lower the mast and remove the load from the forks. Install a valve between the port at the front of the tilt cylinder and the hydraulic line.

Put the load on the forks again. Close the valve.

Tilt the mast forward just past the vertical position. If the mast continues to tilt slowly forward, the seals on the piston are leaking.

4. If the mast does not move, open the gate valve and check the movement again. If the mast moves forward when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve can be worn or damaged. Remove the load from the forks when the checks are complete.

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Torque Specifications

2100 SRM 103 Table 1. Movement Rates (Maximum) for Tilt Cylinders

LIFT TRUCK MODEL

HYDRAULIC OIL TEMPERATURE/MAST TILT RATE 20 C (68 F)

60 C (140 F)

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

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment Adjust the tilt cylinders as described in the section for the Mast.

Torque Specifications PISTON ROD NUT E1.25-1.75XL (E25-35XL) 163 to 190 N•m (120 to 140 lbf ft) J1.60-2.00XMT (J30-40XM) 163 to 190 N•m (120 to 140 lbf ft) E2.00-3.00XL (E40-60XL) 320 to 400 N•m (236 to 295 lbf ft)

10

E/J2.00-3.20XM (E/J40-65XM) 150 N•m (110 lbf ft) E20-30B 244 to 271 N•m (180 to 200 lbf ft) E30-60B, E30-60AC 407 to 475 N•m (300 to 350 lbf ft) E3.50-5.50XL (E70-120XL) 400 to 440 N•m (295 to 325 lbf ft)

2100 SRM 103

Torque Specifications

E60-100B 407 to 440 N•m (300 to 325 lbf ft)

H60-110E 400 to 440 N•m (295 to 325 lbf ft)

H1.25-1.75XL (H25-35XL) 163 to 190 N•m (120 to 140 lbf ft)

H110-150F 678 to 746 N•m (500 to 550 lbf ft)

H/E1.50-1.75XM, H/E2.00XMS (H/E25-35XM, H/E40XMS) 163 to 190 N•m (120 to 140 lbf ft)

H300A 678 to 746 N•m (500 to 550 lbf ft)

H20-30E 136 to 170 N•m (100 to 125 lbf ft) H2.00-3.00XL (H40-60XL) 163 to 190 N•m (120 to 140 lbf ft) S/H2.00-3.20XM (S/H40-65XM) 150 N•m (110 lbf ft) H30-60H, H40-60J 244 to 271 N•m (180 to 200 lbf ft) H3.50-5.00XL (H70-110XL) 400 to 440 N•m (295 to 325 lbf ft) H6.00-7.00XL (H135-155XL) 407 to 440 N•m (300 to 325 lbf ft) H7.00-12.50H (H150-275H) 447 to 475 N•m (330 to 350 lbf ft) H8.00-12.00XL (H165-280XL) 950 to 985 N•m (700 to 725 lbf ft) H13.00-16.00XL (H300-360XL) 1105 to 1140 N•m (815 to 840 lbf ft) H16.00-30.00C (H360-650C) - Early 1356 to 1492 N•m (1000 to 1100 lbf ft) H16.00-30.00C (H360-650C) - Late 1500 to 1600 N•m (1107 to 1181 lbf ft) H17.00-32.00C (H370-700C) 1500 to 1600 N•m (1107 to 1181 lbf ft) H20.00-32.00F (H440-700F/FS) 1500 to 1600 N•m (1107 to 1181 lbf ft) H32.00-44.00B (H700-920B) - Late 1500 to 1600 N•m (1107 to 1181 lbf ft) H36.00-48.00C (H800-1050C) 1500 to 1600 N•m (1107 to 1181 lbf ft) H60-90C 407 to 447 N•m (300 to 330 lbf ft)

H300-350B 447 to 475 N•m (330 to 350 lbf ft) H360-620B 1356 to 1492 N•m (1000 to 1100 lbf ft) H700-800A, H700-920B - Early See Text J2.00-3.00XL (J40-60XL) 320 to 400 N•m (236 to 295 lbf ft) J25-35A 244 to 271 N•m (180 to 200 lbf ft) J25-35B 320 to 400 N•m (236 to 295 lbf ft) J40-60A, J50-60AS 407 to 475 N•m (300 to 350 lbf ft) P40-50A, P60-80A 407 to 447 N•m (300 to 330 lbf ft) P7.00-8.00B (P150-200B) 447 to 475 N•m (330 to 350 lbf ft) S20-30A 136 to 170 N•m (100 to 125 lbf ft) S30-60E, S40-50F 407 to 475 N•m (300 to 350 lbf ft) S40-50C 224 to 271 N•m (165 to 200 lbf ft) S1.25-1.75XL (S25-35XL) 163 to 190 N•m (120 to 140 lbf ft) S25-35XM, S40XMS 163 to 190 N•m (120 to 140 lbf ft) S2.00-3.00XL (S40-60XL) 320 to 400 N•m (236 to 295 lbf ft) S3.00-5.50E (S60-120E) 407 to 440 N•m (300 to 325 lbf ft) S3.50-5.50XL (S70-120XL) 400 to 440 N•m (295 to 325 lbf ft)

11

Torque Specifications

2100 SRM 103

S5.50-7.00A (S125-150A) 542 to 610 N•m (400 to 450 lbf ft)

H7.00-12.50H (H150-275H) 475 to 542 N•m (350 to 400 lbf ft)

S6.00-7.00XL (S135-155XL) 407 to 440 N•m (300 to 325 lbf ft)

H8.00-12.00XL (H165-280XL) 542 to 610 N•m (400 to 450 lbf ft)

RETAINER

H13.00-16.00XL (H300-360XL) 610 to 675 N•m (450 to 500 lbf ft)

E1.25-1.75XL (E25-35XL) 169 to 237 N•m (125 to 175 lbf ft) J1.60-2.00XMT (J30-40XM) 163 to 176 N•m (120 to 130 lbf ft) E2.00-3.00XL (E40-60XL) 400 to 500 N•m (295 to 369 lbf ft) E/J2.00-3.20XM (E/J40-65XM) 170 to 237 N•m (125 to 175 lbf ft) E20-30B 407 to 475 N•m (300 to 350 lbf ft) E30-60B, E30-60AC 475 to 542 N•m (350 to 400 lbf ft) E3.50-5.50XL (E70-120XL) 400 to 500 N•m (295 to 370 lbf ft) E60-100B 576 to 644 N•m (425 to 475 lbf ft) H1.25-1.75XL (H25-35XL) 169 to 237 N•m (125 to 175 lbf ft) H/E1.50-1.75XM, H/E2.00XMS (H/E25-35XM, H/E40XMS) 163 to 176 N•m (120 to 130 lbf ft) H20-30E 203 to 271 N•m (150 to 200 lbf ft) H2.00-3.00XL (H40-60XL) 169 to 237 N•m (125 to 175 lbf ft) S/H2.00-3.20XM (S/H40-65XM) 170 to 237 N•m (125 to 175 lbf ft) H30-60H, H40-60J 407 to 475 N•m (300 to 350 lbf ft) H3.50-5.00XL (H70-110XL) 400 to 500 N•m (295 to 369 lbf ft) H6.00-7.00XL (H135-155XL) 542 to 610 N•m (400 to 450 lbf ft)

12

H16.00-30.00C (H360-650C) - Early 542 to 610 N•m (400 to 450 lbf ft) H16.00-30.00C (H360-650C) - Late 450 to 550 N•m (332 to 406 lbf ft) H17.00-32.00C (H370-700C) 450 to 550 N•m (332 to 406 lbf ft) H20.00-32.00F (H440-700F/FS) 450 to 550 N•m (332 to 406 lbf ft) H32.00-44.00B (H700-920B) - Late 450 to 550 N•m (332 to 406 lbf ft) H36.00-48.00C (H800-1050C) 450 to 550 N•m (332 to 406 lbf ft) H60-90C 475 to 542 N•m (350 to 400 lbf ft) H60-110E 542 to 610 N•m (400 to 450 lbf ft) H110-150F 271 to 305 N•m (200 to 225 lbf ft) H300A H300-350B 475 to 542 N•m (350 to 400 lbf ft) H360-620B 542 to 610 N•m (400 to 450 lbf ft) H700-800A, H700-920B - Early See text J2.00-3.00XL (J40-60XL) 400 to 500 N•m (295 to 369 lbf ft) J25-35A 407 to 475 N•m (300 to 350 lbf ft) J25-35B 400 to 500 N•m (295 to 369 lbf ft) J40-60A, J50-60AS 475 to 542 N•m (350 to 400 lbf ft)

2100 SRM 103

Troubleshooting

P40-50A, P60-80A 475 to 542 N•m (350 to 400 lbf ft)

S25-35XM, S40XMS 163 to 176 N•m (120 to 130 lbf ft)

P7.00-8.00B (P150-200B) 475 to 542 N•m (350 to 400 lbf ft)

S2.00-3.00XL (S40-60XL) 400 to 500 N•m (295 to 370 lbf ft)

S20-30A 203 to 271 N•m (150 to 200 lbf ft)

S3.00-5.50E (S60-120E) 576 to 644 N•m (425 to 475 lbf ft)

S30-60E, S40-50F 475 to 542 N•m (350 to 400 lbf ft)

S3.50-5.50XL (S70-120XL) 400 to 500 N•m (295 to 370 lbf ft)

S40-50C 407 to 475 N•m (300 to 350 lbf ft)

S5.50-7.00A (S125-150A) 176 to 244 N•m (130 to 180 lbf ft)

S1.25-1.75XL (S25-35XL) 169 to 237 N•m (125 to 175 lbf ft)

S6.00-7.00XL (S135-155XL) 542 to 610 N•m (400 to 450 lbf ft)

Troubleshooting PROBLEM Tilt cylinder movement is slow or not smooth.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Air is in the hydraulic system.

Remove air from hydraulic system.

The hydraulic pump is worn or damaged.

Repair or replace hydraulic pump.

Restriction in the hydraulic lines.

Repair hydraulic lines.

Seals in tilt cylinder are damaged.

Replace seals and inspect cylinder bore for damage.

Tilt cylinders have internal damage.

Repair or replace cylinder.

Load is greater than capacity.

Reduce load.

Pressure relief valve(s) is not adjusted correctly or is damaged.

Repair or adjust relief valve(s).

Large leaks between spool and bore.

Replace valve section.

Spool is not fully extended or retracted.

Adjust linkage to spool.

Tilt control spool is damaged.

Repair control valve.

13

Troubleshooting

PROBLEM The tilt cylinders permit the mast to move when the Tilt control lever is in the Neutral position.

14

2100 SRM 103

POSSIBLE CAUSE

PROCEDURE OR ACTION

There are leaks in the hydraulic lines.

Tighten fittings or repair leaks.

Seals in tilt cylinder are damaged.

Replace seals and inspect cylinder bore for damage.

Tilt cylinders have internal damage.

Repair or replace cylinder.

Tilt control spool is damaged.

Repair control valve.

TECHNICAL PUBLICATIONS 2100 SRM 103

9/00 (6/96)(11/95)(5/95)(1/95)(11/94)(3/94)(9/93)(4/93)(5/87)(10/85) Printed in U.S.A.

/,)7 &</,1'(56 ALL, EXCEPT H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), H16.00-30.00C (H360-650C), H32.00-42.00B (H700-920B)

PART NO. 910119

4000 SRM 135

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

4000 SRM 135

Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a "DO NOT OPERATE" tag in the operator’s compartment.

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• Do NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast.

OR 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position. b. Raise the mast to align the bottom crossmember of the inner weldment with a crossmember on the outer weldment. See Figure 1. c. Use a 12 mm (0.5 in.) minimum safety chain with a hook to fasten the crossmembers together so that the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings or other parts on the mast. d. Lower the mast until there is tension in the safety chain. If running, stop the engine. Apply the parking brake. Install a "DO NOT REMOVE" tag on the safety chain(s). e. Install another safety chain 12 mm (0.5 in.) minimum between the top or bottom crossmember of the carriage and a crossmember on the outer weldment.

WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put a "DO NOT OPERATE" tag in the operator’s compartment.

1

Safety Procedures When Working Near Mast

1. INNER WELDMENT

4000 SRM 135

2. OUTER WELDMENT

3. HOOK

4. CARRIAGE

Figure 1. Mast The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a "DO NOT OPERATE" tag in the operator’s compartment.

2

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• Do NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual section for the mast.

WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make

4000 SRM 135

Safety Procedures When Working Near Mast

sure that all parts of the mast that move are fully lowered.

OR 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position. b. Raise the mast to align the bottom of the inner weldment to below the anchor for the tilt cylinders. See Figure 2.

1. INNER WELDMENT

c. Use a 12 mm (0.5 in.) minimum safety chain with a hook to fasten the weldments together so that the inner weldment cannot lower. Install the chain on both sides of the mast.

Make sure the hooks are completely engaged with a link in the chain. d. Lower the mast until there is tension in the safety chain. If the engine is running, stop the engine. Apply the parking brake. Install a "DO NOT REMOVE" tag on the safety chain. Put a "DO NOT OPERATE" tag in the operator’s compartment.

2. TILT CYLINDERS

3. HOOK

Figure 2. Mast

3

Safety Procedures When Working Near Mast The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a "DO NOT OPERATE" tag in the operator’s compartment.

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• Do NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual section for the mast.

WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

OR 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts

4

4000 SRM 135 of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position. b. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment with a crossmember on the outer weldment. On the two-stage and freelift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. On the four-stage mast, it is the first intermediate weldment.

See Figure 3. c. Use a 10 mm (0.375 in.) minimum safety chain with a hook to fasten the crossmembers together so that the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings or other parts on the mast. d. Lower the mast until there is tension in the safety chain and the free-lift cylinder (freelift and three-stage masts only) is completely retracted. If the engine is running, stop the engine. Apply the parking brake. Install a "DO NOT REMOVE" tag on the safety chain(s). e. Install another safety chain 10 mm (0.375 in.) minimum between the top or bottom crossmember of the carriage and a crossmember on the outer weldment.

3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put a "DO NOT OPERATE" tag in the operator’s compartment.

4000 SRM 135

Safety Procedures When Working Near Mast

Figure 3. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

5

Description

4000 SRM 135 Legend for Figure 3

A. TWO-STAGE MAST B. FREE-LIFT MAST

C. THREE-STAGE MAST D. FOUR-STAGE MAST

1.

2.

3.

4.

5.

6.

7.

8.

OUTER WELDMENT INNER WELDMENT INTERMEDIATE WELDMENT FIRST INTERMEDIATE WELDMENT

HOOK FREE-LIFT CYLINDER CROSSMEMBER CROSSMEMBER

General This section has the description for lift cylinders used in masts and the instructions for their repair. There are many different sizes of lift cylinders used in Hyster Company lift trucks. The operation and repair procedures for the different lift cylinders are similar. The illustrations in this section are for typical

lift cylinders. All of the variations in lift cylinders used in lift trucks are not shown. A section for Lift Cylinders For VISTA® Masts is included later in this section.

Description All lift cylinders are single-acting cylinders. See Figure 4. The hydraulic force is applied only in one direction. When hydraulic oil enters one end of the lift cylinder, the hydraulic force extends the piston rod.

When the force is removed, the weight of the carriage and inner mast retracts the piston rod.

A common maintenance problem is the repair of oil leaks from the seals and wiper around the piston rod.

If the bore of the shell of the lift cylinder is damaged and cannot be repaired, the lift cylinder must be replaced.

Lowering Control Valve A lowering control valve is installed in the inlet port.

See Figure 5. It permits easy entry of hydraulic oil into the cylinder, but gives a restriction when the rod is retracted. This restriction gives limits to the speed that a load on the forks can be lowered.

There are two types of lowering control valves. Both types have the same function and similar operation.

The most common type of valve has a design that has good operation using large flows and lower pressures. Some lift trucks have a lift system design using higher pressures and a lower flow. These systems need a different type of lowering control valve.

6

The most common type of lowering control valve uses these parts: (1) a special fitting for the valve body, (2) a spring, and (3) a special washer. There is a variation in the shapes of the special washer. Different lift cylinders use different shapes of special washers.

The volume of the hydraulic oil flowing through the inlet port controls the shape of the special washer.

(A typical shape of a special washer is shown in Figure 5.) When the piston rod is lowered, the oil flow pushes against the special washer and spring. When the oil flow reaches the limit, the special washer is moved against the special fitting. The oil then flows only through the hole in the center of the special washer. This restriction permits the piston rod to lower only at a maximum controlled speed.

The other type of lowering control valve uses these basic parts: (1) valve body, (2) spring, (3) washer, (4) cylinder, (5) orifice sleeve, (6) plunger, and (7) main sleeve. The orifice sleeve position is controlled completely by oil flow. The plunger position is controlled by oil pressure and spring tension. During lifting, oil entering the lift cylinder goes through the center of the main sleeve to the large holes. The oil flow through the plunger and bore moves the orifice sleeve to the end of the plunger. The flange of the orifice sleeve is then aligned with the large part of the bore in the body. This alignment lets the oil flow past the orifice sleeve to the cylinder.

4000 SRM 135

Description

A. INSTALLED

B. NOT INSTALLED

1.

2.

3.

4.

5.

6.

7.

8.

LOWERING CONTROL VALVE PISTON BEARING CHECK VALVE

SHELL NYLON RING RETAINER WIPER SEAL

9.

10.

11.

12.

BACK-UP RING O-RING ROD SINGLE-LIP SEAL

Figure 4. Two-Speed Lift Cylinder

7

Description

4000 SRM 135

A. LOW PRESSURE DESIGN B. LOWERING

C. RESTRICTED FLOW D. HIGH PRESSURE DESIGN

E. LIFTING F. FREE FLOW

1. SPECIAL FITTING OR VALVE BODY 2. SPRING

3. SPECIAL WASHER 4. CYLINDER 5. ORIFICE SLEEVE

6. PLUNGER 7. MAIN SLEEVE

Figure 5. Lowering Control Valves During lowering, oil from the lift cylinder moves the orifice sleeve. The orifice sleeve moves away from the larger inner diameter area of the bore in the valve body. This movement makes a restriction to the oil flow. As the pressure increases, the plunger begins to move against the spring. The movement begins to close the openings of the large holes in the main

8

sleeve. Additional pressure will push the plunger against the main sleeve to close the large holes completely. All the oil must then go through the small holes to the center of the main sleeve. This restriction permits the piston rod to lower only at a maximum controlled speed.

4000 SRM 135

Cylinders (General) Standard masts use a single-stage lift cylinder.

Most three-stage and four-stage masts use two single-stage lift cylinders. A single-stage lift cylinder has one piston rod. See Figure 6.

Most full free-lift masts and some three-stage masts use a two-stage lift cylinder. A two-stage lift cylinder has two telescopic piston rods. See Figure 7. The two-stage lift cylinder operates similar to a one-stage lift cylinder. Hydraulic pressure pushes the primary (larger) piston rod from the cylinder first because it has a larger diameter. The secondary piston rod moves with the primary piston rod. When the primary piston rod reaches the limit of its stroke, the secondary piston rod extends from the primary piston rod.

Spacers are used in some cylinders to give a limit to the stroke of the piston rod. Worn spacers must be replaced with the same size spacer.

Most of the lift cylinders use a single-lip seal assembly to prevent hydraulic oil leaks past the piston and past the retainer. See Figure 4. There are many lift cylinders in use that have an older design chevron-style packing. The chevron-style packing can be replaced with a seal kit that has the newer single lip seal and an adaptor. There are no replacements of single lip seals for chevron-style packing for lift trucks over 7,000 kg (15,000 lb) capacity.

Lift cylinders and other hydraulic parts can have internal leaks. Internal leakage will increase as the temperature of the hydraulic oil increases. The internal leak rate of the hydraulic system is normally checked after every 1000 hours of operation. See Lift System Leak Check for test procedures and leakage rates within the specifications.

During operation, some leakage of hydraulic oil can move past the piston seal to the rod side of the piston. A small leakage is permitted if the internal leak rate of the hydraulic system is not greater than the specification. An internal check valve is installed in

Description the piston of many of the lift cylinders. When the rod extends, the pressure increases more quickly on any oil in the rod end of the cylinder. The hydraulic oil transfers through the check valve to the piston end of the cylinder. This action prevents hydraulic damage to the wiper seal. See Figure 8. Lift cylinders that do not have an internal check valve have a drain line on the outside of the cylinder shell.

Cylinders (H520-620B, H700-800A) The rod side of the lift cylinder is used for the storage of hydraulic oil on the H520-620B and H700-800A lift trucks. This storage decreases the required size of the hydraulic tank. When the piston raises in the cylinder, the oil on the rod side of the piston transfers to the hydraulic tank. When the piston lowers in the cylinder, some of the oil transfers to the rod side of the cylinder. Approximately one half of the oil in the bottom of the cylinder goes through the main control valve to the rod side of the cylinder. See the Main Control Valve of Service Manual for more information. See Figure 9.

Retainer, Install 1. Install the retainer over the piston and into the cylinder. Make sure the single-lip seal assembly, the O-ring, and the back-up ring are not damaged. See Figure 9.

2. Turn the retainer ring into the threads in the cylinder. Turn the retainer ring until it is even with the top of the cylinder.

3. Install the capscrews loosely.

4. The stroke of the cylinder rod can be adjusted by turning the retainer ring one-half turn in either direction.

5. Install and tighten the setscrew.

6. Tighten the capscrews to 36 to 46 N•m (27 to 34 lbf ft).

9

Description

4000 SRM 135

A. MAIN LIFT CYLINDER

B. FREE-LIFT CYLINDER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

WIPER RING SINGLE-LIP SEAL BEARING O-RING RETAINER CHAIN ANCHOR MOUNT

HYDRAULIC LINE MOUNT INTERNAL CHECK VALVE ROD ASSEMBLY SPACER TO SENSING PORT FOR PHASING VALVE PRESSURE

12. LOWERING CONTROL VALVE (ALL CYLINDERS) 13. PISTON RING 14. CUSHION RING

Figure 6. Single-Stage Lift Cylinders

10

4000 SRM 135

Description

A. INSTALLED

B. NOT INSTALLED

1.

2.

3.

4.

5. SINGLE-LIP SEAL 6. O-RING 7. NYLON BACK-UP RING

POPPET SPRING SEAL INLET AND OUTLET PORT

Figure 8. Internal Check Valve and Single-Lip Seal 1.

2.

3.

4.

WIPER RING RETAINER SEAL SCREW (DO NOT CHANGE LENGTH) 5. PRIMARY ROD ASSEMBLY 6. SPACERS 7. BEARING

8. PISTON HALF (1 OF 2) 9. INTERNAL CHECK VALVE 10. SINGLE-LIP SEAL 11. SECONDARY ROD ASSEMBLY 12. O-RING 13. PLUG

Figure 7. Two-Stage Lift Cylinder

Cylinders (H360-460B) The lift cylinders used in the H360-460B lift trucks are displacement cylinders. The design and repairs for these cylinders are similar to the other lift cylinder in this section. A displacement cylinder does not have a piston or piston seal. The rod diameter is almost the same as the inside diameter of the cylinder. There are wear rings on the rod that are the bearings between the rod and the walls of the cylinder. The wiper seal at the top of the cylinder is also the high-pressure seal for these cylinders. The wiper seal has chevron-style packing. See Figure 10.

11

Description

4000 SRM 135

A. LOWERING CONTROL VALVE 1.

2.

3.

4.

SETSCREW (1) CAPSCREW (2) RETAINER RING SINGLE-LIP SEAL ASSEMBLY

5.

6.

7.

8.

9.

RETAINER BACK-UP RING O-RING CYLINDER SHELL ROD

10.

11.

12.

13.

14.

SPACER PISTON PISTON RING NUT NYLON SETSCREW SPRING

Figure 9. Lift Cylinder for H700-800A

12

15.

16.

17.

18.

19.

FLANGE SPACER PLATE SPACER VALVE BODY SPECIAL WASHER

4000 SRM 135

Description Legend for Figure 10 NOTE: OIL LEAKAGE IS NOT CONTROLLED BY THE TORQUE ON THE PACKING GLAND. TIGHTEN THE PACKING RETAINER TO STOP OIL LEAKS. REPLACE CHEVRON-STYLE PACKING WHEN PACKING RETAINER CANNOT COMPRESS PACKING FURTHER TO CONTROL OIL LEAKS. DO NOT TIGHTEN MORE THAN NECESSARY TO STOP OIL LEAKS. 1. WIPER 2. NYLON RING 3. CHEVRON-STYLE PACKING 4. BACK-UP RING 5. O-RING 6. ROD HEAD

7. PACKING RETAINER 8. PACKING GLAND 9. CYLINDER SHELL 10. INLET AND OUTLET PORT 11. WEAR RING

Figure 10. Displacement Cylinders

13

Description

4000 SRM 135

Cylinders (Two-Speed) Two-speed lift cylinders are single-stage lift cylinders with a special valve and path for the hydraulic oil.

The lift cylinder is filled with oil on both sides of the piston. For loads less than 45% of the rated capacity, the cylinder rod can be extended at high speed. When the cylinder rod extends, the oil on the rod side of the

piston transfers to the bottom of the piston. When the oil transfers, the increase almost doubles the flow of oil to the base of the cylinder. The pump pressure is applied to both sides of the piston. The area on the bottom of the piston is greater than the rod side of the piston. The difference in force pushes the piston up the cylinder. See Figure 11.

A. HIGH-SPEED OPERATION FOR NO LOAD OR LIGHT LOADS B. NORMAL OPERATION FOR RATED CAPACITY LOAD OR HEAVY LOADS 1. FORCE 2. FROM HYDRAULIC PUMP

3. GREATER LIFTING FORCE 4. TO HYDRAULIC TANK Figure 11. Two-Speed Lift Cylinders

For loads greater than 45% of capacity, the cylinder rod extends at normal speed. A special valve senses the increased oil pressure caused by the load. The oil is returned from the rod side of the lift cylinder to the hydraulic tank. All of the pump pressure is applied to the bottom side of the piston. The cylinder rod extends at a slower speed, but can lift a greater load. The two-speed lifting system is used only with standard masts. A two-speed lift system is used on the following lift trucks:

14

S60-80B

H150-250E

S125-150A

H150-275H

H60-80C

H250-300A

H300-350B

P125-180A

H110-150F

P150-200B

NOTE: The maximum loads that the above models will lift at high speed are shown on Table 1.

4000 SRM 135

Lift Cylinder Repair Table 1. Lift Trucks with Two-Speed Lift Cylinders

Model

Load

S60-100B

1589 to 2043 kg (3500-4500 lb)

H60-80C

1589 to 2043 kg (3500 to 4500 lb)

H110-150F

1589 to 2043 kg (3500 to 4500 lb)

S125-150A

2270 to 2724 kg (5000 to 6000 lb)

H150-200ES, Standard Masts

2270 to 3087 kg (5000 to 6800 lb)

P125-180A, Standard Masts

2270 to 3087 kg (5000 to 6800 lb)

H150-250E, Heavy Duty Masts

3133 to 4041 kg (6900 to 8900 lb)

P125-180A, Heavy Duty Masts

3133 to 4041 kg (6900 to 8900 lb)

H250-300A

4540 to 4994 kg (10,000 to 11,000 lb)

This table shows the approximate maximum load that the mast will lift at high speed. Loads greater than those shown will cause the mast to lift at normal speed. These loads will have a variation because of the different attachments that can be installed on the lift truck.

Lift Cylinder Repair LIFT CYLINDER REMOVAL WITHOUT REMOVING MAST Remove the carriage before the lift cylinder. See the procedure described in the Masts section. If the mast must be removed for repairs, then remove the lift cylinder when the mast is disassembled. Remove the lift cylinder from the mast as described in the following paragraphs.

Standard Masts with Main Lift Cylinder Fastened to Crossmember of Inner Mast 1. Fully lower the mast. Loosen, but do not disconnect the capscrew that fastens the cylinder rod to the crossmember of the inner mast.

2. Clean the area next to the fittings that connect the hydraulic lines to the lift cylinder. Put a drain pan under the area where the hydraulic lines will be disconnected. Disconnect the hydraulic lines and put a cap on each open fitting.

WARNING Make sure the lifting mechanism has enough capacity to lift the loads. See the Weight Guide for lift cylinders in Table 1.

3. Connect a lifting mechanism to the inner mast.

Lift the inner mast approximately 300 mm (12 in.). Fasten the inner and outer masts together at the crossmembers with a heavy chain.

Make sure that the inner mast cannot move.

Remove the lifting mechanism.

4. Connect a heavy-duty sling to the upper part of the cylinder. Raise the lifting mechanism until the sling is tight. Make sure the sling will not slide.

5. Remove the capscrew and washer connecting the piston rod to the inner mast. Remove the spacer.

CAUTION Oil can come out of the cylinder fittings with pressure when retracting the rod.

6. Loosen the cap on the lower fitting of the cylinder.

Manually retract the piston rod.

7. Remove the capscrew and the plate from the lower side of the cylinder.

8. Raise the cylinder and move it away from the mast. Move the lift cylinder to a position where it can be disassembled.

15

Lift Cylinder Repair

4000 SRM 135

Standard and Full Free-Lift Masts with Lift Cylinder Fastened to Crosshead 1. Remove the lift chains and chain anchors from the mast and the lift cylinder. Connect a sling to the upper area of the lift cylinder. Raise the lifting mechanism until the sling is tight. See Figure 12 and Figure 13.

1.

2.

3.

4.

SHEAVE SNAP RING CROSSHEAD CYLINDER GUIDE ASSEMBLY

5.

6.

7.

8.

9.

CHAIN ANCHOR WASHER AND NUT SHIM GUIDE SHOE BEARING

Figure 13. Free-Lift Cylinder and Crosshead 2. Remove the capscrews that connect the piston rod to the crosshead.

3. Disconnect and remove the crosshead assembly from the mast. Make a note of the shim arrangement on the crosshead guide.

1. CHAIN GUARD 2. CROSSHEAD ASSEMBLY 3. SNAP RING 4. SHEAVE 5. BEARING

6.

7.

8.

9.

10.

11.

CHAIN ANCHOR SPECIAL WASHER LOCK NUT SPACER WEAR PLATE PAD

Figure 12. Standard Mast Cylinder and Crosshead

4. Clean the area next to the fittings that connect the hydraulic lines to the lift cylinder. Put a drain pan under the area where the hydraulic lines will be disconnected. Disconnect the hydraulic lines and put a cap on each open fitting.

5. Remove the snap ring that connects the bottom of the lift cylinder to the outer mast.

6. Raise the lift cylinder and move it away from the mast. Move the lift cylinder to a position where it can be disassembled.

16

4000 SRM 135

Masts that have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder 1. Remove the free-lift cylinder as described in the section above for removing a lift cylinder fastened to a crosshead.

2. Remove the main lift cylinder as described in the section above for removing a lift cylinder fastened to an inner mast.

DISASSEMBLE WARNING Use slings and a crane to handle and disassemble the lift cylinders of most lift trucks. Make sure that the crane and slings can lift the load.

See Table 1.

CAUTION Carefully disassemble and assemble the lift cylinders so that the rods and sliding surfaces are not damaged.

NOTE: Disassembly of single-stage and two-stage lift cylinders is the same except the two-stage lift cylinder has a second piston rod assembly. The disassembly of the secondary piston rod assembly is similar to the disassembly of the primary piston rod assembly.

1. Loosen the retainer with a spanner. Disconnect the retainer from the shell. See Figure 14 and Figure 15.

2. Remove the cap from the inlet and slide the piston rod assembly from the shell. Use drain pans for the hydraulic oil.

3. Remove the retainer from the piston rod. Remove and discard the O-rings, seals, and bearings.

4. Remove the internal check valve.

5. Remove the lowering control valve.

6. Clean all the parts. Check the sliding surfaces for damage. Repair or replace any damaged parts.

Lift Cylinder Repair

ASSEMBLE NOTE: Lubricate all internal parts of the lift cylinder with hydraulic oil during assembly.

Use new O-rings, seals and bearings. Apply lubricant during assembly. Packing lubricant (Part Number 186061) is available.

Make sure the single-lip seal assemblies are installed with the O-ring towards the base of the lift cylinder.

See Figure 8.

The spacers control the maximum stroke of the piston rod assembly. If a new spacer is necessary, make sure the same size spacer is installed.

1. Install the internal check valve. Make sure the arrow on the internal check valve is toward the base of the piston.

CAUTION A difficult and important step in assembling cylinders is the correct installation of the seals without damage. Most cylinder maintenance is caused by seal leakage.

2. Install the seal and bearing (and spacer if equipped) on the rod piston. Use shim material and a band clamp as a guide to move the single-lip seal past the threads of the shell.

3. Carefully push piston and piston rod into the shell. Release the band clamp on the seal when the seal travels past the threads of the shell.

4. Install the seals, O-rings, and bearings (when used) in the retainer. If the wiper seal has a spring backup ring, the spring must be towards the base of the lift cylinder.

5. Carefully install the retainer on the piston rod.

6. Engage the threads and tighten the retainer in the shell to the correct torque. Use a correct spanner. Do not hit the retainer with a hammer and driver.

17

Lift Cylinder Repair

1.

2.

3.

4.

5.

PLUG O-RING RETAINER WIPER RING SINGLE-LIP SEAL

4000 SRM 135

6.

7.

8.

9.

10.

BEARING O-RING CYLINDER SHELL CYLINDER ROD SPACER

11. INTERNAL CHECK VALVE 12. O-RING 13. WASHER 14. SNAP RING

15. BACKUP RING 16. SINGLE-LIP SEAL 17. BEARING

Figure 14. Single-Stage Lift Cylinder

1.

2.

3.

4.

5.

6.

7.

8.

PLUG RETAINER BEARING O-RING SINGLE-LIP SEAL WIPER RING RETAINER SECONDARY CYLINDER ROD

9.

10.

11.

12.

13.

14.

15.

16.

SPACER BEARING SINGLE-LIP SEAL BACKUP RING PRIMARY CYLINDER ROD SPACER O-RING PISTON RING HALF (2)

Figure 15. Two-Stage Lift Cylinder

18

17.

18.

19.

20.

21.

22.

SNAP RING WASHER INTERNAL CHECK VALVE CYLINDER SCREW SEAL

4000 SRM 135

CAUTION When the screw is installed on two-stage cylinders, never use a screw longer than 9.5 mm (0.375 in.). A longer screw will touch and damage the primary piston rod. Always install a seal under the head of the screw. If you do not install the screw and seal, the cylinder will have leaks.

7. Install the lowering control valve. Make sure the special washer and the spring are installed correctly. A wrong installation can cause the load to lower too fast.

LIFT CYLINDER INSTALLATION IN MAST Standard Masts with Main Lift Cylinder Fastened to Crossmember of Inner Mast

Lift Cylinder Repair 8. Install the carriage.

Standard and Full Free-Lift Masts with Lift Cylinder Fastened to Crosshead 1. Put the lift cylinder into position in the mast.

Align the guide pin with the hole in the bottom crossmember.

2. Install the crosshead assembly in the mast.

Align the holes in the piston rod and the crosshead.

3. Fasten the crosshead to the piston rod with capscrews.

4. Fasten the base of the lift cylinder to its mount with a snap ring.

5. Connect the hydraulic lines.

1. Put the lift cylinder into position in the mast.

Make sure the base of the lift cylinder is aligned correctly on its mount.

6. Install the chain anchors.

2. Connect a chain to the upper section of the lift cylinder and the overhead guard. Make sure the chain will hold the lift cylinder in position until it can be fastened to the mast.

8. Install the carriage. See masts section for checks and adjustments.

3. Connect a lifting mechanism to the inner mast.

The replacement seal kits for chevron-style packing have a single-lip seal and an aluminum spacer. The seal kits also have one or two backup rings. If one backup ring is in the seal kit, install it as shown in B of Figure 16. Two backup rings are installed as shown in C of Figure 16. Make sure the single-lip seal is always installed correctly against the direction of pressure.

CAUTION Do not connect a wrench to the sliding surface of the piston rod. Any damage to the sliding surface will cause leaks.

4. Disconnect the inner mast from the outer mast.

Lower the inner mast until it touches the piston rod. Align the holes of the inner mast and the piston rod.

5. Install capscrews, washer, and spacer to fasten the lift cylinder to the crossmember of the inner mast.

6. Fasten the base of the lift cylinder to the crossmember of the outer mast with a capscrew and plate.

7. Connect the hydraulic lines.

7. Install the lifting chains.

CHEVRON-STYLE PACKING

The installation of chevron-style packing on a piston is shown in Chevron-Style Packing Installation on Piston. The installation of chevron-style packing in a packing gland nut used at the top of the cylinder is shown in Chevron-Style Packing Installation in Packing Gland. There will be some variation in the design of the different lift cylinders. The principles of installation of the chevron-style packing is similar.

Lubricate the parts with hydraulic oil or packing lubricant (Part No. 186061) before assembly.

19

Lift Cylinder Repair

4000 SRM 135

A. MANY EARLIER PRODUCTION LIFT TRUCKS WITH LESS THAN 7000 kg (15,000 lb) CAPACITY THAT HAVE CHEVRON-STYLE PACKING CAN BE CHANGED TO SINGLE-LIP SEALS. B. THE PARTS ARE INSTALLED IN THE ARRANGEMENT SHOWN. C. IF TWO BACKUP RINGS ARE IN THE SEAL KIT, THE PARTS ARE INSTALLED IN THE ARRANGEMENT SHOWN. 1. CHEVRON-STYLE PACKING 2. ALUMINUM SPACER

3. BACKUP RING 4. SINGLE-LIP SEAL ASSEMBLY

5. DIRECTION OF OIL PRESSURE

Figure 16. Chevron-Style Packing Replacement Seal Kits

Chevron-Style Packing Installation on Piston STEP 1.

Lubricate the new O-ring with hydraulic oil and then install it on the piston end of the cylinder rod.

STEP 2.

Install a new packing assembly on the piston half.

The packing must extend approximately 3 mm (1/8 in.) beyond the end of the piston half.

1. THIS RING MUST EXTEND 3 mm (1/8 in.)

BEYOND END OF PISTON HALF.

20

4000 SRM 135

Lift Cylinder Repair

STEP 3.

Install the piston half and snap ring.

STEP 4.

Install the nylon spacer.

STEP 5.

Install the piston in the lift cylinder. Carefully push the piston and piston rod into the lift cylinder. Release the clamp on the packing when the packing moves past the threads of the cylinder.

1. PISTON 2. SPECIAL TOOL OR BAND CLAMP TO INSTALL PACKING

21

Lift Cylinder Repair

4000 SRM 135

Chevron-Style Packing Installation in Packing Gland STEP 1.

Assemble the packing gland nut using new packing, O-ring, and backup ring.

1. PACKING ASSEMBLY 2. BACKUP RING 3. O-RING

4. PACKING RING MUST EXTEND 3 mm (1/8 in.)

BEYOND EDGE OF BUSHING.

STEP 2.

Assemble the gland nut using a new O-ring, backup ring, and inner seal.

NOTE: Install inner seal (if equipped).

STEP 3.

Install the bushing assembly and gland nut assembly in the rod.

22

Lift Cylinders for Vista® Masts

4000 SRM 135

STEP 4.

Install a new wiper ring and spring on the retainer. Install the retainer against the packing gland nut. Lightly hit the retainer to move against the internal threads in the cylinder shell. Use a spanner to tighten the retainer.

1. O-RING

Lift Cylinders for Vista® Masts DESCRIPTION All lift cylinders for Vista® masts are single-action hydraulic cylinders. The hydraulic force is applied only in one direction. When hydraulic oil enters one end of the lift cylinder, the hydraulic force extends the piston rod. When the force is removed, the weight of the carriage and inner mast causes the piston rod to retract.

The most common maintenance problem is the repair of oil leaks. If the bore of the shell of the lift cylinder is damaged and cannot be repaired, the lift cylinder must be replaced.

VISTA® two-stage, three-stage, and four-stage masts have two main lift cylinders. The free-lift mast has two main lift cylinders and a shorter free-lift cylinder. See Figure 17 and Figure 18.

Spacers are used in some cylinders to limit the stroke of the piston rod. Worn spacers must be replaced with the same size spacer.

The free-lift cylinder has a single-lip seal on the piston to prevent hydraulic oil leaks past the piston and

retainer. The piston rod is a smaller diameter than the piston.

During operation, some hydraulic oil will leak past the piston area to the rod end of the lift cylinder.

Small leaks are permitted if the internal leak rate of the hydraulic system is not greater than the specification. An internal check valve is installed in the piston of the free-lift cylinders. When the piston rod extends, the pressure increases more quickly on any oil in the rod end of the lift cylinder. The hydraulic oil transfers through the check valve to the piston end of the free-lift cylinder. This action prevents hydraulic damage to the single lip seal and the wiper ring. See Figure 19.

Lowering Control Valve A lowering control valve is installed in the hydraulic line to the bases of the lift cylinders. See Figure 20.

The lowering control valve permits easy entry of hydraulic oil into the cylinders, but gives a restriction when the rods retract. This restriction controls the maximum speed at which a load on the forks can be lowered. The lowering control valve prevents a load

23

Lift Cylinders for Vista® Masts on the forks from freely falling if a hydraulic hose breaks.

Figure 17. Vista® Masts Typical Lift Cylinders

24

4000 SRM 135

Lift Cylinders for Vista® Masts

4000 SRM 135 Legend for Figure 17 1.

2.

3.

4.

5.

SHELL BEARING PISTON PISTON ROD SNAP RING

6.

7.

8.

9.

10.

WASHER INNER PISTON CHECK VALVE O-RING SINGLE-LIP SEAL

11. BACK-UP RING 12. WIPER SEAL 13. RETAINER

1.

2.

3.

4.

5.

6.

SNAP RING INNER PISTON BEARING SINGLE-LIP SEAL BACK-UP RING SPACER

7.

8.

9.

10.

11.

ROD SHELL O-RING BACK-UP RING SEAL RING

12. RETAINER [TIGHTEN 340 to 410 N•m (250 to 300 lbf ft)] 13. WIPER SEAL 14. PISTON 15. 7.9 mm (0.31 in.) DIAMETER HOLE 16. WRENCH FLATS

Figure 18. Free-Lift Mast Main Lift Cylinder The lowering control valve includes the following parts: (1) valve body, (2) spring, (3) washer, (4) cylinder, (5) orifice sleeve, (6) plunger, and (7) main sleeve. The orifice sleeve position is controlled by oil flow. The plunger position is controlled by oil pressure and spring tension. During lifting, oil entering the lift cylinder goes through the center of the main sleeve to the large holes. The oil continues between the plunger and bore to move the orifice sleeve to the end of the plunger. The flange of the orifice sleeve is then aligned with the large part of the bore in the body. This alignment lets the oil flow around the orifice sleeve to the inlet port of the lift cylinder.

During the lowering operation, oil from the lift cylinder moves the orifice sleeve. The sleeve moves away from the larger area of the bore in the valve body. This movement makes a restriction to the oil flow. When the pressure increases, the plunger begins to move against the spring. The movement begins to close the openings of the large holes in the main sleeve. Additional pressure will push the plunger against the main sleeve to close the large holes completely. All the oil must go through the

small holes to the center of the main sleeve. This restriction permits the piston rod to lower only at a maximum controlled speed.

REMOVE NOTE: Remove the carriage before removing the lift cylinder. See the procedure described in the Masts section. If the mast assembly must be removed for repairs, then remove the lift cylinders when the mast assembly is disassembled. When only the lift cylinders must be removed for repairs, then remove the lift cylinders from the mast as described in the following paragraphs.

1. Clean the area around the hydraulic fittings for the lift cylinders. Disconnect the fittings at the lift cylinders and put caps on the open lines.

2. On the free-lift mast, remove the capscrews, washers, and cylinder clamp from the mount for the free-lift cylinder. Remove the free-lift cylinder.

3. Remove the snap rings and washers from the top of each main lift cylinder. Remove the cylinder 25

Lift Cylinders for Vista® Masts clamps near the top of each lift cylinder. Each cylinder clamp is fastened to the top crossmember of the inner mast by two capscrews and washers.

4. Support the cylinder. Connect a crane to the top of the inner mast using chains. Raise the inner mast from the outer mast approximately 30 cm (12 in.). Disengage the piston rod ends of lift cylinders from the top crossmember of the inner mast. Remove the lift cylinders from the mount plates at the bottom of the outer mast.

4000 SRM 135

DISASSEMBLE WARNING Use slings and a crane to handle and disassemble the lift cylinders of most lift trucks. Make sure that the crane and slings can lift the load correctly. See Table 1 for weight guide.

CAUTION Carefully disassemble and assemble the lift cylinders so that the piston rods and sliding surfaces are not damaged.

NOTE: Disassembly of the main lift cylinders and the free-lift cylinder is similar. All of the lift cylinders are disassembled from the rod end of the cylinder shell.

1. Loosen the retainer with a spanner. Disconnect the retainer from the shell.

2. Remove the protective cap from the inlet and slide the rod and piston assembly from the shell.

Drain the hydraulic oil into a container.

NOTE: To remove the retainer, the piston rod and piston assembly must be disassembled if the lift cylinder is the type shown in Figure 18. Use the following procedure: a. Put a round bar through the 7.9 mm (0.31 in.) hole in the piston. Hold the rod in a vise or clamp so that it does not turn. Use the round bar and turn the threaded piston from the piston rod. b. If an adhesive was used on the threaded rod and piston, heat the rod to a maximum of 170 to 225 C (300 to 400 F) to loosen the adhesive.

A. INSTALLED

B. NOT INSTALLED

1. PISTON AND ROD ASSEMBLY 2. CHECK VALVE 3. O-RING

4. INLET AND OUTLET PORT 5. SINGLE-LIP SEAL 6. O-RING 7. BACK-UP RING

Figure 19. Internal Check Valve and Single Lip Seal

26

3. Remove the retainer from the piston rod. Remove and discard the O-rings, seals, and bearings.

4. Remove the internal check valve from the base of the lift cylinder.

5. Clean all the parts. Check the sliding surfaces for damage. Repair or replace any damaged parts.

4000 SRM 135

Lift Cylinders for Vista® Masts

ASSEMBLE

3. Carefully push the piston and rod assembly into the shell. Release the clamp on the seal when the seal travels past the threads of the shell.

NOTE: • Lubricate all internal parts of the lift cylinder with hydraulic oil during assembly.

• Use new O-rings, seals, and bearings. Apply lubricant (hydraulic oil) during assembly. Packing lubricant (Part No. 186061) is also available.

• Make sure the single-lip seal assemblies are installed with the O-ring toward the base of the lift cylinder. (See Figure 19.)

CAUTION A difficult and important step in assembling lift cylinders is the correct installation of the seals. Most lift cylinder maintenance is caused by seal leaks.

1. Install the internal check valve, if installed.

Make sure the arrow on the internal check valve is toward the base of the piston.

2. Install the wear ring, single lip seal, and back-up ring onto the piston assembly. If a spacer sleeve is used, install it. Use shim material and a clamp as a guide to move the single-lip seal over the threads of the shell.

NOTE: When a main lift cylinder of the type shown in Figure 18 is assembled, use the following procedure: a. Install the seal ring and wiper ring into the retainer. Assemble the retainer onto the piston rod. b. Install the piston to the threaded part of the piston rod. Use a round bar through the hole in the piston and tighten the piston to the piston rod. Hold the piston rod in a vise or clamp by the two flats on the top end of the piston rod.

NOTE: Do not use an adhesive on the threads of the piston rod and piston.

4. Install the seal, O-ring, wear ring, and wiper ring in the retainer. If the wiper seal has a spring for a back-up ring, the spring must be toward the base of the lift cylinder.

5. Carefully install the retainer on the piston rod.

A. FREE FLOW B. LIFTING

C. RESTRICTED FLOW D. LOWERING

1. VALVE BODY 2. SPRING

3. WASHER 4. CYLINDER

5. ORIFICE SLEEVE 6. MAIN SLEEVE

Figure 20. Lowering Control Valve

27

Lift System Leak Check

4000 SRM 135

6. Engage the threads and tighten the retainer in the shell until it is tight. Use a correct spanner. Do not hit the retainer with a hammer and driver.

7. Install the lowering control valve. Make sure the special washer and the spring are installed correctly. A wrong installation can cause the load to lower too fast.

INSTALL Main Lift Cylinders

to the top crossmember of the outer mast with the capscrews and washers.

2. Install the lowering control valve on the outer mast. Connect the hydraulic lines and fittings between the lowering control valve and the lift cylinders.

3. Install the chain sheaves and brackets. Connect the lift chains to the chain anchors on the inner mast. Fasten wires between the ends of the lift chains so that they can be controlled during installation of the carriage.

4. Install the carriage. Connect the lift chains.

WARNING Connect slings and a crane to the top of the inner mast [and intermediate mast(s), if it is a 3-stage (4-stage) mast] using chains. If it is a 3-stage mast, make sure that all masts are fastened together. Make sure that the chains will not damage the sheaves, tubing or other parts of the mast. Make sure the crane and slings can lift the load correctly. See Table 1 for weight guide.

1. Install the main lift cylinders to the mounts at the base of the outer mast. Use a crane and lower the inner mast to engage the piston rods of the lift cylinders to the holes in the top crossmember of the inner mast. Install the washers and snap rings, or other locking device, at the top of the lift cylinders. Install the cylinder clamps near the top of each cylinder. Fasten the clamps, if used,

Free-Lift Cylinder 1. When the inner mast is lowered, install the freelift cylinder in the inner mast. A pin in the base of the lift cylinder will fit into the cylinder mount at the base of the inner mast. Fasten the upper end of the cylinder to the center crossmember with the bracket, washers, and capscrews. Install the chain sheave and brackets to the top of the free-lift piston rod.

2. Install the tubes and fittings at the bottom of the main lift cylinders. Install the lowering control valve. Install the hydraulic fitting in the end of the rod at the top of the left main cylinder. Install the tube between the top of the main lift cylinder and the base of the free-lift cylinder.

3. Install the carriage. Install the lift chain.

Lift System Leak Check WARNING Never allow anyone under a raised carriage.

Do not put any part of your body through the lift mechanism unless all parts of the mast are completely lowered and the engine is stopped.

Before making any repairs, use blocks and chains on the mast and carriage so that they can not move. Make sure the moving parts are attached to the parts that can not move.

Do not try to find hydraulic leaks by putting hydraulic components under pressure. Hydraulic oil can be injected into the body by pressure.

28

During the test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests.

1. Operate the hydraulic system. Put a capacity load on the forks and raise and lower the load several times. Lower the load and tilt the mast forward and backward several times. Check for leaks.

2. Raise the carriage and the load 1 m (3 ft). If the carriage lowers slowly with the control valve in a neutral position, there are leaks inside the hydraulic system. The maximum speed that the carriage is allowed to lower is 50 mm (2 in.) per

4000 SRM 135

Specifications

10 minutes when the hydraulic oil is 30 C (90 F).

If the oil temperature is 70 C (160 F), the maximum speed that the carriage can lower is 150 mm (6 in.) per 10 minutes.

3. Check the lift cylinder for internal leaks. Remove the load from the forks. Install a gate valve in the supply line between the main control valve and the mast. Put a capacity load on the forks again.

Raise the carriage 1 m (3 ft). Close the gate valve.

If the carriage or mast lower slowly, the seals in the lift cylinders have leaks.

4. If the carriage does not move, open the gate valve and check the movement again. If the carriage lowers when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve can have a defect. Remove the load from the forks.

NOTE: See the procedures in the mast repair sections for lift chain adjustments, mast adjustments, carriage adjustment, and header hose roller adjustment.

Specifications Table 2. Cylinder Retainer Torque Specifications and Weight Guide Rod Diameter

Typical Outer Retainer Torque Values

mm

N•m

in.

Lifting Mechanism

lbf ft

One-Stage Cylinders for Lift Trucks with Less than 7000 kg (15,000 lb) Capacity 57.2

2.25

373-441

275-325

63.5

2.50

203-271

150-200

69.9

2.75

373-441

275-325

76.2

3.00

407-475

300-350

81.3

3.20

407-475

300-350

88.9

3.50

475-452

350-400

101.6

4.00

407-475

300-350

114.3

4.50

610-678

450-500

Use crane and slings with at least 500 kg (1000 lb) capacity to lift the cylinder.

One-Stage Cylinders for Lift Trucks with More than 7000 kg (15,000 lb) Capacity 108.0

4.25

113.4

5.25

241.3

9.50

254.0

10.00

Tighten retainer or packing gland nut.

Oil leakage is not controlled by the torque on the retainer.

Use crane and slings with at least 1000 kg (2000 lb) capacity to lift the cylinder.

Use crane and slings with at least 2000 kg (4000 lb) capacity to lift the cylinder.

29

Troubleshooting

4000 SRM 135

Table 2. Cylinder Retainer Torque Specifications and Weight Guide (Continued) Rod Diameter

Typical Outer Retainer Torque Values

mm

N•m

in.

Lifting Mechanism

lbf ft

Two-Stage Cylinders for Lift Trucks with Less than 5000 kg (10,000 lb) Capacity 82.6

3.25

373-509

325-375

95.3

3.75

271-305

200-225

101.6

4.00

271-339

200-250

114.3

4.50

339-407

250-300

122.0

5.00

407-475

300-350

Use crane and slings with at least 500 kg (1000 lb) capacity to lift the cylinder.

Inner retainer torque value is 122 N•m (90 lbf ft).

Troubleshooting PROBLEM No movement of lift cylinders or tilt cylinders.

Slow movement of lift or tilt cylinders.

30

POSSIBLE CAUSE

PROCEDURE OR ACTION

Pilot line(s) to control valve are disconnected or leaking.

Tighten or connect fittings.

No oil or not enough oil in the hydraulic tank.

Fill tank. Check for leaks.

Relief valve(s) not set correctly.

Adjust or install new relief valve.

Hydraulic pump does not operate or has damage.

Repair or install new pump.

Remote control valve does not operate.

Check and repair valve.

No oil or not enough oil to lift or tilt cylinders.

Fill tank. Check for leaks.

Cylinders have internal or external leaks.

Repair leaks. Install new parts.

Relief valve is not set correctly.

Adjust or install new relief valve.

There is a restriction in a hydraulic line.

Remove restriction. parts.

Load is more than capacity.

Reduce load.

Install new

4000 SRM 135

PROBLEM Rough movement of the mast assembly.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is air in the hydraulic system.

Remove air. Check for loose connections or breaks in lines.

Lift cylinder(s) is damaged.

Repair or install new lift cylinder.

Mast weldments are damaged or not aligned.

Align weldments. Install new parts.

Mast weldments are not lubricated.

Lubricate correctly.

Load rollers or bearing blocks are damaged or not adjusted correctly.

Repair or adjust the parts.

Lift chains are damaged.

Replace lift chains.

31

TECHNICAL PUBLICATIONS 4000 SRM 135

2/01 (5/95)(9/87)(10/84)(3/83)(4/82)(7/81)(11/80) Printed in U.S.A.

0(75,& $1' ,1&+ 6$( )$67(1(56 ALL MODELS

PART NO. 910442

8000 SRM 231

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

8000 SRM 231

General

General Threaded fasteners, like bolts, nuts, capscrews, and studs, are made to specifications that describe the mechanical strength and hardness of the fastener.

A fastener used in a design application is selected according to its specifications. Hyster® Company buys parts from many countries. Parts that are purchased must be to Hyster® Company standards.

There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar, but cannot be used as a direct replacement. To make sure that you have the correct fastener, order fasteners and parts through the Hyster® Parts Depot.

Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called "Grade" for SAE standards and "property class" for metric standards. This section describes the identification of some common fasteners.

The metric system used by Hyster® Company is described as SI (Le Systeme d’Unites or the International System of Units, also called SI in all languages). The SI system of measurement is described in ISO Standard 1000, 1973. A conversion table of common measurements is shown in Table 7.

shown first in the series [M12 = 12 mm, M20 = 20 mm (1/2 = 1/2 in., 3/4 = 3/4 in.)].

The number of threads per inch is normally not shown for inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter. Metric fasteners show the number of threads per millimeter.

The length of the shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners.

A capscrew will have the following description: Metric

Inch

M12 × 1.75 × 50

1/2 × 13 UNC × 1-1/2

A

A

B

C

B

C

D

A = Thread Size

A = Shank Diameter

B = Pitch

B = Number of Threads Per Unit of Length

C = Length

C = Type of Thread D = Shank Length

NOMENCLATURE, THREADS The thread design is specified by a series of numbers and letters for inch and metric fasteners. See Figure 1. The diameter of the shank of the fastener is

Figure 1. Thread Design

1

General

8000 SRM 231

STRENGTH IDENTIFICATION The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked

with a number on the head of the capscrew or on a nut. Property classes less than 8.8 are often not marked.

Table 1. Bolts and Screws

CAUTION When fasteners must be replaced, the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size.

NOTE: Identification marks are according to bolt strength. The higher the number or the increase in the number of marks indicates increased bolt strength.

2

8000 SRM 231

General

Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have any marks. The following

tables show the marks that identify the grades and property classes for different fasteners.

Table 2. Studs and Nuts

3

General

8000 SRM 231 Table 3. Torque Nuts

4

8000 SRM 231

General Table 4. Torque Nuts with Nylon Insert

5

General

8000 SRM 231

FASTENER TORQUE TABLES Table 5. Torque Values for Metric Fasteners*

Size and Pitch

Property Class 5.8 1

Grade 10.9 3

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

M3 × 0.5 M3.5 × 0.6 M4 × 0.7 M5 × 0.8 M6 × 1

0.62 0.97 1.44 2.91 4.94

0.5 0.7 1.1 2.1 3.6

0.99 1.55 2.30 4.65 7.90

0.7 1.1 2.1 3.6 6

1.34 2.11 3.13 6.33 10.8

1.0 1.6 2.3 4.7 8

M8 × 1.25 M8 × 1 M10× 1.5 M10 × 1.25

12.0 12.8 23.8 25.1

9 9 18 19

19.2 20.5 38.0 40.1

14 15 28 30

26.1 27.9 52 55

19 21 38 41

M12 × 1.75 M12 × 1.25 M14 × 2 M14 × 1.5

41.4 45.3 66 72

31 33 49 53

66 72 105 115

49 53 77 85

90 98 145 155

66 72 105 115

M16 × 2 M16 × 1.5 M20 × 2.5 M20 × 1.5

105 110 200 225

77 81 150 165

165 175 320 355

122 130 235 260

225 240 435 485

165 175 320 360

M24 × 3 M24 × 2 M27× 3 M27 × 2

345 375 505 550

255 275 370 405

555 605 810 875

410 445 600 645

755 820 1,100 1,190

560 605 810 880

M30 × 3.5 M30 × 3 M30 × 2 M33 × 3.5 M33 × 2

690 715 765 940 1,030

510 530 565 695 760

1,100 1,140 1,220 1,500 1,640

810 840 900 1,100 1,210

1,500 1,550 1,660 2,040 2,240

1,100 1,140 1,230 1,510 1,660

M36 × 4 M36 × 3 M39× 4 M39 × 3

1,200 1,280 1,560 1,640

885 945 1,150 1,210

1,930 2,040 2,490 2,630

1,430 1,510 1,840 1,940

2,620 2,780 3,390 3,570

1,940 2,050 2,500 2,640

M42 × 4.5 M42 × 3 M45 × 4.5 M45 × 3 M48 × 5 M48× 3

1,930 2,070 2,410 2,580 2,900 3,160

1,430 1,530 1,780 1,910 2,140 2,330

3,080 3,320 3,850 4,120 4,630 5,040

2,280 2,450 2,840 3,040 3,420 3,720

4,200 4,510 5,240 5,610 6,300 6,860

3,100 3,330 3,870 4,140 4,650 5,060

* Unless otherwise specified 1 Approximately equal to Grade 2 2 Approximately equal to Grade 5 3 Approximately equal to Grade 8

6

Grade 8.8 2

8000 SRM 231

General Table 6. Torque Values for Inch Fasteners* Grade 2 1

Size and Pitch

Grade 5 2

Grade 8 3

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

1/4 1/4

20 UNC 28 UNF

4 5

6 6

6 7

9 10

9 10

12 14

5/16 5/16

18 UNC 24 UNF

8 9

11 13

13 14

18 20

18 20

25 28

3/8 3/8

16 UNC 24 UNF

15 17

20 23

23 26

31 36

33 37

44 50

7/16 7/16

14 UNC 20 UNF

24 27

33 36

37 41

50 56

52 58

71 79

1/2 1/2

13 UNC 20 UNF

37 41

50 56

57 64

77 86

80 90

110 120

9/16 9/16

12 UNC 18 UNF

53 59

72 80

82 91

110 125

115 130

155 175

5/8 5/8

11 UNC 18 UNF

73 83

99 110

115 130

155 175

160 180

215 245

3/4 3/4

10 UNC 16 UNF

130 145

175 195

200 225

270 300

280 315

380 425

7/8 7/8

9 UNC 14 UNF

125 140

170 185

320 355

435 480

455 500

615 680

1 1

8 UNC 14 UNF

185 210

255 285

485 540

655 735

680 765

925 1,040

1-1/8 1-1/8

7 UNC 12 UNF

265 300

360 405

595 670

805 905

965 1,080

1,310 1,470

1-1/4 1-1/4

7 UNC 12 UNF

375 415

510 565

840 930

1,140 1,260

1,360 1,500

1,850 2,050

1-3/8 1-3/8

6 UNC 12 UNF

490 560

665 760

1,100 1,250

1,490 1,700

1,780 2,040

2,420 2,760

1-1/2 1-1/2

6 UNC 12 UNF

650 735

885 995

1,460 1,650

1,980 2,230

2,370 2,670

3,210 3,620

* Unless otherwise specified 1 Approximately equal to metric Property Class 5.8 2 Approximately equal to metric Property Class 8.8 3 Approximately equal to metric Property Class 10.9

7

General

8000 SRM 231

CONVERSION TABLE Table 7. Conversion Table for Metric and English Units By

Multiply

To Get

Multiply

By

To Get

× 0.155

= inches

Area inches feet

2

2

2

(in. )

(ft 2)

× 6.452

= centimeters

× 0.093

= meters

2

2

2

(cm )

centimeters

(m 2)

meters

2

2

(cm 2)

(m 2)

× 10.764 = feet

2

2

(in. 2)

(ft 2)

Linear inches (in.)

× 25.4

= millimeters (mm)

millimeter (mm)

× 0.039

= inches (in.)

feet (ft)

× 0.305

= meters (m)

meter (m)

× 3.281

= feet (ft)

yards (yd)

× 0.914

= meters (m)

meter (m)

× 1.094

= yards (yd)

miles (mi)

× 1.609

= kilometers (km)

kilometer (km)

× 0.621

= miles (mi)

Mass ounces (oz)

× 28.35

= grams (g)

grams (g)

× 0.035

= ounces (oz)

pounds (lb)

× 0.454

= kilograms (kg)

kilograms (kg)

× 2.205

= pounds (lb)

tons (2,000 lb)

× 907.18

= kilograms (kg)

kilograms (kg)

× 0.001

= tons (2,000 lb)

tons (2,000 lb)

× 0.907

= metric ton (t)

metric ton (t)

× 1.102

= tons (2,000 lb)

× 1.34

= horsepower (hp)

× 0.145

= pounds/in.

2

(psi)

× 145.04 = pounds/in.

2

(psi)

Power horsepower (hp)

× 0.746

= kilowatts (kW)

kilowatts (kW)

Pressure pounds/in.

2

pounds/in.

2

(psi) (psi)

× 6.895 × 0.007

= kilopascal (kPa)

kilopascals (kPa)

= megapascal (MPa)

megapascals (MPa)

Temperature ( Fahrenheit−32)

× 0.56

= Celsius (C)

( Celsius × 1.8) +32

= Fahrenheit

Torque pound inches (lbf in.)

× 0.113

= Newton meter (N•m)

Newton meter (N•m)

× 8.851

= pound inches (lb f in.)

pound feet (lbf ft)

× 1.356

= Newton meter (N•m)

Newton meter (N•m)

× 0.738

= pound feet (lb f ft)

× 0.621

= miles/hour (mph)

× 0.061

= inches

3

(in. 3)

3

(in. 3)

Velocity miles/hour (mph)

× 1.609

= kilometer/hour (km/h) kilometer/hr (km/h)

Volume inches

3

(in. )

× 16.387

= centimeters

inches

3

(in. 3)

× 0.016

= liters (l)

liters (l)

× 61.024 = inches

quarts, U.S. (qt)

× 0.946

= liters (l)

liters (l)

× 1.057

= quarts, U.S. (qt)

quarts, U.S. (qt)

× 0.83

= quarts, Imp. (qt)

quarts, Imp. (qt)

× 1.205

= quarts, U.S. (qt)

gallons, U.S. (gal)

× 3.785

= liters (l)

liters (l)

× 0.264

= gallons, U.S. (gal)

gallons, U.S. (gal)

× 0.83

= gallons, Imp. (gal)

gallons, Imp. (gal)

× 1.205

= gallons, U.S. (gal)

ounces (oz)

× 29.57

= milliliters (ml)

milliliters (ml)

× 0.034

= ounces (oz)

8

3

3

3

(cm )

centimeters

3

(cm 3)

TECHNICAL PUBLICATIONS 8000 SRM 231

9/00 (3/98)(6/83) Printed in U.S.A.