100240, OPR, HYSTER, Hyster2, SRM
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//-->INTRODUCTIONGENERALThis section has a description and the service proce-dures for the parts of the frame. These parts includethe counterweight assembly, overhead guard, hydraulictank, access panels, and decal positions.DESCRIPTIONThe frame is a single weldment. The frame has mountsfor the counterweight, overhead guard, upright, steer-ing trunnion, and transaxle assembly. The hy-draulic tank is part of the frame weldment and isfound in the steering compartment behind theFIGURE 1. FRAME AND CONNECTED PARTSbattery compartment. A hood is the access coverover the battery compartment, hydraulic tank, andthe top of the steering trunnion. The hood is fastenedto the counterweight with a hinge. An access panelon the right side of the frame protects the electroniccontroller from dirt and water.Three sizes of battery compartments are available forthe J25-35A series of lift trucks. The frames are simi-lar in design, but have three different lengths becauseof the different battery compartments. The threelengths of the battery compartments are 42.5 cm(16.75 in), 60 cm (23.5 in), and 67.3 cm (26.5 in).The remainder of the frame parts is the same.The weight of the battery is the main part of the coun-terweight system on an electric lift truck. TheJ25A, J30A, and J35A lift trucks have a cast-ironcounterweight fastened to the back of the frame. Whenthe lifting capacity of the lift truck is increased, thesize of the battery is increased. The increased size ofthe battery requires a larger battery compartment. Thecounterweight has a weight of 340 kg (750 lb).The J30AS lift truck uses the same battery and shortframe as the J25A. A heavier counterweight [580 kg(1275 lb)] is installed on the J30AS.A slot in the overhead guard permits the removal ofthe battery without removing the overhead guard.Access panels behind the drive wheels give access tothe traction motors. The floor plate gives access tothe hydraulic and electric components.DISASSEMBLY AND ASSEMBLYOVERHEAD GUARDWARNINGDo not operate the lift truck without theoverhead guard correctly fastened to thelift truck.RemovalA. Remove the battery as described in the sectionPERIODIC MAINTENANCE.B. Access to the capscrews that hold the overheadguard to the counterweight is from the battery com-partment. Remove the two capscrews and washers.C. Remove the four capscrews (two each side) thathold the overhead guard to the cowl.D. Use a lifting device to lift the overhead guard fromthe lift truck.InstallationPut the overhead guard on the lift tuck. Apply Loctite290 or equivalent to the two capscrews that hold theoverhead guard to the counterweight. Install the sixcapscrews and washers that hold the overhead guardto the lift truck. Tighten the four capscrews that holdthe overhead guard to the cowl to 85 N.m ( 63 lf ft)torque. Tighten the two capscrews that hold the over-head guard to the counterweight to 300 N.m (220 lbfft) torque. Install the battery.HOOD AND SEAT ASSEMBLYThe hood has several functions. It protects the bat-tery, protects the operator, and is the mount for theoperator seat. A latch in the front of the hood con-nects to the frame. This latch must be in good condi-tion so that the hood can prevent the battery fromcoming into the operator area if an accident occurs.A gas controlled spring makes easy raising of the hoodfor access to the battery compartment.Removal and InstallationThe seat assembly can stay fastened to the hood whenthe hood is removed from the lift truck. The wire tothe seat switch must be disconnected if the seat orthe hood is removed from the lift truck. A plug fordisconnecting the wire is found under the hood.Disconnect the gas controlled spring. Make anote of the connection of the gas controlled spring tothe hood:front hole for the 67.3 cm (26.6 in) batterycompartment,rear hole for the other two sizes of batterycompartments.Remove the hood from the counterweightby remov-ing the capscrewsthat hold the hinge to the counter-weight. When the hood is installed again,make sure the hood is aligned with the counterweightand frame. Tighten the capscrews for the hinge andinstall the gas controlled spring.COUNTERWEIGHTWARNINGPUTTING THE LIFT TRUCK ONBLOCKSThe lift truck must be put on blocks forsome types of maintenance and repair.The removal of the following assemblieswill cause large changes in the center ofgravity: battery, upright, transaxle, andcounterweight. When the lift truck is puton blocks, put additional blocks in thefollowing positions:1. If the battery and drive axle are re-moved, put blocks under the counter-weight.2. If the battery and counterweight areremoved, put blocks under the uprightassembly.Removal Of The CounterweightCAUTIONIf the battery is not removed for this pro-cedure, use an insulator cover over thebattery to protect the battery.A. Remove the overhead guard as described in theparagraph for the removal of the overhead guard.B. Disconnect the wire to the set switch under thehood. Use a support to hold the hood open and dis-connect the gas controlled spring. Remove the twocapscrews that hold the hood to the counterweight.Remove the hood and the seat.C. Remove the bottom 1/2 UNC x 1 in capscrewand washers that hold the counterweight to the frame.This capscrew is found on the left side of the openingfor the steering wheel.D. Install eyebolts in the threaded holes for the over-head guard. Connect a crane and sling with a mini-mum capacity of 1000 kg (2000 lb) to the eyebolts.Raise the crane until the weight of the counterweightis held by the crane.E. Remove the four 1/2 UNC x 3-1/2 in bolts, nuts,and washers that hold the counterweight to the frame.Make a note of the arrangement of the washers. Thewashers are used for the alignment of the counter-weight on the frame.F. Remove the counterweight from the lift truck.Installation Of The CounterweightA. Install eyebolts in the threaded holes for the over-head guard. Connect a crane and sling with amimimum capacity of 1000 kg (2000 lb) to the eye-bolts. Raise the crane until the weight of the counter-weight is held by the crane. Move the counterweightto the lift truck for installation.B. Install the four 1 /2 UNC x 3-1 /2 in bolts and nutsthat hold the counterweight to the frame. Use wash-ers for shims to align the counterweight and the framefor the capscrew that holds the counterweight at thebottom. Tighten the bolts to 75-80 N.m (55-60 lbfft).C. Install the 1/2 UNC x I in capscrew and washersin the bottom hole in the counterweight.D. Install the seat and hood. Install the gas controlledspring. Connect the wire for the seat switch.E. Install the overhead guard as described in the para-graph for the overhead guard.HYDRAULIC TANK REPAIRSSmall LeaksSmall leaks can be sealed as follows:A. Use steam to clean the area around the leak. Re-move all paint and dirt around the leak.WARNINGDo not use tools that can make sparks,heat or static electricity. The vapors inthe tank can cause an explosion.B. Apply Loctite 290 to the leak. Follow the instruc-tions of the manufacturer.Large LeaksWARNINGSpecial procedures must be followedwhen large leaks or other repairs needwelding or cutting. Special proceduresmust be followed. All work must be doneby authorized personnel. If the tank iscleaned inside of a building, make surethere is enough ventilation. See the fol-lowing manuals for additional information:• “Safe Practices For Welding And Cut-ting Containers That Have Held Combus-tibles” by the American Welding Society,A6.0-65.• “Safety In Welding And Cutting”,American National Standard, ANSI Z49.1 -1973.When cleaning the tank, do not use solutions that makedangerous gases at normal temperatures or whenheated. Wear a device for the protection of the eyes.Protect the body from burns.When cleaning with steam, use a hose with a mini-mum diameter of 19 mm (0.75 inch). Control the pres-sure of the steam by a valve installed at the nozzle ofthe hose. If a metal nozzle is used, it must be made ofa material that does not make sparks. Make an elec-trical connection between the nozzle and the tank. Toprevent static electricity, connect a ground wire to thetank.E. Flush the inside of the tank with boiling water. Makesure all the loose material is removed from the insideof the tank.F. Make an inspection of the inside of the tank. If it isnot clean, repeat steps D and E and make anotherinspection. When making inspections, use a light thatis approved for locations with flammable vapors.G. Put plugs in all the openings in the tank. Wait 15minutes, then remove the inlet and outlet plugs. Test asample of the vapor with a special indicator for gasvapors. If the amount of flammable vapors is abovethe lower flammable limit, repeat the cleaning proce-dures.Chemical Solution Method of CleaningIf the tank cannot be cleaned with steam, use the fol-lowing procedure:A. Mix a solution of water and trisodium phosphateor a cleaning compound with an alkali base. Followthe instructions given by the manufacturer.B. Fill the tank with the cleaning solution. Use com-pressed air to mix the solution in the tank.C. Drain the tank. Flush the inside of the tank withhot (boiling) water. Make sure all the cleaning com-pound is removed.D. Make an inspection of the inside of the tank. If thetank is not clean, repeat steps A to C. Make anotherinspection of the tank. When making inspections, usea light that is approved for locations with flammablevapors.E. Check the tank for flammable vapors using specialindicator for gas vapors. If the amount of flammablevapors is not below the lower flammable limit, repeatthe cleaning procedures.Other MethodsIf nitrogen gas or carbon dioxide gas is available, pre-pare the tank for welding using these gases. See themanual “Safe Practices For Welding and CuttingContainers That Have Held Combustibles” by theAmerican Welding Society, A6.0-65. If these gasesare not available, another method using water can beused as follows:Steam Method Of CleaningClean the tank as follows:A. Remove all the parts from the tank. Install the drainplug.B. Fill the tank 1 /4 full with a solution of water andsodium bicarbonate or sodium carbonate. Mix 0.5kg (1 lb) per 4 litres (1 gal) of water.C. Mix the solution in the tank using air pressure.Make sure all the surfaces on the inside of the tankare flushed with the solution. Drain the tank.D. Put steam into the tank until the tank does nothave odors and the metal is hot. Steam vapors mustcome from all the openings.A. Fill the tank with water to just below the pointwhere the work will be done. Make sure the spaceabove the level of the water has a vent.B. Use acceptable welding practices to repair the tank.NOTEThe nameplate is installed using rivets.The old rivets must be removed beforeinstalling a new nameplate.If the decals or information plates aremissing or have damage, they must bereplaced.A. Make sure the surface is dry and has no oil orgrease. Do not use solvent on new paint. Clean thesurface of old paint using a cleaning solvent.B. Remove the paper from the back of the decal. Donot touch the adhesive surface.C. Carefully hold the decal in the correct positionclose to the surface. The decal can not be movedafter it touches the surface. Put the decal on the sur-face. Make sure all air is removed from under thedecal and the corners and edges are tight.DECAL REPLACEMENT (SEEFIGURE 2)WARNINGDecals that have WARNINGS orCAUTIONS must be replaced if they aredamaged.If an upright of a different size or anaccessory carriage is installed, thecapacity rating can change. Changes intypes of tires can change the capacityrating. See a Hyster Dealer for areplacement nameplate. The nameplateinformation is a safety item and must becorrect.
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