Hyster CHALLENGER H135XL, Service & Repair Manual

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100 SRM 322 Hydraulic Tank Repair
Legend for Figure 4
1. SEAT BELT
2. HIP RESTRAINT
3. SEAT RAIL
4. SEAT BELT
RETRACTOR
Make sure the seat rails are not loose. See Figure 4.
The seat rails must lock securely in position, but
move freely when unlocked. The seat rails must be
securely attached to the mounting surface.
Hydraulic Tank Repair
REMOVE
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine and transmission, and the coun-
terweight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that
any blocks used to support the lift truck are
solid, one piece units.
1. Remove the engine and transmission. See En-
gine Repair.
2. Remove the drain plug and drain the oil from the
tank. Disconnect the hydraulic lines at the tank
and put caps on the open lines.
3. Remove the hooks that hold the tank to the
frame. Remove the hydraulic tank.
INSPECT
Make a visual inspection of all sides of the tank. In-
spect the welds for cracks and leakage. Check for
wet areas, accumulation of dirt, and loose or miss-
ing paint caused by leakage. Areas of the tank that
are not easily seen can be checked with an inspection
mirror and a light that is approved for locations with
flammable vapors.
SMALL LEAKS REPAIR
Use the following procedure to repair small leaks:
1. Use steam to clean the area around the leak. Re-
move all paint and dirt around the leak.
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
2. Apply Loctite
®
290 to the leak. Follow the in-
structions of the manufacturer.
LARGE LEAKS REPAIR
1. Use one of the procedures described under Clean
to clean and prepare the tank for repairs.
2. Use acceptable welding practices to repair the
tank.
See the American National Standards
Safety In Welding and Cutting AWS Z 49.1 -
1999.
CLEAN
WARNING
Special procedures must be followed when
large leaks or other repairs need welding or
cutting. All work must be done by authorized
personnel. If the tank is cleaned inside of a
building, make sure there is enough ventila-
tion. See the following manuals for additional
information:
• "Safe Practices for Welding and Cutting Con-
tainers that have Held Combustibles" by the
American Welding Society, F4.1 - 1999.
• "Safety in Welding and Cutting," American
National Standard, AWS Z 49.1 - 1999.
When cleaning the tank, do not use solutions that
make dangerous gases at normal temperatures or
when heated. Wear eye and face protection. Protect
the body from burns.
When cleaning with steam, use a hose with a mini-
mum diameter of 19 mm (0.75 in.). Control the pres-
sure of the steam by a valve installed at the nozzle of
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