10.Remove the hydraulic oil filter (refer to
HYDRAULIC OIL FILTER Removal procedure
in this section).
Replacement
1. Install a new hydraulic oil filter (refer to
HYDRAULIC OIL FILTER Replacement
procedure in this section).
2. Use pipe thread sealant (Loctite 545 or
equivalent) on the threads of the drain plug
and install it in the opening of the hydraulic
reservoir and tighten.
3. Insert a funnel into the filler neck of the
hydraulic reservoir and pour the new hydraulic
oil into the reservoir.
4. Using the markings on the front of the
reservoir, check the level of the hydraulic oil.
Add oil until the proper level is attained.
5. Install the front cover (refer to FRONT
COVER Replacement procedure in the
FRAME section).
6. Connect the battery and operate the lift
system. Check oil level and fill as needed.
TILT CYLINDERS
Removal
1. Lower the carriage to the floor and tilt the mast
to the vertical position.
2. Disconnect the battery and discharge the
capacitors.
3. Wrap a chain around the top cross members
of the mast and attach it to a lifting device.
4. Remove the slack from the chain so the lifting
device will support the weight of the mast. DO
NOT lift the front of the truck off the floor.
5. Remove the front cover (refer to FRONT
COVER Removal procedure in the FRAME
section).
WARNING
Before disconnecting any hydraulic lines,
relieve the pressure in the lines. Allow the
truck to sit for approximately five minutes.
6. Loosen the hydraulic connections to the tilt
cylinders and disconnect the hoses from the
tilt cylinder fittings (leave the 90
o
fittings on the
cylinder).
7. Disconnect the tilt cylinder from the mast by
removing the screw and retaining washer and
pulling the tilt cylinder pin out of the mount.
WARNING
w
DO NOT use fingers to remove the tilt
cylinder pins.
w
Support the tilt cylinder when removing
the pin so that it does not drop and
damage the truck or the tilt cylinder.
8. Remove the plastic plug from the hole in the
side of the truck.
9. Remove the cotter pin from the tilt cylinder
pin.
10.Using a 1/2" x 12" drift pin, drive the tilt
cylinder pin from the frame mount and remove
the tilt cylinder from the truck.
Replacement
1. Make sure the rear bushing is in place in the
frame mount. Insert the base of the tilt
cylinder into the mount in the frame of the
truck.
2. Insert the pin into the mount from the inner
side.
3. Install the cotter pin into the end of the tilt
cylinder pin and replace the plastic plug in the
frame hole.
4. Connect the hydraulic hoses to the tilt cylinder
and tighten all fittings.
5. Align the rod end of the tilt cylinder with the
mounting bracket on the mast. Make sure the
front bushing is in place in the mast mount.
6. Insert the tilt cylinder pin through the tilt
cylinder and mast mount.
7. Install the retaining washer and screw.
8. Remove the lifting device supporting the mast
assembly.
9. Connect the battery.
10.Operate the tilt function to test for proper
operation and to check for leaks.
11.Install the front cover (refer to FRONT
COVER Replacement procedure in the
FRAME section).
E
lectric
C
ounterbalance
H
igh
O
utput
Lift & Auxiliary
03/21/00
6.5
