1

INTRODUCTION

GENERAL

This section has the description, repair and adjustment
procedures for the W/B/C60-80XT units. A
troubleshooting table for the lift mechanism is at the end
of this section. The lifting mechanism is operated by the
hydraulic system. The lifting mechanism raises the fork
weldment.

DESCRIPTION (See Figure 1)

Most of the truck’s lifting mechanism fastens between
the drive unit frame weldment and fork weldment. The

parts of the lifting mechanism are the cylinder, links,
tension rods and load wheel assemblies. The cylinder
fastens between the drive unit frame and the fork
weldments.

The upper links fastens between the weldments. The
lower linkage (rockers) are attached between both
weldments and the tension rods. Each tension rod
fastens between one of the rockers and a wheel support.
When the cylinder extends, it lifts the fork weldment
and makes the linkage move. As the rockers rotate, each
tension rod pushes a wheel support down. This action
raises the tips of the forks.

1

2

3

4

5

6

7

8

B60XT SHOWN
OTHER MODLES
SIMILAR

1.

HYDRAULIC CYLINDER

2.

UPPER LINK

3.

ROCKER

4.

ROCKER PIVOT PIN

5.

TENSION ROD

6.

WHEEL SUPPORT

7.

YOKE

8.

WHEEL SUPPORT PIN

 
     

REPAIRS

REMOVAL AND DISASSEMBLY
(See Figure 2 and Figure 6)

Electrical and hydraulic parts must be removed to
separate the main frame weldment from the fork

weldment. The following list has the sections giving the

correct removal and installation procedures for these

parts. Select the section that includes the parts that must

2

be removed. For the electrical system see the sections
THE ELECTRICAL SYSTEM, 2200 SRM 279,
CURTIS TRANSISTOR MOTOR CONTROL-
LER, 2200 SRM 411 or DIAGRAMS CURTIS
TRANSISTOR, 8000 SRM 457. For the hydraulic
system see the section THE WALKIE HYDRAULIC
SYSTEM, 1900 SRM 278.

Separate parts of the lifting system can be removed
without disassembling the complete mechanism. It is
not necessary to do EACH step of the procedure to
remove just one part. This procedure has steps to
remove and disassemble the complete lifting
mechanism. Read the procedure and do only the
necessary steps.

1.

Put a solid wood or metal block under each side of

the drive unit frame weldment, near the rockers. The
blocks must be thick enough to just fit under the drive
unit frame weldment. The drive unit frame weldment
must not lower or tilt when the fork weldment is
removed. See the section PERIODIC MAINTE-
NANCE, 8000 SRM 281.

2.

Raise the forks to the maximum height. Put solid

wood or metal blocks under both sides of the fork
weldment at the fork tips and at the battery. The four
blocks must prevent the fork weldment from tipping to
either side. Push the “LOWER” button. Remove the
drive unit compartment hood.




The capacitor in the transistor controller can hold an
electrical charge after the battery is disconnected. To
prevent electrical shock and injury, discharge the ca-
pacitor before inspecting or repairing any compo-
nent in the drive unit compartment. Wear safety
glasses. Make certain the battery has been discon-
nected. Use a screwdriver or jumper wire to make a
short–circuit across the B + and B – terminals of the
transistor controller.

3.

Remove the battery as shown in the section

PERIODIC MAINTENANCE, 8000 SRM 281.




There are close clearances between the MDU, the
fork weldment and the main frame weldment that

can cause serious injury. NEVER put hands, arms,
head or legs between these parts unless the parts
have blocks to prevent movement.




Be careful when removing or installing snap rings.
These snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
protection during removal and installation.

4.

To remove the lift cylinder, remove the snap rings

from the anchor pin that fasten the bottom of the
cylinder to the main frame weldment. Use a drift to
remove the anchor pin. Have a person hold the cylinder
so that it can not fall. Use a drift to remove the roll pin
retaining the upper anchor pin to the fork weldment.
Drive the upper anchor pin from the frame weldment.

5.

Lift the cylinder and put it in a position so that the

hydraulic lines are on top. There is oil inside the
cylinder. Install labels for the correct connection during
assembly and remove the hydraulic lines. Put caps on
the hydraulic lines and the ports to prevent the oil from
draining out.

6.

If the hydraulic cylinder must be disassembled do

the following steps:

a.ąHold the cylinder over a container and

remove the caps from the hydraulic ports. Drain

the oil from the rod port of the cylinder into a

container by pulling on the rod.

b.ąUse a spanner wrench to remove the piston

head.

c.ąRemove the piston head and rod assembly

from the shell.


ąReplace all wipers and seals whenever a

cylinder is disassembled.

d.ąPlace the flat surface of the piston rod

assembly into a softĆjawed vise. Remove the

locknut, piston head with the seal and retainer

from the rod. Remove the seal from the piston

head.

3

1

2

3

4

5

6

6

7

8

9

10

11

12

13

5

10

14

15

15

16

16

17

18

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

31

36

37

38

39

40

41

42

43

44

45

46

47

1.

MDU FRAME WELDMENT

2.

FORK WELDMENT

3.

HYDRAULIC CYLINDER

4.

ANCHOR PIN

5.

ROLL PIN

6.

SNAP RING

7.

ANCHOR PIN

35.

PIVOT PIN

36.

WHEEL SUPPORT ASSEMBLY

37.

CAPSCREW

38.

PIVOT PIN

39.

NUT

40.

SET SCREW

41.

SPACER

42.

ROLLER

43.

CAPSCREW

44.

WEAR STRIP

45.

NUT

46.

ACCESS PLATE

47.

CAPSCREW

22.

BUSHING

23.

LOCKWASHER

24.

CAPSCREW

25.

PIVOT PIN

26.

PIVOT PIN

27.

LOCKWASHER

28.

CAPSCREW

29.

BUSHING

30.

TENSION ROD

31.

JAM NUTS

32.

YOKE

33.

BUSHING

34.

LUBE FITTING

8.

BUSHING

9.

LUBE FITTING

10.

BUSHING

11.

LUBE FITTING

12.

ROLL PIN

13.

PIVOT PIN

14.

UPPER LEVER

15.

LUBE FITTING

16.

LUBE FITTING

17.

ROCKER

18.

BUSHING

19.

CAPSCREW

20.

PIVOT PIN

21.

NUT

19


   

4

e.ąRemove the wiper seal from the retainer.

7.

To remove the upper linkage, remove the roll pins

retaining the pivot pins to the main drive unit weldment.
Remove the pivot pins. Remove the roll pins retaining
the lower pins to the fork weldment. Remove the pins
and upper link from the fork weldment. On the
C60-80XT units disconnect the high speed pedal
harness before separating the weldments. Separate the
drive unit frame weldment from the fork weldment.

8.

Remove the capscrews and lockwashers retaining

the pivot pin to the fork weldment. Remove the pivot
pins from the drive unit frame weldment and the
rockers.

9.

Remove the capscrews and lockwashers retaining

the pivot pins to the rocker arms and the tension rods.
Remove the pivot pins and the rockers. The fork
weldment may now be separated from the drive unit
frame weldment.

10.

Remove the capscrews and locknuts retaining the

torsion rods to the wheel supports. Remove the pivot
pins, spacers, rollers and torsion rods.

11.

Remove the set screws retaining the wheel support

pivot pin. Use a drift to drive the pivot pin from the fork
weldment and wheel support.

12.

If either wheel support must be disassembled do

the following steps:

Single and Dual Wheels (See Figure 3 and
Figure 4)

CAUTION

Do not drive the axle from the end with the grease fit-
ting installed.

a.ąUse a punch to remove the roll pin that

fastens the axle and the load wheel. Use a drift to

remove the axle from the wheel support.

b.ąRemove the axle, guards, wave washers,

bearings and load wheels from the wheel support.

c.ąUse a press to remove the bushings from the

wheel support.

1

2

3

4

5

6

2 3

4

7

8

7

9

1.

WHEEL SUPPORT

2.

GUARD

3.

WAVE WASHER

4.

BEARING

5.

LOAD WHEEL

6.

ROLL PIN

7.

LUBE FITTING

8.

AXLE

9.

BUSHING

FIGURE 3.ąWHEEL SUPPORT - SINGLE

LOAD WHEEL

1

2

3

4

5

5

2

3

4

4

4

3

6

3

7

8

9

10

8

1.

WHEEL SUPPORT

2.

GUARD

3.

WAVE WASHER

4.

BEARING

5.

LOAD WHEEL

6.

SPACER

7.

ROLL PIN

8.

LUBE FITTING

9.

AXLE

10.

BUSHING

FIGURE 4.ąWHEEL SUPPORT - DUAL

LOAD WHEEL

Tandem Wheels (See Figure 5

)

a.ąRemove the nuts retaining the front load

wheels to the bracket. Remove the capscrew,

5

bearings, wave washers, washers and axle sleeve.

Repeat for the rear load wheel.

b.ąRemove the brackets, shims and bushings

from the wheel support.

c.ąUse a press to remove the bushings from the

wheel support.

13.

Remove the jam nuts retaining the torsion rods to

the yokes.

14.

Remove capscrews and nuts retaining the wear

strips.




Cleaning solvents can be flammable and toxic, and
can cause skin irritation. Wear protection when han-
dling solvents and always follow the recommenda-
tions of the manufacturer.

15.

Clean and inspect all components for damage or

wear. Replace any item that is worn or damaged. Use a
press or a block of wood and a hammer to remove the
bushings when necessary.

ASSEMBLY AND INSTALLATION

This assembly and installation procedure is for a lifting
mechanism that is completely disassembled. Do only
the steps necessary to assemble and install the parts of
your unit that have been removed.

1.

Use a bearing tool or a block of wood and a hammer

to install the bushings in all the linkage, including the
upper links, drive unit frame weldment, fork weldment,
rockers, tension rods, yokes and wheel supports. Align
the bushings and linkage so that the edges are even.
After the bushings are installed, line drill a 3.05 mm

(0.12 in) diameter hole through each bushing, using

the grease fitting hole as a guide. Install the grease

fitting.

2.

Install wear strips on the fork weldment, using the

capscrews and nuts to retain the strips. Tighten the
capscrews to 35 N

m (26 lbf ft) torque.

3.

Assemble the wheel support assemblies:

Single and Dual Wheels (See Figure 3 and
Figure 4)

a.ąUse a press or a block of wood and a hammer

to install the bearings into the wheel.

b.ąAlign the wheel and bearing assembly and

the wave washers and guards with the opening in

the wheel support. On the dual wheel assembly

install the spacer between both inner wave

washers. Install the axle shaft. Install the roll pin

to fasten the axle in the wheel support.

c.ąAlign the wheel support assembly in the fork

weldment. Align the roller and spacer inside the

wheel support assembly and install the pivot pin

to retain the roller, spacer and wheel support

assembly to the frame weldment. Align the pivot

pin and install the set screw.

d.ąInstall new grease fittings if necessary.

Tandem Wheels (See Figure 5

)

a.ąUse a press or a block of wood and a hammer

to install the bearings into the load wheels. Install

the axle sleeves in the load wheels.

b.ąPosition the shims and brackets on the wheel

support. Align the load wheels with the bearings

and sleeves between the wave washers, washers

and the brackets and install the axles. Install the

nuts on the axles.

c.ąAlign the wheel support assembly in the fork

weldment. Align the roller and spacer inside the

wheel support assembly and install the pivot pin

to retain the roller, spacer and wheel support

assembly to the fork weldment. Align the pivot

pin and install the set screw.

d.ąInstall new grease fittings if necessary.

4.

Assemble the torsion rods to the yokes. The length

of the torsion rods must be adjusted after the linkage has
been completely assembled.

5.

Align the rockers with the fork weldment and

install the pivot pins using the capscrews and nuts to
retain the rockers.

6.

Position the torsion rods and yokes between the

rockers and the wheel support assemblies. Install the
pivot pins to retain the yokes to the wheel support
assemblies. Install the capscrews and nuts to retain the

6

pivot pins. Align the torsion rods and the rockers and
install the pivot pins. Align the recess in the pivot pins
with the hole in the rockers and install the capscrew and
lockwasher to retain the pivot pins.

1 2

3

4

5 6

7

8

9

10

11

12

13

14

1

5

6

7

2

12

12

14

12

1.

SHIM

2.

BUSHING

3.

NUT

4.

BRACKET

5.

WASHER

6.

WAVE WASHER

11.

CAPSCREW

12.

LUBE FITTING

13.

WHEEL SUPPORT

14.

BUSHING

7.

BEARING

8.

LOAD WHEEL

9.

AXLE SLEEVE

10.

BRACKET

FIGURE 5.ąWHEEL SUPPORT - TANDEM

WHEELS

7.

Align the fork weldment and the rockers. Install the

pivot pins that retain the rockers to the fork weldment.
Install the capscrews and nuts to retain the pivot pins.

8.

Align the main frame weldment with the fork

weldment. Install the upper links to the frame weldment
using the lower pivot pins. Install the upper pivot pins to
retain the main frame weldment and the upper links.
Install roll pins to retain both sets of pivot pins for the
upper links. Connect the high speed pedal harness.

9.

Assemble the hydraulic cylinder if necessary.

NOTE:ąPut clean hydraulic oil on the seals and

wiper before assembly. Use the oil shown in Table 1

of the section PERIODIC MAINTENANCE, 8000

SRM 281.

a.ąInstall a new wiper seal in the the piston head.

Install the piston head onto the piston rod. Install

a new seal in the piston groove. Install the piston,

piston seal and locknut on the piston rod. Align

the flat surfaces of the rod in a softĆjawed vise and

tighten the locknut to 150 N
m (110 lbf ft) torque.
b.ąPut hydraulic oil on the inside of the shell as

described in the NOTE above. Carefully install

the piston rod assembly into the shell. Do not

damage the seal or wiper during assembly.

CAUTION

Do not allow any Loctite to get into the cylinder.

1

2

3

4

5

6

7

8

1.

SHELL

2.

LOCKNUT

3.

SEAL

4.

PISTON

5.

PISTON HEAD

6.

WIPER

7.

PISTON ROD

8.

BUSHING

FIGURE 6.ąHYDRAULIC CYLINDER

7

c.ąPut LoctiteRNo. 242 on the threads of the

piston head. Follow the directions of the

manufacturer.

d.ąTighten the piston head to 27 NSm (20 lbf ft)

torque.




Be careful when removing or installing snap rings.
The snap rings can come loose during removal or
installation with enough force to cause an injury. Al-
ways use the correct snap ring pliers and wear eye
and face protection during removal and installation.

10.

Align the base of the cylinder in the main frame

weldment. Install the anchor pin and snap rings.

12.

Install the hydraulic lines to the hydraulic

cylinder. The hose assembly goes to the bottom port in
the cylinder.

13.

Lubricate all the grease fittings. Connect any

wires removed according to the labels. Install the
battery as shown in the section

PERIODIC

MAINTENANCE, 8000 SRM 281.

14.

Remove the blocks and lower the unit to the floor.

Check the level of the hydraulic oil. Connect the battery
connector. Install the drive unit compartment hood.
Operate the lift truck to check for correct operation. See
the OPERATING MANUAL.

CHECKS AND ADJUSTMENTS

TORSION

ROD ADJUSTMENT

The torsion rods must be adjusted so that the machined
surface on top of the rear link is flush to the frame when
the lift truck is in the lowered position. If the rear link
machined surface is not flush to the fork frame or if the
load wheels are not carrying the load equally, an
adjustment must be made. Make certain to check both
forks and both load wheels.

1.

Position a flat bar across one of the forks. Use a tape

rule or a ruler to measure the distance from the floor to
the top of the fork. Record the dimension.

2.

Move the flat bar to the other fork and make the

same measurement. Record the second measurement.

3.

Turn the key to the ON position and raise the fork to

its maximum height.

4.

Place the flat bar across the first fork that was

measured and take a measurement with the fork in the
raised position. Record the dimension.

5.

Move the flat bar to the other fork and take a

measurement of the second fork.

FIGURE 7.ąMEASURING FORK -

LOWERED POSITION

6.

Compare the measurements taken. If the

measurements taken are not within 4.6 mm (0.18 in) of
each other or if the load wheels are not carrying the load
equally an adjustment is required. The lowered fork
height at the load wheel end should be 81.03 to 85.60
mm (3.19 to 3.37 in).

7.

Remove the four capscrews retaining the access

covers on each fork.

CAUTION

Improper adjustment to the pull rods can cause
excessive wear to one of the load wheels and poor
pallet entry and exit . When making any adjustments

8

be certain that the measurements are the same on
both forks. If an equal measurement can not be
obtained, the problem may be a twisted frame. A
twisted frame must be replaced.

FIGURE 8.ąMEASURING FORK - RAISED

POSITION

8.

There are two nuts on either side of the rear link and

load wheel assembly. Loosen both outer jam nuts and
make the necessary adjustment to the inner jam nuts. To
lower the load wheels, turn the inner nuts clockwise.
This will shorten the working length of the pull rods. To
raise the load wheels, turn the inner nuts
counter-clockwise. The working length of the pull rod
will be increased.

FIGURE 9.ąADJUSTING TORSION ROD

9.

After the adjustments have been made, tighten the

jam nuts to 176 N

m (130 lbf ft) torque.

10.

Install the covers and secure them using the four

access cover capscrews. tighten the capscrews to 19
N

m (7 lbf ft) torque.

REAR FORK ADJUSTMENT

NOTE:ąThis adjustment is available only on lift
trucks that have double pallet forks.ă

1.

Position a flat bar across one of the forks at the

battery end. Use a tape rule or a ruler to measure the
distance from the floor to the top of the fork. Record the
dimension.

2.

Move the flat bar to the other fork and make the

same measurement. Record the second measurement.

3.

Turn the key to the ON position and raise the fork to

its maximum height.

4.

Place the flat bar across the first fork that was

measured and take a measurement with the fork in the
raised position. Record the dimension.

5.

Move the flat bar to the other fork and take a

measurement of the second fork.

6.

Compare the measurements taken. If the

measurements taken are not within 4.6 mm (0.18 in) of
each other, an adjustment is required The lowered fork
height at the battery box end should be 82.80 to 88.90
mm (3.26 to 3.50 in).

7.

Loosen the nuts retaining the capscrews on both

sides of the frame between the battery box and the drive
unit frame. Adjust the capscrew to obtain the proper
dimension when the forks are lowered. Tighten the nuts
to retain the capscrews.

9

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

Forks will not raise

Hydraulic oil level low. See the section PERIODIC
MAINTENANCE, 8000 SRM 281.

Hydraulic pump motor not operating. Check motor electrical power and
control circuits. See the section THE ELECTRICAL SYSTEM, 2200 SRM
411 and the section THE WALKIE HYDRAULIC SYSTEM, 1900 SRM
178. See also the section MAINTENANCE, 620 SRM 294.

Lowering solenoid or valve stays in the lowering position.

Forks will not hold a position

Control valve or solenoid is damaged. See the section THE WALKIE
HYDRAULIC SYSTEM, 1900 SRM 178.

Hydraulic line has a leak.

Cylinder seal or wiper has a leak. See the steps in the

REPAIR

section

that describes cylinder disassembly and assembly.