100137, OPR, HYSTER, Hyster2, SRM
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//-->INTRODUCTIONGENERALThis section has the description of the frame and someconnected parts. See FIGURE 1. Procedures for the re-moval and installation of the counterweight, hood, over-head guard, and engine (including the transmission andradiator) are under REPAIRS. Checks for the operatorrestraint system and procedures for the repair of tanksand replacement of safety labels are included.There is a counterweight for each capacity of lift truck.The counterweights are similar, but are differentweights. The muffler is fastened to the frame inside ofthe counterweight.An overhead guard is fastened to the cowl at the front ofthe lift truck and to a frame plate at the rear of the lifttruck.The hood is connected to the frame plate with hinges. Agas controlled spring gives assistance when raising thehood and holds the hood in the open position. The floorplates can be removed for access to the transmission andother components.DESCRIPTIONThe frame is one weldment and includes the hydraulictank and the fuel tank for gasoline or diesel fuel.REPAIRSWARNINGThe lift truck must be put on blocks for some types ofmaintenance and repair. The removal of the follow-ing assemblies will cause large changes in the centerof gravity: upright, drive axle, engine and transmis-sion, and the counterweight. When the lift truck isput on blocks, put additional blocks in the followingpositions to maintain stability:a. Before removing the upright and drive axle,1.2.3.4.5.HOODFLOOR PLATEOVERHEAD GUARDCOUNTERWEIGHTFRAME14put blocks under the counterweight so that thelift truck can not fall backward.b. Before removing the counterweight, putblocks under the upright assembly so that thelift truck can not fall forward.The surface must be solid, even, and level when thelift truck is put on blocks. Make sure that any blocksused to support the lift truck are solid, one pieceunits.32126335FIGURE 1. FRAME AND CONNECTED PARTS1COUNTERWEIGHTThe counterweight is held in position on the frame bytwo hooks that are part of the frame. Two M20 x 2.5capscrews hold the counterweight to the lower part ofthe frame.c. Turn the tank fuel valve clockwise until the valveis completely closed.d. Run the engine until it stops, then turn the keyswitch to theOFFposition.e. Disconnect the quick disconnect fitting.f. Release the LPG tank latch and remove the tankfrom the bracket.WARNINGDo not operate the lift truck if the capscrews for thecounterweight is not installed. When the capscrewsare removed, the counterweight can fall from the lifttruck.Removal1. If the lift truck has an LPG fuel system, remove theLPG tank and bracket so that the counterweight can beremoved. Additional information on the LPG fuel sys-tem can be found in the following section of theSER-VICE MANUAL:THE LPG FUEL SYSTEM, 900 SRM 15.WARNINGThe counterweight is heavy. Make sure that thecrane and lifting devices have enough capacity tosafely lift the weight. The counterweight castingshave the following approximate weights:H2.00XL (H40XL)1100 kg (2425 lb)H2.50XL (H50XL)1450 kg (3190 lb)H3.00XL (H60XL)1815 kg (4000 lb)3. See FIGURE 2. Install a lifting eye in the lifting holeof the counterweight. Connect a crane to the lifting eyeand raise the crane until it holds part of the weight of thecounterweight. Remove the two M20 x 2.5 capscrewsthat hold the counterweight to the frame. Use the craneto lift the counterweight from the lift truck.WARNINGLPG can cause an explosion. Do not cause sparks orpermit flammable material near the LPG system.LPG fuel systems can be disconnected indoors onlyif the lift truck is at least 8 metres (25 feet) from anyopen flame, motor vehicles, electrical equipment, orignition source.Close the fuel valve on the LPG tank before any partof the engine fuel system is disconnected. Run the en-gine until the fuel in the system is used and the enginestops.If the engine will not run, close the fuel valve on theLPG tank. Loosen the fitting on the supply hose fromthe LPG tank where it enters the filter unit. Permitthe pressure in the fuel system to decrease slowly.Fuel leaving the fitting removes heat. Use a cloth toprotect your hands from the cold fitting.2. Use the following procedure to remove the LPG tank:a. Removable LPG tanks can be removed and re-placed indoors only if the lift truck is at least 8metres (25 feet) from any open flame or ignitionsource.b. Move the lift truck to the area where tanks arechanged.295371. COUNTERWEIGHT CAPSCREWS2. HOLE FOR REMOVAL OF PIVOT SHAFT3. TOW PINFIGURE 2. COUNTERWEIGHTInstallationWhen the counterweight is installed, make sure thehooks on the frame fully engage the counterweight sothat it is aligned with the parts of the frame. Tighten thetwo M20 x 2.5 capscrews to 320 N.m (235 lbf ft).If the lift truck has an LPG fuel system, install the brack-et for the LPG tank. Use the following procedure to in-stall the LPG tank:a. Before the LPG tank is installed on the lift truck,make sure the tank has fuel in it. Check the opera-tion of the fuel gauge. Look at the fuel gauge andmove the tank. If the gauge needle does not move,a new tank must be installed.b. Put the tank in the tank bracket. Make sure thatthe tank is aligned with the alignment pin.c. Close the latch.d. Connect the quick disconnect fitting to the fuelvalve on the tank. Use your hand to tighten the fit-ting. Do not open the fuel valve until the quickdisconnect fitting is completely tightened. Turnthe fuel valve counterclockwise to open the fuelvalve.e. Inspect the fuel system for leaks when the fuelvalve is open. Frost on the surface of the tank,valves or fittings or a strong odor indicates leak-age.sition of the hood with the latch on the front cover.Tighten the capscrews for the hood hinges.WARNINGThe hood, hood latch and hood striker must be cor-rectly adjusted for the correct operation of the op-erator restraint system.2. See FIGURE 4. Use the following procedure to adjustthe hood latch:a. Install the floor plate and tighten the capscrews.b. Install the latch striker in the highest slot positionon the floor plate. Check that the latch striker is inthe center of the jaws of the hood latch.c. Close the hood to the fully closed position. Thehood latch has two positions. The hood is fullyclosed after two clicks of the latch.d. Loosen the capscrews for the latch striker justenough to let the striker move. Push the hooddown until the hood just touches the rubberbumpers on the frame. Make sure the latch strikeris still in the center of the hood latch. Tighten thecapscrews for the striker.e. Check the operation of the hood latch. Have anoperator sit in the seat. Make sure that the hood isfully closed (two clicks). Also check that thehood touches the rubber bumpers. If additionaladjustment is necessary, repeat Step d.MUFFLERThe muffler is inside the counterweight and between thecounterweight and the radiator. A short exhaust pipesends the exhaust gases out of the lift truck through thegrille in the counterweight.The lift truck can have an overhead exhaust system. Theexhaust pipe is fastened to the right rear leg of the over-head guard.RADIATOR AND COOLANT SYSTEMRemoval1. Drain the coolant from the radiator and the engine.2. Remove the capscrews that hold the fan shroud to theradiator. Remove the four capscrews that fasten the fanto the hub and remove both the fan and the fan shroud.3. Disconnect the coolant hoses at the radiator. Discon-nect the lines to the oil cooler in the bottom of the radia-tor. Also disconnect these lines at the transmission hous-ing. Put caps on the open lines and ports. Remove thetwo capscrews that still hold the radiator. Remove theradiator.Installation1. Install the radiator with the two capscrews that do notfasten the fan shroud. Connect the lines for transmissionoil to the oil cooler in the radiator. Also connect these3HOOD (See FIGURE 1.)Removal1. Raise the hood. Hold the hood so that it does not falland disconnect the gas controlled spring at the hood.2. Remove the capscrews that hold the hood hinges tothe frame of the lift truck. Remove the hood.Installation1. Install the hood in position on the lift truck. Install thecapscrews that hold the hood hinges to the frame. Con-nect the gas controlled spring to the hood. Adjust the po-lines at the ports in the transmission housing. Connectthe lower coolant hose to the radiator.2. Install the fan and fan shroud in position on the radia-tor. Install the four capscrews that hold the fan shroudand the radiator to the frame. Install the capscrews thatfasten the fan to the hub. Connect the upper coolant hoseat the radiator.OVERHEAD GUARDWARNINGDo not operate the lift truck without the overheadguard correctly fastened to the lift truck.Changes that are made by welding, or by drillingholes that are too big in the wrong location, can re-duce the strength of the overhead guard. See the in-structions for “Changes to the Overhead Guard” inthe PERIODIC MAINTENANCE (8000 SRM 259)section included with this lift truck.Removal and InstallationConnect a crane or lifting device to remove or install theoverhead guard. If the lift truck has an overhead ex-haust, disconnect and remove the exhaust pipe assem-bly. Four bolts hold the overhead guard to the frame. Theoverhead guard is fastened to the cowl and the rearframe plate. Disconnect any electric wires from underthe cowl that go through the legs of the overhead guard.When the overhead guard is lifted from the frame, makesure any electric wires are moved through the holes inthe frame so that they are not damaged.The end of the seat belt must fasten correctly in the latch.Make sure the seat belt pulls from the retractor assemblyand retracts smoothly. The seat belt must be in good con-dition. A seat belt that is damaged or worn will not giveprotection when it is needed. If the seat belt can not bepulled from the retractor assembly, remove the screwthat keeps the cover on the retractor. Push the bar to re-lease the spool. Straighten the belt so that it will pull andretract smoothly from the retractor assembly. SeeFIGURE 3.14231. OPEN COVER2. SEAT BELT RETRACTOR118063. SEAT BELT4. BARFIGURE 3. RELEASE A JAMMED SEAT BELTSee FIGURE 4. Make sure the seat rails and latch strikerare not loose. The seat rails must lock tightly in position,but move freely when unlocked. The seat rails must becorrectly fastened to the mount surface. If the mountsurface is the hood, the hood must be fastened to thefloor plate with the latch. The floor plate must be fas-tened to the lift truck frame. Try to lift the hood to makesure it is fastened correctly and will not move.Adjust the hood, hood latch and latch striker when anyof the parts of the operator restraint system are installedor replaced. See HOOD in this section for the adjust-ment procedures.OPERATOR RESTRAINT SYSTEM(See FIGURE 3. and FIGURE 4.)The seat belt, hip restraint brackets, seat and mount,hood, latches and floor plates are all part of the operatorrestraint system. Each item must be checked to makesure it is fastened correctly, functions correctly and is ingood condition.4118581.2.3.4.5.LATCH STRIKERHOOD LATCHLATCH LEVERSEATSEAT BELT LATCH6.7.8.9.HIP RESTRAINTSEAT RAILFLOOR PLATEHOODFIGURE 4. CHECK THE HOOD AND SEAT LATCHESENGINE REMOVAL AND INSTALLATIONRemoval of the Engine and Transmission1. Do the following steps as described in the paragraphsat the beginning of this section:a.Remove the hood and seat.b.Remove the floor plates and the front panel from3. Put the lift truck on blocks so that you have accessunder the lift truck.4. Drain the engine oil if the engine will be disas-sembled.5. Disconnect the hydraulic lines.Lift trucks with serial codes A177:a.Mazda and Isuzu engines.Disconnect the inletline and the return hose at the main control valve.Disconnect the return hose at the back of the hy-draulic filter and remove the hydraulic filter andplate from the frame. Disconnect the steering re-turn line and the line from the steering relief valveat the hydraulic tank. Disconnect the steeringsupply line at the hydraulic pump and remove theclamp that holds the line. Disconnect the suctionline at the hydraulic pump on the Isuzu engine.On the Mazda engine, disconnect the hose at thetube that is fastened to the flywheel housing. Put aplug in the hose. Move the hose out of the supportbracket on the flywheel housing.Lift trucks with serial codes B177 and C177:a.Mazda and Isuzu engines.Disconnect the inletline and the return hose at the main control valve.5the engine compartment.c.Remove the counterweight. Make sure that youuse the correct procedures to disconnect and re-move an LPG tank.d.Remove the overhead guard. See CAB RE-PLACEMENT in this section if the lift truck has acab.e. Remove the radiator.WARNINGAlways disconnect the cables at the battery beforeyou make repairs to the engine. Disconnect the cableat the negative terminal first.2. Disconnect the cables at the battery.
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