100436, OPR, HYSTER, Hyster2, SRM
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//-->THE FRAMEGENERALThis section has the description and repair proceduresfor the frame and connected parts. Included in this sec-tion are the frame, counterweight, fenders, hood, hy-draulic and fuel tanks, radiator, operator compartmentand cab. The instructions for removal and installation ofthe engine are included in this section.2.H8.00–9.00XL (H165–210XL) units only.Removethe cover (3) and bracket (5) from the counterweight.3. Install lift chains through the radiator grill in the coun-terweight and attach the chains to a lifting device.H13.00–16.00XL (H300–360XL) units.Remove theradiator hardware. Tilt the radiator away from thecounterweight so that there is clearance when the chainsare installed through the counterweight.4. Remove the single capscrew from the rear of thecounterweight. Raise the counterweight approximately300 mm (12 inches). Remove the counterweight fromthe frame. There can be shims between the counter-weight and the counterweight mounts on the frame. Fas-ten the shims to the frame with tape so they can be usedwhen the counterweight is installed.InstallationDESCRIPTIONThe frame is a one piece weldment and has mounts forthe counterweight, fenders, overhead guard, engine,transmission, axles, hydraulic and fuel tanks, operator’scompartment, and other parts.COUNTERWEIGHTWARNINGThe counterweight is heavy. Make sure that thecrane and lifting devices have the capacity to lift4600 kg (10143 lb).Removal (See FIGURE 2.)1. Remove the hood assembly.WARNINGThe counterweight is very heavy. Make sure that thecrane and lifting devices have the capacity to lift4600 kg (10143 lb).1. Put a chain through the opening in the counterweightand attach the chains to a lifting device.34821271.2.3.4.65.6.7.8.512460MAIN FRAME MEMBERMOUNT, CAB SUPPORTCOUNTERWEIGHT MOUNTSTABILIZER BAR, ONH8.00–12.00XL (H165–280XL) ONLYMOUNT, STEERING AXLEMOUNT, DRIVE AXLEMOUNT, MASTMOUNT, TILT CYLINDERSFIGURE 1. FRAME1H8.00–12.00XL(H165–280XL) ONLYTOP VIEW1.2.3.4.5.6.7.8.9.10.11.12.13.14.COUNTERWEIGHTCAPSCREWCOVERNUTBRACKETSIDE COUNTERWEIGHT*CAPSCREWFRAMECOUNTERWEIGHTFENDER, COUNTERWEIGHTCAPSCREW AND WASHERTOW PINCAPSCREW, WASHER AND NUTSHIMSIDE VIEW12461* SIDE COUNTERWEIGHTS (WHEN INSTALLED) ARE WELDED TOFRAME EXCEPT ON H13.00–16.00XL (H300–360XL) UNITS.H13.00–16.00XL (H300–360XL) SHOWNH8.00–12.00XL (H165–280XL) ARE SIMILARFIGURE 2. COUNTERWEIGHT MOUNTSH13.00–16.00XL (H300–360XL) units.Install the ra-diator hardware. Tilt the radiator ahead so there is clear-ance for the chains that are installed through the coun-terweight.2. Install the counterweight on the frame. Install thecapscrew, lockwasher and flat washer to fasten thecounterweight to the frame. Tighten the capscrew to1140 N.m (840 lbf ft).Fenders. Removal1. Remove the capscrews washers and nuts that fastenthe fender to the frame mount. Install eyebolts in themount holes. Use a smaller washer on the bottom side toclear the hole in the fender mount.2. Fasten a lifting device to the eyebolts. Operate the lift-ing device and lift the fender away from the frame.Fenders, Installation1. Install eyebolts in the fenders as described in Re-moval, step 1. Fasten a lifting device to the eyebolts.2. Raise the fender to the lift truck. Align the eyebolts inthe fender with the holes in the fender mount on theframe. Lower the fender to the fender mount, removethe lifting device and the eyebolts.3. Install the capscrews, washers and nuts that hold thefender to the frame. Tighten the nuts to 320 N.m (240 lbfft).WARNINGThe fenders are part of the lift truck counterweightand are very heavy. Make sure any lifting deviceshave the capacity to lift 1 750 kg (3 860 lb). Make surethe fender is balanced and supported by the chain.The fenders are not of a regular shape and can be dif-ficult to handle.2Side CounterweightsH13.00–16.00XL (H330–360XL)The counterweights located on either side of the lifttruck are fastened to the frame by large capscrews. Nor-mally these counterweights will never have to be re-moved or replaced on the lift truck.Side Counterweights, ReplacementIf replacement of the side counterweight is required, dothe following procedure:4. Carefully lift the counterweight away from the lifttruck frame and lower the counterweight to the floor.5. For installation of the side counterweights, follow theabove procedure in reverse order. Tighten the counter-weight capscrews to 655 N.m (485 lbf ft).HOOD AND AIR CLEANERThe hood and air cleaner assembly, which includes thepre–cleaner and inlet pipe, can be removed from theframe as a single unit.2. Remove the nuts, washers and bar washers that fastenthe hood crossmember to the counterweight. Removethe two capscrews from the front of the hood assemblyat the center bracket. These two capscrews are mountedto the cab. Attach a lifting device and sling. Lift the hoodfrom the frame. See FIGURE 3.InstallationInstall the hood and air cleaner assembly in the reverseprocedure of removal and align the hood as necessaryduring installation. Make sure the hood side panels closecompletely and that the cushioned screw stops (bump-ers) are located correctly.Removal1. Raise both hood side panels and disconnect the air in-take hose (9) at the engine. Disconnect the small hose,that goes to the air compressor, at the air cleaner. Ontrucks with a cab, disconnect the hose from the rear win-dow washer.WARNINGThe side counterweights are heavy. Each sidecounterweight weighs approximately 560 kg (1235lb). Make sure that the crane and lifting devices havethe capacity to lift 908 kg (2000 lb).1. Remove the engine. See the paragraph ENGINE andTRANSMISSION in this section for the correct re-moval and installation procedure.2. Remove each counterweight capscrew and replace itin turn with a long stud. The studs must protrude about152 mm (6 in) beyond the counterweight.3. Use a pry bar and carefully move the counterweightaway from the frame about 50 mm (2 in). Install a nylonlifting sling securely around the counterweight and at-tach it to a lifting device.WARNINGMake sure the counterweight is balanced and cannotfall from the sling, when the sling is raised.3121. HOOD, TRANSMISSION –H13.00–16.00XL (H300–360XL) ONLY2. HOOD, ENGINE3. GAS SPRING (2)4. PRE–CLEANER5. AIR INLET PIPE6. SHIM7. AIR RESTRICTION INDICATOR8. AIR CLEANER9. HOSE, AIR INTAKE10. CLAMP11. ENGINE (REFERENCE)12. FRAME, RIGHT SIDE13. HANDLE (2)14. STOP SCREW15. HOOD, RH PANEL16. ROD, HINGE17. CENTER BRACKET18. CAPSCREW19. LOCKWASHER20. SPRING21. SPACER22. WASHER23. CAPSCREW, WASHER AND NUT24. HOOD CROSSMEMBERFIGURE 3. HOOD AND AIR CLEANER ASSEMBLY431451. HYDRAULICTANK2. BATTERY BOX3. FRAME4. SIDE COVER5. NUT AND WASHER52124635FIGURE 4. HYDRAULIC TANK AND BATTERY BOXHYDRAULIC TANKThe hydraulic tank is installed on the right side of theframe between the front and rear fenders.Removal1. Remove the side cover between the bottom of the op-erator compartment and the top of the hydraulic tank. Ifnecessary, remove the drain plug at the bottom of thetank to drain the oil.2. Disconnect the hoses at the top elbow connection andat the side connection to the tank located on the inside ofthe frame. Use a pan to catch the oil that is in the hydrau-lic lines. Put tags on the lines for identification. Put capson the open lines and the fittings.3. Support the fuel tank with blocks from beneath. First,remove the three capscrews that fasten the bottom of thetank to the running board. Remove the three nuts andwashers that hold the top of the tank to the frame. Installtwo lifting eyes at the outer holes. Attach a lifting deviceand support the tank. Lift the tank from the frame.1. Use steam to clean the area around the leak. Removeall paint and dirt around the leak.WARNINGDo not use tools that can make sparks, heat or staticelectricity. The vapors in the tank can cause an ex-plosion.2. Apply LoctiteR 290 to the leak. Follow the instruc-tions of the manufacturer.LARGE LEAKS1. Use one of the procedures described underCleaningto clean and prepare the tank for repairs.2. Use acceptable welding practices to repair the tank.See the American National StandardSafety in Weldingand CuttingANSI Z49.1–1973.CleaningWARNINGSpecial procedures must be followed when largeleaks or other repairs need welding or cutting. Allwork must be done by authorized personnel. If thetank is cleaned inside of a building, make sure thereis enough ventilation. See the following manuals foradditional information:•“Safe Practices For Welding And Cutting Con-tainers That Have Held Combustibles” by the Ameri-can Welding Society, A6.0–65.•“Safety In Welding and Cutting”, American Na-tional Standard, ANSI Z 49.1 – 1973.5WARNINGMake sure that the tank is supported by blocks be-fore removing the nuts and washers from the top ofthe tank.Repairs, All UnitsSMALL LEAKSUse the following procedures to repair small leaks:
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