Hyster F187 (S3.5FT Europe) Forklift Service Repair Manual by 163114103

SERVICE REPAIR S2.0FT S2.5FT S3.0FT S3.5FT Europe [F187]

100 SRM 1120

General

General WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: â&#x20AC;˘ Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. â&#x20AC;˘ 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

1. 2. 3. 4.

COWL PLATE FENDERS FRAME HOOD MOUNTS

that any blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or the section Periodic Maintenance 8000 SRM 1150 for lift truck models S2.0-3.5FT (S40-70FT, S55FTS) (F187) and H2.0-3.5FT (H40-70FT) (L177) or Periodic Maintenance 8000 SRM 1207 for lift truck models S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001). This section contains the description of the frame (see Figure 1) and connected parts. Procedures for removing and installing the counterweight, hood, overhead guard, engine, cooling system, exhaust system, and LPG fuel tank and bracket are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.

5. COUNTERWEIGHT MOUNTS 6. FUEL TANK (GAS OR DIESEL) 7. HYDRAULIC TANK Figure 1. Frame

Hood, Seat, and Side Covers Replacement

100 SRM 1120

Description The frame is one weldment and includes the hydraulic tank and fuel tank for gasoline or diesel fuel. See Figure 1. There is a counterweight for each capacity of lift truck. The counterweights are similar in appearance, but are different weights. See Table 1, Table 2, Table 3, and Table 4. The muffler is fastened to the frame inside the counterweight.

The overhead guard, cowl, and hood are installed on the frame. The hood is connected to the frame with hinges. Two gas-controlled springs provide assistance when raising the hood and hold the hood in the open position. The floor plate and side covers can be removed for access to the engine, transmission, and other components.

Hood, Seat, and Side Covers Replacement REMOVE 1. Slide the seat to the closest position to the steering column. 2. Fully tilt the steering column forward. 3. If your truck is equipped with an LPG tank, swing the tank off to the side. See Figure 8. 4. Raise the latch on the left, front corner of the hood to unlatch and lift up the hood. See Figure 2. 5. Remove the floor mat and floor plate. See Figure 3 and Figure 4. 6. Remove the two capscrews holding the left and right rear side covers to the frame. Remove the rear side covers from the frame. See Figure 3 and Figure 4. 7. Remove the two capscrews holding the left and right fender covers to the front overhead guard leg. Remove covers. See Figure 3 and Figure 4. 8. Remove the four capscrews holding the left and right front side covers to the frame. Remove covers. 9. Fully lower the steering column. 10. Remove upper steering column cover by pulling up on upper steering column cover to release the latches (one on either side), and pulling cover away from steering column. See Figure 5. 11. Remove the five fasteners (see Figure 5) securing the dash to the top of the cowl. Remove the four clips, located underneath dash, that attach the dash to the kick panel. Lift to remove the dash.

12. Lift the kick panel to remove it from the truck. See Figure 3 and Figure 4. 13. Remove the three capscrews holding the seal plate. Remove seal plate. See Figure 6. 14. Disconnect the seat wire harness connector. See Figure 2.

CAUTION When removing the seat from the hood, do not use an impact wrench to remove the capscrews. Damage can be caused to the threads on the screws and in the holes. 15. If the seat is to be removed, and truck is equipped with a non-swivel seat, remove the seat wire harness from the seat wire harness brackets that are attached to the underside of the hood. Remove the cable clips from the seat wire harness. If truck is equipped with a swivel seat, remove seat wire harness from seat wire harness bracket attached to the underside of the hood and behind the seat (see Figure 2). 16. Remove the four capscrews and washers holding the seat to the hood. Lift the seat off the hood. Pull the seat wire harness through the hood. See Figure 2. 17. Remove the capscrews and washers at the top of the gas springs. Remove gas springs from the hood. 18. Remove the hinge screws, located in the rear of the hood. 19. Lift the hood from the truck. See Figure 2.

100 SRM 1120

Hood, Seat, and Side Covers Replacement

NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES. A. SIDE VIEW OF HOOD AND SEAT B. SIDE VIEW OF HOOD

C. BOTTOM VIEW OF HOOD D. SIDE VIEW OF VENTED HOOD WITH SWIVEL SEAT

1. 2. 3. 4. 5.

10. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (SEMI-SUSPENSION) 11. SEAT WIRE HARNESS BRACKETS 12. SEAT LINER 13. HOOD LATCH 14. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (NON-SUSPENSION) 15. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (FULL SUSPENSION) 16. SPACER

6. 7. 8. 9.

SEAT HOOD FRAME SEAT WIRE HARNESS SEAT WIRE HARNESS CONNECTOR (WITHOUT ELECTRONIC CONTROL) SEAT WIRE HARNESS CONNECTOR (WITH ELECTRONIC CONTROL) CABLE CLIPS HINGE SCREWS GAS SPRING

Figure 2. Hood and Seat Arrangement

Hood, Seat, and Side Covers Replacement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

LOWER STEERING COLUMN COVER UPPER STEERING COLUMN COVER INSERT CLIP DASHBOARD CAPSCREW SEAL GROMMET LEFT HAND REAR PANEL FLOOR PLATE LEFT HAND FENDER COVER SCREW NUT

100 SRM 1120

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

LEFT HAND FRONT PANEL LEFT HAND STEP PANEL LEFT HAND TREAD PLATE PLATE ASSEMBLY SEAL RIGHT HAND FENDER COVER FLOOR MAT RIGHT HAND TREAD PLATE RIGHT HAND FRONT PANEL RIGHT HAND STEP PANEL RIGHT HAND REAR PANEL RADIATOR COVER KICK PANEL PLATE ASSEMBLY

Figure 3. Side Cover, Floor Plate, and Cowl Components, Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001), and S30FT, S35FT, S40FTS (E010)

100 SRM 1120

Hood, Seat, and Side Covers Replacement

Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)

Hood, Seat, and Side Covers Replacement

100 SRM 1120

Legend for Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

DASH ASSEMBLY UPPER STEERING COLUMN COVER LOWER STEERING COLUMN COVER KICK PANEL MUD GUARD (LH) MUD GUARD (RH) LOCK NUT NUT COVER BRACKET PLATE ASSEMBLY GROMMET LEFT FRONT PANEL RIGHT FRONT PANEL

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

LEFT STEP PANEL RIGHT STEP PANEL LEFT STEP PLATE RIGHT STEP PLATE LEFT REAR PANEL RIGHT REAR PANEL FLOOR MAT FLOOR PLATE RADIATOR COVER SEALS CAPSCREW CLIP NUT INSERT PLATE ASSEMBLY SEAL

NOTE: TOP VIEW OF DASH SHOWN. A. INDICATES TO PULL UP TO UNLATCH 1. ALLEN SCREWS 2. COWL

3. UPPER STEERING COLUMN COVER 4. LOWER STEERING COLUMN COVER Figure 5. Remove Dash From Cowl

100 SRM 1120

Hood, Seat, and Side Covers Replacement

1. CAPSCREWS

2. SEAL PLATE Figure 6. Remove Seal Plate From Dash

INSTALL 1. Place the hood onto the lift truck frame. 2. Install the hinge screws, located in the rear of the hood, and tighten to 38 Nâ&#x20AC;˘m (28 lbf ft). See Figure 2. 3. Align the top holes in the gas springs with holes in the hood. Install capscrews and washers to attach gas springs to the hood. Tighten capscrews to 19.2 Nâ&#x20AC;˘m (170 lbf in).

4. Install latch striker in highest slot position. Check that latch striker is in center of jaws of hood latch when hood closes. Open and close the hood to ensure that the center pin strikes the hood latch properly and that the stop screw contacts the frame. A properly closed hood MUST click twice on the hood latch. If the hood latch does not close properly, loosen the capscrews on the back of the center pin and adjust the center pin up or down as required for correct alignment. See Figure 7.

Hood, Seat, and Side Covers Replacement

100 SRM 1120

CAUTION When installing the seat to the hood, do not use an impact wrench to install the capscrews. Damage can be caused to the threads on the screws and in the holes. 7. Place the seat on the hood and thread the seat wire harness through the hole in the hood. See Figure 2. 8. Align the holes in the seat with the holes in the hood. Insert washers and capscrews. Tighten capscrews to 18 Nâ&#x20AC;˘m (159 lbf in). 9. If truck is equipped with a non-swivel seat, tie cable clips to seat wire harness and insert harness into seat wire harness brackets under hood. If truck is equipped with a swivel seat, secure seat harness to bracket. See Figure 2. 10. Install seal plate using three capscrews. See Figure 6. 11. Install kick panel onto truck. See Figure 3 and Figure 4. 12. Install dash to top of cowl. See Figure 5. Install four clips to attach the dash to kick panel. 13. Install upper steering column cover to dash. 1. HOOD 2. HOOD LATCH

3. CENTER PIN 4. CAPSCREW

Figure 7. Hood Latch Adjustment 5. Push down until hood just touches rubber bumper. Make sure latch striker is still in center of hood latch. Open hood and tighten capscrews for latch. 6. Check operation of hood latch. Have an operator sit in the seat. Make sure hood is fully closed (two clicks). Also check that hood touches rubber bumper. If necessary, repeat Step 5.

14. Using four capscrews, install the left and right front side covers to frame. See Figure 3 and Figure 4. 15. Using two capscrews, install the left and right fender covers to front of overhead guard legs. 16. Using two capscrews, install the left and right rear side covers to frame. See Figure 3 and Figure 4. 17. Install the floor mat and floor plate. 18. If truck is equipped with an LPG tank, swing LPG tank into position on back of counterweight. See Figure 8. 19. Adjust the steering column and seat positions.

100 SRM 1120

LPG Tank and Bracket Replacement

LPG Tank and Bracket Replacement REMOVE LPG Tank WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source. Close the shutoff valve on the LPG tank before any part of the engine fuel system is disconnected. Run the engine until the fuel in the system is used and the engine stops. If the engine will not run, close the shutoff valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit. Permit the pressure in the fuel system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

two styles. One style of bracket swings out to the side of the truck and the other swings out to the side and drops down (EZXchangeâ&#x201E;˘ bracket). See Figure 8. 1. Turn the shutoff valve clockwise until the valve is completely closed. 2. Run the engine until it stops. If truck is equipped with a key switch, turn the key switch to the OFF position. If truck is equipped with a Power ON/OFF button, press the Power ON/OFF button to turn engine off. 3. Disconnect the fitting on the LPG tank. See Figure 8. 4. Push in the bracket release pin, swing the tank and bracket out to the side of the lift truck. If your truck is equipped with a swing-out and drop-down LPG tank bracket (EZXchange bracket), swing the tank down to the side of the truck for ease of removal. See Figure 8. 5. Unlatch the tank strap and remove the LPG tank from the bracket.

NOTE: The LPG tank bracket used on these trucks to mount the LPG tank onto the counterweight come in

LPG Tank and Bracket Replacement

100 SRM 1120

A. SWING-OUT LPG BRACKET

B. SWING-OUT AND DROP-DOWN LPG BRACKET (EZXCHANGE BRACKET)

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11.

LPG TANK TANK STRAP FITTING HYDROSTATIC RELIEF VALVE MANIFOLD BLOCK ALIGNMENT PIN

STOP PIN BRACKET HANDLE BRACKET PIVOT GAS SPRING (DROP-DOWN BRACKET ONLY) BRACKET RELEASE PIN (BUTTON)

Figure 8. LPG Tank and Bracket

100 SRM 1120

LPG Tank and Bracket Replacement

A. LPG REGULATOR USED ON GM 2.4L ENGINE FUEL SYSTEMS

B. LPG REGULATOR USED ON MAZDA 2.0L AND 2.2L ENGINE FUEL SYSTEMS

1. 2. 3. 4.

5. HOSE ASSEMBLY TO LPG REGULATOR/LOCK-OFF 6. LPG REGULATOR CONNECTION 7. LPG REGULATOR

FITTING HOSE ASSEMBLY CAPSCREW LPG TANK

Figure 9. LPG Tank Hose Connections (Except 2007 Mazda Emission Compliant Engines)

LPG Tank and Bracket Replacement

LPG Bracket NOTE: The LPG tank must be removed from the lift truck before removing the LPG bracket. See LPG Tank. 1. For all engines except 2007 Mazda emission compliant engines - Disconnect the hose from the LPG fuel lock-off connection on the LPG regulator, and remove hose through hole in counterweight. See Figure 9. 2. 2007 Mazda emission compliant engines only - Disconnect the hose from the LPG fuel filter and remove hose through hole in counterweight. See Figure 10.

100 SRM 1120

WARNING When removing the capscrews for the LPG tank bracket, only remove the capscrew (1, Figure 11) with the LPG bracket in the swing-out or extended position. The LPG tank bracket is heavy and difficult to handle if all the capscrews are removed with the bracket in the swing-out position. Personal injury and damage to the lift truck can result if the bracket is removed and handled while in the swing-out or extended position. 3. Push in the bracket release pin, grab the bracket handle, and swing the bracket out to the side of the lift truck. Remove the capscrew (1, Figure 11). 4. Pull the bracket stop pin and swing the LPG tank bracket back into the resting position on the counterweight. Be sure that the latch clicks shut and locks. 5. Remove the rest of the capscrews, labeled (2, Figure 11), that attach the LPG bracket to the counterweight. 6. Remove the LPG tank bracket from the lift truck.

INSTALL LPG Bracket 1. For all engines except 2007 Mazda emission compliant engines - Place the LPG bracket onto the counterweight. Be sure to align the holes on the counterweight with the holes on the bracket (see Figure 11). Insert hose assembly to LPG regulator/lock-off through the hole in counterweight. 1. 2. 3. 4. 5. 6. 7. 8. 9.

FITTING HOSE ASSEMBLY CAPSCREW LPG TANK HOSE ASSEMBLY TO LPG FUEL FILTER LPG FUEL FILTER CONNECTION HOSE ASSEMBLY TO LPG REGULATOR LPG FUEL FILTER LOW PRESSURE SWITCH

Figure 10. LPG Tank Hose Connections (2007 Mazda Emission Compliant Engines Only)

2. 2007 Mazda emission compliant engines only - Place the LPG bracket onto the counterweight. Be sure to align the holes on the counterweight with the holes on the bracket (see Figure 11). Insert hose assembly to LPG fuel filter through the hole in counterweight. 3. Install and tighten three capscrews (2, Figure 11) to 38 Nâ&#x20AC;˘m (28 lbf ft) to secure the LPG bracket onto the counterweight.

100 SRM 1120

LPG Tank and Bracket Replacement strap can close quickly and with enough force to cause injury to the fingers and hand. 1. Place the LPG tank into the bracket. Be sure the alignment pin on the bracket (see Figure 8) is properly aligned with the hole on the tank. Secure the tank strap around the tank and close the strap. 2. If lift truck is equipped with the swing-out and drop-down bracket (EZXchange bracket) raise bracket to the up position. 3. Pull the stop pin (see Figure 8) and swing the LPG tank bracket into the resting position on the counterweight. Be sure that the bracket locks into position. 4. For all engines except 2007 Mazda emission compliant engines - Connect the hose to the LPG fuel lock-off connection on the LPG regulator. See Figure 9. 5. 2007 Mazda emission compliant engines only - Connect the hose to the LPG fuel filter. See Figure 10.

A. LPG BRACKET - SWING OUT OPTION B. LPG BRACKET - SWING OUT AND DROP DOWN OPTION (EZXCHANGE BRACKET) 1. CAPSCREW - REMOVE WITH BRACKET IN SWING OUT (EXTENDED) POSITION 2. CAPSCREW - REMOVE WITH BRACKET IN RESTING POSITION ON COUNTERWEIGHT. Figure 11. LPG Tank Bracket Removal 4. Push the bracket release pin (button) and pull the bracket handle to swing the bracket out to the side of the lift truck. Install and tighten the capscrew (1, Figure 11) to 38 Nâ&#x20AC;˘m (28 lbf ft).

LPG Tank NOTE: The LPG bracket must be in the swing-out position to install the LPG tank. If your lift truck has the swing-out and drop-down bracket (EZXchange bracket), position the bracket in the drop-down position.

WARNING

6. Connect the fitting on the LPG tank. See Figure 8. 7. Turn the fuel valve counterclockwise to open the fuel valve. 8. Inspect the fuel system for leaks when the fuel valve is open. There are four methods used to inspect the LPG fuel system for leaks: a. Sound - Listen for sound of LPG escaping from a tank fitting or hose connection. b. Smell - LPG has a very distinctive odor. If you smell LPG, DO NOT start the engine. c. Soapy Water - This method is used in conjunction with Step b above. If the odor of LPG is present, but escaping fuel cannot be heard, apply soapy water to the fittings and observe for bubbles. d. Frost - If the amount of LPG escaping is sufficient, frost may appear on the fittings.

When closing the LPG tank strap, do not wrap your fingers around the strap handle. The

Counterweight Replacement

100 SRM 1120

Counterweight Replacement 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 counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. • 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. See the Operating Manual or the section Periodic Maintenance 8000 SRM 1150 for lift truck models S2.0-3.5FT (S40-70FT, S55FTS) (F187) and H2.0-3.5FT (H40-70FT) (L177) and Periodic Maintenance 8000 SRM 1207 for lift truck models S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001).

WARNING Do not operate the lift truck if the capscrew for the counterweight is not installed. When the capscrew is removed, the counterweight can fall from the lift truck.

enters the filter unit. Permit the pressure in the fuel system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting. NOTE: The counterweight is held in position on the frame by two hooks that are part of the frame. One M24 × 3 x 140 capscrew holds the counterweight to the lower part of the frame on lift truck models S3.0-3.5FT (S60-70FT) (F187) and H2.5-3.5FT (H50-70FT) (L177). One M24 × 3 x 90 capscrew holds the counterweight to the lower part of the frame on lift truck models S2.0-2.5FT (S40-50FT, S55FTS) (F187), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001), S30FT, S35FT, S40FTS (E010), and H2.0FT (H40FT) (L177). See Figure 12. NOTE: If lift truck is equipped with an overhead exhaust system, remove the overhead exhaust pipe before removing the counterweight. See the section Exhaust System Repair for the procedures. 1. If the lift truck has an LPG fuel system, use the procedures in the section LPG Tank and Bracket Replacement, to remove the LPG tank and bracket so that the counterweight can be removed. Additional information on the LPG fuel system can be found in the following sections: • LPG Fuel System, GM 2.4L Engine 900 SRM 1124 • LPG Fuel System, Mazda 2.0L and 2.2L Engines 900 SRM 1125 • LPG Fuel System, Mazda 2.0L and 2.2L 2007 Emission Compliant Engines 900 SRM 1326

WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source. Close the shutoff valve on the LPG tank before any part of the engine fuel system is disconnected. Run the engine until the fuel in the system is used and the engine stops. If the engine will not run, close the shutoff valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it

WARNING The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough capacity to lift the weight. The approximate weights of the counterweight castings are shown in Table 1, Table 2, Table 3, and Table 4. 2. Install a lifting eye in the lift hole of the counterweight. See Figure 12 and Figure 13. Connect a crane to the lifting eye and raise the crane until it holds part of the weight of the counterweight. Remove the tow pin and remove the capscrew that holds the counterweight to the frame. See Figure 12. Use the crane to lift the counterweight from the lift truck. Put counterweight on

100 SRM 1120

Counterweight Replacement

the floor so that it has stability and will not fall over. Take care not to damage exhaust or cooling components.

INSTALL 1. Make sure the seals are on the counterweight. See Figure 13. Use a crane to install the counterweight on the lift truck. When the counterweight is installed, make sure the hooks on the frame fully engage the counterweight so it is aligned with the parts of the frame. Install and tighten the M24 × 3 capscrew to 555 N•m (409 lbf ft). 2. Install tow pin and roll pin, see Tow Pin, Remove and Install for procedures. 3. If the lift truck has an LPG fuel system, use the procedures in the section LPG Tank and Bracket Replacement, to install the LPG tank and bracket after the counterweight has been installed. See Figure 8.

Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187) Model

S2.0FT (S40FT)

1040

2293

S2.5FT (S50FT)

1395

3075

S55FTS

1643

3622

S3.0FT (S60FT)

1819

4010

S3.5FT (S70FT)

2153

4747

Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35FT, S40FTS (E010) Model

(S30FT)

772

1702

(S35FT)

963

2123

S40FTS

1131

2493

Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) Model

H1.6FT (H30FT)

812

1790

H1.8FT (H35FT)

887

1955

H2.0FTS (H40FTS)

1047

2308

Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)

1. FRAME HOOK 2. LOWER FRAME MOUNT 3. TOW PIN

4. 5. 6. 7.

Model

H2.0FT (H40FT)

996

2196

H2.5FT (H50FT)

1340

2954

H3.0FTS (H60FTS)

1666

3673

H3.5FTS (H70FTS)

1967

4336

ROLL PIN CAPSCREW WASHERS LIFT HOLE

Figure 12. Counterweight Installation

Overhead Guard Replacement

100 SRM 1120 the section Exhaust System Repair for the procedures.

TOW PIN, REMOVE AND INSTALL 1. Remove the tow pin from the counterweight by driving the roll pin out. See Figure 14. 2. Install tow pin into counterweight and install roll pin.

1. 2. 3. 4. 5.

CAPSCREW LOCKWASHER WASHER COUNTERWEIGHT LIFTING EYEBOLT

6. 7. 8. 9. 10.

TOW PIN ROLL PIN SEAL LIFT HOLE LPG ACCESS HOLE

Figure 13. Counterweight 4. If lift truck is equipped with an overhead exhaust system, install the overhead exhaust pipe. See

1. TOW PIN

2. ROLL PIN Figure 14. Tow Pin

Overhead Guard Replacement REMOVE AND INSTALL WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.

WARNING DO NOT weld mounts for lights or accessories to legs of the overhead guard. Changes that are made by welding, or by drilling holes that are too big or in the wrong location, can reduce the strength of the overhead guard. See your dealer for Hyster lift trucks BEFORE performing any changes to the overhead guard.

NOTE: The lift trucks covered in this SRM are equipped with either a high or low overhead guard. The removal and installation procedures for both types of overhead guards are the same. No welding or drilling on legs of overhead guard is permitted as per previous WARNING. NOTE: The lifting device can be connected to any number of positions on the overhead guard depending upon the lifting device available. The ideal choices are a four point sling connected to all four corners on the top of the overhead guard, or a two point sling connected to two opposite corners of the overhead guard. If a single point hoist is used, make sure that the lift point is as close to the center of the overhead guard. If during the initial start of the lift

100 SRM 1120

Overhead Guard Replacement

the overhead guard is off balance lower immediately and move the hoist to a more centered point. 1. Connect a lifting device to remove or install the overhead guard. Loosen clamp and disconnect the air intake hose from the elbow. Remove bolts, elbow, retainer, and grommet from the overhead guard rear leg. See Figure 15.

1. CLAMP 2. AIR INTAKE HOSE 3. BOLTS

4. ELBOW 5. RETAINER 6. GROMMET

Figure 15. Disconnect Air Intake Hose 2. Disconnect any wires between the frame and the overhead guard. When the overhead guard is lifted from the frame, make sure that any electrical wires are moved through the holes in the frame so that they are not damaged. 3. The rear legs of the overhead guard have two capscrews that are located under the hood inside the engine compartment, next to the radiator. Remove and install the capscrews. See Figure 16.

4. Remove the fender cover, dash, and kick panel to remove and install the three capscrews on the front legs of the overhead guard. See Hood, Seat, and Side Covers Replacement for the removal procedures. 5. When installing the overhead guard, tighten the capscrews for the overhead guard legs to 66 Nâ&#x20AC;˘m (49 lbf ft). See Figure 16.

1. 2. 3. 4.

CAPSCREWS - FRONT LEGS HANDLE CAPSCREWS - REAR LEGS FRAME Figure 16. Overhead Guard

LED TAIL, BACKUP, AND BRAKE LIGHTS, REPLACE These light assemblies are nonrepairable and must be replaced as an assembly. See the section Electrical System 2200 SRM 1142 for the procedures to replace these lights.

Operator Restraint System Replacement

100 SRM 1120

Operator Restraint System Replacement DESCRIPTION The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition. See Figure 17.

Automatic Locking Retractor (ALR) NOTE: S2.0-3.5FT (S40-70FT, S55FTS) lift trucks produced before November 2005 are equipped with the ALR type seat belts. The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced. See Figure 17.

Emergency Locking Retractor (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt. When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat. A seat belt that is damaged worn or does not operate properly will not give protection when it is needed. The end of the belt must fasten correctly in the latch.

The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 17. The following seat belt operation checks must be performed: • With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. if the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly. • With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly. • With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly. Make sure the seat rails and latch striker are not loose. The seat rails must lock securely in position but move freely when unlocked. The seat rails must be securely attached to the mounting surface. The hood must be fully closed. Lift the hood to make sure it is closed and will not move. Adjust hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or replaced. See the section Hood, Seat, and Side Covers Replacement in this manual for the adjustment procedures for the hood.

100 SRM 1120

Engine Replacement

A. AUTOMATIC LOCKING RETRACTOR

B. EMERGENCY LOCKING RETRACTOR

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11.

LATCH STRIKER HOOD LATCH FORWARD/BACKWARD ADJUSTMENT HOOD OPERATOR WEIGHT ADJUSTMENT SEAT RAIL

ARM REST SEAT BELT SEAT HIP RESTRAINT HOOD HINGE

Figure 17. Operator Restraint System

Engine Replacement REMOVE ENGINE ONLY WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. • 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. See the Operating Manual or the section Periodic Maintenance 8000 SRM 1150 for lift truck models S2.0-3.5FT (S40-70FT, S55FTS) (F187) and H2.0-3.5FT (H40-70FT) (L177) and Periodic Maintenance 8000 SRM 1207 for lift truck models S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001). The engine can be removed with or without the transmission. Follow the procedures below to remove the engine without the transmission.

Engine Replacement

WARNING Always disconnect the cables at the battery before you make repairs to the engine. Disconnect the cable at the negative terminal first.

100 SRM 1120 holding ECM and mounting bracket to air filter, before removing the air filter. 8. Disconnect the ground strap from the frame and remove the power distribution module (PDM) from the battery tray. See Figure 18. 9. Remove three capscrews from the battery tray and remove the battery and battery tray.

1. For lift trucks equipped with an LPG fuel system, close the shut-off valve on the tank and run engine until all fuel is gone and engine stops. 2. If lift truck is equipped with an LPG fuel tank, swing tank to the side. See the section LPG Tank and Bracket Replacement, for the procedures. 3. Remove the floor mat and floor plate.

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 4. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under radiator. Remove radiator cap. NOTE: Disposal of lubricants and fluids must meet local environmental regulations. 5. Open the drain plug or disconnect the bottom radiator hose to drain coolant from radiator and engine. 6. Remove the hood and seat combination and rear side covers. See the section Hood, Seat, and Side Covers Replacement for procedures. NOTE: Trucks equipped with a Yanmar diesel engine do not have an ECM. 7. On lift trucks with the GM 2.4L engine, disconnect the ECM from air filter and remove two bolts

1. BATTERY 2. BATTERY TRAY 3. PDM

4. BATTERY LOCKDOWN BAR 5. GROUND STRAP

Figure 18. Power Distribution Module, Disconnection 10. Disconnect the remaining coolant hoses from the radiator and cap them to prevent leakage. 11. On lift trucks equipped with a Mazda engine (except Mazda 2007 emission compliant engines) and Basic Powershift Transmission, disconnect the throttle linkage (see the section Powershift Transmission, Repair 1300 SRM 1129). Disconnect the exhaust system. 12. Remove the radiator fan pulley, shroud, and fan assembly. See the section Cooling System 700 SRM 1123 for the removal procedures.

100 SRM 1120

WARNING All fuels are very flammable and can burn or cause an explosion. Do not use an open flame to check the fuel level or to check for leaks in the fuel system.

Engine Replacement engine adapter to transmission bolts. On trucks equipped with a GM 2.4L engine, remove one starter bolt.

No smoking. Breathing fuel vapor may cause nausea, unconsciousness or death. Long term exposure to gasoline vapors may cause liver or kidney damage and cancer. Avoid breathing vapor. 13. Disconnect the fuel lines at the engine. Put caps on fuel lines to prevent fuel leakage. NOTE: Lift trucks equipped with Yanmar diesel engine do not have an ECM. NOTE: Lift trucks equipped with 2007 Mazda emission compliant engines do not have a governor controller and the ECM for these engines is mounted on the side of the engine. 14. For all Mazda engines except 2007 Mazda emission compliant engines - Disconnect the electronic control module (ECM) connector and governor controller from the side of the frame before removing the engine from the truck. 15. 2007 Mazda emission compliant engines only - Disconnect the engine harness connectors from the right hand chassis harness connectors before removing the engine from the truck. 16. Use the access port on the side of engine and remove the four bolts that attach the flywheel to the torque converter. See Figure 19. 17. Connect a lifting device to the engine. Put a block under the transmission housing to support the transmission. 18. Remove capscrews from transmission bell housing.

WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 363 kg (800 lb).

NOTE: ACCESS PORT IN SIMILAR POSITION ON MAZDA. 1. ACCESS PORT 2. ENGINE MOUNTING BRACKET AND HARDWARE Figure 19. Yanmar Diesel Engine Removal Access Port

CAUTION When separating the engine away from the transmission, place a piece of plywood in front of radiator. This will keep the engine from damaging the radiator.

CAUTION Keep the engine level when the engine is separated from the transmission so the drive plate is not damaged. 20. Use the lifting device to carefully move the engine away from the torque converter. Make sure all hoses, wires, and cables are disconnected from the engine, then lift the engine from the frame and place engine on blocks. See Figure 20 and Figure 21.

19. Remove the flange nuts, washers, bolts, and isolators from the engine mounts. Remove

Engine Replacement

100 SRM 1120

A. MAZDA ENGINE

B. GM 2.4L ENGINE

1. FRAME 2. ENGINE MOUNT

3. NUT

Figure 20. Engine Removal

A. MAZDA AND YANMAR ENGINE MOUNT B. GM ENGINE MOUNT 1. 2. 3. 4. 5. 6. 7.

LEFT ENGINE MOUNT RIGHT ENGINE MOUNT WASHER CAPSCREW CROSSMEMBER ISOLATOR NUT Figure 21. Engine Mounts

100 SRM 1120

REMOVE ENGINE AND TRANSMISSION

Engine Replacement tank fitting. Remove the supply line from hydraulic pump to the main control valve.

WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: â&#x20AC;˘ Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. â&#x20AC;˘ 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. See the Operating Manual or the section Periodic Maintenance 8000 SRM 1150 for lift truck models S2.0-3.5FT (S40-70FT, S55FTS) (F187) and H2.0-3.5FT (H40-70FT) (L177) and Periodic Maintenance 8000 SRM 1207 for lift truck models S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001). for procedures on putting lift truck on blocks. The engine can be removed with or without the transmission. Follow the procedures below to remove the engine with the transmission. 1. Perform Step 1 through Step 13 from the section Remove Engine Only. 2. Remove the seal plate for the brake and throttle pedals. See Figure 6. NOTE: When disconnecting wiring harness connectors during removal, tag each connector to aid in connecting wiring harness during installation. 3. Disconnect the engine wiring harness from transmission wiring harness. Disconnect transmission cooling lines.

WARNING The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb). 5. Connect a lifting device to support the transmission and engine combination. 6. Remove the capscrews that hold the transmission mount to the transmission. NOTE: Lift trucks equipped with 2007 Mazda emission compliant engines do not have a governor controller and the ECM for these engines is mounted on the side of the engine. 7. For all Mazda engines except 2007 Mazda emission compliant engines - Disconnect the electronic control module (ECM) connector and governor controller from the side of the frame before removing the engine from the truck. 8. 2007 Mazda emission compliant engines only - Disconnect the engine harness connectors from the right hand chassis harness connectors before removing the engine from the truck. 9. Make sure the engine and transmission assembly can be raised at an angle so they will clear the frame. Remove the nuts and bolts from the engine mounts (see Figure 19 and Figure 21). Use the lifting device to carefully lift the engine and transmission from the frame. Slip the transmission output yoke out of the transmission. Make sure to not damage the seal.

INSTALL ENGINE ONLY The engine can be installed with or without the transmission. Follow the procedures below to install the engine without the transmission. 1. On trucks equipped with a GM 2.4L engine, install starter bolt.

4. Remove the hydraulic hose between the hydraulic pump and the tank. Put a cap on the

Engine Replacement

WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 340 kg (750 lb).

CAUTION Keep the engine level when installing the engine to the transmission so the drive plate is not damaged. 2. Connect lifting device to engine and lift engine into frame. Install engine to transmission. 3. If isolators fell from engine mounts during removal, install isolators to engine mounts. Install the nuts and bolts for the engine mounts to secure engine to frame. See Figure 20 and Figure 21. Tighten the nuts to 150 N•m (110 lbf ft). 4. Use access port on side of engine and install bolts to hold torque converter to flywheel. Tighten bolt to 56 N•m (41 lbf ft). See Figure 19. 5. Align torque converter housing holes with flywheel housing holes and install bolts. Tighten bolts to 38 N•m (28 lbf ft). 6. Install exhaust pipe to exhaust manifold. 7. Connect the ECM connector and governor controller to lift truck frame.

WARNING All fuels are very flammable and can burn or cause an explosion. Do not use an open flame to check the fuel level or to check for leaks in the fuel system. No smoking. Breathing fuel vapor may cause nausea, unconsciousness or death. Long term exposure to gasoline vapors may cause liver or kidney damage and cancer. Avoid breathing vapor. 8. Connect the wires and wiring harnesses at the engine. Remove caps from fuel lines and connect the fuel lines at the engine. NOTE: On trucks equipped with the GM 2.4L engine, connect the ECM and install ECM and mounting bracket to air filter with two bolts, before installing the air filter to lift truck.

100 SRM 1120 9. On lift trucks equipped with a Mazda engine (except Mazda 2007 emission compliant engines) and Basic Powershift Transmission, connect the throttle linkage (see the section Powershift Transmission, Repair 1300 SRM 1129). Install the air filter assembly. 10. Connect the coolant hoses and lines to the transmission. Fill cooling system with a mixture of 50 percent water and 50 percent ethylene glycol boron-free antifreeze. 11. Install the radiator shroud, fan pulley, and fan assembly. See the section Cooling System 700 SRM 1123 for the installation procedures. 12. Connect the PDM and connect the ground strap to lift truck frame and attach it to battery. Install the battery and battery tray. If lift truck is equipped with an LPG tank, swing tank into position on truck. See the section LPG Tank and Bracket Replacement, for the procedures. 13. Install the rear side covers, floor plates, and hood and seat combination. See the section Hood, Seat, and Side Covers Replacement for the procedures. 14. Check all fluid levels as described in the section Periodic Maintenance 8000 SRM 1150 for lift truck models S2.0-3.5FT (S40-70FT, S55FTS) (F187) and H2.0-3.5FT (H40-70FT) (L177) and Periodic Maintenance 8000 SRM 1207 for lift truck models S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001).

INSTALL ENGINE AND TRANSMISSION The engine can be installed with or without the transmission. Follow the procedures below to install the engine with the transmission.

WARNING The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb). 1. For all engines except 2007 Mazda emission compliant engines - Connect the ECM connector and governor controller before installing the engine on the truck.

100 SRM 1120

Throttle Pedal and Cable Adjustment

2. Using a lifting device, install the engine and transmission into lift truck frame. 3. Install the transmission output yoke onto the transmission. Be sure to not damage the seal. Tighten bolt to 38 N•m (28 lbf ft). 4. Install the nuts and bolts for the engine mounts (see Figure 20 and Figure 21) and transmission mount. Use a maximum of three shims to ensure that the engine is properly set on the mounts. Tighten the nuts to 150 N•m (110 lbf ft).

6. Install the hydraulic hose between the pump and the tank. Install the hydraulic filter and hoses. Connect the supply line to the main control valve. 7. Connect the transmission wiring harness to transmission. Connect transmission cooling lines. 8. Install the seal plate for the brake and throttle pedals. See Figure 6. 9. Perform Step 8 through Step 14 from section Install Engine Only.

5. Remove lifting device from the engine and transmission.

Throttle Pedal and Cable Adjustment NOTE: There are no throttle pedal and cable adjustments for lift trucks equipped with the GM 2.4L engine. The GM 2.4L engine has an electronic throttle that is self-adjusting and self-calibrating. NOTE: For the Mazda 2007 emission compliant engines, there is only a throttle pedal stop adjustment. The engine has an electronic throttle that is self-adjusting and self-calibrating.

MAZDA GAS/LPG ENGINES WITH BASIC POWER SHIFT TRANSMISSION AND MAZDA LPG ENGINE WITH ELECTRONIC TRANSMISSION (EXCEPT MAZDA EMISSION COMPLIANT ENGINES) 1. Remove floor plate and disconnect throttle cable from the bellcrank and engine. See Figure 22. 2. Fully depress throttle pedal and verify that the dimension between the bellcrank and cowl plate is 6 ±2 mm (0.24 ±0.08 in.). 3. If dimension is not correct, adjust ball ends on push rod so that a minimum of 6 mm (0.24 in.) of threaded rod screws into each ball end.

4. Connect throttle cable to bellcrank and engine. See Figure 22. 5. With throttle pedal in full up position, adjust throttle cable, using the jam nuts (item #10 in Figure 22) to remove all slack from the cable. Cable should be adjusted to the point where additional adjustment will pull the throttle crank off the idle stop. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in). NOTE: If lift truck is equipped with a Electronic Control Transmission, see the section Calibration Procedures 8000 SRM 1134 for additional adjustment procedures before going onto Step 7. 6. Fully depress pedal and verify that full pedal stroke brings the throttle crank to within 3.0 mm (0.12 in.) of the wide open throttle stop. See Figure 22. 7. Install floor plate. Fully depress throttle pedal and adjust pedal stop so that it touches floor plate. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in) (item #12 in Figure 22).

Throttle Pedal and Cable Adjustment

100 SRM 1120

Figure 22. Throttle Pedal and Cable Adjustment; Mazda Gas/LPG Engines With Basic Power Shift Transmission, and Mazda LPG Engine With Electronic Transmission

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