THE FRAME
GENERAL
This section has the description and repair procedures for the frame and connected parts. Included in this section are the frame, counterweight, fenders, hood, hydraulic and fuel tanks, radiator, operator compartment and cab. The instructions for removal and installation of the engine are included in this section.
DESCRIPTION
The frame is a one piece weldment and has mounts for the counterweight, fenders, overhead guard, engine, transmission, axles, hydraulic and fuel tanks, operator’s compartment, and other parts.
COUNTERWEIGHT WARNING
The counterweight is heavy. Make sure that the crane and lifting devices have the capacity to lift 4600 kg (10143 lb).
Removal (See FIGURE 2.)
1. Remove the hood assembly.
2. H8.00–9.00XL (H165–210XL) units only. Remove the cover (3) and bracket (5) from the counterweight.
3. Install lift chains through the radiator grill in the counterweight and attach the chains to a lifting device. H13.00–16.00XL (H300–360XL) units. Remove the radiator hardware. Tilt the radiator away from the counterweight so that there is clearance when the chains are installed through the counterweight.
4. Remove the single capscrew from the rear of the counterweight. Raise the counterweight approximately 300 mm (12 inches). Remove the counterweight from the frame. There can be shims between the counterweight and the counterweight mounts on the frame. Fasten the shims to the frame with tape so they can be used when the counterweight is installed.
Installation
WARNING
The counterweight is very heavy. Make sure that the crane and lifting devices have the capacity to lift 4600 kg (10143 lb).
1. Put a chain through the opening in the counterweight and attach the chains to a lifting device.
1.MAIN FRAME MEMBER
AXLE
AXLE
H8.00–12.00XL (H165–280XL) ONLY
* SIDE COUNTERWEIGHTS (WHEN INSTALLED) ARE WELDED TO FRAME EXCEPT ON H13.00–16.00XL (H300–360XL) UNITS.
H13.00–16.00XL (H300–360XL) units. Install the radiator hardware. Tilt the radiator ahead so there is clearance for the chains that are installed through the counterweight.
2. Install the counterweight on the frame. Install the capscrew, lockwasher and flat washer to fasten the counterweight to the frame. Tighten the capscrew to 1140 N.m (840 lbf ft).
Fenders. Removal
WARNING
The fenders are part of the lift truck counterweight and are very heavy. Make sure any lifting devices have the capacity to lift 1 750 kg (3 860 lb). Make sure the fender is balanced and supported by the chain. The fenders are not of a regular shape and can be difficult to handle.
H13.00–16.00XL (H300–360XL) SHOWN H8.00–12.00XL (H165–280XL) ARE SIMILAR
1. Remove the capscrews washers and nuts that fasten the fender to the frame mount. Install eyebolts in the mount holes. Use a smaller washer on the bottom side to clear the hole in the fender mount.
2. Fasten a lifting device to the eyebolts. Operate the lifting device and lift the fender away from the frame.
Fenders, Installation
1. Install eyebolts in the fenders as described in Removal, step 1. Fasten a lifting device to the eyebolts.
2. Raise the fender to the lift truck. Align the eyebolts in the fender with the holes in the fender mount on the frame. Lower the fender to the fender mount, remove the lifting device and the eyebolts.
3. Install the capscrews, washers and nuts that hold the fender to the frame. Tighten the nuts to 320 N.m (240 lbf ft).
Side Counterweights
H13.00–16.00XL
(H330–360XL)
The counterweights located on either side of the lift truck are fastened to the frame by large capscrews. Normally these counterweights will never have to be removed or replaced on the lift truck.
Side Counterweights, Replacement
If replacement of the side counterweight is required, do the following procedure:
WARNING
The side counterweights are heavy. Each side counterweight weighs approximately 560 kg (1235 lb). Make sure that the crane and lifting devices have the capacity to lift 908 kg (2000 lb).
1. Remove the engine. See the paragraph ENGINE and TRANSMISSION in this section for the correct removal and installation procedure.
2. Remove each counterweight capscrew and replace it in turn with a long stud. The studs must protrude about 152 mm (6 in) beyond the counterweight.
3. Use a pry bar and carefully move the counterweight away from the frame about 50 mm (2 in). Install a nylon lifting sling securely around the counterweight and attach it to a lifting device.
WARNING
Make sure the counterweight is balanced and cannot fall from the sling, when the sling is raised.
4. Carefully lift the counterweight away from the lift truck frame and lower the counterweight to the floor.
5. For installation of the side counterweights, follow the above procedure in reverse order. Tighten the counterweight capscrews to 655 N.m (485 lbf ft).
HOOD AND AIR CLEANER
The hood and air cleaner assembly, which includes the pre–cleaner and inlet pipe, can be removed from the frame as a single unit.
2. Remove the nuts, washers and bar washers that fasten the hood crossmember to the counterweight. Remove the two capscrews from the front of the hood assembly at the center bracket. These two capscrews are mounted to the cab. Attach a lifting device and sling. Lift the hood from the frame. See FIGURE 3.
Installation
Install the hood and air cleaner assembly in the reverse procedure of removal and align the hood as necessary during installation. Make sure the hood side panels close completely and that the cushioned screw stops (bumpers) are located correctly.
Removal
1. Raise both hood side panels and disconnect the air intake hose (9) at the engine. Disconnect the small hose, that goes to the air compressor, at the air cleaner. On trucks with a cab, disconnect the hose from the rear window washer.
1.HOOD, TRANSMISSION –H13.00–16.00XL (H300–360XL) ONLY
2.HOOD, ENGINE
3.GAS SPRING (2)
4.PRE–CLEANER
5.AIR INLET PIPE
6.SHIM
7.AIR RESTRICTION INDICATOR
8.AIR CLEANER
9.HOSE, AIR INTAKE
10.CLAMP
11.ENGINE (REFERENCE)
12.FRAME, RIGHT SIDE
13.HANDLE (2)
14.STOP SCREW
15.HOOD, RH PANEL
16.ROD, HINGE
17.CENTER BRACKET
18.CAPSCREW
19.LOCKWASHER
20.SPRING
21.SPACER
22.WASHER
23.CAPSCREW, WASHER AND NUT
24.HOOD CROSSMEMBER
HYDRAULIC TANK
The hydraulic tank is installed on the right side of the frame between the front and rear fenders.
Removal
1. Remove the side cover between the bottom of the operator compartment and the top of the hydraulic tank. If necessary, remove the drain plug at the bottom of the tank to drain the oil.
2. Disconnect the hoses at the top elbow connection and at the side connection to the tank located on the inside of the frame. Use a pan to catch the oil that is in the hydraulic lines. Put tags on the lines for identification. Put caps on 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 the tank to the running board. Remove the three nuts and washers that hold the top of the tank to the frame. Install two lifting eyes at the outer holes. Attach a lifting device and support the tank. Lift the tank from the frame.
WARNING
Make sure that the tank is supported by blocks before removing the nuts and washers from the top of the tank.
Repairs, All Units
SMALL LEAKS
Use the following procedures to repair small leaks:
1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.
WARNING
Do not use tools that can make sparks, heat or static electricity. The vapors in the tank can cause an explosion.
2. Apply Loctite 290 to the leak. Follow the instructions of the manufacturer.
LARGE LEAKS
1. Use one of the procedures described under Cleaning to clean and prepare the tank for repairs.
2. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting ANSI Z49.1–1973.
Cleaning
WARNING
Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside of a building, make sure there is enough ventilation. See the following manuals for additional information:
• “Safe Practices For Welding And Cutting Containers That Have Held Combustibles” by the American Welding Society, A6.0–65.
• “Safety In Welding and Cutting”, American National Standard, ANSI Z 49.1 – 1973.
When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.
When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 inch). Control the pressure of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between the nozzle and the tank. Connect a ground wire to the tank to prevent static electricity.
Steam Method of Cleaning
Use the following procedure to clean the tank with steam:
1. Remove all the parts from the tank. Install the drain plug.
2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 litres (1 gal) of water.
3. Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank.
4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come from all the openings.
5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank.
6. Make an inspection of the inside of the tank. If it is not clean, repeat steps 4. and 5. and make another inspection. When making inspections, use light that is approved for locations with flammable vapors.
7. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.
Chemical Solution Method of Cleaning
If the tank cannot be cleaned with steam, use the following procedure:
1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer.
2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank.
3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning compound is removed.
4. Make an inspection of the inside of the tank. If the tank is not clean, repeat steps 1 through 3. Make another inspection of the tank. When making inspections, use a light that is approved for locations with flammable vapors.
5. Check the tank for flammable vapors using special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.
Other Methods Of Preparation For Repair
If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices For Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, A6.0–65. If these gases are not available, another method using water can be used as follows:
1. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent.
2. Use acceptable welding practices to repair the tank. See the American National Standard Safety In Welding And Cutting ANSI Z 49.1–1973.
Installation
1. Connect a lifting device to the outer holes in the top of the hydraulic tank. Put the hydraulic tank in position on the frame. Put blocks under the tank to provide support. Install the lower three capscrews and washers that fasten the top of the hydraulic tank to the frame.
2. Make sure the tank is supported by the upper capscrews. Install the three nuts and washers that fasten the bottom of the hydraulic tank to the running board.
3. Connect the hydraulic return line to the upper elbow connection of the hydraulic tank. Attach the suction hose to the side tank connection on the inside of the frame member.
4. Fill the hydraulic tank to the correct level with the oil specified in the maintenance table. See the section PERIODIC MAINTENANCE, 8000 SRM 433.
FUEL TANK
The fuel tank is installed on the left–hand frame channel.
Removal
1. If necessary, remove the drain plug to drain the fuel from the tank.
WARNING
If the fuel is drained from the fuel tank, put the fuel in a can or barrel that has a protected seal cap.
2. Disconnect the fuel lines at the tank.
3. Support the fuel tank with blocks from beneath the tank. First, remove the three capscrews that fasten the bottom of the tank to the running board. Remove the three nuts and washers that hold the top of the tank to the frame. Install two lifting eyes at the outer holes. Attach a lifting device and support the tank. Lift the tank from the frame.
WARNING
Make sure that the tank is supported by blocks before removing the nuts and washers from the top of the tank.
Repairs
Repair the fuel tank as described in the repair procedures for the hydraulic tank.
WARNING
Do not use tools that can make sparks, heat or static electricity. The vapors in the tank can cause an explosion.
Installation
1. Connect a lifting device to the outer holes in the top of the fuel tank. Put the fuel tank in position on the frame. Put blocks under the tank to provide support. Install the lower three capscrews and washers that fasten the top of the fuel tank to the frame.
2. Make sure the tank is held by the upper capscrews, then install the three nuts and washers that fasten the bottom of the fuel tank to the running board.
3. Connect the fuel lines to the tank.
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RADIATOR (See FIGURE 7.)
Removal
1. Remove the hood. See the paragraphs Hood And Air Cleaner.
2. Drain the radiator. Disconnect the coolant hoses at the radiator.
3. Disconnect the transmission oil lines at the radiator.
4. Remove the fan from the drive pulley.
5. Remove the capscrews between the fan shroud and the radiator.
6. Remove the two capscrew and grommet assemblies that hold the radiator shroud to the bracket on the frame. Remove the radiator and shroud.
Installation
1. Install the brackets on the radiator. Install the radiator and shroud in the frame. Install the two capscrew and grommet assemblies that fasten the shroud weldment to the bracket on the frame. Install the capscrews between the fan shroud and the radiator.
2. Connect the coolant hoses to the radiator.
3. Connect the transmission oil lines to the bottom of the radiator.
4. Install the counterweight and hood assembly.
5. Fill the radiator with coolant. See Maintenance Schedule in the section PERIODIC MAINTENANCE, 8000 SRM 433 for quantity and anti–freeze requirements.
ENGINE and TRANSMISSION
See the sections PERKINS ENGINE, 600 SRM 412 for repair of the engine. See the transmission section, POWERSHIFT TRANSMISSION, 1300 SRM 438 for earlier production lift trucks.
Later production lift trucks use the Hyster T–50 powershift transmission. An installation kit is available that enables the installation of the T–50 transmission in earlier production lift trucks. See the section, THREE–SPEED POWERSHIFT TRANSMISSION, REPAIRS, 1300 SRM 518 for lift trucks with this transmission. The removal of this transmission is described later in this section. See HYSTER T–50 TRANSMISSION, REMOVAL.
Removal (Earlier Production Lift Trucks)
1. Disconnect the cables at the battery. (Remove the ground cable first.) Remove the bracket for the battery cables.
2. H13.00–16.00XL (H300–360XL) units. Remove the operator compartment. See the paragraph Operator Compartment.
3. H8.00–12.00XL (H165–280XL) units. Removal of the operator compartment is not required. Tilt the opera-
tor compartment forward to remove the engine and transmission.
4. Remove the hood and air cleaner assembly. See the paragraph Hood And Air Cleaner
5. Drain the coolant from the cooling system. Remove the radiator. See the paragraph Radiator.
6. Disconnect the exhaust system. Remove the header pipe at the exhaust manifold.
7. Disconnect the air lines at the air compressor. Loosen the fittings slowly to vent any compressed air.
8. Disconnect fuel lines at the fuel tank. Disconnect throttle linkage.
1.CAB (REFERENCE)
7.FRAME, H8.00–9.00XL (H165–210XL) and H13.00–16.00XL (H300–360XL)
8.ENGINE
9. Disconnect wires and wiring harnesses at the engine. Disconnect the heater hoses at the engine.
10. Disconnect the drive shaft.
11. Connect a lifting device to the engine and transmission. Make sure the lifting device has a capacity of at least 1135 kg (2500 lb).
12. Remove the capscrews that hold the engine and transmission mount brackets to the frame mounts.
13. Make sure all the connections have been removed. Carefully lift the engine and transmission assembly from the frame.
WARNING
Put blocks under the engine and transmission to make sure the assembly has good support while removing components.
H13.00–16.00XL (H300–360XL) SHOWN
14. Remove the bracket and linkage for the transmission.
FIGURE 10. TRANSMISSION INSTALLATION (EARLIER PRODUCTION)
Installation (Earlier Production Lift Trucks)
1. Connect a lifting device to the engine and transmission. Make sure the lifting device has a capacity of at least 1200 kg (2500 lb).
2. Install the engine and transmission assembly in the frame. Install and tighten the nuts and capscrews for the engine and transmission mounts.
3. Connect the drive shaft to transmission. Tighten the bolts for the universal joint to 68 N.m (50 lbf ft).
4. Install the hydraulic lines to the pump.
5. Connect the exhaust pipes to the engine and muffler.
6. Connect the heater hoses, air lines, wiring harnesses, wires and throttle cable to the engine.
7. Install the radiator. Connect the coolant hoses to the radiator. Connect the oil cooler lines to the transmission.
8. Connect the fuel lines between the fuel filter on the engine assembly and fuel tank and primary.
9. Install and connect the hood and air cleaner assembly.
10. Connect the battery cables to the battery (Connect the positive cable first, then the ground cable.). Fill cooling system with coolant. Check all oil levels. Start the engine and check for leaks and correct operation.
Hyster T–50 Transmission, Removal
NOTE: On H8.00–12.00XL (H165–280XL) lift trucks, the transmission can be removed through the operator’s compartment or from under the lift truck. On H13.00–16.00XL (H300–360XL) lift trucks, the transmission can be removed from the engine compartment or from under the lift truck.
1. Remove the forks. Put the lift truck on blocks so that there is access under the lift truck. See “How To Put The Lift Truck On Blocks” in the OPERATING MANUAL or the PERIODIC MAINTENANCE, 8000 SRM 433, section. Tilt the mast fully forward to release hydraulic pressure in the system.
1. Disconnect the cables at the battery. (Remove the ground cable first.) Remove the bracket for the battery cables.
2. H13.00–16.00XL (H300–360XL) units. Remove the operator compartment. See the paragraph Operator Compartment.
3. H8.00–12.00XL (H165–280XL) units. Removal of the operator compartment is not required. Tilt the operator compartment forward to remove the engine and transmission.
4. Remove the hood and air cleaner assembly. See the paragraph Hood And Air Cleaner
5. Drain the coolant from the cooling system. Remove the radiator. See the paragraph Radiator.
6. Disconnect the exhaust system. Remove the header pipe at the exhaust manifold.
7. Disconnect the air lines at the air compressor. Loosen the fittings slowly to vent any compressed air.
8. Disconnect fuel lines at the fuel tank. Disconnect throttle linkage.
9. Disconnect wires and wiring harnesses at the engine. Disconnect the heater hoses at the engine.
10. Disconnect the drive shaft at the yokes. Remove the drive shaft between the transmission and the differential.
11. Disconnect the wiring harnesses on top of the transmission. Disconnect the wires at the solenoids on the transmission control valve. Disconnect the wires at the pressure sending unit and the temperature sending unit on the transmission. Put identification tags on the wires so that they can be correctly connected again.
12. Apply the service brakes repeatedly until the air pressure in the air tank decreases to 0 kPa (0 psi). Disconnect the air brake hose from the air tank so that there is clearance at the transmission.
13. Disconnect the wire to the starter solenoid.
14. Disconnect the cables at the spools on the transmission control valve. Remove the linkage bracket from the transmission housing.
15. Remove the drain plug from the transmission sump to drain the oil from the transmission [approximately 28 litres (29 qt)]. Disconnect the oil lines to the oil cooler at the transmission. Drain the oil lines into the drain pan. Put plugs and caps in the open fittings.
16. Disconnect the oil hoses at the hydraulic pump. Disconnect the hose from the hydraulic pump to the steering system. Put plugs and caps on the open fittings.
17. The hydraulic pump is fastened to the transmission cover with four capscrews. The hydraulic pump weighs approximately 45 kg (100 lb). Use a lifting device to hold and lift the hydraulic pump. Remove the hydraulic pump. The drive shaft of the hydraulic pump is engaged in splines in the drive gear. The drive shaft of the hydraulic pump will slide from the drive gear when the hydraulic pump is removed.
18. Disconnect and remove the dipstick assembly from the transmission.
19. The temperature sender for the transmission oil can be easily damaged. Remove the temperature sender from the transmission sump.
20. Install blocks and a jack under the flywheel end of the engine as a support. If the support is put under the engine oil sump, make sure the support is across the width of the oil sump so that the weight of the engine does not damage the oil sump.
21. A 5/8 inch machined hole with UNC threads is in the top of the transmission housing. Install an eyebolt in the 5/8 inch UNC hole. Connect a lifting device to the engine and transmission. Make sure the lifting device has a capacity of at least 1200 kg (2500 lb).
22. Remove the two 3/4 x 31/2 inch bolts that fasten the transmission mounts to the frame. These bolts have been tightened to 270 N.m (200 lbf ft).
23. Remove the capscrews that hold the engine mount brackets to the frame mounts.
24. Make sure all the connections have been removed. Carefully lift the engine and transmission assembly from the frame.
Hyster T–50 Transmission, Installation
1. If the mounts were removed from the sides of the transmission housing, install them and tighten the capscrews to 270 N.m (200 lbf ft).
2. Connect a lifting device to the engine and transmission. Make sure the lifting device has a capacity of at least 1200 kg (2500 lb).
3. Install the engine and transmission assembly in the frame. Install and tighten the nuts and capscrews for the engine and transmission mounts. Install the two 3/4 x 31/2 inch bolts (item 5, FIGURE 12.) for the transmission mounts. Tighten the locknuts to 270 N.m (200 lbf ft).
4. Connect the drive shaft to the yoke on the transmission. Make sure the slip joint is installed as shown in FIGURE 12. Tighten the capscrews at the yoke to 50 N.m (35 lbf ft).
1.FRAME (REFERENCE)
2.DIPSTICK ASSEMBLY
5. Install the dipstick assembly on the transmission. Adjust the handle of the dipstick so that it is 368 to 394 mm (14.5 to 15.5 in) from the centerline of the transmission as shown in FIGURE 12.
6. Use a lifting device to hold and lift the hydraulic pump. Install the hydraulic pump. The drive shaft of the hydraulic pump is engaged in splines in the drive gear. The drive shaft of the hydraulic pump will slide into the drive gear when the hydraulic pump is installed.
7. Connect the hose from the hydraulic pump to the steering system. Connect the hydraulic hoses to the hydraulic pump.
8. Install the temperature sender for the transmission oil into the transmission sump.
9. Connect the wiring harnesses on the top of the transmission. Connect the wires to the solenoids on the control valve. Make sure the yellow wire is connected to the reverse solenoid and the black wire is connected to the forward solenoid. Connect the wires at the temperature sending unit and the pressure sending unit on the transmission. Use the straps and clamps to hold the wires in position.
10. Install the starter solenoid shown in item 6, FIGURE 12.
11. Connect the air brake hose to the air tank.
12. Fasten the bracket (item 7, FIGURE 13.) to the transmission housing. Connect the cables to the control spools in the transmission control valve. See the adjustment procedure in the section, THREE–SPEED POWERSHIFT TRANSMISSION, REPAIRS, 1300 SRM 518.
13. Connect the exhaust pipes to the engine and muffler.
14. Connect the heater hoses, air lines, wiring harnesses, wires and throttle cable to the engine.
15. Install the radiator. Connect the coolant hoses to the radiator. Connect the oil cooler lines to the transmission The hose from the upper fitting on the transmission goes to the right–hand fitting (as seen from the operator’s position) on the oil cooler. The hose from the lower fitting on the transmission goes to the left–hand fitting on the oil cooler.
16. Connect the fuel lines between the fuel filter on the engine assembly and fuel tank and primary.
17. Install and connect the hood and air cleaner assembly.
18. Fill the transmission with the correct transmission oil [29 liters (31 qt)]. Transmission oil is available in the following sizes:
Hyster Part No. 336830 in one quart containers
Hyster Part No. 336831 in eight quart containers
Hyster Part No. 336832 in 20 quart containers.
19. Connect the battery cables to the battery (Connect the positive cable first, then the ground cable.). Fill cooling system with coolant. Add oil to the engine. Check all oil levels. Check that all connections have been made. Start the engine and check for leaks and correct operation.
20. When the lift truck can be operated, check the forward and reverse clutch pressures as described in the “Checks And Adjustments” in the section, THREE–SPEED POWERSHIFT TRANSMISSION, REPAIRS, 1300 SRM 518.
21. Install the floor plates and seat and doors or the hood as necessary.