Hyster E024 (S6.0FT Europe) Forklift Service Repair Manual

6(59,&( 5(3$,5 S6.0FT, S7.0FT ((XURSH) [024]

PART NO. 1652525

8000 SRM 1320

8000 SRM 1320

Capacities

Lift Truck Lifting Capacity Model

Weight

S6.0FT (S135FT)

6123 kg (13,500 lb)

S7.0FT (S155FT)

7030 kg (15,500 lb)

H6.0FT (H135FT)

6123 kg (13,500 lb)

H7.0FT (H155FT)

7030 kg (15,500 lb)

NOTE: Load center at 600 mm (24 in.).

Counterweight Weights Model

Weight

S6.0FT, S7.0FT (S135FT, S155FT)

2779 kg (6127 lb)

H6.0FT (H135FT)

2622 kg (5780 lb)

H7.0FT (H155FT)

3135 kg (6911 lb)

Tire Sizes Truck

Drive Tires

Steer Tires

S6.0FT, S7.0FT (S135FT, S155FT)

28 × 12 × 22

22 × 8 × 16

H6.0FT, H7.0FT (H135FT, H155FT)

8.25 × 15

8.25 × 15

Capacities Table 1. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Item

Quantity

Specifications

Fuel Capacity Gas

65.8 liter (17.4 gal)

87 Octane

LPG

38.6 liter (10.2 gal) Empty 19.0 kg (41 lb) Full 38.2 kg (84.51 lb)

LPG-HD 5, HD 10

Diesel

65.8 liter (17.4 gal)

Diesel No. 2

1

Capacities

8000 SRM 1320

Table 1. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models (Continued) Item

Quantity

Specifications

Engine Oil GM 4.3L

4.7 liter (5.0 qt)

7 C ( 20 F) and below SAE 5W-20 16 C (60 F) and below SAE 5W-30 18 C (0 F) and above SAE 10W-30 API SL ILSAC GF3 SAE J2362

Cummins 4.5L Diesel

13.0 liter (13.7 qt)

0 C (32 F) and below SAE 0W-30 25 to 20 C ( 13 to 68 F) SAE 5W-30 20 to 20 C ( 4 to 68 F) SAE 10W-30 15 C (5 F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4

Cummins QSB 3.3L Diesel

7.5 liter (8.0 qt)

0 C (32 F) and below SAE 0W-30 25 to 20 C ( 13 to 68 F) SAE 5W-30 20 to 20 C ( 4 to 68 F) SAE 10W-30 15 C (5 F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4

2

8000 SRM 1320

Capacities

Table 1. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models (Continued) Item

Quantity

Specifications

Cooling System GM 4.3L

15.1 liter (15.9 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer.

50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Cummins 4.5L Diesel

13.5 liter (14.2 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer.

50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Cummins QSB 3.3L Diesel

10.4 liter (11.0 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer.

50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Hydraulic Tank Oil Capacity All Trucks

64 liter (68 qt) Initial Fill 60.5 liter (64 qt) Drain and Fill

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Hyster dealer.

ISO VG-46 Hydraulic Oil 15 C (5 F) and above

3

Capacities

8000 SRM 1320

Table 1. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models (Continued) Item

Quantity

Specifications

Basic Powershift Transmission (2-Speed)

24 liter (25.4 qt)

John Deere JDM J20C

DuraMatchâ„¢ (3-Speed)

24 liter (25.2 qt)

John Deere JDM J20C

Drive Axle Housing Arm Oil Right Chamber

8.8 liter (9.3 qt)

John Deere JDM J20C

Drive Axle Housing Arm Oil Left Chamber

8.8 liter (9.3 qt)

John Deere JDM J20C

Right Wheel Hub Oil

1.6 liter (1.7 qt)

John Deere JDM J20C

Left Wheel Hub Oil

1.6 liter (1.7 qt)

John Deere JDM J20C

Transmission Oil Capacity

Wet Brake Drive Axle Oil Capacities

Brake Oil (Master Cylinder) All Lift Truck Models

0.35 liter (0.74 pt)

WARNING DO NOT use DOT fluid; only use Dexron III oil from sealed container to prevent possible damage to the brake system. Failure to observe the above Warning could result in death or serious injury.

Dexron III From Sealed Container Wet Brake Center Section Oil All Lift Truck Models

4

4.2 liter (4.4 qt)

John Deere JDM J20C

8000 SRM 1320

Capacities

Table 2. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Item

Quantity

Specifications

Fuel Capacity Gas

74.8 liter (19.7 gal)

87 Octane

LPG

38.6 liter (10.2 gal) Empty 19.0 kg (41 lb) Full 38.2 kg (84.51 lb)

LPG-HD 5, HD 10

Diesel

74.8 liter (19.7 gal)

Diesel No. 2

Engine Oil GM 4.3L

4.7 liter (5.0 qt)

7 C ( 20 F) and below SAE 5W-20 16 C (60 F) and below SAE 5W-30 18 C (0 F) and above SAE 10W-30 API SL ILSAC GF3 SAE J2362

Cummins 4.5L Diesel

13.0 liter (13.7 qt)

0 C (32 F) and below SAE 0W-30 25 to 20 C ( 13 to 68 F) SAE 5W-30 20 to 20 C ( 4 to 68 F) SAE 10W-30 15 C (5 F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4

Cummins QSB 3.3L Diesel

7.5 liter (8.0 qt)

0 C (32 F) and below SAE 0W-30 25 to 20 C ( 13 to 68 F) SAE 5W-30 20 to 20 C ( 4 to 68 F) SAE 10W-30 15 C (5 F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4

5

Capacities

8000 SRM 1320

Table 2. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models (Continued) Item

Quantity

Specifications

Cooling System GM 4.3L

15.1 liter (15.9 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer.

50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Cummins 4.5L Diesel

13.5 liter (14.2 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer.

50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Cummins QSB 3.3L Diesel

10.4 liter (11.0 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer.

50% Water and 50% Ethylene Glycol, Boron-Free Antifreeze Hydraulic Tank Oil Capacity All Trucks

75 liter (79 qt) Initial Fill 71.7 liter (75.7 qt) Drain and Fill

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Hyster dealer.

ISO VG-46 Hydraulic Oil 15 C (5 F) and above Transmission Oil Level

6

Basic Powershift Transmission (2-Speed)

24 liter (25.4 qt)

John Deere JDM J20C

DuraMatch™ (3-Speed)

24 liter (25.4 qt)

John Deere JDM J20C

8000 SRM 1320

Electrical System

Table 2. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models (Continued) Item

Quantity

Specifications

7.8 liter (8.25 qt)

John Deere JDM J20C

7.8 liter (8.25 qt)

John Deere JDM J20C

Right Wheel Hub Oil

N/A

N/A

Left Wheel Hub Oil

N/A

N/A

Wet Brake Drive Axle Oil Capacities Drive Axle Housing Arm Oil Right Chamber Drive Axle Housing Arm Oil Left Chamber

Brake Oil (Master Cylinder) All Lift Truck Models

0.35 liter (0.74 pt)

WARNING DO NOT use DOT fluid; only use Dexron III oil from sealed container to prevent possible damage to the brake system. Failure to observe the above Warning could result in death or serious injury.

Dexron III From Sealed Container Wet Brake Center Section Oil All Lift Truck Models

4.6 liter (4.9 qt)

John Deere JDM J20C

Electrical System Table 3. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Item

GM 4.3L

Cummins 4.5L and QSB 3.3L Diesel

Battery

12-volt, negative ground

12-volt, negative ground

Spark Plugs

AC 41-993

N/A

Spark Plug Gap

1.5 mm (0.059 in.)

N/A

Gas

Not Adjustable

N/A

LPG

Not Adjustable

N/A

Diesel

N/A

Not Adjustable

Ignition Timing

7

Electrical System

8000 SRM 1320

GM 4.3L Alternator Output (14 Volts)

G and LPG

GS and LPS

Idle

50 amps @ 750 rpm

38 amps @ 750 rpm

Governed Speed

65 amps @ 2400 rpm

45 amps @ 2400 rpm

Cummins 4.5L (Diesel) Alternator Output (13.5 Volts)

D

DS

Low Idle

54 amps @ 800 rpm

28 amps @ 800 rpm

Governed Speed

95 amps @ 2225 rpm

45 amps @ 2225 rpm

Cummins QSB 3.3L (Diesel) Alternator Output (13.5 Volts)

D

DS

Low Idle

30 amps @ 800 rpm

N/A

Governed Speed

95 amps @ 2230 rpm

N/A

Table 4. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Item

GM 4.3L

Cummins 4.5L

Battery

12-volt, negative ground

12-volt, negative ground

Spark Plugs

AC 41-993

N/A

Spark Plug Gap

1.5 mm (0.059 in.)

N/A

Gas

Not Adjustable

N/A

LPG

Not Adjustable

N/A

Diesel

N/A

0.90 mm (0.035 in.)

Ignition Timing:

GM 4.3L Alternator Output (14 Volts)

G and LPG

GS and LPS

Idle

50 amps @ 750 rpm

38 amps @ 750 rpm

Governed Speed

65 amps @ 2400 rpm

45 amps @ 2400 rpm

Cummins 4.5L (Diesel) Alternator Output (13.5 Volts)

D

DS

Low Idle

54 amps @ 800 rpm

32 amps @ 800 rpm

High Idle

95 amps @ 2225 rpm

45 amps @ 2225 rpm

Cummins QSB 3.3L (Diesel)

8

Alternator Output (13.5 Volts)

D

DS

Low Idle

30 amps @ 800 rpm

20 amps @ 800 rpm

Governed Speed

95 amps @ 2230 rpm

45 amps @ 2230 rpm

8000 SRM 1320

Transmission Oil Pressures

Transmission Oil Pressures 3-Speed Transmission All Pressures at 2000 rpm and Oil at 50 to 65 C (120 to 150 F) Port 1 Transmission Pump

Port 2

Port 3

Port 4

Port 5

Port 6

Port 7

Port 8

Low and High Pressure

Reverse Clutch (R1 and R2)

Forward Low Clutch (F1 and F2)

Forward High Clutch (F3)

Torque Converter

Lubrication

First Test Port (F1 and R1)

Second Test Port (F2, F3 and R2)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

758 kPa (110 psi)

69 to 276 kPa (10 to 40 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068* kPa (260 to 300 psi)

*Relief Pressure

9

Hydraulic System Relief Pressures

8000 SRM 1320

2-Speed Transmission All Pressures at 2000 rpm and Oil at 50 to 65 C (120 to 150 F) Port 1 Transmission Pump

Port 2

Port 3

Port 4

Port 5

Port 6

Port 7

Port 8

Low and High Pressure

Reverse Clutch (R1 and R2)

Forward Low Clutch (F1)

Forward High Clutch (F2)

Torque Converter

Lubrication

First Test Port (F1 and R1)

Second Test Port (F2, and R2)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

758 kPa (110 psi)

69 to 276 kPa (10 to 40 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068* kPa (260 to 300 psi)

*Relief Pressure

Hydraulic System Relief Pressures

10

Item

Specification

Oil Temperature

50 to 65 C (122 to 149 F)

Primary Relief Valve Pressure (High Idle)

22.1 ±0.48 MPa (3205 ± 70 psi)

Secondary Relief Valve Pressure (High Idle)

15.51 ±0.48 MPa (2250 ±70 psi)

8000 SRM 1320

Stall Speeds (in RPM ±100 rpm)

Steering System Table 5. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Item

Quantity

Oil Temperature

50 to 65 C (122 to 149 F)

Steering Relief Pressure at 800 rpms

12.4 ±0.3 MPa (1798 ±43.5 psi)

Steering Cylinder Stroke (Each Side)

210.8 mm (8.3 in.)

Inside Steering Tire Angle

80.3

Number of Turns to Lock

4.07

Turning Radius (±50 mm NO LOAD)

Outside

Inside

All Trucks

2585

107

Table 6. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Item

Quantity

Oil Temperature

55 to 65 C (131 to 149 F)

Steering Relief Pressure at 800 rpms

12.4 ±0.3 MPa (1798 ±43.5 psi)

Steering Cylinder Stroke (Each Side)

224.0 mm (8.3 in.)

Inside Steering Tire Angle

74.5

Number of Turns to Lock

3.50

Turning Radius (±76 mm NO LOAD)

Outside

Inside

H6.0FT (H135FT)

3319

293

H7.0FT (H155FT)

3376

293

Stall Speeds (in RPM ±100 rpm) GM 4.3L GAS S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) Transmission

New Engine

Broken-In Engine (30 hrs)

Basic Powershift

2160

2210

DuraMatch™

N/A*

N/A*

*DuraMatch™ transmission has torque limiting feature.

11

Stall Speeds (in RPM ±100 rpm)

8000 SRM 1320

GM 4.3L LPG S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) Transmission

New Engine

Broken-In Engine (30 hrs)

Basic Powershift

2070

2170

DuraMatch™

N/A*

N/A*

*DuraMatch™ transmission has torque limiting feature.

GM 4.3L GAS H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Transmission

New Engine

Broken-In Engine (30 hrs)

Basic Powershift

2160

2210

DuraMatch™

N/A*

N/A*

*DuraMatch™ transmission has torque limiting feature.

GM 4.3L LPG H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Transmission

New Engine

Broken-In Engine (30 hrs)

Basic Powershift

2070

2170

DuraMatch™

N/A*

N/A*

*DuraMatch™ transmission has torque limiting feature.

CUMMINS 4.5L DIESEL S6.0FT, S7.0FT, (S135FT,S155FT) (D024) Transmission

New Engine

Broken-In Engine (30 hrs)

Basic Powershift

1900

2050

DuraMatch™

N/A*

N/A*

*DuraMatch™ transmission has torque limiting feature.

12

8000 SRM 1320

Stall Speeds (in RPM ±100 rpm)

CUMMINS QSB 3.3L DIESEL S6.0FT, S7.0FT, (S135FT,S155FT) (E024) Transmission

New Engine

Broken-In Engine (30 hrs)

Basic Powershift

1935

1950

DuraMatch™

N/A*

N/A*

*DuraMatch™ transmission has torque limiting feature.

CUMMINS 4.5L DIESEL H6.0FT, H7.0FT (H135FT, H155FT) (H006) Transmission

New Engine

Broken-In Engine (30 hrs)

Basic Powershift

1900

2050

DuraMatch™

N/A*

N/A*

*DuraMatch™ transmission has torque limiting feature.

CUMMINS QSB 3.3L DIESEL H6.0FT, H7.0FT (H135FT, H155FT) (J006) Transmission

New Engine

Broken-In Engine (30 hrs)

Basic Powershift

1935

1950

DuraMatch™

N/A*

N/A*

*DuraMatch™ transmission has torque limiting feature.

13

Mast Speeds

8000 SRM 1320

Mast Speeds NOTE: Lift speed is measured in meters/sec (inch/ sec) at governed engine RPM with full open valve and 65 C (149 F) oil temperature.

Plus or minus 10% acceptable lifting or lowering.

Lowering speed is measured in meters/sec (inch/sec) with full open valve and 65 C (149 F) oil temperature.

Table 7. Lift Truck Models S6.0FT(S135FT) (D024, E024)

Engine

GM 4.3L

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.54 (21.0)

0.53 (21.0)

3-Stage FFL

0.41 (16.0)

0.53 (21.0)

0.52 (20.0)

0.51 (20.0)

Table 8. Lift Truck Models S7.0FT (S155FT) (D024, E024)

Engine

GM 4.3L

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.54 (21.0)

0.53 (21.0)

3-Stage FFL

0.41 (16.0)

0.55 (22.0)

0.52 (20.0)

0.51 (20.0)

Table 9. Lift Truck Models S6.0FT(S135FT) (D024, E024)

Engine

Cummins 4.5L and QSB 3.3L

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.50 (20.0)

0.49 (19.0)

3-Stage FFL

0.41 (16.0)

0.53 (21.0)

0.48 (19.0)

0.47 (19.0)

Table 10. Lift Truck Models S7.0FT (S155FT) (D024, E024)

Engine

Cummins 4.5L and QSB 3.3L

14

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.46 (18.0)

0.45 (18.0)

3-Stage FFL

0.41 (16.0)

0.55 (22.0)

0.44 (17.0)

0.43 (17.0)

8000 SRM 1320

Mast Speeds Table 11. Lift Truck Models H6.0FT (H135FT) (H006, J006)

Engine

GM 4.3L

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.54 (21.0)

0.53 (21.0)

3-Stage FFL

0.41 (16.0)

0.53 (21.0)

0.52 (20.0)

0.51 (20.0)

Table 12. Lift Truck Models H7.0FT (H155FT) (H006, J006)

Engine

GM 4.3L

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.54 (21.0)

0.53 (21.0)

3-Stage FFL

0.41 (16.0)

0.55 (22.0)

0.52 (20.0)

0.51 (20.0)

Table 13. Lift Truck Models H6.0FT (H135FT) (H006, J006)

Engine

Cummins 4.5L

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.50 (20.0)

0.49 (19.0)

3-Stage FFL

0.41 (16.0)

0.53 (21.0)

0.48 (19.0)

0.47 (19.0)

Table 14. Lift Truck Models H7.0FT (H155FT) (H006, J006)

Engine

Cummins 4.5L

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.46 (18.0)

0.45 (18.0)

3-Stage FFL

0.41 (16.0)

0.55 (22.0)

0.44 (17.0)

0.43 (17.0)

15

Front End Equipment - Mast Creep

8000 SRM 1320

Tilt Angles Lift truck should be on level ground and in unloaded condition.

Table 15. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Mast Type

Forward

2-Stage FFL, 3-Stage FFL, 3-Stage LFL

6

+1 ,

0.5

6

+0 ,

0.5

2-Stage LFL

6

+1 ,

0.5

10

+0 ,

0.5

Tolerance

Back

Tolerance

Table 16. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Mast Type

Forward

2-Stage FFL, 3-Stage FFL, 3-Stage LFL

5

+1 ,

0.5

6

+0 ,

0.5

2-Stage LFL

5

+1 ,

0.5

10

+0 ,

0.5

Tolerance

Back

Tolerance

Front End Equipment - Mast Creep MAST CREEP Measure with rated load at 2.5 m (8.0 ft) high and with the lift, tilt, and auxiliary control levers in neutral position.

NOTE: Mast should be 90 vertical prior to test.

Table 17. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Lift Truck Models Hydraulic Oil Temperature

16

Maximum Vertical Creep at Carriage

Maximum Tilt Creep Mast Angle

Cylinder Stroke

C

F

mm/Min

in./Min

/Min

mm/Min

in./Min

20

68

2.2

0.086

0.11

1.24

0.054

30

86

3.3

0.130

0.16

1.80

0.071

40

104

6.3

0.247

0.31

3.50

0.137

50

122

10.0

0.394

0.50

5.62

0.221

60

140

14.6

0.575

0.73

8.20

0.323

8000 SRM 1320

Engine Specifications

Table 18. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Truck Models Hydraulic Oil Temperature

Maximum Tilt Creep

Maximum Vertical Creep at Carriage

Mast Angle

Cylinder Stroke

C

F

mm/Min

in./Min

/Min

mm/Min

in./Min

20

68

2.2

0.086

0.11

1.30

0.051

30

86

3.3

0.130

0.16

1.90

0.075

40

104

6.3

0.247

0.31

3.67

0.145

50

122

10.0

0.394

0.50

5.92

0.233

60

140

14.6

0.575

0.73

8.65

0.341

Engine Specifications Item

GM 4.3L

No. of Cylinders

6

Firing Order

1-6-5-4-3-2

Bore

101.6 mm (3.9 in.)

Stroke

88.4 mm (3.48 in.)

Displacement

4.3 liter (262.4 in. 3 )

Horsepower (Gasoline)

100 @ 2400 rpm

Horsepower (LPG)

93 @ 2400 rpm

Engine Timing

Timing is controlled by the Electronic Control Module (ECM) Compression Ratio

Gas

9.4:1

LPG

9.4:1

Oil Pressure

207-380 ± 30 kPa (30-55 ± 4.4 psi) @ 2000 rpm 80 C (176 F) Valve Clearance

Intake

Not Adjustable

Exhaust

Not Adjustable

Idle Speed - Gas

750 ±25 rpm

Idle Speed - LPG

750 ±25 rpm

Governed Speed High Idle (No Load)

2400 ±25 rpm

17

Engine Specifications

8000 SRM 1320

Item

GM 4.3L Thermostat Range

STARTS TO OPEN

82 ±1.5 C (180 ±35 F)

FULL OPEN

128 ±1.5 C (260 ±35 F)

Cooling System Pressure

103 kPa (15 psi)

Item

Cummins 4.5L Diesel

No. of Cylinders

4

Firing Order

1-3-4-2

Bore and Stroke

102 mm × 138 mm (4.01 in. × 5.43 in.)

Displacement

4506 cc

Compression Ratio

17.6:1

Horsepower/rpm

78 @ 2050 rpm

Oil Pressure @ 80 C (176 F)

at low idle 69 kPa (10 psi) @ 800 rpm at high idle 207 kPa (30 psi) @ 2250 rpm Valve Clearance

Intake

0.254 mm (0.010 in.)

(COLD)

Exhaust

0.508 mm (0.020 in.)

(COLD)

Idle Speed (Cold Engine)

770 ±50 rpm

Idle Speed (Hot Engine)

800 ±50 rpm

Governed Speed High Idle (No Load)

2250 ±50 rpm

Thermostat Range STARTS TO OPEN

82 C (180 F)

FULL OPEN

95 C (203 F)

Cooling System Pressure

103 kPa (15 psi)

Item

Cummins QSB 3.3L Diesel

No. of Cylinders Firing Order Bore and Stroke Displacement Compression Ratio Horsepower/rpm (basic transmission)

18

4 1-3-4-2 95 mm × 115 mm (3.74 in. × 4.53 in.)

3261 cc 17.3:1 80 @ 2200 rpm

8000 SRM 1320

Torque Specifications

Item

Cummins QSB 3.3L Diesel

Horsepower/rpm (Duramatch transmission)

99 @ 2200 rpm

Oil Pressure

49 kPa (7 psi)

Valve Clearance Intake

0.35 mm (0.014 in.)

Exhaust

0.50 mm (0.02 in.)

Idle Speed

800 ±25 rpm

Governed Speed High Idle (No Load)

2230 ±25 rpm

Thermostat Range START TO OPEN

82 C (180 F)

FULL OPEN

95 C (203 F)

Cooling System Pressure

103 kPa (15 psi)

Torque Specifications FRAME

STEERING SYSTEM

Overhead Guard Mount Capscrews 66 N•m (49 lbf ft)

Hub Nut (Slotted Nut), Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) 203 N•m (150 lbf ft) initial 35 N•m (26 lbf in) final

Cowl-to-Overhead Guard Legs 66 N•m (49 lbf ft) Counterweight Capscrews 1020 N•m (750 lbf ft)

MAST, LIFT TRUCK MODELS S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) Mast Mounting Capscrews Mast to Drive Axle 320 N•m (236 lbf ft) Tilt/Cylinder Adjust 90 N•m (66 lbf ft) Pivot Pin Retainer 68 N•m (50 lbf ft)

MAST, LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Mast Mounting Capscrews Mast to Drive Axle 755 to 830 N•m (557 to 612 lbf ft) Tilt/Cylinder Adjust 90 to 99 N•m (66 to 73 lbf ft) Pivot Pin Retainer 68 N•m (50 lbf ft)

Hub Nut (Slotted Nut), Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) 203 N•m (150 lbf ft) initial 34 N•m (25 lbf in) final Steering Axle Mounting Bolts and Nuts, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) 250 to 275 N•m (184 to 203 lbf ft) Steering Axle Mounting Bolts and Nuts, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) 270 N•m (199 lbf ft) Spindle Bearing Cap Capscrew, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) 52 N•m (38 lbf ft)

19

Torque Specifications Spindle Bearing Cap Capscrew, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) 47 N•m (35 lbf ft) Steering Cylinder Mounting Bolts 225 N•m (166 lbf ft)

TRANSMISSION Transmission Mounting Bracket to Differential Housing Capscrew 225 to 255 N•m (166 to 188 lbf ft) Torque Converter Housing to Transmission Case Capscrews 38 N•m (28 lbf ft) Torque Converter Access Bolts 55 N•m (41 lbf ft) Drive Shaft to Output Yoke Capscrews 55 to 63 N•m (41 to 47 lbf ft) Control Valve Mounting Capscrews 20 to 25 N•m (15 to 18 lbf ft) Engine Mounting Bracket to Frame Bolts 320 N•m (236 lbf ft)

ENGINE - GM 4.3L Alternator Pulley 61 N•m (45 lbf ft) Balance Shaft Gear Capscrew 20 N•m (177 lbf in) Plus 35 Degrees Balance Shaft Retainer Capscrews 12 N•m (106 lbf in) Camshaft Retainer Screws 12 N•m (106 lbf in) Camshaft Sprocket Capscrews 28 N•m (21 lbf ft)

8000 SRM 1320 Coolant Pump to Engine Block 41 N•m (30 lbf ft) Cooling Fan to Pulley 24 N•m (212 lbf in) Cylinder Head See the section GM Engines, 4.3 Liter V-6 600 SRM 1251 for torque value and tightening sequence to use.

Distributor Mount Capscrew 25 N•m (18 lbf ft) Exhaust Manifold 15 N•m (133 lbf in) - first step 30 N•m (22 lbf ft) - second step Flywheel 100 N•m (74 lbf ft) Flywheel Housing 48 N•m (35 lbf ft) Inlet Manifold to Cylinder Head 3 N•m (27 lbf in) - first step 12 N•m (106 lbf ft) - second step 15 N•m (133 lbf in) - third step (final) Main Bearing Cap 105 N•m (77 lbf ft) Motor Mount to Engine 31 N•m (23 lbf ft) Oil Pump Cover 12 N•m (106 lbf in) Oil Pump to Crankcase 90 N•m (66 lbf ft) Oil Pressure Switch 27 N•m (20 lbf ft) Oil Screen Support to Crankcase 50 N•m (37 lbf ft)

Camshaft Sprocket Nut 25 N•m (18 lbf ft)

Oil Pan to Crankcase Capscrews 25 N•m (18 lbf ft) Nuts 25 N•m (18 lbf ft)

Chain Control Block for Hydraulic Pump Drive 19 N•m (168 lbf in) with Adhesive Sealant

Rear Oil Seal Retainer Screws and Nut 15 N•m (133 lbf in)

Connecting Rod Cap 27 N•m (240 lbf in) After this step, tighten nuts an additional 70 degrees.

Rocker Arm Cover 12 N•m (106 lbf in)

20

Rocker Arm Nuts 25 N•m (18 lbf ft)

8000 SRM 1320

Torque Specifications

Rocker Arm Studs 47 N•m (35 lbf ft)

Vibration Damper 95 N•m (70 lbf ft)

Rocker Arm Bolts 30 N•m (22 lbf ft)

ENGINE - CUMMINS 4.5L AND QSB 3.3L DIESEL

Thermostat Housing 25 N•m (18 lbf ft)

For torque instructions for the Cummins 4.5L and QSB 3.3L diesel engine, contact your local Hyster dealer or see Hyster Hypass Online.

Timing Cover 12 N•m (106 lbf in) Valve Lifter Retainer Capscrews 16 N•m (142 lbf in)

21

100 SRM 1316

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: • 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.

1. COWL PLATE 2. FENDERS

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 1319.

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, 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.

3. HOOD MOUNTS 4. COUNTERWEIGHT MOUNTS

5. HYDRAULIC TANK 6. FUEL TANK (GAS OR DIESEL)

Figure 1. Frame

1

Hood, Seat, Dash, and Side Covers Replacement

100 SRM 1316

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 2. 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, Dash, and Side Covers Replacement REMOVE 1. Remove the floor mat and floor plate. See Figure 3.

11. Remove the five fasteners (see Figure 4) 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.

2. Slide the seat to the closest position to the steering column.

12. Lift the kick panel to remove it from the truck.

See Figure 3.

3. Fully tilt the steering column forward.

13. Remove the three capscrews holding the seal plate. Remove seal plate. See Figure 5.

4. If your truck is equipped with an LPG tank, swing the tank off to the side. 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. Raise the hood latch, unlatch and lift up the hood.

See Figure 2.

6. Remove the two capscrews holding the left and right rear side panel to the frame. Remove the rear side panel from the frame. See Figure 3.

7. Remove the two capscrews holding the left and right fender covers to the front overhead guard leg. Remove covers. See Figure 3.

8. Remove the four capscrews holding the left and right front side panels to the frame. Remove panels.

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 4.

2

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 flange nuts 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. See Figure 2.

100 SRM 1316

Hood, Seat, Dash, and Side Covers Replacement

18. Remove the hinge screws, located in the rear of the hood.

19. Lift the hood from the truck. See Figure 2.

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. 3-D VIEW OF VENTED HOOD WITH SWIVEL SEAT

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

SEAT HOOD FRAME SEAT WIRE HARNESS SEAT WIRE HARNESS CONNECTOR CABLE CLIPS HINGE SCREWS GAS SPRING ATTACHMENT HOLES ATTACHING HOOD TO SEAT (SEMI-SUSPENSION)

SEAT WIRE HARNESS BRACKETS SEAT LINER HOOD LATCH ATTACHMENT HOLES ATTACHING HOOD TO SEAT (NON-SUSPENSION) 14. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (FULL SUSPENSION) 15. SPACER 16. FLANGE NUTS

Figure 2. Hood and Seat Arrangement

3

Hood, Seat, Dash, and Side Covers Replacement

1.

2.

3.

4.

DEBRIS COVER COUNTERWEIGHT COVER RADIATOR COVER LEFT SIDE REAR PANEL (GAS AND DIESEL SHOWN) 5. RIGHT SIDE REAR PANEL 6. UPPER STEERING COLUMN COVER

7. LOWER STEERING COLUMN COVER 8. SEAL 9. FLOOR MAT 10. FLOOR PLATE 11. SPLASH SHIELD (GAS AND DIESEL) 12. CAPSCREW

100 SRM 1316

13. FOLD OVER NUT 14. SEAL PLATE ASSEMBLY 15. RIGHT SIDE FRONT FENDER COVER 16. RIGHT SIDE STEP PLATE 17. RIGHT SIDE STEP PLATE 18. DASH ASSEMBLY 19. KICK PANEL

Figure 3. Side Covers, Floor Plate, and Cowl Components

4

100 SRM 1316

Hood, Seat, Dash, and Side Covers Replacement

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 4. Remove Dash From Cowl

5

Hood, Seat, Dash, and Side Covers Replacement

1. CAPSCREWS

100 SRM 1316

2. SEAL PLATE Figure 5. 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 N•m (28 lbf ft). See Figure 2.

3. Align the holes in the gas springs with holes in the hood. There are two sets of holes used to install the gas springs to the hood, based on the

6

type of seat the installed on the lift truck. One set is for installing the cylinder end of the gas springs and the other set is for attaching the rod end of the gas springs. Install capscrews and washers to attach gas springs to the hood. Refer to Figure 6 and Table 1 for correct holes used to connect the rod end of the cylinder, depending on the type of seat installed on the lift truck.

Tighten capscrews to 19.2 N•m (170 lbf in).

100 SRM 1316

Hood, Seat, Dash, and Side Covers Replacement

NOTE: SEE TABLE 1 FOR HOLES TO USE TO ATTACH ROD END OF GAS SPRING. A. LEFT SIDE B. RIGHT SIDE

C. FULL SUSPENSION SEAT D. NON-SUSPENSION SEAT

1. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT 2. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT Figure 6. Gas Spring Installation Table 1. Gas Spring Installation, Holes for Installing Rod Ends (See Figure 6) Counterweight Type Standard Counterweight

Full or Semi Suspension Seat

Non-Suspension Seat

Left Side

Right Side

Left Side

Right Side

2

2

1

1

7

Hood, Seat, Dash, and Side Covers Replacement 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.

100 SRM 1316

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.

6. Place the seat on the hood and thread the seat wire harness through the hole in the hood. See Figure 2.

7. Align the holes in the seat with the holes in the hood. Insert washers and capscrews. Tighten capscrews to 18 N•m (159 lbf in).

8. 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.

9. 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.

10. Using three capscrews, Install seal plate. See Figure 5.

11. Install kick panel onto truck. See Figure 3.

12. Install dash to top of cowl. See Figure 4. Install four clips to attach the dash to kick panel.

Tighten capscrews to 0.5 to 0.6 N•m (5 to 6 lbf in).

13. Install upper and lower steering column covers by connecting the two covers together and pressing each side until latched.

14. Using four capscrews, install the left and right front side panels to frame. See Figure 3.

15. Using two capscrews install the left and right fender covers to front of overhead guard legs.

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.

8

16. Using two capscrews, Install the left and right rear side covers to frame. See Figure 3.

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 1316

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 (EZXchange™ 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 power 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

9

LPG Tank and Bracket Replacement

100 SRM 1316

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

10

100 SRM 1316

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. 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. Remove capscrew (1, Figure 10) first, then remove rest of capscrews (2, Figure 10) that attach the LPG bracket to counterweight.

3. Remove the LPG tank bracket from the lift truck.

NOTE: EZXCHANGEâ„¢ BRACKET SHOWN. A. SIDE VIEW OF COUNTERWEIGHT AND LPG FUEL SYSTEM

B. FRONT VIEW OF COUNTERWEIGHT AND LPG FUEL SYSTEM

1.

2.

3.

4.

7.

8.

9.

10.

11.

12.

13.

14.

QUICK-DISCONNECT CONNECTION HOSE ASSEMBLY CAPSCREW HOSE ASSEMBLY TO LPG REGULATOR/LOCK-OFF (THROUGH HOLE IN COUNTERWEIGHT) 5. MOUNTING BRACKET 6. LPG REGULATOR CONNECTION

LPG FUEL FILTER LPG REGULATOR FILTER HOSE LPG REGULATOR HOSE TO INTAKE MANIFOLD COOLANT HOSES HOSE TO FUEL RAIL TANK STRAP LPG TANK BRACKET

Figure 9. LPG Tank Hose Connections, GM 4.3L Engine

11

LPG Tank and Bracket Replacement

INSTALL LPG Bracket 1. Place the LPG bracket onto the counterweight.

Be sure to align the holes on the counterweight with the holes on the bracket (see Figure 10).

Insert hose assembly to LPG regulator/lock-off through the hole in counterweight.

2. Install and tighten three capscrews (2, Figure 10) to 38 N•m (28 lbf ft) to secure the LPG bracket onto the counterweight.

3. Install and tighten capscrew (1, Figure 10) to 38 N•m (28 lbf ft).

100 SRM 1316 the swing-out and drop-down bracket (EZXchange bracket), position the bracket in the drop-down position.

WARNING When closing the LPG tank strap, do not wrap your fingers around the strap handle. The 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. Connect the hose to the LPG fuel lock-off connection on the LPG regulator. See Figure 9.

5. Connect the fitting on the LPG tank. See Figure 8.

6. Turn the fuel valve counterclockwise to open the fuel valve.

7. 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.

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 10. LPG Tank Bracket Removal

LPG Tank NOTE: The LPG bracket must be in the swing-out position to install the LPG tank. If your lift truck has

12

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.

100 SRM 1316

Counterweight Replacement

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 1319 for lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024).

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.

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.

NOTE: The counterweight is held in position on the frame by two hooks that are part of the frame. One M30 x 3.5 x 120 capscrew holds the counterweight to the lower part of the frame. See Figure 11.

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 section LPG Fuel System, GM 4.3L Engine 900 SRM 1242.

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 2.

2. Install a lifting eye in the lift hole of the counterweight. See Figure 11. 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 11. Use the crane to lift the counterweight from the lift truck. Put counterweight on the floor so that it has stability and will not fall over. Take care not to damage exhaust or cooling components.

13

Counterweight Replacement

100 SRM 1316 Table 2. Weight of Counterweights Model

Weight

S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)

2779 kg (6126 lb)

INSTALL 1. Make sure the seals are on the counterweight.

See Figure 12. 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 capscrew to 1020 N•m (750 lbf ft).

2. Install tow pin and roll pin, see Tow Pin, Remove and Install for procedures.

1.

2.

3.

4.

FRAME HOOK SEALS CAPSCREW COUNTERWEIGHT COVER

5.

6.

7.

8.

COUNTERWEIGHT TOW PIN ROLL PIN WASHER

Figure 11. Counterweight Installation

14

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.

4. If lift truck is equipped with an overhead exhaust system, install the overhead exhaust pipe. See the section Exhaust System Repair for the procedures.

100 SRM 1316

1.

2.

3.

4.

CAPSCREW COUNTERWEIGHT COVER COUNTERWEIGHT TOW PIN

Counterweight Replacement

5. ROLL PIN 6. WASHER 7. SEALS Figure 12. Counterweight Components

15

Overhead Guard Replacement

100 SRM 1316

TOW PIN, REMOVE AND INSTALL 1. Remove the tow pin from the counterweight by driving the roll pin out. See Figure 13.

2. Install tow pin into counterweight and install roll pin.

1. TOW PIN

2. ROLL PIN Figure 13. Tow Pin

Overhead Guard Replacement REMOVE 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 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

16

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 in the center of the overhead guard. If during the initial start of the lift, the overhead guard is off balance, lower immediately and move the hoist to a more centered point.

1. Connect a lifting device to remove 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 14.

2. Disconnect wires between the frame and the overhead guard. When the overhead guard is lifted from the frame, make sure that electrical wires are moved through the holes in the overhead guard 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 the capscrews. See Figure 15.

100 SRM 1316

1. CLAMP 2. AIR INTAKE HOSE 3. BOLTS

Overhead Guard Replacement

4. ELBOW 5. RETAINER 6. GROMMET

Figure 14. Disconnect Air Intake Hose 4. Remove the fender cover, dash, and kick panel to remove the three capscrews on the front legs of the overhead guard. See Hood, Seat, Dash, and Side Covers Replacement for the removal procedures.

5. Using a lifting device, remove overhead guard from frame and place on floor.

INSTALL 1. Connect lifting device to top of overhead guard.

Install overhead guard in position on lift truck.

2. Install the three capscrews on the front legs of the overhead guard. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 15.

1.

2.

3.

4.

CAPSCREWS - FRONT LEGS HANDLE CAPSCREWS - REAR LEGS FRAME Figure 15. Overhead Guard

4. Install the two capscrews on the rear legs of the overhead guard. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 15.

5. Connect air intake hose by installing bolts, elbow, retainer, and grommet to overhead guard rear leg. See Figure 14.

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.

3. Install the fender cover, dash, and kick panel.

See Hood, Seat, Dash, and Side Covers Replacement for the installation procedures.

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Engine Replacement

100 SRM 1316

Engine Replacement REMOVE ENGINE ONLY

WARNING

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.

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 equipments, or ignition source.

1. For lift trucks equipped with an LPG fuel system, close the shutoff 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

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 1319 for lift truck models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024).

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.

The engine can be removed with or without the transmission. Follow the procedures below to remove the engine without the transmission. See Figure 16.

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.

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

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. See Figure 17.

Legend for Figure 16 NOTE: PART OF THE FRAME NOT SHOWN FOR CLARITY. A. GM 4.3L ENGINE B. CUMMINS 4.5L DIESEL ENGINE

C. CUMMINS QSB 3.3L DIESEL ENGINE

1.

2.

3.

4.

5.

6. FRAME 7. ENGINE HARNESS CONNECTOR 8. LEFT CHASSIS WIRING HARNESS CONNECTOR

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TRANSMISSION ISOLATOR ASSEMBLY TRANSMISSION MOUNTING BRACKET ENGINE MOUNTING BRACKET ENGINE CROSSMEMBER ENGINE ISOLATOR ASSEMBLY