Hyster B238 (H360-36HD, H360-48HD) Internal Combustion Engine Trucks Service Repair Manual

Hyster B238 (H360-36HD, H360-48HD) Internal Combustion Engine Trucks Service Repair Manual

FRAME AND MAIN COMPONENTS

PART NO. 4147656

0100 SRM 1978

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

Do not lift heavy parts by hand, use a lifting mechanism.

Wear safety glasses.

DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

Keep the unit clean and the working area clean and orderly.

Use the correct tools for the job.

Keep the tools clean and in good condition.

Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

Be sure to follow the WARNING and CAUTION notes in the instructions.

Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS Series Code / Model Designation Reference Table ................................................................................................ 1 General .....................................................................................................................................................................1 Description ...............................................................................................................................................................2 Remove and Install ..................................................................................................................................................3 Air Filter Assembly (Tier 3/Stage IIIA) ............................................................................................................. 3 Remove ............................................................................................................................................................ 3 Install .............................................................................................................................................................. 3 Air Filter Assembly (Tier 4F/Stage IV) ..............................................................................................................4 Remove ............................................................................................................................................................ 4 Install .............................................................................................................................................................. 4 Exhaust System (Tier 3/Stage IIIA) ...................................................................................................................5 Remove ............................................................................................................................................................ 5 Install .............................................................................................................................................................. 5 Exhaust System (Tier 4F/Stage IV) ................................................................................................................... 6 Exhaust Pipes High Mount ............................................................................................................................ 6 Remove ........................................................................................................................................................6 Install ..........................................................................................................................................................6 Exhaust Pipes and Diffuser Low Mount ....................................................................................................... 8 Remove ........................................................................................................................................................8 Install ..........................................................................................................................................................8 Engine After Treatment (EAS) System (Tier4F\Stage IV) ..............................................................................8 Preparation ..................................................................................................................................................... 8 Remove ............................................................................................................................................................ 9 Install ............................................................................................................................................................ 10 Exhaust Seal Rings .......................................................................................................................................10 Selective Catalytic Reducer (SCR) ...............................................................................................................11 Remove ......................................................................................................................................................11 Install ........................................................................................................................................................11 Decomposition Reactor Tube (DRT) ............................................................................................................ 12 Remove ......................................................................................................................................................12 Install ........................................................................................................................................................12 Diesel Oxidation Catalyst (DOC) .................................................................................................................12 Remove ......................................................................................................................................................12 Install ........................................................................................................................................................12 Hood Assembly ..................................................................................................................................................12 Remove .......................................................................................................................................................... 12 Install ............................................................................................................................................................ 14 Running Boards, Steps and Mud Flaps ........................................................................................................... 14 Hydraulic Tank ................................................................................................................................................. 16 Remove .......................................................................................................................................................... 16 Inspect ........................................................................................................................................................... 18 Clean ..............................................................................................................................................................18 Steam Cleaning Method ...........................................................................................................................19 Chemical Solution Cleaning Method .......................................................................................................19 Repair ............................................................................................................................................................ 19 Small Leaks .............................................................................................................................................. 19 Large Leaks .............................................................................................................................................. 19 Inspection after Repair .................................................................................................................................20 Install ............................................................................................................................................................ 20 Fuel Tank .......................................................................................................................................................... 22

©2015 HYSTER COMPANY

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Table of Contents

TABLE OF CONTENTS (Continued) Remove .......................................................................................................................................................... 22 Clean and Repair .......................................................................................................................................... 24 Install ............................................................................................................................................................ 24 Engine and Transmission (Tier 3/Stage IIIA) ................................................................................................. 24 Remove .......................................................................................................................................................... 24 Precautions ............................................................................................................................................... 24 Remove Air Conditioning Compressor .................................................................................................... 25 Drain the Engine Cooling System ........................................................................................................... 25 Drain Hydraulic Oil ................................................................................................................................. 26 Drain Transmission Oil ........................................................................................................................... 26 Disconnect Drive Shaft, Fan Clutch, Tubes, Pipes, Cables, Wires and Lines ...................................... 26 Remove Engine and Transmission .......................................................................................................... 28 Install ............................................................................................................................................................ 30 Install Engine and Transmission ............................................................................................................ 30 Install Air Conditioning Compressor ...................................................................................................... 30 Connect Drive Shaft, Fan, Tubes, Pipes, Cables, Wires and Lines .......................................................30 Refill the Systems .....................................................................................................................................31 Starting the Engine ..................................................................................................................................31 Engine and Transmission (Tier 4F/Stage IV) ..................................................................................................32 Remove .......................................................................................................................................................... 32 Precautions ............................................................................................................................................... 32 Remove Air Conditioning Compressor .................................................................................................... 32 Drain the Engine Cooling System ........................................................................................................... 33 Drain Hydraulic Oil ................................................................................................................................. 33 Drain Transmission Oil ........................................................................................................................... 34 Disconnect Drive Shaft, Fan Clutch, Tubes, Pipes, Cables, Wires and Lines ...................................... 34 Remove Engine and Transmission .......................................................................................................... 36 Install ............................................................................................................................................................ 38 Install Engine and Transmission ............................................................................................................ 38 Install Air Conditioning Compressor ...................................................................................................... 38 Connect Drive Shaft, Fan, Tubes, Pipes, Cables, Wires and Lines .......................................................38 Refill the Systems .....................................................................................................................................39 Starting the Engine ..................................................................................................................................39 Operator's Cab ...................................................................................................................................................40 Remove .......................................................................................................................................................... 40 Install ............................................................................................................................................................ 42 Cab Tilt System Oil Filling .......................................................................................................................... 43 Counterweight ...................................................................................................................................................44 Remove .......................................................................................................................................................... 44 Install ............................................................................................................................................................ 45 Label Replacement ............................................................................................................................................46 Capacities and Specifications ............................................................................................................................... 47 Torque Values for Frame and Main Components ........................................................................................... 47 This section is for the following models:

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0100 SRM 1978

Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table This section is for the following models: Series Code B238

Model Designation Europe

Model Designation America

H16XM-9, H16XM-12, H18XM-7.5, H360-36HD, H360-48HD H18XM-9

General This manual contains the procedures for removal and installation of main components mounted on the frame of the B238 lift truck series. The manual includes air filter assembly, exhaust system, hood assembly, handrails and steps, hydraulic tank, fuel tank, engine, transmission, operator’s cab and counterweight.

•

Steering System 1600SRM1932

•

Mast 4000SRM1664

For information on torque values, see the section Metric & Inch Fasteners 8000SRM0231.

For information on the drive axle, steering axle and mast refer to: •

Kessler Drive Axle 1400SRM1667

1

Description

0100 SRM 1978

Description DO NOT initiate repairs to the frame without consulting a Hyster service representative or damage to the lift truck may occur.

The frame is a one-piece weldment that has mounts for the main and/or additional components: counterweight, engine, transmission, drive and steer axles, hydraulic and fuel tanks, operator's compartment, and other parts. See Figure 1.

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CAUTION

COUNTERWEIGHT MOUNT TIE DOWN EYES COOLING ASSEMBLY MOUNT (DEF TANK) EXTENSION PLATE (TIER 4F) DEF TANK MOUNT FUEL TANK MOUNT DEF FILTER MOUNT CAB LOCK MOUNT DRIVE AXLE MOUNT FRAME

MAST MOUNT HYDRAULIC TANK MOUNT CAB SIDE TILT EXTENSION PLATE AFTER TREATMENT FRAME MOUNT ENGINE MOUNT TRANSMISSION MOUNT TILT CYLINDER MOUNT CAB TILT BRACKET MAIN CONTROL VALVE MOUNT

Figure 1. Frame Mounts

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0100 SRM 1978

Remove and Install

Remove and Install AIR FILTER ASSEMBLY (TIER 3/STAGE IIIA)

4. Remove the cap from the turbocharger.

Remove

5. Rotate and connect air filter hose to air filter housing and the turbocharger and tighten hose clamps to 8 N•m (6 lbf ft).

1. Open left-hand hood door. See Hood Assembly.

6. Close the hood doors. See Figure 15.

2. Tag and disconnect the electrical connector from vacuum switch by pressing the metal clip.

7. Install the Precleaner, with the air duct attached, on the air cleaner.

3. Loosen the air duct clamp at the filter housing.

See Figure 2.

8. Open left-hand hood door.

4. Close left-hand hood door to access the Precleaner.

5. Remove the Precleaner, with the air duct attached, from the air filter housing.

9. Install and tighten the air duct clamp.

10. Connect electrical connector to vacuum switch.

11. Close the hood door.

6. Open left-hand and right-hand hood doors.

7. Loosen the hose clamps on the air filter hose and remove the hose. See Figure 2.

8. Place a cap on the air inlet of the turbocharger to avoid dirt entering the turbocharger.

9. Place a support under the air filter assembly.

10. Remove the cap screws and washers from the mounting clamps that hold the air filter assembly.

11. Rotate the air filter until the air duct connection clears the center of the hood opening and move the air filter to the right-hand side of the truck.

12. Remove the retaining hardware from the mounting clamps and remove the clamps from the hood by removing the hardware.

Install 1. Install the retaining hardware to the mounting clamps and install the clamps under the hood.

2. Position the air filter housing into the mounting clamps with the air intake aligned with the hole in the mounting plate.

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AIR FILTER HOSE AIR FILTER HOUSING VACUUM SWITCH AIR DUCT CLAMP AIR DUCT PRECLEANER AIR FILTER BRACKETS HOSE CLAMP FILTER HOUSING MOUNTING CLAMP Figure 2. Air Filter Assembly (Tier 3/Stage IIIA)

3. Install cap screws and washers and tighten to 38 N•m (28 lbf ft).

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Remove and Install

0100 SRM 1978

AIR FILTER ASSEMBLY (TIER 4F/STAGE IV)

4. Remove cap from the air inlet on the turbocharger.

Remove

5. Connect air filter hose to the turbocharger and to the air filter housing and tighten the hose clamps to 8 N•m (6 lbf ft).

1. Open left-hand and right-hand hood door. See Hood Assembly.

2. Tag and disconnect the connectors to the vacuum switch and to the TBAP sensor (Temperature and Barometric Air Pressure sensor).

3. Remove the three cap screws, nuts and washers from the air duct bracket on the center hood.

See Figure 3.

4. On trucks with High Mount Precleaner, remove the U-clamp from the support bracket. See Figure 4.

6. Connect the connectors to the vacuum switch and to the Temperature and Barometric Air Pressure (TBAP) sensor according the tags.

7. Close the hood doors.

8. Install the Precleaner, with the air duct attached, to the center hood.

9. On trucks with High Mount Precleaner, install the U-clamp to the support bracket.

5. Remove the Precleaner, with the air duct attached, from the air filter housing.

6. Open left-hand and right-hand hood doors. See Figure 15.

7. Loosen the hose clamps on the air filter hose and remove the hose from the air filter and the turbocharger.

8. Place a cap on the air inlet of the turbocharger to avoid dirt entering the turbocharger.

9. Remove the four cap screws that retain the brackets of the air filter unit to the hood.

10. Lower the air filter unit until it is clear from the hood.

11. Remove the air filter to the right-hand side of the truck.

Install 1. Open left-hand and right-hand hood doors.

2. Position the air filter housing with the air intake aligned with the hole in the mounting plate.

3. Install the air filter housing with the four washers and cap screws and tighten to 65 N•m (48 lbf ft).

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AIR FILTER HOSE VACUUM SWITCH HOSE CLAMP TBAP SENSOR HOUSING BRACKET AIR DUCT BRACKET AIR DUCT PRECLEANER AIR FILTER HOUSING Figure 3. Air Filter Assembly with Low Mount Precleaner (Tier 4F/Stage IV)

0100 SRM 1978

A. HIGH MOUNT PRECLEANER FOR CABS WITHOUT AIRCO B. HIGH MOUNT PRECLEANER FOR CABS WITH AIRCO 1.

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PRECLEANER PRECLEANER CLAMP AIR DUCT U-CLAMP SUPPORT BRACKET AIR DUCT CLAMP Figure 4. Air Filter Assembly with High Mount Precleaner (Tier 4F/Stage IV)

Remove and Install

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MUFFLER CAP SCREW AND WASHER CLAMP EXHAUST PIPE ASSEMBLY V-BAND CLAMP Figure 5. Exhaust System (Tier 3/Stage IIIA)

5. Place a cap on the air inlet of the turbocharger to avoid dirt entering the turbocharger.

6. Remove the hardware that retains the muffler to the center hood and remove the muffler.

EXHAUST SYSTEM (TIER 3/STAGE IIIA)

Install

Remove

1. Place the muffler on the center hood and attach the hardware.

WARNING Exhaust system must be at room temperature before starting disassembly or personal injury may occur.

1. Open left- and right-hand hood doors. See Hood Assembly.

2. Remove V-band clamp from turbocharger See Figure 5.

3. Remove V-band clamp from the muffler.

2. Remove the cap from the air inlet of the turbocharger.

3. Install the exhaust pipe assembly.

4. Tighten the band clamp on the muffler to 54 81 N•m (40 - 60 lbf ft).

5. Tighten the band clamp on the turbocharger to 5.6 N•m (4 lbf ft).

6. Close the hood doors.

4. Remove the exhaust pipe assembly.

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Remove and Install

EXHAUST SYSTEM (TIER 4F/STAGE IV) WARNING Exhaust system must be at ambient temperature before starting disassembly or personal injury may occur.

Wait at least 100 seconds after the engine has been switched off then move the battery disconnect switch to the disconnected position. Disconnect the ground cable from the batteries.

0100 SRM 1978 2. Install the U-clamp on the lower end of the end pipe.

3. Install the retainer bracket at the top of the end pipe.

4. Install the diluter.

5. Install the exhaust pipe assembly in the end pipe and to the outlet of the SCR. See Figure 8.

6. Tighten the band clamp that retains the exhaust frame to the SCR to 4.95 N•m (3.65 lbf ft).

Exhaust Pipes High Mount Remove 1. Loosen the clamp at the connection between exhaust pipe assembly and end pipe. See Figure 6.

2. Remove the band clamp from the Selective Catalic Reducer (SCR) outlet.

3. Remove the exhaust pipe assembly.

4. Remove the cap screws from the diluter to counterweight connection. See Figure 7.

5. Remove the diluter.

6. Remove the end pipe retainer bracket on the counterweight.

7. Remove the U-clamp from the end pipe.

8. Remove the end pipe from the counterweight tube at the top of the counterweight.

Install 1. Insert the end pipe in the counterweight tube at the top of the counterweight. See Figure 8.

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DILUTER ASSEMBLY EXHAUST END PIPE U-CLAMP EXHAUST PIPE ASSEMBLY V-BAND CLAMP

Figure 6. Exhaust Pipe High Mount (Tier 4F/Stage IV)

0100 SRM 1978

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COUNTERWEIGHT CAP SCREW WASHER DILLUTER CAP SCREW WASHER END PIPE RETAINER BRACKET END PIPE Figure 7. Diluter Assembly (Tier 4F/Stage IV)

Remove and Install

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DILUTER EXHAUST END PIPE EXHAUST PIPE ASSEMBLY AFTER TREATMENT SYSTEM SUBFRAME HEAT SHIELD INSULATION PIPE ASSEMBLY Figure 8. Exhaust System High Mount (Tier 4F/ Stage IV)

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Remove and Install

Exhaust Pipes and Diffuser Low Mount Remove 1. Remove the clamp from the Selective Catalytic Reducer (SCR) outlet. See Figure 9.

2. Place a support under the diffuser.

3. Remove the cap screws and washers from the isolators.

0100 SRM 1978

ENGINE AFTER TREATMENT (EAS) SYSTEM (TIER4F\STAGE IV) NOTE: Due to difficult accessibility of wire and hose connections it is advised to first remove the entire EAS assembly, followed by the replacement of individual EAS components. When replacing components of the EAS make sure to replace the exhaust seals and obtain the correct and final assembly position, before tightening clamps.

4. Remove the diffuser and exhaust assembly out of the SCR outlet.

Preparation

Install

2. Lower the mast completely.

1. Install the diffuser and exhaust assembly by inserting the exhaust assembly in the SCR outlet.

3. Apply the parking brake.

2. Install the isolators, washer and cap screws to the bottom side of the frame and tighten the cap screws to 35 N•m (26 lbf ft).

3. Tighten clamp to 54 - 81 N•m (40 - 60 lbf ft).

1. Place the truck on a solid, level surface.

4. Switch the engine OFF. 5. Put the lift truck on blocks. See Periodic Maintenance 8000SRM1983.

6. Remove the V-band clamps from the flanges of the insulated exhaust pipe. See Figure 13, Item 8 and 9.

7. Remove the insulation pipe from the engine and remove the flange seals.

8. Remove the exhaust pipes. a. For High Mount System, see Exhaust Pipes High Mount. b. For Low Mount System, see Exhaust Pipes and Diffuser Low Mount.

1. DIFFUSER 2. ISOLATOR MOUNTS 3. EXHAUST PIPE ASSEMBLY 4. CLAMP 5. CAP SCREW Figure 9. Exhaust Pipe Connections Low Mount (Tier 4F/Stage IV)

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0100 SRM 1978

Remove 1. Disconnect the electrical connections from the After Treatment System, mounted on the frame, on the left-hand side:

Remove and Install 3. Disconnect the cooling hoses from the Coolant Solenoid valve.

4. Put plugs on the hoses and caps on the hose connections.

a. Disconnect the ECM/EAS Harness connector from the Frame Harness connector. See Figure 10.

5. Disconnect the DEF pressure hose from the DEF pump. See Figure 12.

b. Disconnect the ECM/EAS Harness connectors from the engine. See Figure 11.

6. Use a forklift truck with a pallet to support the after treatment system.

2. Put caps on the connectors to prevent from damage.

7. Remove the cap screws that retain the after treatment system to the frame.

8. Gently lower the pallet with the after treatment system and move it away from the truck.

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ECM/EAS HARNESS CONNECTOR SELECTIVE CATALYTIC REDUCER (SCR) COOLANT SOLENOID VALVE INJECTOR COOLING SUPPLY HOSE INJECTOR COOLING RETURN HOSE TRANSMISSION FRAME

Figure 10. Coolant Solenoid Valve Connections (Tier 4F/Stage IV)

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CPS133 FAN CLUTCH CRP12 ECM CROSS OVER CRP03 ECM TIER 4 CPP03 ENGINE ECM SIGNALS

Figure 11. ECM/EAS Harness Connectors (Tier 4F/ Stage IV)

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Remove and Install

0100 SRM 1978

Exhaust Seal Rings In the high pressure part of the exhaust system, the tubes and pipes are sealed by means of metal seal rings. These seal rings deform when V-band clamps are tightened and will stick to one of the exhaust components at disassembly. Remove the used seal and replace by a new one at re-assembly. Pay attention to the different sizes and shapes of seals at the different locations. Pay attention to the different torque value of the V-band clamp at the connection with the turbo. See Figure 13.

1. DEF PUMP 2. DEF PRESSURE HOSE TO INJECTOR Figure 12. DEF Supply Hose (Tier 4F/Stage IV)

Install 1. Move the pallet with the after treatment system under the truck.

2. Install the cap screws that retain the after treatment system to the frame.

3. Re-connect the hoses and electrical connections.

4. Install a new seal and move the flanges of the insulated exhaust pipe and the Diesel Oxidation Catalyst (DOC) against each other. See Figure 13, item 8 and 9.

5. Tighten the V-band clamp to 13.5 ± 1.5 N•m (10 ± 1 lbf ft).

6. Install the flange seals and install the insulation pipe to the engine.

7. Tighten the V-band clamp to 7 ± 1 N•m (5 ± 0.7 lbf ft).

8. Install the exhaust system. a. For High Mount System, see Exhaust Pipes High Mount. b. For Low Mount System, see Exhaust Pipes and Diffuser Low Mount.

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1. BAND CLAMP 2. V-BAND CLAMP AND SEAL RING 5” – SPHERICAL 3. V-BAND CLAMP AND SEAL RING 4” – SPHERICAL 4. V-BAND CLAMP AND SEAL RING 4” – SPHERICAL 5. BAND CLAMP 6. V-BAND CLAMP AND SEAL RING 4” – SPHERICAL 7. V-BAND CLAMP AND SEAL RING 4” – SPHERICAL 8. V-BAND CLAMP AND SEAL RING 4” – STANDARD 9. V-BAND CLAMP AND SEAL RING 3.5" – 70° Figure 13. Exhaust Seal Rings

0100 SRM 1978

Remove and Install NOTE: When replacing components of the EAS make sure to replace the exhaust seals and obtain the correct and final assembly position, before tightening clamps.

Selective Catalytic Reducer (SCR) Remove 1. Disconnect the two 4-pin connectors from the SCR. See Figure 14.

2. Remove the V-band clamp from the connection between SCR and connection pipe to the DRT and move the flanges apart.

3. Remove the strap clamps that connect the SCR to the exhaust sub-frame.

4. Remove the SCR from the exhaust sub-frame.

Install 1. Install the SCR to the exhaust sub-frame, with the strap clamps. Hand-tighten the strap clamps.

2. Insert a new seal and move the flanges of the SCR and the connection pipe to the DRT against each other.

A. SCR CONNECTIONS B. DRT CONNECTIONS C. DOC CONNECTIONS 1.

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NOX SENSOR SELECTIVE CATALIC REDUCER (SCR) DECOMPOSITION REACTOR TUBE (DRT) DIESEL OXIDATION CATALYST (DOC) ELECTRICAL CONNECTORS ON SCR ELECTRICAL CONNECTOR ON DRT DEF HOSE ON DRT COOLING HOSES ON DRT ELECTRICAL CONNECTORS ON DOC Figure 14. EAS System (Tier 4F/Stage IV)

3. Make sure that the SCR is in its final assembly position.

4. Tighten the V-band clamp to 13.5 ± 1.5 N•m (10 ± 1 lbf ft). the strap 5. Tighten 4.95 N•m (3.65 lbf ft).

clamps

to

6. Connect the two 4-pin connectors to the SCR.

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Remove and Install

0100 SRM 1978

Remove

2. Remove the V-band clamp at the connection between DOC and DRT and separate the flanges to the DRT.

1. Disconnect and plug both coolant hoses from the DRT. See Figure 14.

3. Remove the strap clamps that connect the DOC to the exhaust sub-frame.

2. Disconnect and plug the DEF hose from the DRT.

4. Remove the DOC from the exhaust sub-frame.

Decomposition Reactor Tube (DRT)

3. Disconnect the electrical connector from the DRT. 4. Remove the V-band clamp at the outlet of the DRT, and separate the flanges of DRT and the connection elbow to the SCR. 5. Remove the V-band clamp at the connection between DRT and DOC and separate the flanges to the DOC. 6. Remove the band clamp that connect the DRT to the exhaust sub-frame bracket.

7. Remove the DRT from the exhaust sub-frame.

Install 1. Install the DRT to the exhaust sub-frame bracket, with the band clamp. Hand-tighten the strap clamp.

Install 1. Install the DOC with the strap clamps to the exhaust sub-frame.

2. Install new seals between the DOC and DRT. 3. Make sure that the DOC is in its final assembly position.

4. Mount the V-band clamp and tighten the Vband clamp to 13.5 ± 1.5 N•m (10 ± 1 lbf ft).

5. Tighten the strap clamps that retain the DOC to the exhaust to 4.95 N•m (3.65 lbf ft).

HOOD ASSEMBLY NOTE: Only for trucks with Tier 3/Stage IIIA engines, the hood also carries a muffler. On trucks with Tier 4F/Stage IV engines, the hood just holds the air intake precleaner.

2. Insert new seals at the connection with DOC and SCR and make sure that the SCR is in its final assembly position.

Remove

3. Tighten the V-band clamp to 13.5 ± 1.5 N•m (10 ± 1 lbf ft).

2. Apply parking brake.

4. Reconnect the DEF hose and the cooling hoses to the DRT. 5. Reconnect the electrical connector to the DRT.

1. Tilt mast completely forward.

3. Switch the engine OFF. 4. Completely tilt (raise) the cab. See the section Operator's Cab 0100SRM1390.

5. Disconnect the battery cables from the battery.

6. Tighten the band clamp that retains the DRT to the exhaust frame bracket to 3.44 N•m (2.5 lbf ft).

6. Open rear cover and disconnect the two gas springs from the counterweight. See Figure 15.

Diesel Oxidation Catalyst (DOC)

7. Remove the rear cover by sliding it sideways off its flexible hinge.

Remove

8. Open left- and right-hand hood door.

1. Disconnect the two 4-pin connectors from the DOC. See Figure 14.

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0100 SRM 1978

Remove and Install

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CENTER HOOD LEFT-HAND HOOD DOOR AIR INTAKE PRECLEANER MUFFLER REAR COVER RIGHT-HAND HOOD DOOR HOOD FRONT PLATE Figure 15. Hood Assembly (Tier 3/Stage IIIA)

9. On trucks with Tier 3/Stage IIIA engines, remove upper exhaust pipe, flex tube, and clamp from muffler.

CAP SCREW, WASHER AND NUT ISOLATOR COUNTERWEIGHT RADIATOR HOOD SUPPORT EXPANSION TANK MOUNTING (TIER 3/STAGE IIIA ONLY) 7. MUFFLER MOUNTING (TIER 3/STAGE IIIA ONLY) Figure 16. Hood Support 15. Remove four cap screws, nuts, and eight washers that hold the hood front plate to the frame.

See Figure 17.

16. Attach a lifting device to hood assembly.

10. Remove the muffler.

11. Remove air filter unit. See chapter Air Filter Assembly (Tier 3/Stage IIIA) or Air Filter Assembly (Tier 4F/Stage IV), depending on your lift truck.

12. Remove nuts and washers from two isolator assemblies on top of radiator and remove isolator assemblies. See Figure 16.

13. Remove all tie-wraps holding electrical cables to hood assembly.

14. Remove two cap screws, nuts, and four washers that hold the hood support to the frame. See Figure 16.

1. HARDWARE 2. HOOD FRONT PLATE Figure 17. Hood Front Plate (Tier 3/Stage IIIA shown)

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Remove and Install

0100 SRM 1978

Use caution when lifting the hood assembly to avoid damage to the rear of the operator’s cab.

8. Install air filter unit. See chapter Air Filter Assembly (Tier 3/Stage IIIA) or Air Filter Assembly (Tier 4F/Stage IV), depending on your lift truck.

17. Slowly lift the hood assembly from the frame and make sure all electric cables are removed from the hood.

9. On trucks with Tier 3/Stage IIIA engines, install upper exhaust pipe, flex tube, and clamp to muffler.

18. Place the hood assembly on the ground and place a support under the rear of the hood frame.

10. Use tie wraps to hold electrical cables in original position on hood assembly.

CAUTION

19. Close left- and right-hand hood door.

Install 1. Open left- and right-hand hood door. See Figure 15.

2. Attach a lifting device to hood assembly.

CAUTION Use caution when installing the hood assembly to avoid damage to the rear of the operator’s cab.

3. Position hood assembly on frame.

4. Install eight washers, four cap screws and four nuts holding hood front plate to the frame. See Figure 17.

5. Install four washers, two cap screws and nuts holding hood support to frame. See Figure 16.

6. Position two isolator assemblies between cooling system and hood support. See Figure 16.

7. Install washers and nuts to two isolator assemblies on top of cooling system.

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11. Close left- and right-hand hood door.

12. Close rear cover.

13. Completely lower the cab. See Operator's Cab 0100SRM1390.

14. Start the engine and check for leaks.

RUNNING BOARDS, STEPS AND MUD FLAPS The running boards and steps can be removed from the frame for access to components. See Figure 18.

Use a lifting device to secure floor plates, handrails and steps before loosening the fasteners that attach them. First detach the bolt connection with other components such as fenders and other floor plates, before loosening the bolted connection with the frame.

The truck can be equipped with mud flaps. The front mud flaps are installed at the front side of the fender. The front mud flap contains a bracket that holds the flap in front of the drive wheel. The rear mud flaps are installed on the counterweight. Before installation, first remove the cap screws that are installed in the threaded holes. After removal of the mud flaps, install the cap screws back in the holes.

0100 SRM 1978

Remove and Install

1. REAR MUDFLAP 2. CAP SCREW AND WASHER 3. ISOLATOR

4. FRONT FENDER 5. FRONT MUDFLAP 6. MUDFLAP BRACKET

Figure 18. Running Boards, Steps and Mud Flaps

15

Remove and Install

HYDRAULIC TANK The hydraulic tank is located at the right side of the frame between the front fender and the counterweight and has a maximum capacity of 172 liter (45.4 gal).

Remove

WARNING At operating temperature, the hydraulic oil is HOT. Before draining oil, make sure hydraulic oil has cooled down. Do not permit the oil to contact the skin and cause a burn.

CAUTION Make sure not to damage the hydraulic hoses and electrical cables during tank removal.

1. Place the truck on a solid, level surface.

2. Lower the mast completely.

0100 SRM 1978 battery box assembly it is necessary to disconnect all cables which are connected to the truck. Leave the cable gland on the cable to avoid damage to the cable.

10. Remove the PDM box cover by removing six screws.

11. Disconnect and remove all cables which are connected to the truck from the battery box.

See Figure 20.

12. Close the PDM box cover to prevent the parts from getting damaged.

13. Disconnect and remove the batteries from the battery box.

14. Remove the step from the top of the hydraulic tank, by removing the cap screws and washers.

15. The running board between the front fender and the counterweight weighs 26 kg (57.5 lb), therefore support the running board with a hand pallet truck or forklift truck.

3. Apply the parking brake.

4. Switch the engine OFF. 5. Remove the four cap screws and washers holding the right-hand panel on top of the hydraulic tank and remove the right-hand panel. See Figure 19.

6. Remove the four cap screws and washers holding the right-hand extension plate and remove the extension plate.

7. Remove the isolator.

8. Move the battery disconnect switch to the disconnected position (pointer up) and lock the switch.

CAUTION Disconnect the negative (ground) cable first or lift truck damage may occur.

9. Disconnect the negative (ground) and positive (power) cables from the batteries.

NOTE: The battery box is attached to the hydraulic tank. To be able to remove the hydraulic tank/

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1.

2.

3.

4.

5.

6.

7.

8.

9.

LEVEL INDICATOR HYDRAULIC TANK BATTERY BOX STEP RIGHT-HAND PANEL HYDRAULIC RETURN FILTER CAP SCREW AND WASHER RIGHT-HAND EXTENSION PLATE CAP SCREW, WASHER AND ISOLATOR Figure 19. Hydraulic Tank

0100 SRM 1978

Remove and Install

Legend for Figure 20 1.

2.

3.

4.

5.

6.

7.

CAB FUSEBOX PDM GLAND STARTER MOTOR TO FUSE ALTERNATOR FRAME SUPPLY BATTERY NEGATIVE (GROUND)

7.

8.

9.

10.

11.

MAIN VALVE RETURN HOSE HYDRAULIC TEMPERATURE SENSOR BRACKET MAIN PUMP SUCTION HOSE BRAKE COOLING PUMP SUCTION HOSE

Figure 20. Disconnect Cables from the Battery Box

1.

2.

3.

4.

5.

6.

TANK BREATHER MAIN PUMP LEAK HOSES MAIN VALVE DRAIN HOSE SERVICE BRAKE RETURN HOSE BRAKE VALVE RELIEF HOSE DRAIN PLUG

Figure 21. Hydraulic Tank Connections

17

Remove and Install

0100 SRM 1978

16. Remove the cap screws and washers from the running board.

17. Lift the running board slightly to remove the isolators.

CAUTION Support the hydraulic tank with a hand pallet lift with blocks or a lift truck.

18. Remove the running board from the truck.

31. At the back side bracket, remove the cap screw that retains the hydraulic tank to the frame.

NOTE: Use a drain pan to collect the oil from the hydraulic tank and hoses. The hydraulic system contains 172 liter (45.4 gal) of hydraulic fluid.

32. Remove cap screws and washers from the top of the hydraulic tank.

19. Remove the hydraulic return filter. See Figure 19.

20. Use a separate pump to empty the tank by putting a drain hose through the tank opening for the return filter.

21. When the hydraulic tank is empty, put a drain pan under the hydraulic tank.

22. Remove the drain plug at the bottom of the tank to drain remaining oil. Reinstall the plug.

NOTE: Before disconnecting the hydraulic hoses, place a suitable container under the hydraulic hose connections to catch the hydraulic oil from the hydraulic hoses.

23. Tag all hoses and tubes connected to the hydraulic tank to facilitate re-installing.

24. Loosen and remove the hose clamps from the main pump suction hose and from the wet brake pump suction hose at the lower backside of the hydraulic tank. See Figure 21.

25. Put caps on the suction hoses.

26. Disconnect the wet brake return, the main valve return and the main valve drain hoses from the hydraulic tank.

27. Disconnect the lift cylinder drain hose at the top of the hydraulic tank.

28. Put caps on the hoses and on the connections on the hydraulic tank.

29. Tag and disconnect the wire from the temperature sensor at the lower backside of the tank.

Remove the sensor if necessary.

30. Remove the disconnected cables from the access hole of the hydraulic tank.

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33. Lift the hydraulic tank slightly to remove the isolators.

34. Carefully move the hydraulic tank away from the truck.

35. Remove the hydraulic tank breather and plug the tank opening to prevent the breather from getting damaged.

Inspect

WARNING DO NOT use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are difficult to inspect can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

Clean

WARNING 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, F4.1 1999.

•

"Safety in Welding and Cutting," American National Standard, AWS Z 49.1 - 1999.

0100 SRM 1978

WARNING

Remove and Install

Chemical Solution Cleaning Method

When cleaning the tank, do not use solutions, that create dangerous gases at normal temperatures or when heated. Wear eye protection. Protect the body from burns.

1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer.

When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). 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.

2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank.

Steam Cleaning Method 1. Remove all the parts from the hydraulic tank.

2. Install the drain plug.

3. 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 liter (1 gal) of water.

3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all cleaning compound is removed.

4. Make an inspection of the inside of the tank. If the tank is not clean, repeat Step 1 through Step 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 a special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.

4. Mix the solution in the tank using compressed air. Verify all the surfaces on the inside of the tank are flushed with the solution.

Repair

5. Drain the tank.

NOTE: Before repairing a leak use steam to clean the area around the leak. See the section Steam Cleaning Method for preparations for leak repairs.

6. 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.

7. Flush the inside of the tank with boiling water.

Verify all the loose material is removed from the inside of the tank.

8. Make an inspection of the inside of the tank. If it is not clean, repeat Step 6 and Step 7 and make another inspection. When making inspections, use light that is approved for locations with flammable vapors.

9. 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.

Small Leaks

1. Remove all paint and dirt around the leak.

2. Apply Loctite 290® to the leak. Follow the instructions of the manufacturer.

Large Leaks

WARNING Disconnect all control modules before welding to the truck. Completely remove the control modules located within 2 m (6.5 ft) of the area to be welded.

Locate the ground for the welder as near as possible to the welding location.

Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel.

NOTE: If the tank cannot be cleaned with steam, use the following procedure:

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