SERVICE REPAIR H13.00XM H14.00XM H16.00XM Europe [E019]
100 SRM 927
Counterweight Repair
General This section has the description and repair procedures for the frame and connected parts. Included in this section are the frame, counterweight, fenders, hood, hydraulic and fuel tanks, radiator/cooling section, operator compartment, and cab. The instructions for removal and installation of the engine are included in this section. If the lift truck is fitted with a battery disconnect switch, open the switch if welding on the engine and remove the ECM (Engine Control Module). If welding on the lift truck chassis, verify the ground clamp
is placed as close to the welding point as possible and NOT near the ECM. If it is necessary to weld near the ECM, remove the ECM from the engine to avoid damage from welding arc radiation.
Description The frame is a one-piece weldment and has mounts for the counterweight, fenders, engine, transmission,
axles, hydraulic and fuel tanks, operator’s compartment, and other parts. See Figure 1.
1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11.
MAIN MOUNT COUNTERWEIGHT MOUNT STEERING MOUNT DRIVE AXLE MOUNT TILT CYLINDERS MOUNT CAB CYLINDER MOUNT
CAB HINGE MAST MOUNT SIDE COUNTERWEIGHT MOUNT FENDERS CAB LATCH MOUNT
Figure 1. Frame
Counterweight Repair REMOVE WARNING The counterweight is heavy. Make sure that the crane and lifting devices have the capacity to lift 4600 kg (10,141 lb).
1. Remove the hood spine assembly. See Hood and Air Cleaner Repair. 2. H8.00-12.00XM (H170-280HD) units only. Remove the counterweight by placing an eyebolt through the hole in the top of the counterweight. See Figure 2. The eyebolt must be able to support the weight of the counterweight. Attach a lifting device to eyebolt.
1
Counterweight Repair
100 SRM 927
H13.00-16.00XM (H300-360HD) and H10.0012.00XM-12EC (H330-360HD-EC) units. Remove the fenders, noting shims used and location of shims. Remove the radiator fan, shroud, and hardware. Tilt the radiator away from the counterweight so there is clearance when removing the counterweight. See Figure 2. Install eyebolt
1. LH FENDER COUNTERWEIGHT 2. RH FENDER COUNTERWEIGHT 3. CAPSCREW 4. WASHER 5. NUT 6. WASHER 7. TOW PIN 8. GRIP 9. PIN 10. PIN
11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
into the top of the counterweight. The eyebolt must be able to support the weight of the counterweight. Attach lifting device. 3. Remove the single capscrew from the rear of the counterweight. Remove the counterweight from the frame.
SHIM WASHER LOCKWASHER WASHER SHIM SHIM SHIM COUNTERWEIGHT CAPSCREW SLAB COUNTERWEIGHT PLATE LOCKWASHER
Figure 2. Counterweight Mounts
2
23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
CAPSCREW RH SLAB COUNTERWEIGHT LH SLAB COUNTERWEIGHT CAPSCREW WASHER WASHER NUT ISOLATOR LOCKWASHER NUT RUBBER STOP
100 SRM 927
INSTALL WARNING
Counterweight Repair 3. Install the capscrews, washers, and nuts that hold the fender to the frame. Tighten the nuts to 320 N•m (236 lbf ft).
The counterweight is heavy. Make sure that the crane and lifting devices have the capacity to lift 4600 kg (10,141 lb).
SIDE COUNTERWEIGHTS H13.00-16.00XM (H300-360HD)
1. Put a chain into top opening of the counterweight and attach chain to a lifting device. See Figure 2.
The counterweights located on either side of the lift truck are fastened to the frame by large capscrews. Normally these counterweights will never have to be removed or replaced on the lift truck.
2. H13.00-16.00XM (H300-360HD) and H10.0012.00XM-12EC (H330-360HD-EC) units only. Install the radiator hardware. Tilt the radiator ahead so there is clearance for the chain that is installed through the counterweight. 3. Install the counterweight on the frame. Install the capscrew, lockwasher, and flat washer to fasten the counterweight to the frame. Tighten the capscrew to 1140 N•m (841 lbf ft).
FENDERS Remove WARNING The fenders are part of the lift truck counterweight and are very heavy. Make sure any lifting devices have the capacity to lift 1750 kg (3858 lb). Make sure the fender is balanced and supported by the chain. The fenders are not of a regular shape and can be difficult to handle. 1. Remove the capscrews, washers, and nuts that fasten the fender to the frame mount. Install eyebolts in the mount holes. Use mount holes to pick up fender from frame. 2. Fasten a lifting device to the eyebolts. Operate the lifting device and lift the fender away from the frame.
Install 1. Install eyebolts in the fenders as described in Remove, Step 1. Fasten a lifting device to the eyebolts. 2. Raise the fender to the lift truck. Align the eyebolts in the fender with the holes in the fender mount on the frame. Shim fenders to correct height. Lower the fender to the fender mount and remove the lifting device and the eyebolts.
SIDE COUNTERWEIGHT, REPLACE If replacement of the side counterweight is required, do the following procedure:
WARNING The side counterweights are heavy. Each side counterweight weighs approximately 560 kg (1235 lb). Make sure that the crane and lifting devices have the capacity to lift 908 kg (2433 lb). 1. Remove the extension covers from both side tanks. 2. Remove each counterweight capscrew and replace it in turn with a long stud. The studs must protrude about 152 mm (6 in.) beyond the counterweight. 3. Use a pry bar and carefully move the counterweight away from the frame about 50 mm (2 in.). Install a nylon lifting sling securely around the counterweight and attach it to a lifting device.
WARNING Make sure the counterweight is balanced and cannot fall from the sling when the sling is raised. 4. Carefully lift the counterweight away from the lift truck frame and lower the counterweight to the floor. 5. For installation of the side counterweights, follow the above procedure in reverse order. Tighten the counterweight capscrews to 655 N•m (483 lbf ft).
3
Hood and Air Cleaner Repair
100 SRM 927
Hood and Air Cleaner Repair The hood and air cleaner assembly, which includes the rain cap or optional precleaner and inlet pipe, can be removed from the frame as a single unit, or pivoted out of the way for access.
connecting hood to hood spine support and loosen the 2 bolts at opposite side.
REMOVE
2. Open hood panel until gas spring locks hood panel in open position.
NOTE: The hood and air cleaner assembly can be pivoted out of the way to gain access to many components. In order to pivot hood and air cleaner assembly, remove 2 bolts, nuts, and washers at one side
3. Attach a lifting device and sling to support hood spine and attaching components. See Figure 3 and Figure 4.
1. 2. 3. 4. 5.
HOOD SPINE HARDWARE HOOD SPINE COUNTERWEIGHT HOOD SPINE SUPPORT AIR INTAKE HOSE
1. Unlock hood with an allen wrench.
6. 7. 8. 9. 10.
EXHAUST STACK CLAMP RAIN CAP GAS SPRING HOOD PANEL EXHAUST STACK
Figure 3. Hood and Air Cleaner Assembly (E019 and F007)
4
100 SRM 927
1. 2. 3. 4. 5.
Hood and Air Cleaner Repair
HOOD SPINE HARDWARE HOOD SPINE COUNTERWEIGHT HOOD SPINE SUPPORT AIR INTAKE HOSE
6. 7. 8. 9.
EXHAUST STACK CLAMP RAINCAP HOOD PANEL EXHAUST STACK
Figure 4. Hood and Air Cleaner (F019 and G007) 4. Loosen air intake hose to turbocharger at inlet side of turbocharger.
7. Disconnect washer hoses from washer container and mark for reconnecting.
5. Loosen clamps at upper exhaust stack.
8. Disconnect the washer hoses from hood and air cleaner assembly.
6. Remove bolts, nuts, washers, and bar washers that fasten hood spine to counterweight and hood support.
9. Using lifting device, lift hood assembly from frame. Air filter assembly and exhaust stack will remain attached to hood and spine assembly.
5
Hydraulic Tank Repair
100 SRM 927
INSTALL Install the hood and air cleaner assembly in the reverse procedure of removal and align the hood as
necessary during installation. Make sure the hood side panels close completely and that the cushioned screw stops (bumpers) are located correctly.
Hydraulic Tank Repair The hydraulic tank is installed on the right side of the frame between the front and rear fenders.
oil that is in the hydraulic lines. Put tags on the lines for identification. Put caps on the open lines and the fittings.
REMOVE 1. Remove the side cover between the bottom of the operator compartment and the top of the hydraulic tank. See Figure 5. If necessary, remove the drain plug at the bottom of the tank to drain the oil. See Figure 6 and Figure 7. 2. Remove the extension panel. NOTE: Do not remove items 14, 15, 16, and 17 from the tank. 3. Disconnect the hoses at the top elbow connection and at the side connection to the tank located on the inside of the frame. Use a pan to catch the
1. HYDRAULIC TANK 2. BATTERY BOX 3. FRAME
WARNING Make sure that the tank is supported by blocks before removing the nuts and washers from the top of the tank. 4. Support the fuel tank with blocks from beneath. First, remove the three capscrews that fasten the bottom of the tank to the running board. Remove the three nuts and washers that hold the top of the tank to the frame. Install two lifting eyes at the outer holes. Attach a lifting device and support the tank. Lift the tank from the frame.
4. SIDE COVER 5. NUT AND WASHER 6. EXTENSION PANEL Figure 5. Hydraulic Tank and Battery Box
6
Thank you very much for your reading. Please Click Here Then Get More Information. NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
100 SRM 927
Hydraulic Tank Repair
1. 2. 3. 4. 5. 6. 7. 8. 9.
SIGHT GLASS FILTER FILTER HEAD SPRING O-RING CAPSCREW PLUG BREATHER WASHER
10. 11. 12. 13. 14. 15. 16. 17.
NUT DRAIN PLUG O-RING HYDRAULIC TANK COVER SEAL WASHER CAPSCREW
Figure 7. Hydraulic Tank (G007 and F019) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
WASHER (3) LOCKWASHER (3) BREATHER FILTER HEAD O-RING DIPSTICK O-RING SEAL SPRING WASHER FILTER
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
DRAIN PLUG NUT (3) ADAPTER ADAPTER HYDRAULIC TANK O-RING RETAINING RING FITTING FITTING PLUG
Figure 6. Hydraulic Tank (F007 and E019)
REPAIRS, ALL UNITS Small Leaks Use the following procedures to repair small leaks: 1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.
WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion. 2. Apply Loctite® 290 to the leak. Follow the instructions of the manufacturer.
7
Hydraulic Tank Repair
Large Leaks 1. Use one of the procedures described under Cleaning to clean and prepare the tank for repairs.
CAUTION Welding on the truck may cause damage to the engine, transmission, and/or hydraulic electronic control units if proper precautions are not taken. Disconnect the negative battery terminal from the battery. Disconnect all ECM’s. If welding must be done in a close proximity of an ECM, that ECM must be removed. When welding to the chassis, attach the ground cable as close to the weld as possible. 2. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting AWS Z 49.1 1999.
CLEAN WARNING Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside of a building, make sure there is enough ventilation. See the following manuals for additional information:
CAUTION Welding on the truck may cause damage to the engine, transmission, and/or hydraulic electronic control units if proper precautions are not taken. Disconnect the negative battery terminal from the battery. Disconnect all ECM’s. If welding must be done in a close proximity of an ECM, that ECM must be removed. When welding to the chassis, attach the ground cable as close the weld as possible. • 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. When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or
8
100 SRM 927 when heated. Wear eye and face protection. Protect the body from burns. When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 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.
Steam Method Use the following procedure to clean the tank with steam: 1. Remove all the parts from the tank. Install the drain plug. 2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water. 3. Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank. 4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come from all the openings. 5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank.
WARNING When making inspections, use light that is approved for locations with flammable vapors. 6. Make an inspection of the inside of the tank. If it is not clean, repeat Step 4 and Step 5 and make another inspection. 7. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.
100 SRM 927
Chemical Solution Method If the tank cannot be cleaned with steam, use the following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer. 2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank. 3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning compound is removed.
WARNING When making inspections, use a light that is approved for locations with flammable vapors. 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. 5. Check the tank for flammable vapors using special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.
OTHER METHODS OF PREPARATION FOR REPAIR If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be used as follows: 1. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent.
Hydraulic Tank Repair not taken. Disconnect the negative battery terminal from the battery. Disconnect all ECM’s. If welding must be done in a close proximity of an ECM, that ECM must be removed. When welding to the chassis, attach the ground cable as close the weld as possible. 2. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting AWS Z 49.1 1999.
INSTALL NOTE: When installing the filter after cleaning, it is important that you grease the O-ring before installation. 1. Connect a lifting device to the outer holes in the top of the hydraulic tank. Put the hydraulic tank in position on the frame. Put blocks under the tank to provide support. Install the lower three capscrews and washers that fasten the top of the hydraulic tank to the frame. 2. Make sure the tank is supported by the upper capscrews. Install the three nuts and washers that fasten the bottom of the hydraulic tank to the running board. 3. Connect the hydraulic return line to the upper elbow connection of the hydraulic tank. Attach the suction hose to the side tank connection on the inside of the frame member. 4. Install the extension piece and side cover. See Figure 5. 5. Fill the hydraulic tank to the correct level with the oil specified in the maintenance table. See the section Periodic Maintenance 8000 SRM 934 for E019 and F007 trucks or Periodic Maintenance 8000 SRM 1099 for F019 and G007 trucks.
CAUTION Welding on the truck may cause damage to the engine, transmission, and/or hydraulic electronic control units if proper precautions are
9
Fuel Tank Repair
100 SRM 927
Fuel Tank Repair The fuel tank is installed on the left-hand frame channel. See Figure 8.
REPAIRS WARNING
REMOVE 1. If necessary, remove the drain plug to drain the fuel from the tank.
Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion. Repair the fuel tank as described in the repair procedures for the hydraulic tank.
WARNING If the fuel is drained from the fuel tank, put the fuel in a can or barrel that has a protected seal cap. 2. Remove the extension piece between fuel tank and frame. 3. Disconnect the fuel lines at the tank.
WARNING Make sure that the tank is supported by blocks before removing the nuts and washers from the top of the tank. 4. Support the fuel tank with blocks from beneath the tank. First, remove the three capscrews that fasten the bottom of the tank to the running board. Remove the three nuts and washers that hold the top of the tank to the frame. Install two lifting eyes at the outer holes. Attach a lifting device and support the tank. Lift the tank from the frame.
INSTALL 1. Connect a lifting device to the outer holes in the top of the fuel tank. Put the fuel tank in position on the frame. Put blocks under the tank to provide support. Install the lower three capscrews and washers that fasten the top of the fuel tank to the frame. 2. Make sure the tank is held by the upper capscrews, then install the three nuts and washers that fasten the bottom of the fuel tank to the running board. 3. Connect the fuel lines to the tank. 4. Install extension piece between fuel tank and frame. 5. Fill fuel tank to the correct level per specifications. See the section Periodic Maintenance 8000 SRM 934 for E019 and F007 trucks or Periodic Maintenance 8000 SRM 1099 for F019 and G007 trucks.
Legend for Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
10
HOSE HOSE CLAMP STRAP FUEL TANK PLUG OIL SEAL FITTING TUBE FITTING TUBE CLAMP TUBE
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
FITTING FITTING TUBE FITTING FITTING CLAMP BRACKET CAPSCREW WASHER FILTER CAPSCREW WASHER
25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.
NUT WASHER NUT O-RING PIPE PLUG WASHER STRAP CLAMP TUBE FITTING FITTING FUEL CAP
100 SRM 927
Fuel Tank Repair
Figure 8. Fuel Tank
11
Cooling System and Radiator Repair
100 SRM 927
Cooling System and Radiator Repair REMOVE 1. Disconnect the cables at the battery. (Remove the ground cable first.) Remove the bracket for the battery cables. 2. Pivot hood and spine assembly to right side. See Hood and Air Cleaner Repair.
5. Remove four capscrews and washers mounting the charged air cooler (F019/G007 Perkins engine only). 6. Disconnect the transmission oil lines at the radiator. 7. Cap an plug all open lines.
3. Let the coolant cool to room temperature. Put drain pan under radiator. Remove radiator cap. Open the drain valve and drain the radiator. Disconnect the coolant hoses at the radiator. See Figure 9 and Figure 10.
8. Remove the fan from the drive pulley (Perkins engine only).
4. Disconnect charged air cooler hoses from the charged air cooler (F019/G007 Perkins engine only).
10. Remove the two capscrew and grommet assemblies that hold the radiator shroud to the bracket on the frame. Remove the radiator and shroud.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
11. 12. 13. 14. 15. 16. 17. 18. 19.
COOLANT RECOVERY TANK RADIATOR CAP RADIATOR TOP HOSE RADIATOR SHROUD CHARGED AIR COOLER BRACKET ON FRAME FRAME LOWER HOSE BRACKET
9. Remove the capscrews between the fan shroud and the radiator.
ISOLATOR PIN DRAIN VALVE FAN V-BELT CAPSCREW WASHER (2) GROMMET NUT TRANSMISSION OIL COOLER IN/OUT
Figure 9. Cooling System/Radiator (E019/F007)
12
100 SRM 927
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Cooling System and Radiator Repair
COOLANT RECOVERY TANK RADIATOR CAP RADIATOR TOP HOSE RADIATOR SHROUD CHARGED AIR COOLER BRACKET ON FRAME FRAME LOWER HOSE BRACKET ISOLATOR AND/WITH PIN
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
DRAIN VALVE FAN CAPSCREW LOCKWASHER WASHER NUT TRANSMISSION OIL COOLER IN/OUT WASHER CAPSCREW GROMMET
Figure 10. Cooling System/Radiator (F019/G007 Perkins Engine Shown)
INSTALL 1. Install the radiator and shroud in the frame. Install the two capscrew and grommet assemblies that fasten the shroud weldment to the bracket on the frame. Install the capscrews between the fan shroud and the radiator. 2. Install the fan on the drive pulley. 3. Connect the coolant hoses to the radiator.
4. Connect the transmission oil lines to the bottom of the radiator. 5. Install four capscrews and washers mounting the charged air cooler (Perkins engine only). 6. Connect charged air cooler hoses to the charged air cooler (Perkins engine only). 7. Pivot hood and spine assembly back into position and tighten mounting hardware.
13
Engine and Transmission Repair 8. Fill the radiator with coolant. See Maintenance Schedule in the section Periodic Maintenance 8000 SRM 934 for E019 and F007 trucks or Periodic Maintenance 8000 SRM 1099 for F019
100 SRM 927 and G007 trucks, for quantity and antifreeze requirements.
Engine and Transmission Repair See engine manufacturer’s repair manual for repair of the engine. See the section Three-Speed Powershift Transmission, Repairs (Hyster Model T-50) 1300 SRM 931 for transmission repairs. The removal of this transmission is described later in this section. See Hyster T-50 Transmission, Remove.
HYSTER T-50 TRANSMISSION, REMOVE NOTE: The transmission can be removed from above or under the lift truck. See Figure 11. 1. Remove the forks. Put the lift truck on blocks so that there is access under the lift truck. See "How to Put Lift Truck on Blocks" in the section Operating Manual or the section Periodic Maintenance 8000 SRM 934 for E019 and F007 trucks or Periodic Maintenance 8000 SRM 1099 for F019 and G007 trucks. Tilt the mast fully forward to release hydraulic pressure in the system. 2. Disconnect the cables at the battery. (Remove the ground cable first.) Remove the bracket for the battery cables. 3. Tilt the operator compartment up to remove the engine and transmission. 4. Drain the coolant from the cooling system. See Cooling System and Radiator Repair. 5. Disconnect the exhaust system. Remove the header pipe at the exhaust manifold. 6. Disconnect the air lines at the air compressor. Loosen the fittings slowly to vent any compressed air. 7. Disconnect fuel lines at the fuel tank. Disconnect throttle linkage. 8. Disconnect wires and wiring harnesses at the engine. Disconnect the heater hoses at the engine. 9. Disconnect the drive shaft at the yokes. Remove the drive shaft between the transmission and the differential.
14
10. Disconnect the wiring harnesses on top of the transmission. Disconnect the wires at the solenoids on the transmission control valve. Disconnect the wires at the pressure sending unit and the temperature sending unit on the transmission. Put identification tags on the wires so that they can be correctly connected again. 11. Apply the service brakes repeatedly until the air pressure in the air tank decreases to 0 kPa (0 psi) or pressure is removed from hydraulic system on wet brakes. Disconnect the air brake hose from the air tank so that there is clearance at the transmission. 12. Disconnect the wire to the starter solenoid. 13. Disconnect the cables at the spools on the transmission control valve. Remove the linkage bracket from the transmission housing. 14. Remove the drain plug from the transmission sump to drain the oil from the transmission [approximately 28 liter (30 qt)]. Disconnect the oil lines to the oil cooler at the transmission. Drain the oil lines into the drain pan. Put plugs and caps in the open fittings. 15. Disconnect the oil hoses at the hydraulic pump. Disconnect the hose from the hydraulic pump to the steering system. Put plugs and caps on the open fittings. 16. The hydraulic pump is fastened to the transmission cover with four capscrews. The hydraulic pump weighs approximately 45 kg (100 lb). Use a lifting device to hold and lift the hydraulic pump. Remove the hydraulic pump. The drive shaft of the hydraulic pump is engaged in splines in the drive gear. The drive shaft of the hydraulic pump will slide from the drive gear when the hydraulic pump is removed. 17. Disconnect and remove the dipstick assembly from the transmission.
100 SRM 927
Engine and Transmission Repair
1. FRAME (REFERENCE) 2. DIPSTICK ASSEMBLY 3. DRIVE SHAFT
4. OUTPUT YOKE 5. TRANSMISSION MOUNT 6. STARTER SOLENOID
7. TORQUE CONVERTER
Figure 11. Hyster T-50 Transmission Arrangement 18. The temperature sender for the transmission oil can be easily damaged. Remove the temperature sender from the transmission sump. 19. Install blocks and a jack under the flywheel end of the engine as a support. If the support is put under the engine oil sump, make sure the support is across the width of the oil sump so that the weight of the engine does not damage the oil sump. 20. A 5/8" machined hole with UNC (United National Course) threads is in the top of the transmission housing. Install an eyebolt in the 5/8" UNC hole. Connect a lifting device to the engine and transmission. Make sure the lifting device has a capacity of at least 1200 kg (2650 lb).
HYSTER T-50 TRANSMISSION, INSTALL 1. If the mounts were removed from the sides of the transmission housing, install them and tighten the capscrews to 270 N•m (199 lbf ft). 2. Connect a lifting device to the engine and transmission. Make sure the lifting device has a capacity of at least 1200 kg (2650 lb). 3. Install the engine and transmission assembly in the frame. Install and tighten the nuts and capscrews for the engine and transmission mounts. Install the two 3/4 × 3 1/2 inch bolts (Figure 11) for the transmission mounts. Tighten the lock nuts to 270 N•m (199 lbf ft).
21. Remove the two 3/4 × 3 1/2 inch bolts that fasten the transmission mounts to the frame. These bolts have been tightened to 270 N•m (199 lbf ft).
4. Connect the drive shaft to the yoke on the transmission. Make sure the slip joint is installed as shown in Figure 11. Tighten the capscrews at the yoke to 50 N•m (37 lbf ft).
22. Remove the capscrews that hold the engine mount brackets to the frame mounts.
5. Install the dipstick assembly on the transmission.
23. Make sure all the connections have been removed. Carefully lift the engine and transmission assembly from the frame.
6. Use a lifting device to hold and lift the hydraulic pump. Install the hydraulic pump. The drive shaft of the hydraulic pump is engaged in splines
15