INTRODUCTION

GENERAL
This section has the description and repair procedures for the lift truck frame and connected parts. Included in this section are the frame, counterweight, fenders, hood, hydraulic and fuel tanks, radiator and operator compartment. The instructions for removal and installation of the engine are included in this section.
1 3 2 6

DESCRIPTION (See FIGURE 1.)

The frame is a one piece weldment and has mounts for the counterweight and fenders, engine, transmission, axles, hydraulic and fuel tanks, operators compartment and other parts.

8 1. 2. 3. 4. COUNTERWEIGHT MOUNT TENSION BAR LADDER OPERATOR COMPARTMENT MOUNT 5. 6. 7. 8. TILT CYLINDER MOUNT MAST MOUNT DRIVE AXLE MOUNT STEERING AXLE MOUNT

7
12720

FIGURE 1. FRAME

REPAIRS
COUNTERWEIGHT
3. Remove the two bolts that hold the counterweight to the frame. Raise the counterweight approximately 150 mm (six inches). Carefully remove the counterweight from the frame and lower it to the floor.

WARNING
The counterweight is very heavy. Make sure that the lifting devices and lift truck have the capacity to lift 7 000 kg (15 450 lb). Make sure no one gets under the parts being moved.

Installation (See FIGURE 2.)

1. Put the forks of a lift truck under the counterweight. Fasten a nylon lifting sling around the counterweight and attach the sling to the carriage or load backrest of the lift truck. 2. Install the counterweight on the frame. Install the bolts, washers and nuts. Tighten the nuts to 814 N.m (600 lbf ft).
1

Removal (See FIGURE 2.)

1. Remove the ballast cover from the frame. 2. Put the forks of another lift truck under the counterweight. Fasten a nylon lifting sling around the counterweight and attach the sling to the carriage or load backrest of the lift truck.

4 4 3 4 1 7 3

4 2 1. COUNTERWEIGHT 2. FENDER 3. FENDER DOWEL 4. 5. 6. 7. NUT AND BOLT BALLAST COVER HOOD SLOT

12403

FIGURE 2. COUNTERWEIGHT MOUNTS

FENDERS Removal (See FIGURE 2.)

2. Raise the fender to the lift truck. Align the tapered dowels (3) of the fender with the holes in the frame. Do not disconnect the chain sling. 3. Install the bolts, washers and nuts. Tighten the nuts to 814 N.m (600 lbf ft).

WARNING
The fenders are part of the lift truck counterweight system and are very heavy. Make sure any lifting devices have the capacity to lift 1750 kg (3860 lb). 1. Remove the ballast cover from the frame. 2. Fasten a chain or cable around the middle of the fender. Put the chain or cable through the slot (7) in the fender. 3. Operate the lifting device just enough to give support to the fender. Remove the nuts, washers and bolts that hold the fender to the frame. 4. Carefully lift the fender away from the frame and lower it to the floor.

HOOD (See FIGURE 3.)

The hood can be removed from the frame. Disconnect the exhaust system at the flexible tube connection. (See FIGURE 8.) Disconnect the air filter at the rubber elbow connection and the hose from the air restriction indicator. (See FIGURE 7.) To remove the hood, remove the three nuts and capscrews at the front and the three nuts and capscrews at the rear of the hood assembly. Lift the hood from the frame. During installation, align the hood as necessary. Make sure the clamps for the air intake tubes are tight. Air leaks can cause engine damage. To remove the ballast cover, remove the four capscrews that hold it to the frame. Lift the cover away from the frame.

Installation (See FIGURE 2.)

1. Fasten a chain or cable around the middle of the fender. Make sure the chain or cable is in the slot (7) on the side of the fender.
2

4 7

1 5 4. 5. 6. 7. 8. 6 AIR FILTER CONNECTION HOOD LATCH HANDLE LATCH FOR TILT CAB GAS SPRING
12730

1. BALLAST COVER 2. HOOD 3. EXHAUST COVER

FIGURE 3. HOOD ASSEMBLY

HYDRAULIC TANK
The hydraulic tank is installed on the right side of the lift truck frame.

4. Carefully pull the hydraulic tank from the side of the lift truck. Remove the top of the hydraulic filter(s) if necessary for clearance. 5. Remove the filter assemblies from the tank. Remove the backpressure valve from the tank. Remove the cover and breathers from the top of the tank.

Removal (See FIGURE 4.)

1. Lower the mast completely. Disconnect the three return lines at the side of the hydraulic tank. Put caps on the open lines. 2. Put a drain pan under the tank and remove the plug to drain the tank. (The hydraulic tank holds 325 litres/ 86 gallons of oil.) Disconnect the two supply lines to the hydraulic pumps. Put caps on the open lines. 3. Remove the three capscrews that hold the base of the hydraulic tank to the frame. Remove the access door from the hinges on the tank.

Repairs
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.
3

. Safe Practices For Welding And Cutting Containers That Have Held Combustibles by the American Welding Society, A6.065. . Safety In Welding and Cutting, American National Standard, ANSI Z 49.1 1973.

When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear device for the protection of the eyes. Protect the body from burns. When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 inch). Control the pressure of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between the nozzle and the tank. Connect a ground wire to the tank to prevent static electricity.

3 2 1
12741

1. 2. 3. 4. 5. 6. 7.

FILTER ASSEMBLY BACK PRESSURE VALVE RETURN LINE SUPPLY TO TANDEM PUMP SUPPLY TO SINGLE PUMP RETURN LINE FROM BRAKE SYSTEM COVER PLATE

Steam Method of Cleaning

Use the following procedure to clean the tank with steam: 1. Remove all the parts from the tank. Install the drain plug. 2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 litres (1 gal) of water. 3. Mix the solution in the tank using compressed air. Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank. 4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come from all the openings. 5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank. 6. Make an inspection of the inside of the tank. If it is not clean, repeat steps 4 and 5 and make another inspection. When making inspections, use light that is approved for locations with flammable vapors. 7. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.

FIGURE 4. HYDRAULIC TANK

2. Apply Loctite 290 to the leak. Follow the instructions of the manufacturer. LARGE LEAKS 1. Use one of the procedures described under Cleaning to clean and prepare the tank for repairs. 2. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting ANSI Z49.11973.

Cleaning

WARNING
Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside of a building, make sure there is enough ventilation. See the following manuals for additional information:
4

Chemical Solution Method of Cleaning

If the tank cannot be cleaned with steam, use the following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer. 2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank. 3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning compound is removed. 4. Make an inspection of the inside of the tank. If the tank is not clean, repeat steps 1 to 3. Make another inspection of the tank. When making inspections, use a light that is approved for locations with flammable vapors. 5. Check the tank for flammable vapors using special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.

3. Install the backpressure valve and adapter in the tank. Connect the two supply lines for the pumps to the fittings on the tank. 4. Install the hydraulic filter assemblies in the tank. Install the cover and breathers on top of the tank. Install the access door on the hinges of the tank. 5. Fill the hydraulic tank to the correct level with the oil specified in the maintenance table. See the section PERIODIC MAINTENANCE, 8000 SRM 487.

FUEL TANK
The fuel tank is installed between the frame rails, behind the mast.
3 1 3 5 3

Other Methods Of Preparation For Repair

12738

If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices For Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, A6.065. If these gases are not available, another method using water can be used as follows: 1. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent. 2. Use acceptable welding practices to repair the tank. See the American National Standard Safety In Welding And Cutting ANSI Z 49.11973.

4 4 1. 2. 3. 4. 5. HYDRAULIC MANIFOLD BLOCK TILT CYLINDER MANIFOLD LINES TO LIFT CYLINDERS LINES TO TILT CYLINDERS LINES TO BRAKE SYSTEM

FIGURE 5. CONNECTIONS AT THE MANIFOLD BLOCKS

Removal (See FIGURE 5.)

WARNING
If the fuel is drained from the fuel tank, put the fuel in a can or barrel that has a sealed cap. 1. Lower the mast completely. Put a drain pan under the fuel tank. Remove the drain plug to drain the fuel from the tank. Disconnect the fuel lines at the tank. Put caps on the open lines. 2. Disconnect and remove the hydraulic lines to the manifold blocks for the lift cylinders and tilt cylinders.
5

Installation
1. Use a lifting device to move the hydraulic tank next to the frame. Push the hydraulic tank into position in the frame. Install the three capscrews and washers that hold the hydraulic tank to the frame. 2. Connect the three return lines to the tank.

Put tags for identification on the lines. Put caps on the open lines. Remove the manifold blocks from the tank. 3. Disconnect and remove the brake lines that are on top of the fuel tank. Put tags for identification on the lines. Put caps on the open lines. 4. Remove the capscrews that hold the filler tube to the tank. Loosen the filler tube from the tank. 5. Connect a lifting device to the tank. Remove the four capscrews that hold the tank to the frame. Lift the tank from the frame.

4. Install the manifold blocks for the lift and tilt cylinders on the top of the fuel tank. Connect the lines to the manifold blocks. 5. Install and connect the brake lines that fit over the fuel tank.

RADIATOR Removal (See FIGURE 6.)

1. Remove the ballast cover. 2. Disconnect the air filter intake elbow and air restriction indicator hose from under the center hood panel. Disconnect the exhaust system between the muffler exhaust pipe and the exhaust swivel connection. Remove the hood assembly. Remove the ballast cover. 3. Remove the fan from the engine. 4. Disconnect the transmission oil lines at the bottom of the radiator. Disconnect the coolant hoses at the radiator. 5. Remove the bracket for the transmission oil filter at the radiator bracket. 6. Remove the bolts that hold the radiator bracket to the frame. Remove the radiator and bracket. Remove the radiator from the brackets.

Repairs
Repair the fuel tank as described in the repair procedures for the hydraulic tank.

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

Installation (See FIGURE 5.)

1. Put the tank in position on the frame. Install the capscrews to hold the tank to the frame. 2. Use a new gasket and install the filler tube on the tank. 3. Connect the fuel lines to the tank and filler tube.

Installation (See FIGURE 6.)

1. Install the brackets on the radiator. Install the radiator and brackets in the frame. Install the bolts for the brackets.

1 2 3 6 2

7 4 1. RADIATOR 2. BRACKET 3. RADIATOR MOUNT 4 4. PORTS FOR TRANSMISSION OIL COOLER 5. TOP HOSE 8 6. FRAME OF LIFT TRUCK 7. BOTTOM HOSE 8. DRAIN VALVE
12725

FIGURE 6. RADIATOR 2. Install the fan on the engine. 3. Connect the coolant hoses to the radiator. Connect the transmission oil lines to the bottom of the radiator. 4. Attach a lifting device and sling and install the hood assembly. Align the hood as necessary. Install the rubber elbow to the precleaner tube and small hose to the air restriction indicator connections under the center hood panel. Make sure the clamps for the air intake tubes are tight. Air leaks can cause engine damage. Connect the muffler to the exhaust pipe at the flexible tube connection. Install the ballast cover. 5. Fill the cooling system with coolant after the engine installation is complete. See the section PERIODIC MAINTENANCE, 8000 SRM 487. NOTE: The engine can be removed with or without the transmission. The following procedures are for the removal of the engine only. 1. Disconnect the cables at the battery. (Remove the ground cable first.) 2. Disconnect the air filter intake elbow and air restriction indicator hose from under the center hood panel. Disconnect the exhaust system at the flexible tube connection. (See FIGURE 8.) Remove the hood assembly. 3. Drain the coolant from the cooling system. Disconnect the hoses at the radiator. Remove the radiator. (See FIGURE 6.) 4. Remove the tubes between the engine and air filter. (See FIGURE 7.) 5. Disconnect the exhaust system. Remove the pipe at the turbocharger. 6. Disconnect fuel lines at the fuel injection pump and the fuel pump. Disconnect the throttle linkage.

ENGINE Removal (See FIGURE 9.)

8 2 3 9 10

4 5 5 6 3 2 1

3 4 1. 2. 3. 4. 5. AIR FILTER HOSE CLAMP RUBBER ELBOW TUBE CLAMP 6. 7. 8. 9. 10. 2 BRACKET HOSE PRECLEANER AIR RESTRICTION INDICATOR HOOD

12723

FIGURE 7. AIR FILTER ARRANGEMENT

2 3

6 5

7 3

4 1

9 3

1. 2. 3. 4. 5.

EXHAUST STACK RAIN CAP CLAMP EXHAUST COVER MUFFLER

6. 7. 8. 9. 10.

TURBOCHARGER EXHAUST TUBE BRACKET FLEXIBLE TUBE CLAMP

10
12722

FIGURE 8. EXHAUST SYSTEM

7. Disconnect wires and wiring harnesses at the engine. Disconnect the heater hoses at the engine. 8. Disconnect the transmission dipstick tube from the engine. 9. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 680 kg (1500 lb) (engine only). 10. Remove the plug in the flywheel housing. Remove the capscrews that hold the drive plate to the flywheel. Remove the capscrews that hold the torque converter housing to the flywheel housing. 11. Remove the capscrews that hold the mount at the fan end of the engine to the frame. 12. Carefully lift the engine from the frame. Make sure all the connections have been removed. Make sure the torque converter stays with the engine and does not fall.

2. Lubricate the pilot bushing in the flywheel with multipurpose grease. Make sure the torque converter stays in the transmission. Install the engine to the transmission, making sure the flywheel is aligned with the torque converter. Install the capscrews that hold the torque converter housing to the flywheel housing. 3. Install the bolt for the front engine mount. Remove the lifting device. 4. Install the capscrews and washers that hold the drive plate to the flywheel. Tighten the capscrews to 36 N.m (26 lbf ft). Install the plug in the flywheel housing. 5. Install the radiator. Connect the coolant hoses and transmission oil lines to the radiator. Connect the oil line at the top of the torque converter. 6. Connect the heater hoses, wiring harnesses, wires and throttle linkage to the engine. Connect the transmission dipstick tube to the engine. 7. Connect the fuel lines at the fuel injection pump and the fuel pump.
9

Installation (See FIGURE 9.)

1. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 680 kg (1500 lb).

1. 2. 3. 4. 5.

ENGINE MOUNT LIFTING EYE ENGINE FLYWHEEL DRIVE PLATE TRANSMISSION MOUNT

6. 7. 8. 9. 10. 11.

BOLT WASHER RUBBER MOUNT MOUNT BRACKET WASHER NUT 2 10

9 8

6 7

11

1 5

4
12728

FIGURE 9. ENGINE INSTALLATION 8. Install the air filter and connecting tubes. Make sure the clamps for the air intake tubes are tight. Air leaks can cause engine damage. 9. Attach a lifting device and sling and install the hood assembly. Install the rubber elbow to the precleaner tube and the small hose to the air restriction indicator. Connect the muffler to the exhaust system at the flexible tube connection. 10. Connect the battery cables to the battery. Fill cooling system with coolant. Check all oil levels. Start the engine and check for leaks and correct operation. sion and brake system controls, attachment controls and the seat. The overhead guard is built into the operator compartment. The cab has doors, windows, window wipers, fan and a heater system. The operator compartment is installed on a platform and support base above the main frames members. On lift trucks with the tilt cab, the support platform is hinged and can tilt forward, toward the mast. Stairways and steps on both sides of the lift truck give access to the operator platform. The operator compartment can be installed in the center of the frame or to the left side of the lift truck.The operator compartment is a separate module from the frame of the lift truck and can be removed as a complete unit. On lift trucks with the tilt cab, the operator compartment can be removed with or without the support platform.

OPERATOR COMPARTMENT AND CAB General (See FIGURE 10.)

The operator compartment includes the hydraulic control levers, steering wheel, instrument panel, transmis10

1. 2. 3. 4. 5.

ACCELERATOR PEDAL BRAKE PEDAL INCHING/BRAKE PEDAL PARKING BRAKE KNOB LOW BRAKE PRESSURE INDICATOR LIGHT 17 18 19

21

22 23 24

16 15

12 11 10 13 9 14

20 26

25

8 6. PARKING BRAKE INDICATOR LIGHT 7. FUSE PANEL 8. SWITCHES, LEFT TO RIGHT: OPTIONAL REAR WIPER TOP WIPER FRONT WIPER LIGHT LIGHT LIGHT 7 5

4 3 2 6

17. 18. 19. 20.

9. 10. 11. 12. 13. 14. 15. 16.

TRANS. OIL TEMP. GAUGE TRANS. OIL PRESS. GAUGE VOLTMETER ENGINE OIL PRESS. GAUGE TWIST LOCK CONTROL COOLANT TEMP. GAUGE RANGE LEVER DIRECTION LEVER

21. 22. 23. 24. 25. 26.

HOUR METER FUEL GAUGE KEY SWITCH WARNING INDICATORS: ALTERNATOR ENGINE OIL PRESSURE TRANS. OIL PRESSURE TRANS. OIL TEMP. FAN HEATER CONTROLS ATTACHMENT CONTROLS TILT CONTROL LEVER LIFT/LOWER CONTROL LEVER SEAT

FIGURE 10. OPERATOR COMPARTMENT AND CAB

Removal (See FIGURE 11. and FIGURE 22.)

NOTE: If the operator compartment/cab needs repair or replacement, remove it using the following procedures. 1. Remove the doors from the cab. Remove the capscrews for the floor plates. Remove the center floor plate and seat. 2. Remove the panel from the hydraulic control console. Put tags for identification on the hydraulic lines. Dis-

connect the hydraulic lines at the control valves. Disconnect the wiring harness at the switches. Remove the floor plate and console. 3. Put tags for identification on the hydraulic lines. Disconnect the hydraulic lines at the steering control unit. 4. Disconnect the hydraulic lines at the parking brake valve. Disconnect the hydraulic lines at the brake pedal valves or move the floor plate and pedals out of the way. If necessary, disconnect the throttle cable at the accelerator pedal.
11

2 1

22 21

20 6 12 7 8 9

10

11 13 19

18
12507

14

15 16 1. 2. 3. 4. 5. 6. 17 WINDOW RETAINER TOP WINDOW WINDOW CLAMP TOP WIPER MOTOR DEFROSTER VENT TOP WIPER ARM

7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

SIDE WINDOW CAB FRAME FRONT WIPER ARM FRONT QUARTER WINDOW LOWER DOOR WINDOW REAR QUARTER WINDOW REAR WINDOW REAR WIPER DOOR RETAINER LATCH DOOR RETAINER DOOR AIR VENT FUSE PANEL FRONT WINDOW MIRROR FRONT WIPER MOTOR

FIGURE 11. OPERATOR COMPARTMENT AND CAB ASSEMBLY 5. Disconnect the wiring from the fuse panel at the engine, transmission and other components.
12

6. Disconnect the hoses at the heater core and the heater valve. Disconnect the wiring harness at the heater.

7. Remove the bolts and nuts that hold the operator compartment to the frame mounts. For tilt cabs, remove the bolts and nuts between the operator compartment and the cab platform.

Installation (See FIGURE 11. and FIGURE 22.)

NOTE: If the operator compartment/cab was removed for repair or replacement, install it using the following procedures.

WARNING
Make sure that the lifting device has the capacity to lift a minimum of 454 kg (1000 lb). 8. See FIGURE 12. Connect a lifting device to a spreader bar that is through the door openings at the top of the operator compartment (under the overhead guard structure). Put material that will be a cushion at the top of the door openings to prevent damage. Carefully lift the cab away from the lift truck. Set the cab assembly in a storage area and put blocks under the unit to give it stability.

WARNING
Make sure that the lifting device has the capacity to lift a minimum of 454 kg (1000 lb). 1. See FIGURE 12. Connect a lifting device to a spreader bar that is through the door openings at the top of the operator compartment (under the overhead guard tubes). Put material that will be a cushion at the top of the door openings to prevent damage. Install the operator compartment on the mounts. Install the rubber mounts, washers, nuts and bolts for the mounts. 2. Connect the hydraulic lines to the steering control unit. 3. Install the floor plate with the brake pedals. If necessary, connect the hydraulic lines. Connect the throttle cable. Connect the hydraulic lines to the parking brake valve. 4. Connect the hydraulic lines for the control valves at the hydraulic console. Make sure the lines are connected to the correct ports. 5. Connect the wiring and wires at the fuse panel and other components in the operator compartment. 6. Connect the hoses at the heater core and the heater valve. 7. Install the floor plates and the seat. 8. Install the doors. 9. Operate the brakes, steering and hydraulic system and check for leaks and correct operation.

CAUTION
Make sure all hydraulic lines, brake lines, electrical wires and other hoses and attachments are not damaged.

1 4

Repairs
3
12468

GAUGES AND SWITCHES 1. The gauges and switches on the cowl are fastened to removable panels. Disconnect the wiring harnesses and remove the screws that hold the panels to the instrument panel. The electrical wiring diagrams are in the section DIAGRAMS, 8000 SRM 488. These diagrams will help identify the wiring harnesses and components.
13

1. SPREADER BAR 2. SLING

3. CAB 4. CUSHION

FIGURE 12. MOVE THE CAB

2. See the section INSTRUMENT PANEL INDICATORS AND SENDERS, 2200 SRM 143 to replace the gauges 3. The rocker switches are replaced by pressing in on the flexible tabs at the back side to release the switch assembly from the instrument panel. The replacement switch is installed from the top side of the instrument panel and pressed in until the tabs on the switch lock in the opening for the switch.
1 3 2

have wiper motor assemblies that have one wiper arm attached to a single wiper blade. Replace the single arm unit as follows: a. To replace this motor assembly, first remove the arm (or arms) and the blade from the outside. Remove the nut and washers from the threaded shaft tube that passes through the metal frame of the operator compartment. b. Remove the one mount screw from the single arm wiper motor, disconnect the electrical wire and remove from the operator compartment. c. When you install the wiper motor be sure to connect the electrical wires first. Replace the double arm unit as follows: a. To replace this motor assembly, first remove the arms and the blade from the outside. Remove the nuts and washers from the two threaded shaft tubes that passes through the metal frame of the operator compartment. b. Disconnect the electrical wires and remove the wiper motor from the front window.

3 4 1. 2. 3. 4.

12510

4 THREADED TUBE MOTOR GEAR ASSEMBLY WIRE HARNESS 4 1. 2. 3. 4. 5. FRONT WASHER MOTOR/PUMP TOP WASHER MOTOR/PUMP REAR WASHER MOTOR/PUMP CHECK VALVE RESERVOIR

12743

FIGURE 13. WINDOW WIPERS 4. Remove the remote control valves as described in the section THE HYDRAULIC SYSTEM, 1900 SRM 492. WINDOW WIPERS (See FIGURE 13.) Three window wiper motor assemblies are installed in the operator compartment. The front window motor assembly has two wiper arms connected to a single wiper blade. The rear window and the top (overhead) window
14

FIGURE 14. WINDOW WASHERS

Window Washer Motor/Pumps (See FIGURE 14.)

Three window washer motor/pump assemblies, and a water reservoir are installed just below and at the right rear part of the operator compartment. When cleaning or replacing any of the hoses, make sure the check valves are installed so that the arrows are toward the nozzles.

Heater Assembly
REMOVAL (See FIGURE 15.) Heater Control Panel Assembly: 1. Remove the righthand access panel (22) and discon-

nect the control cables from the damper rod (10) and the heater valve (14). 2. Remove the four screws (26) from the face plate (4). Disconnect the blower electrical harness from the blower control switch (23) and remove the heater control panel (4) and cable assemblies (9 and 15).

24 15 4 23 23 9 26

12384

25 1 2

17 3 4 18

5 19

6 7 16 15 9 10 22 14 13 12 1. 2. 3. 4. 5. 6. 7. 8. 9. RETAINER BLOWER ASSEMBLY COVER CONTROL ASSEMBLY HEATER CORE SUPPORT PLATE CLAMP DAMPER PLATE DAMPER CONTROL CABLE 10. 11. 12. 13. 14. 15. 16. 17. 18. DAMPER ROD HEATER HOSE (RETURN) HEATER HOSE (SUPPLY) HOSE GROMMET HEATER VALVE HEAT CONTROL CABLE BLOWER GASKET ADHESIVE SEALANT INTAKE COVER 11 8

21

20
12511

19. 20. 21. 22. 23. 24. 25. 26.

SPRING FILTER VENTS ACCESS PANEL, RH BLOWER CONTROL SW. HEAT CONTROL LEVER DAMPER CONTROL LEVER SCREW (4)

FIGURE 15. HEATER SYSTEM

15

Blower and Core Assemblies: 1. Remove the righthand access panel (22) and disconnect the control cables from the damper rod (10) and the heater valve (14). 2. Remove the sheet metal screws and the cover panel (3) from the cowl. Disconnect the blower electrical harness from the blower control switch (23) as the cover panel is removed. 3. Disconnect the blower harness from the electrical harness and disconnect the ground wire. Remove the two screws that fasten the blower retainer over the base of the blower assembly (at the top). Pivot the blower assembly downward and then position the assembly so that is can be lifted out of the cowl area. FIGURE 16. FUSE PANEL 4. The heater core can be removed by disconnecting the heater hoses (through the righthand access panel). Remove the capscrews and clamp (7) that fasten the core to the support panel. Remove the heater core. INSTALLATION See FIGURE 15. Install the heater assembly in the reverse order of removal.

12384

Operator Restraint System (See FIGURE 17. and FIGURE 18.)

The seat belt, seat and mounting are all part of the operator restraint system. Each part must be inspected to make sure the attachment points are fastened correctly and that the part operates correctly and is in good condition.
1. SEAT BELT RETRACTOR 2. SEAT BELT LATCH 3. SEAT RAIL

Fuse Panel (See FIGURE 16.)

2 1

The fuse panel with the fuses for the window wipers, lights, fan and heater system is inside the operator compartment. This fuse panel is behind a door at the front of the left instrument console. The fuse panel can be pulled away or removed from the mount by loosening two capscrews, then sliding the panel upward and out. See the section DIAGRAMS, 8000 SRM 488 for the electrical wiring of the operator compartment.
16

11157

FIGURE 17. CHECK THE SEAT The seat belt must fasten correctly. Make sure the seat belt can be pulled from the retractor and retracts

smoothly and is not worn or damaged. If the seat belt can not be pulled from the retractor assembly, remove the screw that keeps the cover on the retractor assembly. Push the bar to release the spool. Straighten the belt so that it pulls out and retracts smoothly. The seat belt must latch securely. (See FIGURE 18.) Make sure the seat rails are fastened correctly at the attachment points. The seat must lock in position on the seat rails, but the seat must slide freely when it it unlocked.

1. OUTSIDE DOOR HANDLE 2. CAPSCREW 3. PLUG

1 1 5 2 4 3 2

4
11806

4. DOOR 5. INSIDE DOOR HANDLE 6. CAB FRAME 7. DOOR SEAL

12505

1. COVER OPEN 2. SEAT BELT RETRACTOR

3. SEAT BELT 4. BAR

FIGURE 19. DOOR HANDLE ASSEMBLY

FIGURE 18. RELEASE A JAMMED SEAT BELT

Door Handle Assembly (See FIGURE 19.)

The door handle assemblies are made up of three components; an outside handle with lock, an inside lever type handle and latch mechanism and a striker. The outside door handle is fastened to the door by a capscrew and washer installed through an access hole from the inside of the door. The inside door handle is fastened to the door by two capscrews and washers. This handle assembly has a latch mechanism that contacts the striker. The striker is installed on the forward door post by two capscrews and washers.

Door Retainer Assemblies (See FIGURE 20.)

The door retainer assembly will lock the door in the full open position. A latch mechanism is mounted behind the doors on each side of the operator compartment. This latch contacts the retainer plate on the door when the door is in the fully open position and is pressed into the retainer. A door release handle and link assembly is located just inside the door at the lower hinge area. This handle and link assembly will operate a crank inside the bracket on the outside of the cab. The door (if open and locked in position) will release when the handle is pulled.

17

1. Install the rubber seal in in window opening.

3 4 7 5

CAUTION
When installing the glass, use glass installation tools with edges that are not sharp to help avoid breaking the glass. Use these tools between the glass and the rubber seal. 2. Install the two side panels of glass into the groove in the rubber seal. The main panel is installed last. NOTE: Make sure the glass is dry, clean and free of grease.

10 1

8 9

3 4 2 5

3. Install the spacers (8), one midway vertically at the edges of the side and main window panels. This procedure will make sure there is even space between the panels before and after the silicone sealant is applied.
12505

6 1. 2. 3. 4. 5. DOOR RELEASE ROD SIDE OF CAB CRANK DOOR RETAINER 6. 7. 8. 9. 10.

4. Install the main glass panel into the groove in the bottom of the rubber seal. 5. When the glass is in the groove, the rubber seal will initially hold the glass away from the edges of the side quarter panels. Place the palms of both hands, one at either side of the window panel and press evenly toward the operator compartment. The panel will go into place. 6. Put masking tape on the inside corners where the two panels of glass come together. Apply the correct amount of silicone sealant to make a good seal with no holes. Make a template to fit around the outside corner of the windows. (See FIGURE 21.). Use the template to remove all excess silicone sealant from the window panels. LOWER DOOR WINDOWS These windows are installed into the window openings with the use of the same type rubber seal described for the front and rear window installations. UPPER DOOR (SLIDER) WINDOWS 1. Use a hand drill with a 4 mm (5/32 in) bit to remove the rivets that hold the window frames to the door frame assembly. Use a chisel and a punch if necessary to completely remove the rivets. NOTE: The windows are installed at the factory with a silicone sealant on all seams and window trim. Remove all old silicone sealant.

LATCH SPACER LATCH SPRING SPACER

FIGURE 20. DOOR RETAINER ASSEMBLY

Window Replacement (See FIGURE 21.)

The front, rear and lower door windows can be replaced as separate units. These windows are held in their openings by a rubber seal. The slider windows and frames in the doors must be replaced as a complete unit. The top window is a single piece of material with no frame and is fastened by clamps and adhesive.

WARNING
All windows installed in the cab are made of special material, not regular glass. All new windows must be made of the correct material and thickness as the windows furnished with the lift truck. See TABLE 1 for correct material for each window. FRONT AND REAR WINDOWS The glass in the front and rear window assemblies is laminated at the connecting edges by silicone sealant. Use the following procedure to replace the windows.
18

FRONT WINDOW 3 8 8 3

Cut spacer (PN 3767840) in half. Insert half of the spacer between the main and quarter glass on each side, midway between top and bottom. Adjust the quarter window to obtain even space between the two glass panels. 9 ** 3

*
REAR WINDOW 5 9 ** 6

IMMEDIATELY REMOVE EXCESS SILICONE ADHESIVE WITH A TEMPLATE. WINDOW DURING APPLICATION OF SILICONE ADHESIVE. REMOVE TAPE WHEN DRY.

1*

** USE TAPE AT INSIDE OF CORNER OF

7

RADIUS = 4 mm (0.16 in) 1. APPLY SILICONE ADHESIVE 2. GLASS MUST BE DRY, CLEAN AND FREE OF GREASE 3. FRONT WINDOW 4. FRONT QUARTER WINDOW 5. REAR WINDOW 6. REAR QUARTER WINDOW 7. TEMPLATE 8. SPACER 9. TAPE

12508

1*

FIGURE 21. REPLACEMENT OF WINDOWS TABLE 1. MATERIAL SPECIFICATIONS FOR CAB WINDOWS
LOCATION OF WINDOW FRONT, MAIN FRONT, QTR. REAR, MAIN REAR, QTR. DOORS UPPER RH UPPER LH LOWER, R/L TOP HYSTER PART NO. 1301371 1301373 1301372 1301374 1311302 1311303 1301375 333908 MATERIAL SPECIFICATION TINTED LAMINATED SAFETY GLASS per ANSI Z26.1 AS1 REQUIREMENTS THICKNESS mm 5.97.5 inches 0.230.29 0.220.27

TINTED LAMINATED or TEMPERED SAFETY GLASS per ANSI Z26.1 AS2 REQUIREMENTS 5.66.8 TINTED TEMPERED SAFETY GLASS per ANSI Z26.1 AS2 REQUIREMENTS

5.66.2

0.220.25 0.220.27 0.12

TINTED LAMINATED or TEMPERED 5.66.8 SAFETY GLASS per ANSI Z26.1 AS2 REQUIREMENTS TINTED LEXAN MR 5004310351 3.0

TOP WINDOW Remove the two screws and window clamps, then lift out the window. Use the silicone sealant on the top of the cross bar on the overhead assembly. Install the top window under the two clips at the rear. Lower the window onto the adhe-

sive and fasten it at the front with the two window clamps and screws. 2. Have a dealer for Hyster lift trucks, or a qualified glass supplier replace any damaged window or frame parts. Be sure that the material and the thickness of the window parts are correct. (See TABLE 1.)
19

3. Align the window frame with the upper opening in the door frame. Use a drill to make new holes for the fasteners, if new window frames are used. Apply silicone sealant (Hyster part no. 280472) to the mounting sur-

faces for the window frames. Fasten the window to the door frame with rivets (or capscrews, washers and lock nuts).

14 9 8

10 15 4

16 5 10 13

11 9 14 12 11

1 6 2 2 3 11 13 1 1. PUMP 2. PORT (RAISE) 3. PORT (LOWER) 4. CYLINDER 5. CABLE FOR CAB SUPPORT 6. HOSE (RAISE) 10 5 4 3

7. HOSE (LOWER) 8. HOSE (LATCH RELEASE) 9. LATCH CYLINDER 10. SNAP RING 11. PIN 12. BUSHING 13. LIFT TRUCK FRAME 14. CAB PLATFORM 15. CAB SUPPORT 16. SPRING

FIGURE 22. TILT CAB ARRANGEMENT

20

TILT CAB General (See FIGURE 22., FIGURE 23.)

The tilt cab arrangement uses a hand operated pump and a hydraulic cylinder to raise and lower the cab. A hydraulic latch, also operated by the pump, releases the hook that holds the cab platform to the lift truck frame.

14

10 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. PUMP PORT (RAISE) PORT (LOWER) CYLINDER CABLE FOR CAB SUPPORT HOSE (RAISE) HOSE (LOWER) HOSE (LATCH RELEASE) LATCH CYLINDER SNAP RING PIN BUSHING HANDLE CAB PLATFORM CAB SUPPORT SPRING 16 11

11 8 15 10

4 13 6 10 1

11

2 5 6 3

FIGURE 23. TILT CAB ARRANGEMENT

21

Repairs (See FIGURE 22., FIGURE 23. and FIGURE 24.)

6. Connect the hydraulic lines to the tilt cylinder. 7. Operate pump in the RAISE position. Make sure the cab support is in the correct position then remove the safety chain. Lower the cab and raise it again to check for leaks and correct operation. LATCH (See FIGURE 23. and FIGURE 24.)

WARNING
Make sure the cab support is engaged before you place any part of your body under the raised cab. Make sure no one is under the cab when lowering the cab. TILT CYLINDER (See FIGURE 22., FIGURE 23. and FIGURE 24.) 1. Raise the cab. Connect a safety chain between a hand rail on the cab and a crossmember on the mast. The safety chain must hold the cab in the raised position when the tilt cylinder is removed. 2. Remove the pins at the ends of the tilt cylinder. Remove the pin for the cable at the cab platform. 3. Disconnect the hydraulic lines at the tilt cylinder. Put tags on the lines for identification. 4. Disassemble the tilt cylinder assembly and repair as necessary. 5. Install the tilt cylinder in the correct position. Make sure the cab support is installed correctly. Install the pins and snap rings for the tilt cylinder and cable.

1. Remove the access panel at the back of the operators compartment. Disconnect the hydraulic line at the latch. 2. Remove the capscrews that hold the latch to the cab platform. 3. Disassemble and repair the latch as necessary. 4. Install the latch and connect the hydraulic line. Operate the pump to make sure the latch opens and closes correctly. PUMP (See FIGURE 23. and FIGURE 24.) 1. Disconnect the hydraulic lines at the pump. Put tags on the lines for identification. 2. Remove the capscrews that hold the pump to the mount. 3. Disassemble and repair the pump as necessary. 4. Install the pump and connect the hydraulic lines. Operate the pump to make sure the cab raises and lowers correctly.

22

TILT CYLINDER

2 3

5 6 5 7 4 5 6 5 7 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. SEAL ROD LATCH PISTON CYLINDER PUMP RESERVOIR PUMP BODY SPOOL PLUNGER SET SCREW LEVER RELIEF VALVE GASKET OUTLET INLET ORIFICE WAVE WASHER

10 12 11 9 2 8 10 10 10

13

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

CYLINDER SHELL RETAINING RING SCREEN LOCK SCREW SPRING BALL PLUG WIPER BACKUP RING ORING GLAND PISTON

14

PUMP ASSEMBLY

LATCH ASSEMBLY 13 17 10 9 8 16 15 8 9 10 17 6 29 28 6

21 22 20 23 18

24 10 7 25 7

5 25 6

10

3 2 3 19

27

26

FIGURE 24. PARTS FOR THE TILT CAB

23

LABEL REPLACEMENT (See FIGURE 25.)

1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint using a cleaning solvent. 2. Remove the paper from the back of the label. Do not touch the adhesive surface. 3. Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface. Make sure all air is removed from under the label and the corners and edges are tight. If the labels or information plates are missing or damaged, they must be replaced.

WARNING
If labels that have warnings or cautions are damaged, they must be replaced.

If a mast of a different size or an accessory carriage is installed, the capacity rating can change. Changes in the size of drive tires can change the capacity rating. See a dealer for Hyster lift trucks for a replacement nameplate. The nameplate information is a safety item and must be correct.

24

1. PARKING BRAKE AND HYDRAULIC PRESSURE 2. PARKING BRAKE WARNING 3. WARNING FOR SAFETY 4. NAMEPLATE TAG 5. FUSE PANEL 6. PATENT PLATE

1 3 4

2 6 8 5

9 10 11 12 18 15 16 14 17 19 7 13

20b

20a 7. 8. 9. 10. 11.

21a 21b 22

MAST CONTROL ATTACHMENT CONTROL CASE FOR OPERATING MANUAL REPLACE OPERATING MANUAL TRANSMISSION CONTROL AND TWIST LOCK OPERATION 12. FAN WARNING 13. DOOR RELEASE 14. MODEL LABEL 15. MODEL SIZE 16. DIESEL STARTING AID 17. NO RIDERS 18. MAST LABEL 19. MAST SAFETY 20a. BATTERY DISCONNECT SWITCH H20.0032.00F (H440700F) 20b. BATTERY DISCONNECT SWITCH H440700FS

22

LEFT SIDE OF LIFT TRUCK

12718

21a. TILT CAB OPERATION LABEL H20.0032.00F (H440700F) 21b. TILT CAB OPERATION LABEL H440700FS 22. HYDRAULIC TEST PORT LABEL

FIGURE 25. LABEL POSITIONS

25