INTRODUCTION

GENERAL tank and the fuel tank for gasoline and diesel fuel.

This section has the description of the frame and some There is a counterweight for each capacity of lift truck.
connected parts. See FIGURE 1. Procedures for the re- The counterweights are similar, but are different
moval and installation of the counterweight, hood, weights.
overhead guard and engine are under REPAIRS in this
section. Checks for the operator restraint system and An overhead guard is fastened to the frame of the lift
procedures for the repair of tanks and replacement of truck. The overhead guard has the mounts for the seat
safety labels are included. plate and the hood.
DESCRIPTION
The hood is connected at mounts on the cowl and the
The frame is one weldment and includes the hydraulic frame.

1. OVERHEAD GUARD
2. COUNTERWEIGHT
3. HOOD
4. FLOOR PLATE
5. FRAME

11640

FIGURE 1. FRAME AND CONNECTED PARTS

1
 REPAIRS

Installation (See FIGURE 2.)

WARNING
The lift truck must be put on blocks for some types of 1. Connect a strap and lifting device to the counter-
maintenance and repair. The removal of the follow- weight. Lift the counterweight into position on the
ing assemblies will cause large changes in the center frame. Make sure the counterweight is in position on
of gravity: upright, drive axle, engine and transmis- the mounts.
sion and the counterweight. When the lift truck is 2. Install the bolt for the counterweight. Install the
put on blocks, but additional blocks in the following cover for the hydraulic pump. Install the grille.
positions to maintain stability: 3. Install the bracket for the hood mount. Install the
a. Before removing the upright and drive axle, capscrews for the hood mount. Adjust the hood as de-
put blocks under the counterweight so that the scribed in the procedures for the hood.
lift truck can not fall backward.
b. Before removing the counterweight, put
blocks under the upright assembly so that the
lift truck can not fall forward.
The surface must be solid, even and level when the
lift truck is put on blocks. Make sure that any blocks
used to support the lift truck are solid, one piece
units.

COUNTERWEIGHT

WARNING
Do not operate the lift truck if the capscrew for the
counterweight is not installed. When the capscrew is
removed, the counterweight can fall from the lift
truck.

Removal (See FIGURE 2.)

1. Remove the grille and the cover for the hydraulic

pump.
11630

2. Remove the bracket for the rear hood mount from the
frame. Put a block between the hood and the radiator.
WEIGHT OF COUNTERWEIGHTS
WARNING H6.00XL (H135XL) H7.00XL (H155XL)
Make sure any lifting devices have the correct capac- 25942654 kg 30923162 kg
(57205852 lb) (68186972 lb)
ity for the parts being removed.
FIGURE 2. COUNTERWEIGHT
3. Put a lifting strap through the hole in the counter-
weight. Connect a lifting device to the strap. Remove HOOD
the bolt that holds the counterweight to the frame.
Removal
4. Lift the counterweight from the frame. Put the coun- Remove the hood (both sides) as an assembly. Remove
terweight in a position so that it has stability. the capscrews that hold the hood mount bracket to the

2
frame. Remove the capscrews that hold the hood to the Installation (See FIGURE 3.)
bracket on the overhead guard. Lift the hood from the
1. Connect a lifting device to the top of the overhead
frame.
guard. Put the overhead guard in position on the lift
truck.
Installation
2. Make sure the rubber bushings are in the mount
Install the hood assembly on the frame. Install the holes at the rear of the overhead guard. Install the
capscrews that hold the brackets to the frame and capscrews at the rear of the overhead guard. Install the
bracket on the overhead guard. If necessary, adjust the capscrews that hold the overhead guard to the cowl and
hood as follows: tighten them to 285 N.m (210 lbf ft). Connect the wir-
1. Loosen the capscrews at the mounts for the hood as- ing harness for the cab. Install the doors for the cab.
sembly. Put the hood assembly in a position so that the 3. Connect the hose for the air cleaner. Connect the ex-
center of the hood is in the center of the counterweight haust system. Install the brake fluid reservoir.
and overhead guard. Tighten the capscrews.

2. Adjust the mount (on the frame) and the hood stops
at the rear of the hood so that the top of the hood aligns
with the counterweight. Make sure the hood does not
touch the counterweight.

3. Adjust the other hood stops so that they just touch

the sides of the hood when they are closed.

OVERHEAD GUARD (See FIGURE 3.)

WARNING
Do not operate the lift truck without the overhead
guard correctly fastened to the lift truck.
Changes that are made by welding or by drilling
holes that are too big in the wrong location, can re-
duce the strength of the overhead guard. See the in-
structions for Changes to the Overhead Guard in
the PERIODIC MAINTENANCE section included
with this lift truck.

Removal (See FIGURE 3.)

11635

1. Remove the hood as an assembly. Disconnect the

1. OVERHEAD GUARD 3. FRAME
hose to the air cleaner. Disconnect the exhaust system 2. COWL 4. RUBBER BUSHING
from the overhead guard leg. Remove the capscrews
that hold the brake reservoir to the overhead guard. If a FIGURE 3. OVERHEAD GUARD AND COWL
cab is installed, disconnect the wiring harness for the
cab. Lift the doors from the cab. OPERATOR RESTRAINT SYSTEM
(See FIGURE 4.)
2. Connect a lifting device to the top of the overhead
guard. Remove the capscrews (in the engine compart- The seat belt, hip restraint brackets, seat and mounting
ment) that hold the overhead guard to the frame. Re- are all part of the operator restraint system. Each item
move the capscrews that hold the overhead guard to the must be checked to make sure it is attached securely,
cowl. Lift the overhead guard from the lift truck. functions correctly and is in good condition.

3
The end of the seat belt must fasten correctly in the Repairs, Small Leaks
latch. Make sure the seat belt pulls from the retractor
Use the following procedure to repair small leaks:
assembly and retracts smoothly. The seat belt must be
in good condition. A seat belt that is damaged or worn a. Use steam to clean the area around the leak. Re-
will not give protection when it is needed. move all paint and dirt around the leak.
See FIGURE 4. Make sure the seat rails are not loose. WARNING
The seat rails must lock securely in position, but move
Do not use tools that can make sparks, heat or static
freely when unlocked. The seat rails must be securely
electricity. The vapors in the tank can cause an ex-
attached to the mounting surface.
plosion.

b. Apply Loctite
290 to the leak. Follow the in-

1. SEAT BELT
2. HIP RESTRAINT structions of the manufacturer.
3. SEAT RAIL
4. SEAT BELT RETRACTOR Repairs, 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 Standards Safety In Weld-
ing and Cutting ANSI Z 49.1 1973.

12478 Cleaning

WARNING
Special procedures must be followed when large
FIGURE 4. CHECK THE SEAT 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
HYDRAULIC TANK is enough ventilation. See the following manuals for
additional information:
Removal
 Safe Practices For Welding And Cutting Con-
1. Remove the engine and transmission. tainers That Have Held Combustibles by the
American Welding Society, A6.065.
2. Remove the drain plug and drain the oil from the
tank. Disconnect the hydraulic lines at the tank and put  Safety In Welding and Cutting, American
caps on the open lines. National Standard, ANSI Z 49.1 1973.

3. Remove the hooks that hold the tank to the frame. When cleaning the tank, do not use solutions that make
Remove the hydraulic tank. dangerous gases at normal temperatures or when
heated. Wear eye and face protection. Protect the body
Inspection from burns.

Make a visual inspection of all sides of the tank. In- When cleaning with steam, use a hose with a minimum
spect the welds for cracks and leakage. Check for wet diameter of 19 mm (0.75 in). Control the pressure of
areas, accumulation of dirt and loose or missing paint the steam by a valve installed at the nozzle of the hose.
caused by leakage. Areas of the tank that are not easily If a metal nozzle is used, it must be made of a material
seen can be checked with an inspection mirror and a that does not make sparks. Make an electrical connec-
light that is approved for locations with flammable va- tion between the nozzle and the tank. Connect a ground
pors. wire to the tank to prevent static electricity.

4
Steam Method of Cleaning d. Make an inspection of the inside of the tank. If the
tank is not clean, repeat steps a. to c.. Make an-
Use the following procedure to clean the tank with other inspection of the tank. When making in-
steam: spections, use a light that is approved for loca-
a. Remove all the parts from the tank. Install the tions with flammable vapors.
drain plug. e. Check the tank for flammable vapors using a spe-
cial indicator for gas vapors. If the amount of
b. Fill the tank 1/4 full with a solution of water and
flammable vapors is not below the lower flam-
sodium bicarbonate or sodium carbonate. Mix
mable limit, repeat the cleaning procedures.
0.5 kg (1 lb) per 4 litres (1 gal) of water.

c. Mix the solution in the tank using air pressure. Other Methods Of Preparation For Repair
Make sure all the surfaces on the inside of the If nitrogen gas or carbon dioxide gas is available, pre-
tank are flushed with the solution. Drain the tank. pare the tank for welding using these gases. See the
manual Safe Practices For Welding and Cutting Con-
d. Put steam into the tank until the tank does not
tainers That Have Held Combustibles by the American
have odors and the metal is hot. Steam vapors
Welding Society, A6.065. If these gases are not avail-
must come out of all the openings.
able, another method using water can be used as fol-
e. Flush the inside of the tank with boiling water. lows:
Make sure all the loose material is removed from a. Fill the tank with water to just below the point
the inside of the tank. where the work will be done. Make sure the space
above the level of the water has a vent.
f. Make an inspection of the inside of the tank. If it
is not clean, repeat steps d. and e. and make an- b. Use acceptable welding practices to repair the
other inspection. When making inspections, use a tank. See the American National Standard
light that is approved for locations with flamma- Safety In Welding And Cutting ANSI Z 49.1
ble vapors. 1973.

g. Put plugs in all the openings in the tank. Wait 15 Installation

minutes, then remove the inlet and outlet plugs.
Test a sample of the vapor with a special indicator 1. Put the tank in position in the frame and install the
for gas vapors. If the amount of flammable va- hooks.
pors is above the lower flammable limit, repeat 2. Connect the hydraulic lines to the fittings on the
the cleaning procedures. tank.

Chemical Solution Method of Cleaning 3. Install the engine and transmission. Fill the tank with
the correct hydraulic oil. Operate the system and check
If the tank cannot be cleaned with steam, use the fol- for leaks and correct operation.
lowing procedure:
FUEL TANK
a. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Fol- Removal
low the instructions given by the manufacturer.
1. Remove the engine and transmission.
b. Fill the tank with the cleaning solution. Use com-
pressed air to mix the solution in the tank.
WARNING
Do not use tools that can make sparks, heat or static
c. Drain the tank. Flush the inside of the tank with electricity. The vapors in the tank can cause an ex-
hot (boiling) water. Make sure all the cleaning plosion. Clean all fuel spills. Make sure the fuel from
compound is removed. the tank is put in a closed container.

5
2. Remove the drain plug and drain the fuel from the 2. Remove the hood. Remove the air cleaner assembly.
tank. Disconnect the fuel lines at the tank and put caps Disconnect the brake fluid reservoir from the bracket.
on the openings. If necessary, remove the overhead guard.

3. Remove the filler neck from the fuel tank. Remove 3. Drain the coolant from the cooling system. Remove
the hooks that hold the tank to the frame. Remove the the radiator.
fuel tank. 4. Disconnect the drive shaft for the hydraulic pump at
the crankshaft pulley.
Repairs
5. Disconnect the exhaust system.
Repair the fuel tank as described in the repair proce-
dures for the hydraulic tank. 6. Disconnect the hydraulic lines at the steering pump.
Put caps on the open lines.
Installation 7. Disconnect fuel lines and the throttle linkage.
1. Put the tank in position in the frame. Install the filler 8. Disconnect wires and wiring harnesses at the engine.
neck and the hooks.
9. Connect a lifting device to the engine. Make sure the
2. Install the engine and transmission. Connect the fuel lifting device has a capacity of at least 450 kg (1000 lb)
lines to the tank. (engine only).
10. On units with a powershift transmission, remove
RADIATOR the capscrews that hold the torque converter to the fly-
Removal wheel. Put blocks under the output end of the transmis-
sion. Remove the capscrews that connect the engine to
1. Remove the hood as an assembly. the flywheel housing.
2. Drain the coolant from the radiator. Disconnect the 11. Remove the capscrews that hold the mount at the
radiator hoses. If equipped, disconnect the lines from fan end of the engine to the frame.
the powershift transmission. Put caps on the open lines. 12. Carefully lift the engine from the frame. Make sure
3. Remove the screws that hold the fan shroud to the all the connections have been removed. Make sure the
radiator. Remove the nuts that hold the radiator to the torque converter stays with the transmission and does
frame. not fall.

4. Remove the radiator. Installation (See FIGURE 3.)

1. Connect a lifting device to the engine. Make sure the
Installation lifting device has a capacity of 450 kg (1000 lb).
1. Put the fan shroud in position over the fan. Install the 2. Make sure the drive plate is installed on the torque
radiator to the mounts on the frame. Install the fan converter. Lubricate the pilot bushing in the flywheel
shroud on the radiator. with multipurpose grease. Install the engine in the
frame. Make sure the torque converter stays in the
2. Connect the radiator hoses and lines for the power-
transmission. Fit the flywheel on the pilot of the torque
shift transmission.
converter. Install the capscrews that hold the flywheel
3. Install the hood. Fill the radiator with coolant, then housing to the engine. Tighten the capscrews to 31 N.m
operate the engine and check for leaks. (23 lbf ft).
3. Install the capscrews and washers for the engine
ENGINE mount at the fan end of the engine. Install the
capscrews and adjust the mounts at the flywheel end of
Removal
the engine. Tighten the capscrews to the correct torque
1. Disconnect the cables at the battery. values as shown on FIGURE 3.

6
4. Install the capscrews that hold the drive plate for the ter it touches the surface. Put the label on the sur-
torque converter to the flywheel. Tighten the capscrews face. Make sure all air is removed from under the
to 44 N.m (32 lbf ft) on all units. Remove the lifting de- label and the corners and edges are tight.
vice.

5. Connect the wiring harness and wires at the engine.

6. Connect the throttle linkage and fuel lines at the en-

gine.

7. Connect the pipe for the exhaust system.

8. Connect the drive shaft for the hydraulic pump.

9. Install the radiator. Connect radiator hoses and cool-

ing line for the powershift transmission.

10. Install the overhead guard. Install the brake fluid

reservoir on the bracket. Install the hood. Connect the
cables at the battery.
FAN END OF ENGINE
SAFETY LABELS (See FIGURE 6.) (DIESEL SHOWN)

WARNING
Safety labels are installed on the lift truck to give in-
formation about operation and possible hazards. It
is important that all safety labels are installed on the
lift truck and can be read.
DO NOT add to or modify the lift truck. Any change
to the lift truck, the tires or its equipment can change
the lifting capacity. The lift truck must be rated as
equipped and the nameplate must show the new ca- 12392

pacity rating. Contact your dealer for Hyster lift

trucks for a replacement nameplate.
Cleaning solvents can be flammable and toxic, and
FLYWHEEL END OF ENGINE
cause skin irritation. When using cleaning solvents,
* Use as necessary to align Ujoint to within
always follow the recommendations of the manufac- 0.51.5 mm (0.020.06 in) of true vertical
turer. alignment

If a label must be replaced, use the following procedure A = 40 N.m (30 lbf ft) Torque
B = 56 N.m (41 lbf ft) Torque
to install a new label: C = 50 N.m (37 lbf ft) Torque
D = 165 N.m (122 lbf ft) Torque
a. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean 1. FRAME 6. ENGINE MOUNT
2. MOUNT BRACKET 7. WASHER*
the surface of old paint with a cleaning solvent. 3. WASHER 8. REBOUND WASHER
4. ENGINE 9. TORQUE
b. Remove the paper from the back of the label. Do 5. OVERLOAD CONVERTER OR
not touch the adhesive surface. WASHER CLUTCH HOUSING

c. Carefully hold the decal in the correct position FIGURE 5. ENGINE MOUNTS
above the surface. The label cannot be moved af-

7
 EARLY MODELS
18

LATE MODELS

1. WARNING FOR SAFETY

17 2. MAST SAFETY (2)
3. CASE FOR OPERATING
MANUAL
4. REPLACE OPERATING
MANUAL (NOT FOR ENGLISH
SPEAKING COUNTRIES)
5. NO RIDERS (2)
6. DEALER WARNING LABEL

11640

12654
7. NAMEPLATE
8. LABEL FOR CONTROL LEVERS
9. LABEL FOR RANGE LEVER 13. INSPECTION PLATE, UL
(POWERSHIFT TRANSMISSION) 14. FAN WARNING
10. LABEL FOR DIRECTION CONTROL LEVER 15. FAN WARNING
11. OPERATOR RESTRAINT (FOR EQUIPPED 16. FLAMMABLE LP GAS
UNITS) OR TIPOVER WARNING (FOR 17. MAST WARNING LABEL
OTHER UNITS) 18. RADIAL TIRE WARNING
12. PARKING BRAKE WARNING LABEL
FIGURE 6. LABEL POSITIONS

8
CAB (See FIGURE 7.) nal windows. See TABLE 1 for the correct window
materials.
Some lift trucks are equipped with a cab. The cab has
an overhead guard with doors and windows. The cab 1. Remove the rivets or screws that hold the window
has front and rear windshield wipers and a heater with a frames to the cab assembly. Use a chisel and a punch if
fan. The heater is on a mount on the instrument panel. necessary to completely remove the rivets.
2. Have a dealer for Hyster lift trucks or a qualified
Cab Replacement supplier of glass, replace any damaged window or
NOTE: Disconnect all electric wires. Remove any oth- frame parts. Make sure the material and the thickness
er parts between the cab and the lift truck. Remove the of the window parts are according to the specifications
cab assembly. Use a crane to lift the cab. in Table 1.

Each leg of the cab assembly is attached to the lift truck 3. Install the new window in the position on the cab.
frame with a bolt, washers and rubber pads. See Align the window frame with the opening in the cab
FIGURE 3. If necessary, the cab can be replaced as a frame or door frame. Use a drill to make new holes for
complete unit. the fasteners, if new window frames are used. Some
windows are installed with an adhesive/sealant (Hyster
Window Replacement part no. 330318). Before applying the adhesive/sealant,
clean the area with window weld primer (Hyster part
The front, rear and side windows and window frames no. 365337).
are replaced as single units. A window and frame are
not available as separate units. The top window has no Windshield Wipers and Heater
frame.
WARNING
WARNING When the heater hoses must be replaced in the cab,
All windows installed in the cab are made of special make sure to use heater hoses of the correct material
material, not regular glass. New windows must meet and size. All hoses must conform to SAE Specifica-
the material and thickness specifications of the origi- tion 20R3 Class C or 20R3 Class D2.

9
 1. FRAME ASSEMBLY,
CAB
2. WIPER ASSEMBLY
(FRONT)
3. WINDSHIELD
4. TOP WINDOW
5. WIPER ASSEMBLY
(REAR)

12660

6. DOOR WINDOW (RH)

7. DOOR ASSEMBLY (RH)
8. REAR WINDOW
9. SIDE WINDOW

FIGURE 7. CAB

TABLE 1. MATERIAL SPECIFICATIONS FOR CAB WINDOWS

LOCATION OF HYSTER MATERIAL THICKNESS
WINDOW PART NO. SPECIFICATION
mm in

FRONT 1319363 CLEAR LAMINATED SAFETY GLASS 5.9 to 7.5 0.23 to 0.30
per ANSI Z26.1 AS1

REAR 1319365 CLEAR LAMINATED TEMPERED SAFETY 5.6 to 6.8 0.22 to 0.27
REAR SIDE 1319364 GLASS per ANSI Z26.1 AS2 5.6 to 6.8 0.22 to 0.27

(RH) 1319368 CLEAR TEMPERED SAFETY GLASS 5.6 to 6.2 0.22 to 0.24
DOORS
(LH) 1319367 per ANSI Z26.1 AS2
TOP 365283 CLEAR LEXAN MR 5004 or EQUIVALENT 6.0 0.24

10