FRAME

H8.00-12.00XM (H170-280HD) [F007, G007];

H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]

PART NO. 1494123 100 SRM 927

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 back-
ground. The CAUTION symbol and word are on yellow background.
Frame Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Counterweight Repair ....................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 2
Fenders ........................................................................................................................................................... 2
Remove....................................................................................................................................................... 2
Install ......................................................................................................................................................... 2
Side Counterweights H13.00-16.00XM (H300-360HD) ............................................................................... 4
Side Counterweight, Replace ........................................................................................................................ 4
Hood and Air Cleaner Repair ............................................................................................................................ 4
Remove ........................................................................................................................................................... 4
Install ............................................................................................................................................................. 4
Hydraulic Tank Repair ...................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Repairs, All Units .......................................................................................................................................... 9
Small Leaks ............................................................................................................................................... 9
Large Leaks ............................................................................................................................................... 9
Clean .............................................................................................................................................................. 9
Steam Method............................................................................................................................................ 9
Chemical Solution Method........................................................................................................................ 10
Other Methods of Preparation for Repair .................................................................................................... 10
Install ............................................................................................................................................................. 10
Fuel Tank Repair ............................................................................................................................................... 11
Remove ........................................................................................................................................................... 11
Repairs ........................................................................................................................................................... 11
Install ............................................................................................................................................................. 11
Cooling System and Radiator Repair................................................................................................................ 13
Remove ........................................................................................................................................................... 13
Install ............................................................................................................................................................. 13
Cab Repair.......................................................................................................................................................... 16
Rear Cab Assembly........................................................................................................................................ 16
Bottom Cab Assembly ................................................................................................................................... 17
Raising and Lowering Cab ............................................................................................................................ 17
Raise Cab ................................................................................................................................................... 17
Lower Cab .................................................................................................................................................. 18
Cab Repair ..................................................................................................................................................... 18
Remove....................................................................................................................................................... 18
Install ......................................................................................................................................................... 19
Engine and Transmission Repair...................................................................................................................... 20
Hyster T-50 Transmission, Remove ............................................................................................................. 20
Hyster T-50 Transmission, Install................................................................................................................ 22
TE-10 Transmission ...................................................................................................................................... 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 26
Label Replacement............................................................................................................................................. 28

©2011 HYSTER COMPANY i

Table of Contents Frame

TABLE OF CONTENTS (Continued)

This section is for the following models:

H8.00-12.00XM (H170-280HD) [F007, G007];

H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]

ii
100 SRM 927 Description

General
This section has the description and repair proce- remove the ECM (Engine Control Module). If weld-
dures for the frame and connected parts. Included ing on the lift truck chassis, verify the ground clamp
in this section are the frame, counterweight, fenders, is placed as close to the welding point as possible and
hood, hydraulic and fuel tanks, radiator/cooling sec- NOT near the ECM. If it is necessary to weld near
tion, operator compartment, and cab. The instruc- the ECM, remove the ECM from the engine to avoid
tions for removal and installation of the engine are damage from welding arc radiation.
included in this section.

If the lift truck is fitted with a battery disconnect

switch, open the switch if welding on the engine and

Description
The frame is a one-piece weldment and has mounts axles, hydraulic and fuel tanks, operator’s compart-
for the counterweight, fenders, engine, transmission, ment, and other parts. See Figure 1.

1. MAIN MOUNT 7. CAB HINGE

2. COUNTERWEIGHT MOUNT 8. MAST MOUNT
3. STEERING MOUNT 9. SIDE COUNTERWEIGHT MOUNT
4. DRIVE AXLE MOUNT 10. FENDERS
5. TILT CYLINDERS MOUNT 11. CAB LATCH MOUNT
6. CAB CYLINDER MOUNT

Figure 1. Frame

1
Counterweight Repair 100 SRM 927

Counterweight Repair
REMOVE ahead so there is clearance for the chain that is
installed through the counterweight.
WARNING 3. Install the counterweight on the frame. Install
The counterweight is heavy. Make sure that the capscrew, lockwasher, and flat washer to fas-
the crane and lifting devices have the capacity ten the counterweight to the frame. Tighten the
to lift 4600 kg (10,141 lb). capscrew to 1140 N•m (841 lbf ft).
1. Remove the hood spine assembly. See Hood and
Air Cleaner Repair.
FENDERS

2. H8.00-12.00XM (H170-280HD) units only. Re- Remove

move the counterweight by placing an eyebolt
through the hole in the top of the counterweight. WARNING
See Figure 2. The eyebolt must be able to sup- The fenders are part of the lift truck counter-
port the weight of the counterweight. Attach a weight and are very heavy. Make sure any lift-
lifting device to eyebolt. ing devices have the capacity to lift 1750 kg
(3858 lb). Make sure the fender is balanced and
H13.00-16.00XM (H300-360HD) and H10.00- supported by the chain. The fenders are not of
12.00XM-12EC (H330-360HD-EC) units. Re- a regular shape and can be difficult to handle.
move the fenders, noting shims used and location
of shims. Remove the radiator fan, shroud, and 1. Remove the capscrews, washers, and nuts that
hardware. Tilt the radiator away from the coun- fasten the fender to the frame mount. Install
terweight so there is clearance when removing eyebolts in the mount holes. Use mount holes to
the counterweight. See Figure 2. Install eyebolt pick up fender from frame.
into the top of the counterweight. The eyebolt
must be able to support the weight of the coun- 2. Fasten a lifting device to the eyebolts. Operate
terweight. Attach lifting device. the lifting device and lift the fender away from
the frame.
3. Remove the single capscrew from the rear of the
counterweight. Remove the counterweight from Install
the frame.
1. Install eyebolts in the fenders as described in Re-
INSTALL move, Step 1. Fasten a lifting device to the eye-
bolts.
WARNING 2. Raise the fender to the lift truck. Align the eye-
The counterweight is heavy. Make sure that bolts in the fender with the holes in the fender
the crane and lifting devices have the capacity mount on the frame. Shim fenders to correct
to lift 4600 kg (10,141 lb). height. Lower the fender to the fender mount
and remove the lifting device and the eyebolts.
1. Put a chain into top opening of the counterweight
and attach chain to a lifting device. See Figure 2. 3. Install the capscrews, washers, and nuts that
hold the fender to the frame. Tighten the nuts
2. H13.00-16.00XM (H300-360HD) and H10.00-
to 320 N•m (236 lbf ft).
12.00XM-12EC (H330-360HD-EC) units only.
Install the radiator hardware. Tilt the radiator

2
100 SRM 927 Counterweight Repair

1. LH FENDER 11. SHIM 23. CAPSCREW

COUNTERWEIGHT 12. WASHER 24. RH SLAB COUNTERWEIGHT
2. RH FENDER 13. LOCKWASHER 25. LH SLAB COUNTERWEIGHT
COUNTERWEIGHT 14. WASHER 26. CAPSCREW
3. CAPSCREW 15. SHIM 27. WASHER
4. WASHER 16. SHIM 28. WASHER
5. NUT 17. SHIM 29. NUT
6. WASHER 18. COUNTERWEIGHT 30. ISOLATOR
7. TOW PIN 19. CAPSCREW 31. LOCKWASHER
8. GRIP 20. SLAB COUNTERWEIGHT 32. NUT
9. PIN 21. PLATE 33. RUBBER STOP
10. PIN 22. LOCKWASHER

Figure 2. Counterweight Mounts

3
Hood and Air Cleaner Repair 100 SRM 927

SIDE COUNTERWEIGHTS H13.00-16.00XM 2. Remove each counterweight capscrew and re-

(H300-360HD) place it in turn with a long stud. The studs
must protrude about 152 mm (6 in.) beyond the
The counterweights located on either side of the lift counterweight.
truck are fastened to the frame by large capscrews.
Normally these counterweights will never have to be 3. Use a pry bar and carefully move the counter-
removed or replaced on the lift truck. weight away from the frame about 50 mm (2 in.).
Install a nylon lifting sling securely around the
SIDE COUNTERWEIGHT, REPLACE counterweight and attach it to a lifting device.

If replacement of the side counterweight is required,

do the following procedure:
WARNING
Make sure the counterweight is balanced and
cannot fall from the sling when the sling is
WARNING raised.
The side counterweights are heavy. Each side
counterweight weighs approximately 560 kg 4. Carefully lift the counterweight away from the
(1235 lb). Make sure that the crane and lift- lift truck frame and lower the counterweight to
ing devices have the capacity to lift 908 kg the floor.
(2433 lb).
5. For installation of the side counterweights, follow
1. Remove the extension covers from both side the above procedure in reverse order. Tighten the
tanks. counterweight capscrews to 655 N•m (483 lbf ft).

Hood and Air Cleaner Repair

The hood and air cleaner assembly, which includes 5. Loosen clamps at upper exhaust stack.
the rain cap or optional precleaner and inlet pipe,
can be removed from the frame as a single unit, or 6. Remove bolts, nuts, washers, and bar washers
pivoted out of the way for access. that fasten hood spine to counterweight and hood
support.
REMOVE
7. Disconnect washer hoses from washer container
NOTE: The hood and air cleaner assembly can be piv- and mark for reconnecting.
oted out of the way to gain access to many compo-
8. Disconnect the washer hoses from hood and air
nents. In order to pivot hood and air cleaner assem-
cleaner assembly.
bly, remove 2 bolts, nuts, and washers at one side con-
necting hood to hood spine support and loosen the 2 9. Using lifting device, lift hood assembly from
bolts at opposite side. frame. Air filter assembly and exhaust stack
will remain attached to hood and spine assembly.
1. Unlock hood with an allen wrench.

2. Open hood panel until gas spring locks hood INSTALL

panel in open position.
Install the hood and air cleaner assembly in the re-
3. Attach a lifting device and sling to support hood verse procedure of removal and align the hood as nec-
spine and attaching components. See Figure 3 essary during installation. Make sure the hood side
and Figure 4. panels close completely and that the cushioned screw
stops (bumpers) are located correctly.
4. Loosen air intake hose to turbocharger at inlet
side of turbocharger.

4
100 SRM 927 Hood and Air Cleaner Repair

1. HOOD SPINE HARDWARE 6. EXHAUST STACK CLAMP

2. HOOD SPINE 7. RAIN CAP
3. COUNTERWEIGHT 8. GAS SPRING
4. HOOD SPINE SUPPORT 9. HOOD PANEL
5. AIR INTAKE HOSE 10. EXHAUST STACK

Figure 3. Hood and Air Cleaner Assembly (E019 and F007)

5
Hood and Air Cleaner Repair 100 SRM 927

1. HOOD SPINE HARDWARE 6. EXHAUST STACK CLAMP

2. HOOD SPINE 7. RAINCAP
3. COUNTERWEIGHT 8. HOOD PANEL
4. HOOD SPINE SUPPORT 9. EXHAUST STACK
5. AIR INTAKE HOSE

Figure 4. Hood and Air Cleaner (F019 and G007)

6
100 SRM 927 Hydraulic Tank Repair

Hydraulic Tank Repair

The hydraulic tank is installed on the right side of oil that is in the hydraulic lines. Put tags on the
the frame between the front and rear fenders. lines for identification. Put caps on the open lines
and the fittings.
REMOVE
1. Remove the side cover between the bottom of WARNING
the operator compartment and the top of the hy- Make sure that the tank is supported by blocks
draulic tank. See Figure 5. If necessary, remove before removing the nuts and washers from the
the drain plug at the bottom of the tank to drain top of the tank.
the oil. See Figure 6 and Figure 7.
4. Support the fuel tank with blocks from beneath.
2. Remove the extension panel. First, remove the three capscrews that fasten the
bottom of the tank to the running board. Remove
NOTE: Do not remove items 14, 15, 16, and 17 from the three nuts and washers that hold the top of
the tank. the tank to the frame. Install two lifting eyes
at the outer holes. Attach a lifting device and
3. Disconnect the hoses at the top elbow connection support the tank. Lift the tank from the frame.
and at the side connection to the tank located on
the inside of the frame. Use a pan to catch the

1. HYDRAULIC TANK 4. SIDE COVER

2. BATTERY BOX 5. NUT AND WASHER
3. FRAME 6. EXTENSION PANEL

Figure 5. Hydraulic Tank and Battery Box

7
Hydraulic Tank Repair 100 SRM 927

1. SIGHT GLASS 10. NUT

2. FILTER 11. DRAIN PLUG
3. FILTER HEAD 12. O-RING
4. SPRING 13. HYDRAULIC TANK
5. O-RING 14. COVER
6. CAPSCREW 15. SEAL
7. PLUG 16. WASHER
8. BREATHER 17. CAPSCREW
9. WASHER

Figure 7. Hydraulic Tank (G007 and F019)

1. WASHER (3) 12. DRAIN PLUG
2. LOCKWASHER (3) 13. NUT (3)
3. BREATHER 14. ADAPTER
4. FILTER HEAD 15. ADAPTER
5. O-RING 16. HYDRAULIC TANK
6. DIPSTICK 17. O-RING
7. O-RING 18. RETAINING RING
8. SEAL 19. FITTING
9. SPRING 20. FITTING
10. WASHER 21. PLUG
11. FILTER

Figure 6. Hydraulic Tank (F007 and E019)

8
100 SRM 927 Hydraulic Tank Repair

REPAIRS, ALL UNITS not taken. Disconnect the negative battery ter-
minal from the battery. Disconnect all ECM’s.
Small Leaks If welding must be done in a close proximity
of an ECM, that ECM must be removed. When
Use the following procedures to repair small leaks: welding to the chassis, attach the ground cable
as close the weld as possible.
1. Use steam to clean the area around the leak. Re-
move all paint and dirt around the leak. • Safe Practices for Welding and Cutting Contain-
ers That Have Held Combustibles by the American
WARNING Welding Society, F4.1 - 1999.
Do not use tools that can make sparks, heat, or • Safety in Welding and Cutting, American National
static electricity. The vapors in the tank can Standard, AWS Z 49.1 - 1999.
cause an explosion.
When cleaning the tank, do not use solutions that
2. Apply Loctite® 290 to the leak. Follow the in- make dangerous gases at normal temperatures or
structions of the manufacturer. when heated. Wear eye and face protection. Protect
the body from burns.
Large Leaks
When cleaning with steam, use a hose with a mini-
1. Use one of the procedures described under Clean- mum diameter of 19 mm (0.75 in.). Control the pres-
ing to clean and prepare the tank for repairs. sure 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 elec-
CAUTION trical connection between the nozzle and the tank.
Welding on the truck may cause damage to the Connect a ground wire to the tank to prevent static
engine, transmission, and/or hydraulic elec- electricity.
tronic control units if proper precautions are
not taken. Disconnect the negative battery ter- Steam Method
minal from the battery. Disconnect all ECM’s.
If welding must be done in a close proximity Use the following procedure to clean the tank with
of an ECM, that ECM must be removed. When steam:
welding to the chassis, attach the ground cable
1. Remove all the parts from the tank. Install the
as close to the weld as possible.
drain plug.
2. Use acceptable welding practices to repair the
2. Fill the tank 1/4 full with a solution of water and
tank. See the American National Standard
sodium bicarbonate or sodium carbonate. Mix
Safety in Welding and Cutting AWS Z 49.1 -
0.5 kg (1 lb) per 4 liter (1 gal) of water.
1999.
3. Mix the solution in the tank using air pressure.
CLEAN Make sure all the surfaces on the inside of the
tank are flushed with the solution. Drain the
WARNING tank.
Special procedures must be followed when
large leaks or other repairs need welding or 4. Put steam into the tank until the tank does not
cutting. All work must be done by authorized have odors and the metal is hot. Steam vapors
personnel. If the tank is cleaned inside of a must come from all the openings.
building, make sure there is enough ventila- 5. Flush the inside of the tank with boiling water.
tion. See the following manuals for additional Make sure all the loose material is removed from
information: the inside of the tank.

CAUTION
Welding on the truck may cause damage to the
engine, transmission, and/or hydraulic elec-
tronic control units if proper precautions are

9
Hydraulic Tank Repair 100 SRM 927

1. Fill the tank with water to just below the point

WARNING where the work will be done. Make sure the
When making inspections, use light that is ap- space above the level of the water has a vent.
proved for locations with flammable vapors.

6. Make an inspection of the inside of the tank. If it CAUTION

is not clean, repeat Step 4 and Step 5 and make Welding on the truck may cause damage to the
another inspection. engine, transmission, and/or hydraulic elec-
tronic control units if proper precautions are
7. Put plugs in all the openings in the tank. Wait 15 not taken. Disconnect the negative battery ter-
minutes, then remove the inlet and outlet plugs. minal from the battery. Disconnect all ECM’s.
Test a sample of the vapor with a special indi- If welding must be done in a close proximity
cator for gas vapors. If the amount of flammable of an ECM, that ECM must be removed. When
vapors is above the lower flammable limit, repeat welding to the chassis, attach the ground cable
the cleaning procedures. as close the weld as possible.
Chemical Solution Method 2. Use acceptable welding practices to repair the
tank. See the American National Standard
If the tank cannot be cleaned with steam, use the Safety in Welding and Cutting AWS Z 49.1 -
following procedure: 1999.
1. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Fol-
INSTALL
low the instructions given by the manufacturer. NOTE: When installing the filter after cleaning, it is
important that you grease the O-ring before installa-
2. Fill the tank with the cleaning solution. Use com-
tion.
pressed air to mix the solution in the tank.
1. Connect a lifting device to the outer holes in the
3. Drain the tank. Flush the inside of the tank with
top of the hydraulic tank. Put the hydraulic tank
hot (boiling) water. Make sure all the cleaning
in position on the frame. Put blocks under the
compound is removed.
tank to provide support. Install the lower three
capscrews and washers that fasten the top of the
WARNING hydraulic tank to the frame.
When making inspections, use a light that is ap-
proved for locations with flammable vapors. 2. Make sure the tank is supported by the upper
capscrews. Install the three nuts and washers
4. Make an inspection of the inside of the tank. that fasten the bottom of the hydraulic tank to
If the tank is not clean, repeat Step 1 through the running board.
Step 3. Make another inspection of the tank.
3. Connect the hydraulic return line to the upper
5. Check the tank for flammable vapors using elbow connection of the hydraulic tank. Attach
special indicator for gas vapors. If the amount the suction hose to the side tank connection on
of flammable vapors is not below the lower the inside of the frame member.
flammable limit, repeat the cleaning procedures.
4. Install the extension piece and side cover. See
OTHER METHODS OF PREPARATION FOR Figure 5.
REPAIR 5. Fill the hydraulic tank to the correct level with
If nitrogen gas or carbon dioxide gas is available, pre- the oil specified in the maintenance table. See
pare the tank for welding using these gases. See the the section Periodic Maintenance 8000 SRM
manual Safe Practices for Welding and Cutting Con- 934 for E019 and F007 trucks or Periodic
tainers That Have Held Combustibles by the Ameri- Maintenance 8000 SRM 1099 for F019 and
can Welding Society, F4.1 - 1999. If these gases are G007 trucks.
not available, another method using water can be
used as follows:

10
100 SRM 927 Fuel Tank Repair

Fuel Tank Repair

The fuel tank is installed on the left-hand frame REPAIRS
channel. See Figure 8.
WARNING
REMOVE Do not use tools that can make sparks, heat, or
1. If necessary, remove the drain plug to drain the static electricity. The vapors in the tank can
fuel from the tank. cause an explosion.

Repair the fuel tank as described in the repair proce-

WARNING dures for the hydraulic tank.
If the fuel is drained from the fuel tank, put the
fuel in a can or barrel that has a protected seal INSTALL
cap.
1. Connect a lifting device to the outer holes in the
2. Remove the extension piece between fuel tank top of the fuel tank. Put the fuel tank in position
and frame. on the frame. Put blocks under the tank to pro-
vide support. Install the lower three capscrews
3. Disconnect the fuel lines at the tank. and washers that fasten the top of the fuel tank
to the frame.
WARNING
Make sure that the tank is supported by blocks 2. Make sure the tank is held by the upper cap-
before removing the nuts and washers from the screws, then install the three nuts and washers
top of the tank. that fasten the bottom of the fuel tank to the run-
ning board.
4. Support the fuel tank with blocks from beneath
the tank. First, remove the three capscrews that 3. Connect the fuel lines to the tank.
fasten the bottom of the tank to the running 4. Install extension piece between fuel tank and
board. Remove the three nuts and washers that frame.
hold the top of the tank to the frame. Install two
lifting eyes at the outer holes. Attach a lifting 5. Fill fuel tank to the correct level per specifica-
device and support the tank. Lift the tank from tions. See the section Periodic Maintenance
the frame. 8000 SRM 934 for E019 and F007 trucks or Pe-
riodic Maintenance 8000 SRM 1099 for F019
and G007 trucks.

11
Fuel Tank Repair 100 SRM 927

Figure 8. Fuel Tank

12
100 SRM 927 Cooling System and Radiator Repair

Legend for Figure 8

1. HOSE 13. FITTING 25. NUT
2. HOSE 14. FITTING 26. WASHER
3. CLAMP STRAP 15. TUBE 27. NUT
4. FUEL TANK 16. FITTING 28. O-RING
5. PLUG 17. FITTING 29. PIPE PLUG
6. OIL SEAL 18. CLAMP 30. WASHER
7. FITTING 19. BRACKET 31. STRAP
8. TUBE 20. CAPSCREW 32. CLAMP
9. FITTING 21. WASHER 33. TUBE
10. TUBE 22. FILTER 34. FITTING
11. CLAMP 23. CAPSCREW 35. FITTING
12. TUBE 24. WASHER 36. FUEL CAP

Cooling System and Radiator Repair

REMOVE 10. Remove the two capscrew and grommet assem-
blies that hold the radiator shroud to the bracket
1. Disconnect the cables at the battery. (Remove the on the frame. Remove the radiator and shroud.
ground cable first.) Remove the bracket for the
battery cables. INSTALL
2. Pivot hood and spine assembly to right side. See 1. Install the radiator and shroud in the frame. In-
Hood and Air Cleaner Repair. stall the two capscrew and grommet assemblies
that fasten the shroud weldment to the bracket
3. Let the coolant cool to room temperature. Put
on the frame. Install the capscrews between the
drain pan under radiator. Remove radiator cap.
fan shroud and the radiator.
Open the drain valve and drain the radiator. Dis-
connect the coolant hoses at the radiator. See 2. Install the fan on the drive pulley.
Figure 9 and Figure 10.
3. Connect the coolant hoses to the radiator.
4. Disconnect charged air cooler hoses from the
charged air cooler (F019/G007 Perkins engine 4. Connect the transmission oil lines to the bottom
only). of the radiator.

5. Remove four capscrews and washers mounting 5. Install four capscrews and washers mounting the
the charged air cooler (F019/G007 Perkins engine charged air cooler (Perkins engine only).
only).
6. Connect charged air cooler hoses to the charged
6. Disconnect the transmission oil lines at the radi- air cooler (Perkins engine only).
ator.
7. Pivot hood and spine assembly back into position
7. Cap an plug all open lines. and tighten mounting hardware.

8. Remove the fan from the drive pulley (Perkins 8. Fill the radiator with coolant. See Maintenance
engine only). Schedule in the section Periodic Maintenance
8000 SRM 934 for E019 and F007 trucks or Pe-
9. Remove the capscrews between the fan shroud riodic Maintenance 8000 SRM 1099 for F019
and the radiator. and G007 trucks, for quantity and antifreeze re-
quirements.

13
Cooling System and Radiator Repair 100 SRM 927

1. COOLANT RECOVERY TANK 11. ISOLATOR PIN

2. RADIATOR CAP 12. DRAIN VALVE
3. RADIATOR 13. FAN
4. TOP HOSE 14. V-BELT
5. RADIATOR SHROUD 15. CAPSCREW
6. CHARGED AIR COOLER 16. WASHER (2)
7. BRACKET ON FRAME 17. GROMMET
8. FRAME 18. NUT
9. LOWER HOSE 19. TRANSMISSION OIL COOLER IN/OUT
10. BRACKET

Figure 9. Cooling System/Radiator (E019/F007)

14
100 SRM 927 Cooling System and Radiator Repair

1. COOLANT RECOVERY TANK 12. DRAIN VALVE

2. RADIATOR CAP 13. FAN
3. RADIATOR 14. CAPSCREW
4. TOP HOSE 15. LOCKWASHER
5. RADIATOR SHROUD 16. WASHER
6. CHARGED AIR COOLER 17. NUT
7. BRACKET ON FRAME 18. TRANSMISSION OIL COOLER IN/OUT
8. FRAME 19. WASHER
9. LOWER HOSE 20. CAPSCREW
10. BRACKET 21. GROMMET
11. ISOLATOR AND/WITH PIN

Figure 10. Cooling System/Radiator (F019/G007 Perkins Engine Shown)

15
Cab Repair 100 SRM 927

Cab Repair
REAR CAB ASSEMBLY NOTE: Interior covers are affixed with self-tapping
screws.
See Figure 11 for rear cab assembly.

1. COVER PLATE 6. HEADLINER

2. FUSE SECTION 7. REAR DUCT ASSEMBLY
3. RELAY SECTION 8. CONSOLE COVER
4. HYDRAULIC VALVE CONTROLLER 9. CONSOLE TOP
5. FOAM COVER 10. INSTRUMENT PANEL

Figure 11. Rear Cab Assembly

16
100 SRM 927 Cab Repair

BOTTOM CAB ASSEMBLY 1. Tilt mast fully forward.

See Figure 12 for bottom cab assembly. 2. Remove all unsecured items from cab.

3. Close and securely latch both cab doors.

4. Clear all obstacles from right-hand side (as seen

from driver’s position) of truck. Provide mini-
mum of 2 m (7 ft) of clearance space.

5. Use pump lever to turn direction valve clockwise

to "Raise" position. See Figure 13.

1. WIPER MOTOR 4. COVER PLATE

ASSEMBLY 5. STEERING PUMP
2. WIPER COUPLING 6. HORN 1. PUMP LEVER CONNECTION
3. AIR FILTER 2. DIRECTION VALVE SELECTION: CLOCKWISE -
RAISE, COUNTERCLOCKWISE - LOWER
Figure 12. Bottom Cab Assembly
Figure 13. Pump and Direction Valve

RAISING AND LOWERING CAB 6. Operate pump with pump lever until cab locks in
partially open position.
Raise Cab
NOTE: Just before fully open position is reached,
movement may be gravity controlled.
WARNING
Make sure no one is under cab when raising or 7. Pull tilt latch release and continue to raise cab to
lowering cab. fully open position. See Figure 14.

NOTE: If cab will not fully raise, lower cab until cab
WARNING locks in partially open position, and fill tilt system
Before you place any part of your body under with oil. See Oil Filling for Tilt System.
cab, always make sure that cab is fully tilted,
or when partially open, is locked by tilt latch. NOTE: Raising cab gives access to components such
as engine, transmission/hydraulic compartment,
throttle/brake and steering control, heater, air con-
CAUTION
ditioner, and electrical connectors.
Cab damage may occur if mast is not com-
pletely tilted forward.

17
Cab Repair 100 SRM 927

electric tilt system contains a push button located on

left side of pump direction control. Procedure to raise
or lower is the same.

CAB REPAIR
Remove

WARNING
Before removing heater hoses, allow time for
heater hoses to cool down. Hot water may
cause severe burns.

WARNING
1. CAB Make sure the lifting device has a minimum ca-
2. FRAME pacity to lift 1000 kg (2205 lb). A lifting device
3. TILT LATCH RELEASE that does not have the minimum capacity can
4. PUMP LEVER
break causing the cab to drop and may result
Figure 14. Pump Lever and Tilt Latch Release in serious personal injury.
Knob
CAUTION
Lower Cab Lift the operator’s cab carefully. Make sure
all wires and attachments are disconnected
WARNING and loose components are not obstructing the
Make sure no one is under cab when raising or movement.
lowering cab.
1. Switch off engine.

WARNING 2. Disconnect battery ground lead.

Before you place any part of your body under
cab, always make sure that cab is fully tilted, 3. Raise operator’s cab. See Raise Cab.
or when partially open, is locked by tilt latch.
4. Remove four hex bolts holding steering pump.
See Figure 15 and Figure 16.
CAUTION
5. Remove two bolts holding brake valve.
Cab damage may occur if mast is not com-
pletely tilted forward. 6. Disconnect inching cable. See Inching and Brake
Pedals.electrical cable to throttle pedal sensor.
1. Use pump lever to turn direction valve counter-
See Sensor Adjustment.
clockwise to "Lower" position. See Figure 13.
7. Disconnect electrical cable.
2. Check that all foreign items/tools are cleared
away. 8. Disconnect electrical plugs that are located to
right of heater unit.
3. Operate pump with pump lever until cab locks in
partially open position. 9. Disconnect window washer hoses and mark their
positions.
4. Pull tilt latch release and continue to lower cab
until it is in fully lowered position and latched. 10. Remove three bolts and swing heater unit down.
See Figure 14.
11. Disconnect electrical connections, control cables,
NOTE: An electric-powered cab tilt system is avail- and air duct from heater unit.
able to replace standard manual tilt system. The

18
100 SRM 927 Cab Repair

18. Carefully lift cab away from lift truck. Set cab as-
sembly in a suitable storage area and put blocks
under cab to stabilize and prevent damage.

1. STEERING PUMP HEX BOLTS

2. BRAKE VALVE BOLTS
3. STEERING PUMP
4. PEDAL END INCHING
5. CABLE ADJUSTMENT
6. BRAKE VALVE 1. STEERING PUMP HEX BOLTS
7. ELECTRICAL CONNECTIONS 2. BRAKE VALVE BOLTS
3. STEERING PUMP
Figure 15. Steering Pump, Throttle and 4. BRAKE VALVE
Inching Connections 5. ELECTRICAL CONNECTIONS

12. Disconnect ground lead. Figure 16. Steering Pump, Throttle and
Inching Connections
CAUTION 19. Remove four rubber isolation mounts from frame
When lowering cab, make sure loose compo- and inspect for damage. Reinstall or replace if
nents are not obstructing the movement. necessary.

13. Lower operator’s cab. See Lower Cab. Install

14. Remove left and right side panels giving access 1. Connect lift strap under overhead guard struc-
to cab mounting bolts. ture. Provide cushion at top of door area to pre-
vent damage.
15. Remove four mounting bolts, two on left side and
two on right side of truck. 2. Make sure that insulators are in place. See Fig-
ure 17.
16. Remove cab doors before attaching a lifting de-
vice. 3. Lift operator’s cab.
17. Connect a lift strap under overhead guard struc- 4. Carefully lower cab on insulators and make sure
ture. Provide a cushion at top of door area to pre- that it is properly centered.
vent damage.

19
Engine and Transmission Repair 100 SRM 927

5. Mount cab with washers and bolts.

6. Tighten cab mounting bolts to 66 N•m (49 lbf ft).

7. Raise cab. See Raise Cab.

8. Connect electrical cables, ground wire, hoses,

steering pump, and brake valve. Make sure that
all connections have been restored.

9. Mount heater unit to hinge. Connect control ca-

bles and electrical connections. Pivot unit up and
install with three bolts.

10. Connect inching and throttle cables. See Inching

and Brake Pedals.
1. TOP PART OF 3. BOLT 11. Lower cab. See Lower Cab.
INSULATOR 4. WASHER
2. BOTTOM PART OF 5. LOCKWASHER
INSULATOR 12. Install doors.

Figure 17. Insulators 13. Connect battery ground lead.

14. Install side panels.

Engine and Transmission Repair

See engine manufacturer’s repair manual for repair 4. Drain the coolant from the cooling system. See
of the engine. See the section Three-Speed Pow- Cooling System and Radiator Repair.
ershift Transmission, Repairs (Hyster Model
T-50) 1300 SRM 931 for transmission repairs. 5. Disconnect the exhaust system. Remove the
header pipe at the exhaust manifold.
The removal of this transmission is described later in
this section. See Hyster T-50 Transmission, Remove. 6. Disconnect the air lines at the air compressor.
Loosen the fittings slowly to vent any compressed
HYSTER T-50 TRANSMISSION, REMOVE air.

NOTE: The transmission can be removed from above 7. Disconnect fuel lines at the fuel tank. Disconnect
or under the lift truck. See Figure 18. throttle linkage.

1. Remove the forks. Put the lift truck on blocks 8. Disconnect wires and wiring harnesses at the en-
so that there is access under the lift truck. See gine. Disconnect the heater hoses at the engine.
"How to Put Lift Truck on Blocks" in the section
9. Disconnect the drive shaft at the yokes. Remove
Operating Manual or the section Periodic
the drive shaft between the transmission and the
Maintenance 8000 SRM 934 for E019 and F007
differential.
trucks or Periodic Maintenance 8000 SRM
1099 for F019 and G007 trucks. Tilt the mast 10. Disconnect the wiring harnesses on top of the
fully forward to release hydraulic pressure in transmission. Disconnect the wires at the
the system. solenoids on the transmission control valve. Dis-
connect the wires at the pressure sending unit
2. Disconnect the cables at the battery. (Remove the
and the temperature sending unit on the trans-
ground cable first.) Remove the bracket for the
mission. Put identification tags on the wires so
battery cables.
that they can be correctly connected again.
3. Tilt the operator compartment up to remove the
engine and transmission.

20
100 SRM 927 Engine and Transmission Repair

1. FRAME (REFERENCE) 4. OUTPUT YOKE 7. TORQUE CONVERTER

2. DIPSTICK ASSEMBLY 5. TRANSMISSION MOUNT
3. DRIVE SHAFT 6. STARTER SOLENOID

Figure 18. Hyster T-50 Transmission Arrangement

11. Apply the service brakes repeatedly until the air lifting device to hold and lift the hydraulic pump.
pressure in the air tank decreases to 0 kPa (0 psi) Remove the hydraulic pump. The drive shaft of
or pressure is removed from hydraulic system the hydraulic pump is engaged in splines in the
on wet brakes. Disconnect the air brake hose drive gear. The drive shaft of the hydraulic pump
from the air tank so that there is clearance at the will slide from the drive gear when the hydraulic
transmission. pump is removed.

12. Disconnect the wire to the starter solenoid. 17. Disconnect and remove the dipstick assembly
from the transmission.
13. Disconnect the cables at the spools on the trans-
mission control valve. Remove the linkage 18. The temperature sender for the transmission oil
bracket from the transmission housing. can be easily damaged. Remove the temperature
sender from the transmission sump.
14. Remove the drain plug from the transmission
sump to drain the oil from the transmission [ap- 19. Install blocks and a jack under the flywheel end
proximately 28 liter (30 qt)]. Disconnect the oil of the engine as a support. If the support is put
lines to the oil cooler at the transmission. Drain under the engine oil sump, make sure the sup-
the oil lines into the drain pan. Put plugs and port is across the width of the oil sump so that
caps in the open fittings. the weight of the engine does not damage the oil
sump.
15. Disconnect the oil hoses at the hydraulic pump.
Disconnect the hose from the hydraulic pump to 20. A 5/8" machined hole with UNC (United National
the steering system. Put plugs and caps on the Course) threads is in the top of the transmission
open fittings. housing. Install an eyebolt in the 5/8" UNC hole.
Connect a lifting device to the engine and trans-
16. The hydraulic pump is fastened to the transmis- mission. Make sure the lifting device has a ca-
sion cover with four capscrews. The hydraulic pacity of at least 1200 kg (2650 lb).
pump weighs approximately 45 kg (100 lb). Use a

21
Engine and Transmission Repair 100 SRM 927

21. Remove the two 3/4 × 3 1/2 inch bolts that fas- on the control valve. Make sure the yellow wire
ten the transmission mounts to the frame. These is connected to the reverse solenoid and the black
bolts have been tightened to 270 N•m (199 lbf ft). wire is connected to the forward solenoid. Con-
nect the wires at the temperature sending unit
22. Remove the capscrews that hold the engine and the pressure sending unit on the transmis-
mount brackets to the frame mounts. sion. Use the straps and clamps to hold the wires
in position.
23. Make sure all the connections have been re-
moved. Carefully lift the engine and transmis- 10. Install the starter solenoid shown in Figure 18.
sion assembly from the frame.
11. Connect the air brake hose to the air tank.
HYSTER T-50 TRANSMISSION, INSTALL
12. Fasten the bracket to the transmission hous-
1. If the mounts were removed from the sides of the ing. See Figure 19. Connect the cables to the
transmission housing, install them and tighten control spools in the transmission control valve.
the capscrews to 270 N•m (199 lbf ft). See the adjustment procedure in the section
Three-Speed Powershift Transmission, Re-
2. Connect a lifting device to the engine and trans- pairs (Hyster Model T-50) 1300 SRM 931 .
mission. Make sure the lifting device has a ca-
pacity of at least 1200 kg (2650 lb).

3. Install the engine and transmission assembly in

the frame. Install and tighten the nuts and cap-
screws for the engine and transmission mounts.
Install the two 3/4 × 3 1/2 inch bolts (Figure 18)
for the transmission mounts. Tighten the lock
nuts to 270 N•m (199 lbf ft).

4. Connect the drive shaft to the yoke on the trans-

mission. Make sure the slip joint is installed as
shown in Figure 18. Tighten the capscrews at the
1. SLEEVE 5. INCHING CABLE
yoke to 50 N•m (37 lbf ft). 2. SNAP RING 6. SPRING
3. BUSHING 7. BRACKET
5. Install the dipstick assembly on the transmis- 4. SPRING GUIDE 8. INCHING SPOOL
sion.
Figure 19. Connect Control Cables (T50 Only)
6. Use a lifting device to hold and lift the hydraulic
pump. Install the hydraulic pump. The drive 13. Connect the exhaust pipes to the engine and muf-
shaft of the hydraulic pump is engaged in splines fler.
in the drive gear. The drive shaft of the hydraulic
pump will slide into the drive gear when the hy- 14. Connect the heater hoses, air lines, wiring har-
draulic pump is installed. nesses, wires, and throttle cable to the engine.

7. Connect the hose from the hydraulic pump to the 15. Connect the coolant hoses to the radiator. Con-
steering system. Connect the hydraulic hoses to nect the oil cooler lines to the transmission. The
the hydraulic pump. hose from the upper fitting on the transmission
goes to the right-hand fitting (as seen from the
8. Install the temperature sender for the transmis- operator’s position) on the oil cooler. The hose
sion oil into the transmission sump. from the lower fitting on the transmission goes
to the left-hand fitting on the oil cooler.
9. Connect the wiring harnesses on the top of the
transmission. Connect the wires to the solenoids

22
100 SRM 927 Engine and Transmission Repair

16. Connect the fuel lines between the fuel filter on 7. Disconnect the wiring harnesses on the trans-
the engine assembly and fuel tank and primary mission and wires for the temperature sending
fuel filter. unit on the transmission. Put identification tags
on the wires so they can be correctly connected
17. Install and connect the hood and air cleaner as- again.
sembly.
8. Place a suitable container under the transmis-
18. Fill the transmission with the correct transmis- sion sump and remove the transmission sump
sion oil [29 liter (31 qt)]. Transmission oil is drain plug and drain the transmission oil [ap-
available in the following sizes: proximately 25.4 liter (6.7 gal)].
Hyster Part No. 336830 in 1 quart containers
Hyster Part No. 336831 in 8 quart containers 9. Disconnect the oil lines to the oil cooler at the
Hyster Part No. 336832 in 20 quart contain- transmission. Drain the oil into a drain pan. Put
ers. plugs and caps on open lines/fittings.

19. Connect the battery cables to the battery. (Con- 10. Disconnect the oil hoses at the hydraulic pump.
nect the positive cable first, then the ground ca- Disconnect the hose from the hydraulic pump to
ble.) Fill cooling system with coolant. Add oil to the steering system. Put plugs and caps on open
the engine. Check all oil levels. Check that all lines/fittings.
connections have been made. Start the engine
and check for leaks and correct operation. 11. The hydraulic pump is connected to the trans-
mission cover with four capscrews. Attach a lift-
20. When the lift truck can be operated, check ing device to hold the hydraulic pump, remove
the forward and reverse clutch pressures as the capscrews, and remove the hydraulic pump.
described in Checks and Adjustments in the The drive shaft of the hydraulic pump is engaged
sections Three-Speed Powershift Transmis- in the splines of the drive gear. The drive shaft
sion, Repairs (Hyster Model T-50) 1300 SRM of the hydraulic pump will slide out of the drive
931 and Transmission 1300 SRM 1082. gear when the hydraulic pump is removed.

21. Lower cab into position. 12. Disconnect and remove the dipstick assembly
from the transmission.
TE-10 TRANSMISSION
13. Install blocks and a jack under the flywheel end
Remove of the engine as a support. If the support is under
the engine oil sump, make sure that the support
1. Tilt the mast fully forward to release hydraulic is across the width of the oil sump so the weight
pressure in the system. of the engine does not damage the oil sump.
2. Turn the key to OFF position to shutdown the 14. A 3/4 inch machined hole with UNC threads is
engine. in the top of the transmission housing. Install
an eyebolt in the 3/4 inch UNC hole. Connect a
3. Apply the parking brake. lifting device to the eye bolt. Verify the lifting
4. Disconnect the cables at the battery. Disconnect device has a lifting capacity of at least 1200 kg
the ground cable first and then the positive cable. (2650 lb). To stabilize the transmission, wrap a
lifting strap around the output yoke to keep the
5. Tilt the operator compartment up to gain access transmission from tipping while being removed.
to the transmission. See the section Operator’s See Figure 21.
Cab 100 SRM 1100 .

6. Disconnect the drive shaft at the yokes. Remove

the drive shaft between the transmission and the
differential. See Figure 20.

23
Engine and Transmission Repair 100 SRM 927

Figure 20. Transmission Arrangement

24
100 SRM 927 Engine and Transmission Repair

Legend for Figure 20

1. FRAME (REFERENCE) 6. TRANSMISSION
2. DIPSTICK ASSEMBLY 7. TORQUE CONVERTER
3. DRIVE SHAFT 8. DRIVE PLATE CAPSCREWS (8 EACH)
4. OUTPUT YOKE 9. HOUSING CAPSCREWS (12 EACH)
5. TRANSMISSION MOUNT

15. Remove the two 3/4 × 3 1/2-inch bolts that fasten

the transmission mounts to the frame.

16. Remove the access plug at the bottom of the fly-

wheel housing to gain access to and allow rota-
tion of the flywheel. See Figure 22.

1. CONVERTOR HOUSING
2. ACCESS HOLE TO FLYWHEEL
3. ACCESS PLUG

Figure 22. Access Plug to Flywheel

17. Remove the access plug at the engine side to gain

access to the drive plate capscrews. See Fig-
ure 23.

1. 3/4 INCH UNC HOLE

2. OUTPUT YOKE
1. ACCESS HOLE TO DRIVEPLATE CAPSCREWS
Figure 21. Rear View of Transmission (8 EACH)
2. ACCESS PLUG
3. CONVERTOR HOUSING

Figure 23. Access Plug for Drive Plate

Capscrews

25
Engine and Transmission Repair 100 SRM 927

CAUTION
Do not drop the capscrews into the converter
housing. They will be difficult to retrieve.

NOTE: You must turn the flywheel to gain access to

each screw. See Figure 22.

18. Remove the eight capscrews retaining the drive

plate to the flywheel. See Figure 20 item 8.

19. Raise the lifting device to hold the weight of the

transmission only. Remove the twelve capscrews
that fasten the torque converter housing to the
flywheel housing.

CAUTION
Keep the transmission level when the transmis-
sion is separated from the engine so the drive
plate is not damaged.

20. Make sure that all connections have been re-

moved and carefully lift the transmission assem-
bly from the frame and engine.

Install
1. Remove all burrs from the flywheel mounting
face and bore.
1. FLYWHEEL HOUSING
2. Clean the drive plate surface with solvent. 2. DIAL INDICATOR MOUNTING POSITION
3. FLYWHEEL
3. Check engine flywheel and housing for confor- 4. FLYWHEEL PILOT BORE
mance to standard SAE No. 3 per SAE J927 5. ENGINE
and J1033 tolerance specifications for pilot bore
size, pilot bore runout, and mounting face flat- Figure 24. Flywheel and Housing Check
ness. Measure and record engine crankshaft end
play. See Figure 24.

CAUTION
Keep the transmission level when the transmis-
sion is installed to the engine so the drive plate
is not damaged.

4. Connect a lifting device to the transmission.

Make sure the lifting device has a lifting capac-
ity of at least 1200 kg (2650 lb). To stabilize
the transmission, wrap a lifting strap around
the output yoke to keep the transmission from
tipping while being installed. Install the trans-
mission into the frame.

5. Install two 63.50 mm (2.50 in.) long guide studs Figure 25. Flywheel Alignment Studs
in the engine flywheel housing as shown in Fig-
ure 25.

26
100 SRM 927 Engine and Transmission Repair

Legend for Figure 25

1. FLYWHEEL HOUSING
2. ALIGNMENT STUDS
3. FLYWHEEL

6. Rotate the engine flywheel to align a drive plate

mounting capscrew hole with the flywheel hous-
ing access hole.

7. Align holes by turning the converter and flywheel

by moving the engine and transmission against
each other. See Figure 26.

8. Install transmission to flywheel housing cap-

screws. Tighten capscrews to specified torque
in the section Transmission 1300 SRM 1082,
Torque Specifications. Remove transmission to
engine guide studs. Install remaining capscrews
and tighten to specified torque.

9. Install drive plate attaching capscrew and

washer. Snug capscrew but do not tighten. Some
engine flywheel housings have a hole located
on the flywheel housing circumference in line
with the drive plate capscrew access hole. See
Figure 23. A screwdriver or pry bar used to hold
the drive plate against the flywheel will facil-
itate installation of the drive plate capscrews.
Rotate the engine flywheel and install the seven 1. FLYWHEEL HOUSING
remaining capscrews. Snug capscrews but do not 2. STUD WITH LOCK NUT AND WASHER
tighten. After all eight capscrews are installed, 3. FLYWHEEL
4. IMPELLER COVER
torque each one to 35 to 39 N•m (26 to 29 lbf ft). 5. DRIVE PLATES
This will require tightening each capscrew and
rotating the engine flywheel until all eight cap- Figure 26. Flywheel Housing and Drive Plates
screws have been tightened to specified torque. Alignment

10. Measure engine crankshaft end play after trans- 15. Connect the oil lines to the oil cooler at the trans-
mission has been completely installed on engine mission.
flywheel. This value must be within 0.025 mm
(0.001 in.) of the end play recorded in Step 3. 16. Connect the wiring harnesses on the transmis-
sion and wires for the temperature sending unit
11. Install the two 3/4 × 3 1/2 inch bolts that fasten on the transmission.
the transmission mounts to the frame.
17. Place the drive shaft between the transmission
12. Install the dipstick assembly on the transmis- and the differential. Connect the drive shaft at
sion. the yokes.

13. Use a lifting device to hold and lift the hydraulic 18. Connect the heater hoses at the engine. Connect
pump. Install the hydraulic pump. The drive wires and wiring harnesses at the transmission/
shaft of the hydraulic pump is engaged in splines. engine.
The pump will slide into the drive gear when the
hydraulic pump is installed. 19. Connect the cables at the battery. Connect the
positive cable first and then the ground cable.
14. Connect the hose from the hydraulic pump to the
steering system. Connect the oil hoses at the hy- 20. Fill the transmission to the correct level [approx-
draulic pump. imately 25.6 liter (6.7 gal)].

27
Label Replacement 100 SRM 927

21. Check all oil levels and that all connections have 23. Turn the key to OFF position to shutdown the
been made. engine.

22. Start the engine and check for leaks and for cor- 24. Lower cab into position. See the section Opera-
rect operation. tor’s Cab 100 SRM 1100.

Label Replacement
the surface of old paint using a cleaning solvent.
WARNING See Figure 27 and Figure 28.
Labels that have WARNINGS or CAUTIONS
must be replaced if they are damaged. If a 2. Remove the paper from the back of the label. Do
mast of a different size or an accessory car- not touch the adhesive surface.
riage is installed, the capacity rating can
change. Changes in the kind of drive tires 3. Carefully hold the label in the correct position
can change the capacity rating. See a dealer above the surface. The label cannot be moved
for Hyster lift trucks for a replacement name- after it touches the surface. Put the label on the
plate. The nameplate information is a safety surface. Make sure all air is removed from under
item and must be correct for the equipment the label and the corners and edges are tight.
and configuration of the lift truck.

1. Make sure the surface is dry and has no oil or

grease. Do not use solvent on new paint. Clean

Legend for Figure 27

1. NO RIDERS 25. LH FORK LABEL
2. PATENTS AND TRADEMARKS 26. RH FORK LABEL
3. NAMEPLATES COVER 27. EXTEND AND RETRACT LABEL
4. NAMEPLATE LABEL RIVET (NOT SHOWN) 28. HOIST LABEL
5. FAN WARNING 29. TILT LABEL
6. PARK BRAKE WARNING 30. SIDESHIFT LABEL
7. SLIP-RESISTANT TREAD 31. CLAMP LABEL
8. GAS SPRING LABEL 32. JOYSTICK (FLT/ECH WITH SUSPENSION
9. HYSTER LABEL HOOKS) LABEL
10. CAB TILT WARNING 33. EMPTY CONTAINER HANDLER CONTROL
11. OPERATOR WARNING LABEL
12. OPERATOR RESTRAINT 34. MODEL NUMBER LABEL
13. FUSE PANEL LABEL 35. CAB TILT PUMP LABEL
14. DOOR RELEASE LABEL 36. FUEL FILL LABEL
15. NAMEPLATE TAG 37. HYDRAULIC OIL FILL LABEL
16. MAST WARNING 38. PARK BRAKE LABEL
17. MAST WARNING 39. FLAMMABLE LPG LABEL (LPG TRUCKS ONLY
18. HYSTER LABEL [LOCATED ON THE OPPOSITE SIDE SHOWN
19. INCOMPLETE TRUCK LABEL ATTACHED TO THE LPG BRACKET])
20. POWER TILT LABEL 40. LPG TANK IDENTIFIER (LPG TRUCKS ONLY
21. NAMEPLATE (EEC) [LOCATED ON THE OPPOSITE SIDE SHOWN
22. EXTEND AND RETRACT LABEL ATTACHED TO THE LPG BRACKET])
23. ETHER WARNING LABEL 41. OPERATOR PRESENCE SYSTEM LABEL
24. TWIST LOCK AND UNLOCK LABEL

28
100 SRM 927 Label Replacement

Figure 27. Label Positions (UK Trucks)

29
Label Replacement 100 SRM 927

Figure 28. Label Positions (US Trucks)

30
100 SRM 927 Label Replacement

Legend for Figure 28

1. NO RIDERS 24. LH FORK LABEL
2. PATENTS AND TRADEMARKS 25. RH FORK LABEL
3. OVERHEAD GUARD/CAPACITY PLATE LABEL 26. TWIST LOCK AND UNLOCK LABEL
4. NAMEPLATE LABEL RIVET (NOT SHOWN) 27. EXTEND AND RETRACT LABEL
5. FAN WARNING 28. HOIST LABEL
6. PARK BRAKE WARNING 29. TILT LABEL
7. SLIP-RESISTANT TREAD 30. SIDESHIFT LABEL
8. GAS SPRING LABEL 31. CLAMP LABEL
9. HYSTER LABEL 32. JOYSTICK (FLT/ECH WITH SUSPENSION
10. CAB TILT WARNING HOOKS) LABEL
11. OPERATOR WARNING 33. EMPTY CONTAINER HANDLER CONTROL
12. OPERATOR RESTRAINT LABEL
13. FUSE PANEL LABEL 34. MODEL NUMBER LABEL
14. DOOR RELEASE LABEL 35. CAB TILT PUMP LABEL
15. NAMEPLATE TAG 36. PARK BRAKE LABEL
16. MAST WARNING 37. OPERATOR PRESENCE SYSTEM LABEL
17. MAST WARNING 38. FLAMMABLE LPG LABEL (LPG TRUCKS ONLY
18. HYSTER LABEL [LOCATED ON THE OPPOSITE SIDE SHOWN
19. INCOMPLETE TRUCK LABEL ATTACHED TO THE LPG BRACKET])
20. POWER TILT LABEL 39. LPG TANK IDENTIFIER (LPG TRUCKS ONLY
21. NAMEPLATE LABEL [LOCATED ON THE OPPOSITE SIDE SHOWN
22. EXTEND AND RETRACT LABEL ATTACHED TO THE LPG BRACKET])
23. ETHER WARNING LABEL

31
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32
 TECHNICAL PUBLICATIONS

100 SRM 927 1/11 (1/06)(12/03)(11/03)(2/01) Printed in U.S.A.