Hyster CHALLENGER H135XL, Service & Repair Manual

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Engine Repair 100 SRM 322
Engine Repair
REMOVE
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine and transmission, and the coun-
terweight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot 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.
1. Disconnect the cables at the battery.
2. Remove the hood. Remove the air cleaner assem-
bly. Disconnect the brake fluid reservoir from
the bracket. If necessary, remove the overhead
guard. See Overhead Guard Repair.
3. Drain the coolant from the cooling system. Re-
move the radiator. See Radiator Repair.
4. Disconnect the drive shaft for the hydraulic
pump at the crankshaft pulley.
5. Disconnect the exhaust system.
6. Disconnect the hydraulic lines at the steering
pump. Put caps on the open lines.
7. Disconnect fuel lines and the throttle linkage.
8. Disconnect wires and wiring harnesses at the en-
gine.
9. Connect a lifting device to the engine. Make sure
the lifting device has a capacity of at least 450 kg
(1000 lb) (engine only).
10. On units with a powershift transmission, remove
the capscrews that hold the torque converter to
the flywheel. Put blocks under the output end
of the transmission. Remove the capscrews that
connect the engine 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
transmission and does not fall.
INSTALL
1. Connect a lifting device to the engine. Make
sure the lifting device has a capacity of 450 kg
(1000 lb).
2. Make sure the drive plate is installed on the
torque converter. Lubricate the pilot bushing in
the flywheel with multipurpose grease. Install
the engine in the frame. Make sure the torque
converter stays in the transmission. Fit the fly-
wheel on the pilot of the torque converter. Install
the capscrews that hold the flywheel housing to
the engine. Tighten the capscrews to 31 N•m
(23 lbf ft).
3. Install the capscrews and washers for the engine
mount at the fan end of the engine. Install the
capscrews and adjust the mounts at the flywheel
end of the engine. Tighten the capscrews to the
correct torque values as shown on Figure 5.
4. Install the capscrews that hold the drive plate
for the torque converter to the flywheel. Tighten
the capscrews to 44 N•m (32 lbf ft) on all units.
Remove the lifting device.
5. Connect the wiring harness and wires at the en-
gine.
6. Connect the throttle linkage and fuel lines at the
engine.
7. Connect the pipe for the exhaust system.
8. Connect the drive shaft for the hydraulic pump.
9. See Radiator Repair, and install the radiator.
Connect radiator hoses and cooling line for the
powershift transmission.
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