Hyster CHALLENGER H135XL, Service & Repair Manual

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100 SRM 322 Overhead Guard Repair
Hood Repair
REMOVE
Remove the hood (both sides) as an assembly. Re-
move the capscrews that hold the hood mount
bracket to the frame. Remove the capscrews that
hold the hood to the bracket on the overhead guard.
Lift the hood from the frame.
INSTALL
Install the hood assembly on the frame. Install the
capscrews that hold the brackets to the frame and
bracket on the overhead guard. If necessary, adjust
the hood as follows:
1. Loosen the capscrews at the mounts for the hood
assembly. Put the hood assembly in a position
so the center of the hood is in the center of the
counterweight and overhead guard. Tighten the
capscrews.
2. Adjust the mount (on the frame) and the hood
stops at the rear of the hood so 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 they just touch the
sides of the hood when they are closed.
Overhead Guard 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:
upright,
drive axle, engine and transmission, and 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 upright and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the upright 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.
WARNING
Do not operate the lift truck without the over-
head guard correctly fastened to the lift truck.
Changes that are made by welding or by
drilling holes that are too big in the wrong lo-
cation can reduce the strength of the overhead
guard. See the instructions for Changes to the
Overhead Guard in the Periodic Maintenance
section included with this lift truck.
1. Remove the hood as an assembly. Disconnect the
hose to the air cleaner. Disconnect the exhaust
system from the overhead guard leg. Remove the
capscrews that hold the brake reservoir to the
overhead guard. If a cab is installed, disconnect
the wiring harness for the cab. Lift the doors
from the cab. See Figure 3.
2. Connect a lifting device to the top of the overhead
guard. Remove the capscrews (in the engine com-
partment) that hold the overhead guard to the
frame. Remove the capscrews that hold the over-
head guard to the cowl. Lift the overhead guard
from the lift truck.
INSTALL
1. Connect a lifting device to the top of the overhead
guard. Put the overhead guard in position on the
lift truck. See Figure 3.
2. Make sure the rubber bushings are in the mount
holes at the rear of the overhead guard. Install
the capscrews at the rear of the overhead guard.
Install the capscrews that hold the overhead
guard to the cowl and tighten them to 285 N•m
(210 lbf ft). Connect the wiring harness for the
cab. Install the doors for the cab.
3. Connect the hose for the air cleaner. Connect the
exhaust system. Install the brake fluid reservoir.
3