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Exhaust System Repair

100 SRM 726

Figure 6. LPG/GAS Exhaust System (Without Low Emissions) Later Model Lift Trucks

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Summary of Contents for H100XM

Page 1: ...Hyster L005 H70XM H120XM Forklift ...

Page 2: ...FRAME H3 50 5 50XM H70 120XM K005 L005 PART NO 1467898 100 SRM 726 ...

Page 3: ...d 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 follo...

Page 4: ... Exhaust Pipe Lift Trucks Without Low Emissions 8 Remove 8 Install 11 EPA Compliant LPG Gas Engine Exhaust System 11 Remove 11 Install 13 Diesel Engine Exhaust Pipe 13 Remove 13 Install 15 Engine Repair 15 Remove 15 Install 17 Throttle Pedal Adjustment 19 Perkins 1104C 44 RE Diesel Engine 19 Lift Trucks With an Accelerator Pedal 19 Lift Trucks With a MONOTROL Pedal 20 Fuel and Hydraulic Tanks Repa...

Page 5: ...Table of Contents Frame TABLE OF CONTENTS Continued This section is for the following models H3 50 5 50XM H70 120XM K005 L005 ii ...

Page 6: ... 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 WARNING Make sure that the lifting device used has the correct lift capacity...

Page 7: ...more information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions please write to me admin servicemanualperfect com ...

Page 8: ...erweight When the lift truck is put on blocks put ad ditional blocks in the following positions 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 tr...

Page 9: ...d tighten b Loosen the capscrews for the hood latch just enough to let the latch move Position the latch Tighten the capscrews for the latch c Check the operation of the hood latch Have an operator sit in the seat Make sure that the hood is fully closed two clicks Also check that the hood touches the rubber bumpers If necessary repeat Step b 1 LATCH STRIKER 2 HOOD LATCH 3 LATCH LEVER 4 SEAT 5 SEAT...

Page 10: ...move the capscrews that hold the overhead guard to the cowl and module Lift the overhead guard from the lift truck INSPECT Inspect the condition of the mount isolators located at the rear legs of the overhead guard for any dam age Replace if damaged INSTALL 1 Connect a lifting device to the top of the overhead guard Put the overhead guard in position on the lift truck 2 Install the capscrews at th...

Page 11: ...ruck 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 The seat belt hip restraint brackets seat and mount ing hood and latches are all part of the operator re straint system Each item must be checked to make sure it is attached securely functions correctly and is in g...

Page 12: ... hoses 5 On the GM powered lift truck remove the clamp and hose from the bottom of the radiator 6 Remove the top radiator support plate 7 Disconnect the coolant recovery reservoir hose from the radiator 8 Remove the coolant recovery reservoir from the overhead guard leg 9 Remove the upper and lower fan shroud halves from the radiator 10 Remove the radiator from the lower radiator mounting plate IN...

Page 13: ...100 SRM 726 Radiator Repair Figure 4 Radiator 7 ...

Page 14: ...unterweight See Counterweight Repair Remove in this SRM 3 Remove the lower exhaust pipe from the muffler and disconnect the upper exhaust pipe from the muffler 4 Remove the muffler from the mounting bracket Install 1 Install the muffler on the mounting bracket Tighten bolts until all clearance has been re moved then tighten one additional turn See Figure 5 or Figure 6 2 Connect the upper exhaust p...

Page 15: ...XHAUST PIPE 12 COUNTERWEIGHT EXHAUST PIPE 13 HEAT SHIELD 14 CLAMP 15 HEAT SHIELD SLEEVE 16 HEAT SHIELD SLEEVE 17 INTERMEDIATE UPPER EXHAUST PIPE 18 MUFFLER MOUNTING BRACKET 19 ISOLATOR 20 WASHER 21 HEX HEAD BOLT 22 WASHER 23 NUT 24 HEX HEAD BOLT 25 LOCKWASHER 26 RIGHT SIDE EXHAUST MANIFOLD 27 LEFT SIDE EXHAUST MANIFOLD Figure 5 LPG GAS Exhaust System Without Low Emissions Early Model Lift Trucks 9...

Page 16: ...Exhaust System Repair 100 SRM 726 Figure 6 LPG GAS Exhaust System Without Low Emissions Later Model Lift Trucks 10 ...

Page 17: ...trucks only install the metal heat shield on the left and right engine exhaust pipes 4 Connect the intermediate upper exhaust pipe to the left side engine exhaust pipe and connect the upper exhaust pipe to the intermediate upper ex haust pipe 5 Connect the upper exhaust pipe to the left side of the muffler and install the counterweight ex haust pipe on the right side of the muffler 6 Connect the u...

Page 18: ...Exhaust System Repair 100 SRM 726 Figure 7 EPA Compliant LPG GAS Exhaust System 12 ...

Page 19: ...all the metal heat shield to the engine ex haust pipes 4 Connect upper exhaust pipe to the left and right side engine exhaust pipes 5 Connect the upper exhaust pipe to the left side of the muffler and install the counterweight ex haust pipe on the right side of the muffler 6 Connect the lower exhaust pipe from the right side of the muffler and the upper exhaust pipe from the left side of the muffl...

Page 20: ... EXHAUST PIPE 6 ENGINE EXHAUST PIPE 7 ADAPTER 8 OVERHEAD EXHAUST PIPE 9 HEX HEAD BOLT 10 SPRING 11 SEAL 12 HEAT SHIELD SLEEVE 13 COUNTERWEIGHT EXHAUST PIPE 14 BRACKET 15 HEX HEAD BOLT 16 WASHER 17 ISOLATOR 18 NUT 19 WASHER 20 HEX HEAD BOLT 21 WASHER 22 ENGINE EXHAUST MANIFOLD Figure 8 Diesel Exhaust System 14 ...

Page 21: ...il tank 5 Remove the engine only as described in the fol lowing steps a Remove the brake pedal assembly as follows see Figure 9 Disconnect the wires at the brake switch Disconnect the brake lines at the brake booster master cylinder and put plugs and caps on the openings Disconnect the inching link at the transmission Remove the spring from the inching link Remove the return spring from the inchin...

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