Hyster k019 (h360 hd2 ec) forklift service repair manual

SERVICE REPAIR
H300HD2, H330HD2, H360HD2, H360HD2-EC,
H210-48HD2, H230-48HD2, H250-48HD2 [K019]

Counterweight Weights
Unit Main Counterweight
H190HD/H8.00XM 3051 kg (6,726 lb)
H210HD/H9.00XM 3366 kg (7,420 lb)
H230HD/H10.00XM-6 4276 kg (9,426 lb)
H250HD 4451 kg (9,812 lb)
H280HD/H12.00XM 5131 kg (11,311 lb)
H300HD/H13.00XM 5295 kg (11,673 lb)
H330HD/H14.00XM/H10.00XM-12EC 5930 kg (13,073 lb)
H360HD/H16.00XM-6/H12.00XM-12EC/H360HD-EC 6985 kg (15,399 lb)
Table 1. Counterweight Weights
Model Weight
H8XM-6 (H190HD2) 3051 kg (6,726 lb)
H9XM-6 (H210HD2) 3366 kg (7,420 lb)
H10XM-6 (H230HD2) 4276 kg (9,426 lb)
H10XMS (H250HD2/H230HD2S) 4451 kg (9,812 lb)
H12XM-6 (H280HD2) 5131 kg (11,311 lb)
H13XM-6 (H300HD2) 5295 kg (11,673 lb)
H14XM-6/H10XM-EC (H330HD2) 5930 kg (13,073 lb)
H16XM-6/H12XM-EC (H360HD2 H360HD2-EC) 6985 kg (15,399 lb)
8000 SRM 1937 Counterweight Weights
1

Lift Truck Weights
Table 2. Basic Truck
Model "MIN" Weight "MAX" Weight
H190HD2 H8-XM-6 9,400 kg (20,723 lb) 10,150 kg (22,376 lb)
H210HD2 H8-XM-6 9,700 kg (21,384 lb) 10,450 kg (23,038 lb)
H230HD2 H10-XM-6 10,700 kg (23,589 lb) 11,450 kg (25,242 lb)
H250HD2 10,900 kg (24,030 lb) 11,600 kg (25,573 lb)
H280HD2 H12-XM-6 11,550 kg (25,463 lb) 12,300 kg (27,116 lb)
H300HD2 H13-XM-6 12,500 kg (27,557 lb) 13,700 kg (30,203 lb)
H330HD2 H14-XM-6 13,200 kg (29,101 lb) 14,350 kg (31,636 lb)
H360HD2 H16XM-6 14,250 kg (31,415 lb) 15,400 kg (33,951 lb)
NOTE: Add 90 kg (198.4 lb) for a completely topped off fuel tank.
NOTE: The minimum weight indicates the weight for trucks with an open cab and pneumatic tires. The
maximum weight indicates the weight for trucks with an open cab and solid tires. To calculate the total
weight of the basic truck include the weight of following options:
• Add 200 kg (440.9 lb) for a closed cab.
• Add 50 kg (110 lb) for air conditioning.
• Add 90 kg (198.4 lb) for a completely topped up fuel tank.
Capacities
Item Quantity
Engine Oil
Tier 3, QSB6.7L 16 liter (16.9 qt)
Tier 4, QSB4.5L 10.5 liter (11.0 qt)
Lift Truck Weights 8000 SRM 1937
2

Item Quantity
Cooling System
Tier 3, QSB6.7L 25.5 liter (27 qt)
Tier 4, QSB4.5L 22.4 liter (23.6 qt)
Hydraulic Tank (FULL mark) 125 liter (33 gal)
Hydraulic System (Total Capacity)
8 to 12 ton 151 liter (39.9 gal)
13 to 16 ton 172 liter (45.4 gal)
Transmission ZF 27 liter (28.5 qt)
Drive Axle and Differential
8 to 12 ton 19 liter (5 gal)
Planetary Gears
8 to 12 ton 4.4 liter (4.7 qt)
13 to 16 ton 5.5 liter (5.3 qt)
Fuel Tank
10 to 12 ton 140 liter (37 gal)
13 to 16 ton 158 liter (41.7 gal)
Diesel Exhaust Fluid (DEF) 18.9 liter (5 gal)
Electrical System
All Models 24 Volt, Negative Ground
Alternator Output at 24°C (75°F)
All Engines
21 amps at 750 rpm
76 amps at 2200 rpm
8000 SRM 1937 Capacities
3

Engine Specifications
Table 3. Cummins QSB4.5
Item Specification
Type Cummins QSB4.5
Number of Cylinders 4
Firing Order 1-3-2-4
Bore 107 mm (4.2 in.)
Stroke 120 mm (4.7 in.)
Displacment 4.5 liter (275 in.3)
Compression Ratio 17.2:1
Oil Pressure (Minimum, at Low Idle) 52 kPa (7.5 psi)
Oil Pressure (At low idle) 69 kPa (10 psi)
Governed Speed (Full power at Normal Operating
Temperature)
2450 rpm with load
± 50 rpm no load
Idle Speed 800 rpm ±2%
Stall Speed (Broken-in Engine) 2016 + 100/-50 rpm
Thermostat
Begin to open 82°C (179°F)
Fully open 95°C (203°F)
Valve Clearance (Cold)
Intake 0.25 mm (0.01 in.)
Exhaust 0.51 mm (0.02 in.)
Minimum Cranking Speed 120 rpm
Weight (Dry) 371 kg (818 lb)
Table 4. Cummins QSB6.7
Item Specification
Type Cummins QSB6.7
Number of Cylinders 6
Firing Order 1-5-3-6-2-4
Bore 102 mm (4.02 in.)
Stroke 120 mm (4.62 in.)
Displacement 6.7 liter (409 in.3)
Compression Ratio 17.2:1
Oil Pressure (Minimum, at 2500 rpm and normal op-
erating temperature)
69-380 kPa (10-55 psi)
Engine Specifications 8000 SRM 1937
4

Table 4. Cummins QSB6.7 (Continued)
Item Specification
Oil Pressure (At low idle) 52 kPa (7.5 psi)
Governed Speed (Full power at Normal Operating
Temperature)
2300 rpm with load
2450 ±30 no load
Idle Speed 800 rpm ±2%
Stall Speed (Broken-in Engine) 1966 to 2116 rpm
Thermostat
Begin to open 82°C (179°F)
Fully open 95°C (203°F)
Valve Clearance (Cold)
Intake 0.25 mm (0.01 in.)
Exhaust 0.51 mm (0.02 in.)
Minimum Cranking Speed 125 rpm
Weight (Dry) 485 kg (1069 lb)
Mast Speeds
Unit
Lifting and Lowering Speeds
90 cc/Rev
@2050 rpm
105 cc/Rev
@2050 rpm
120 cc/Rev
@2050 rpm
m/ sec ft/ min m/ sec ft/ min m/ sec ft/ min
Rated Load Rated Load Rated Load
H190HD2 2 STG NFL 0.47 92.5 0.54 106 0.55 108
H8XM 3 STG FFL
(2ND/FREE)
0.32/0.30 62.9/59 0.37/0.35 72.8/68.8 0.37/0.32 72.8/63
H210HD2 2 STG NFL 0.47 92.5 0.54 106 0.55 108
H9XM 3 STG FFL
(2ND/FREE)
0.32/0.30 62.9/59 0.37/0.35 72.8/68.8 0.37/0.32 72.8/63
H230HD2 2 STG NFL 0.36 70.8 0.41 80 0.42 82.7
H10XM 3 STG FFL
(2ND/FREE)
0.30/0.29 59/57 0.38/0.36 74.8/70.8 0.39/0.34 77/67
H250HD2 2 STG NFL 0.36 70.8 0.41 80 0.42 82.7
3 STG FFL
(2ND/FREE)
0.30/0.29 59/57 0.38/0.36 74.8/70.8 0.39/0.34 77/67
8000 SRM 1937 Engine Specifications
5

Unit
Lifting and Lowering Speeds
90 cc/Rev
@2050 rpm
105 cc/Rev
@2050 rpm
120 cc/Rev
@2050 rpm
m/ sec ft/ min m/ sec ft/ min m/ sec ft/ min
Rated Load Rated Load Rated Load
H280HD2 2 STG NFL 0.36 70.8 0.41 80 0.42 82.7
H12XM 3 STG FFL
(2ND/FREE)
0.30/0.29 59/57 0.38/0.36 74.8/70.8 0.39/0.34 77/67
H300HD2 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H13XM 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H330HD2 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H14XM 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H360HD2 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H16XM 2 STG NFL 0.28 55 - - 0.34 66.9
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 - - 0.30/0.29 59/57
H6XM-12EC 2 STG NFL - - - - 0.52 102.36
H360XM2-EC 2 STG NFL - - - - 0.52 102.36
H7XM-12EC 2 STG NFL - - - - 0.52 102.36
Tire Sizes
NOTE: Refer to Truck Nameplate for correct tire
pressure.
Model Tire Size Tire Pressure
H8.00-9.00XM-6 (H190-210HD2) 9.00 × 20-14 ply 900 kPa (130 psi)
H10.00-12.00XM-6 (H230-280HD2) 10.00 × 20-16 ply 900 kPa (130 psi)
H10.00-12.00XM-EC (H360HD2-EC) 12.00 × 20-16 ply 1000 kPa (145 psi)
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2)
12.00 × 20-16 ply 1000 kPa (145 psi)
All Michelin XZM Radial Tires 1000 kPa (145 psi)
Mast Speeds 8000 SRM 1937
6

Hydraulic System
Item Quantity
Cummins Diesel Hydraulic Pump Capacity @ 2300 rpm
90 cc (3 oz) 196 liter/min (51.7 gal/min)
120 cc (4 oz) 262 liter/min (69.2 gal/min)
25 cc (0.8 oz)
Wet Brake Cooling Pump
57 liter/min (15.0 gal/min)
Relief Pressures *
Main Control Valve 22.5 MPa (3262.5 psi)
Steering Circuit 16 ±1 MPa (2320 ±145 psi)
*Oil temperature 20°C (68°F)
Torque Specifications, General
TRANSMISSION ZF
Nuts, Locking System Pressure Tubes Into
Rear Transmission Cover
42 N•m (31 lbf ft)
Screw, Holding Segment on Pressure Tubes
23 N•m (17 lbf ft)
Capscrews, Screen Into Front Transmission
Cover
23 N•m (17 lbf ft)
Capscrews, Tubes and Suction Tube Into
Front Transmission Cover
23 N•m (17 lbf ft)
Capscrews, Rear Transmission Cover to Front
Transmission Cover
4 N•m (34 lbf ft)
Capscrews, Output Flange to Transmission
Housing
34 N•m (25 lbf ft)
Capscrews, Torque Converter Bell Housing to
Transmission Housing
46 N•m (34 lbf ft)
Oil Fill Tube with Dipstick and Oil Drain
Plug
80 N•m (59 lbf ft)
Capscrews, Torque Converter Bell Housing to
Transmission Housing
46 N•m (34 lbf ft)
Capscrews, Transmission Oil Filter Head
23 N•m (21 lbf ft)
Capscrews, Torque Converter Housing to Fly-
wheel Housing
46 N•m (34 lbf ft)
Capscrews, Hydraulic Pumps to Transmis-
sion
25 N•m (18 lbf ft)
See the section Transmission Repair (ZF-
WG161) 1300SRM1456 for other torque values.
DRIVELINE AND AXLE
Capscrews, Universal Yoke
50 N•m (37 lbf ft)
Bolts, Axle to Frame
920 N•m (679 lbf ft)
COUNTERWEIGHT
Top Capscrews
1500 N•m (1106 lbf ft)
8000 SRM 1937 Tire Sizes
7

Rear Capscrews
1500 N•m (1106 lbf ft)
DIFFERENTIAL
See the section Drive Axle1400SRM1931.
BRAKES - WET
See the sections Brake and Hydraulic Cooling
System 1800SRM1933.
STEERING
Nut, Steering Wheel
68 N•m (50 lbf ft)
Capscrews, Steer Cylinder Mount
435 N•m (321 lbf ft)
Capscrews, Bearing Cap
75 N•m (55 lbf ft)
Nut, Wheel Bearing
Initial 203 N•m (150 lbf ft)
Final 34 N•m (25 lbf ft)
Note: Torque lock nut to Initial torque while
rotating wheel hub. Back off lock nut until wheel
hub turns freely with no end play. (Torque at
this point should be less than 27 N•m (20 lbf ft)).
Retorque to Final torque and lock in place at
first alignment position which occurs at or above
final torque spec.
Capscrews, Steer Axle Mount
270 N•m (199 lbf ft)
WHEEL NUTS
Drive Wheels (Final Torque Value)
615 to 710 N•m (454 to 524 lbf ft)
Steer Wheels (Final Torque Value)
615 to 710 N•m (454 to 524 lbf ft)
HYDRAULIC SYSTEM
Priority Valve (A)
217to 231 N•m (160 to 170 lbf ft)
Check Valve (K)
27 to 34 N•m (20 to 25 lbf ft)
Check Valve (L)
122 to 136 N•m (90 to 100 lbf ft)
Check Valve (Q)
9 to 12 N•m (7 to 9 lbf ft)
Shuttle Valves
26 to 30 N•m (34 to 40 lbf ft)
Full Flow Relief Valve (C) and (G)
217to 231 N•m (160 to 170 lbf ft)
Pilot Supply Valve (F)
45 to 50 N•m (33 to 37 lbf ft)
Load Sense Selector Valve (D)
35 to 40 N•m (26 to 30 lbf ft)
Coil Retaining Nut for Load Sense Selector
Valve (D)
4 to 6 N•m (35 to 53 lbf in)
Lift Pressure Selector Valve (B)
35 to 40 N•m (26 to 30 lbf ft)
Coil Retaining Nut for Lift Pressure Selector
Valve (B)
4 to 6 N•m (35 to 53 lbf in)
Solenoid Capscrews
6.3 N•m (56 lbf in)
Mount Capscrews
14 N•m (124 lbf in)
Pump Flangehead Screws
46 to 49 N•m (34 to 36 lbf ft)
Pump to Motor Capscrews
25 N•m (221 lbf in)
Torque Specifications, General 8000 SRM 1937
8

Suction Hose Adapter to Hydraulic Pump
91 to 100 N•m (67 to 74 lbf ft)
Pressure Line Fitting to Hydraulic Pump
49 to 59 N•m (36 to 44 lbf ft)
Counterbalance Valves
60 N•m (44.3 lbf ft)
MAST
Capscrews, Pivot Pin
435 N•m (321 lbf ft)
Capscrew, Bearing Block
9 N•m (7 lbf ft)
Capscrews, Bearing Block Bracket
44 N•m (32 lbf ft)
Nuts, Wear Plate
53 N•m (39 lbf ft)
Retainer, Lift Cylinder
H8-9XM-6 (H170-210HD2) 400 to 475 N•m
(295 to 350 lbf ft)
H10-12XM-6 (H230-280HD2) 475 to 550 N•m
(350 to 406 lbf ft)
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2); H10-12XM-12EC (H360HD2-EC)
550 to 625 N•m (406 to 461 lbf ft)
CARRIAGE
Capscrew, Bearing Block
9 N•m (7 lbf ft)
Capscrews, Bearing Block Bracket
44 N•m (32 lbf ft)
Nut, Sideshift Cylinder Rod
675 N•m (498 lbf ft)
TILT CYLINDERS
Nut, Cylinder Rod
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2); H10-12XM-12EC (H360HD2-EC)
949 to 983 N•m (700 to 725 lbf ft)
H13-16XM-6 (H300-360HD2) 1105 to 1140 N•m
(815 to 841 lbf ft)
Retainer
H8-12XM-6 (H170-280HD2) 542 to 610 N•m
(400 to 450 lbf ft)
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2); H10-12XM-12EC (H360HD2-EC)
610 to 675 N•m (450 to 498 lbf ft)
Lock Nut, Rod End
66 N•m (49 lbf ft)
Capscrew, Pin Anchor
165 N•m (122 lbf ft)
WIPER ARMS, FRONT
Capscrews, Bracket to Cab
20 to 25 N•m (14.7 to 18.4 lbf ft)
Capscrews, Arm to Bracket
22 to 27 N•m (16.2 to 19.9 lbf ft)
Capscrews, Blade to Arm
8 to 10 N•m (6 to 7.4 lbf ft)
Capscrew, Arm Set
35 to 45 N•m (25.8 to 33.2 lbf ft)
Torque Specifications, Cummins Diesel
LUBRICATION SYSTEM
Plug, Oil Sump, Steel Oil Pan
80 N•m (59 lbf ft)
All other Torque Specifications are found in Cummins Engine Manual. Contact Cummins Engine for any
torque specifications not listed for this engine.
8000 SRM 1937 Torque Specifications, General
9

Series Code / Model Designation Reference Table
This section is for the following models:
Series Code European Model Americas Model
K019 H13-16XM-6 H210-250-48HD2, H300-360HD2
K019EC H6-7XM-12EC H360HD2-EC
L007 H8-12XM-6, H10XMS-6 H190-280HD2, H230HDS2
General
This manual contains the procedures for removal
and installation of main components mounted on
the frame of the L007 and K019 lift truck series.
The manual includes air filter assembly, exhaust
system, hood assembly, handrails and steps, hy-
draulic tank, fuel tank, engine, transmission, oper-
ator’s cab and counterweight.
For information on the drive axle, steering axle and
mast refer to:
• Drive Axle 1400SRM1931
• Steering System 1600SRM1932
• 2-Stage Mast 4000SRM1647
Description
CAUTION
DO NOT initiate repairs to the frame without con-
sulting a Hyster service representative or damage
to the lift truck may occur.
The frame is a one-piece weldment that has mounts
for the main and/or additional components: coun-
terweight, engine, transmission, drive and steer
axles, hydraulic and fuel tanks, operator's compart-
ment, and other parts. See Figure 1.
0100 SRM 1900 Series Code / Model Designation Reference Table
1

1. MAIN COUNTERWEIGHT MOUNT
2. COOLING ASSEMBLY MOUNT
3. TILT CYLINDER MOUNT
4. MAST MOUNT
5. DRIVE AXLE MOUNT
6. MAIN FRAME
7. SIDE TILTING CAB MOUNT
8. HYDRAULIC TANK MOUNT
9. STEER AXLE MOUNT
10. ENGINE MOUNT
11. TRANSMISSION MOUNT
12. MAIN CONTROL VALVE MOUNT
13. CAB TILT CYLINDER MOUNT
14. EXHAUST SYSTEM MOUNT
15. HYDRAULIC TANK MOUNT
16. CAB LOCK MOUNT
17. RUNNING BOARD BRACKETS
18. DEF TANK MOUNT
Figure 1. Frame Mounts
Description 0100 SRM 1900
2

Remove and Install
AIR FILTER ASSEMBLY (TIER 3/STAGE
IIIA)
Remove
1. Open left-hand hood door. See Hood Assembly.
2. Tag and disconnect the electrical connector
from vacuum switch by pressing the metal clip.
3. Loosen the air duct clamp at the filter housing.
See Figure 2.
4. Close left-hand hood door to access the Pre-
cleaner.
5. Remove the Precleaner, with the air duct at-
tached, from the air filter housing.
6. Open left-hand and right-hand hood doors.
7. Loosen the hose clamps on the air filter hose
and remove the hose. See Figure 2.
8. Place a cap on the air inlet of the turbocharger
to avoid dirt entering the turbocharger.
9. Place a support under the air filter assembly.
10. Remove the cap screws and washers from the
mounting clamps that hold the air filter assem-
bly.
11. Rotate the air filter until the air duct connec-
tion clears the center of the hood opening and
move the air filter to the right-hand side of the
truck.
12. Remove the retaining hardware from the
mounting clamps and remove the clamps from
the hood by removing the hardware.
Install
1. Install the retaining hardware to the mounting
clamps and install the clamps under the hood.
2. Position the air filter housing into the mount-
ing clamps with the air intake aligned with the
hole in the mounting plate.
3. Install cap screws and washers and tighten to
38 N•m (28 lbf ft).
4. Remove the cap from the turbocharger.
5. Rotate and connect air filter hose to air filter
housing and the turbocharger and tighten hose
clamps to 8 N•m (6 lbf ft).
6. Close the hood doors. See Figure 10.
7. Install the Precleaner, with the air duct at-
tached, on the air cleaner.
8. Open left-hand hood door.
9. Install and tighten the air duct clamp.
10. Connect electrical connector to vacuum switch.
11. Close the hood door.
1. AIR FILTER HOSE
2. AIR FILTER HOUSING
3. VACUUM SWITCH
4. AIR DUCT CLAMP
5. PRECLEANER
6. AIR DUCT
7. HOSE CLAMP
8. MOUNTING CLAMP
Figure 2. Air Filter Assembly (Tier 3/Stage IIIA)
0100 SRM 1900 Description
3

AIR FILTER ASSEMBLY (TIER 4F/STAGE
IV)
Remove
1. Open left-hand hood door. See Hood Assembly.
2. Tag and disconnect the connectors to the vac-
uum switch and to the TBAP sensor (Tempera-
ture and Barometric Air Pressure sensor).
3. Remove the three cap screws and washers from
the air duct bracket on the center hood. See
Figure 3.
4. On trucks with High Mount Precleaner, remove
the U-clamp from the support bracket. See Fig-
ure 4.
5. Remove the Precleaner, with the air duct at-
tached, from the air cleaner.
6. Open left-hand and right-hand hood doors. See
Figure 10.
7. Loosen the hose clamps on the air filter hose
and remove the hose from the air filter and the
turbocharger.
9. Remove the four cap screws that retain the
brackets of the air filter unit to the hood.
10. Lower the air filter unit it is clear from the
hood.
11. Remove the air filter to the right-hand side of
the truck.
Install
1. Open left-hand and right-hand hood doors.
2. Position the air filter housing with the air in-
take aligned with the hole in the mounting
plate.
3. Install the air filter with the four washers and
cap screws and tighten to 65 N•m (48 lbf ft).
4. Remove cap from the air inlet on the turbo-
charger.
5. Connect air filter hose to the turbocharger and
to the air filter housing and tighten the hose
clamps to 8 N•m (6 lbf ft).
6. Connect the connectors to the vacuum switch
and to the Temperature and Barometric Air
Pressure (TBAP) sensor according the tags.
7. Close the hood doors.
8. Install the Precleaner, with the air duct at-
tached, to the center hood.
9. On trucks with High Mount Precleaner, install
the U-clamp to the support bracket.
10. Install the air duct with the three cap screws to
the center hood.
1. AIR FILTER HOSE
2. AIR FILTER HOUSING
3. AIR FILTER HOUSING BRACKET
4. PRECLEANER
5. AIR DUCT
6. AIR DUCT BRACKET
7. TBAP SENSOR
Figure 3. Air Filter Assembly with Low Mount
Precleaner (Tier 4F/Stage IV)
Remove and Install 0100 SRM 1900
4

A. HIGH MOUNT PRECLEANER FOR CABS WITH-
OUT AIRCO
B. HIGH MOUNT PRECLEANER FOR CABS WITH
AIRCO
1. PRECLEANER
2. PRECLEANER CLAMP
3. AIR DUCT
4. U-CLAMP
5. SUPPORT BRACKET
6. AIR DUCT CLAMP
Figure 4. Air Filter Assembly with High Mount
Precleaner (Tier 4F/Stage IV)
EXHAUST SYSTEM (TIER 3/STAGE IIIA)
Remove
WARNING
Exhaust system must be at room temperature be-
fore starting disassembly or personal injury may
occur.
1. Open left- and right-hand hood doors. See Hood
Assembly.
2. Remove clamp from turbocharger See Figure 5.
3. Remove clamp from the flex tube.
4. Remove the exhaust pipe and flex tube as an
assembly.
6. Remove the hardware that retains the muffler
to the center hood and remove the muffler.
Install
1. Place the muffler on the center hood and attach
the hardware.
2. Remove the cap from the air inlet of the turbo-
charger.
3. Install the exhaust pipe and flex tube assembly.
4. Tighten the clamp on the flex tube to 70 ±
10 N•m (52 ± 7 lbf ft).
5. Tighten the V-clamp on the turbocharger to 54 -
81 N•m (40 - 60 lbf ft).
6. Close the hood doors.
1. MUFFLER
2. CAP SCREW AND WASHER
3. CLAMP
4. FLEX PIPE
5. EXHAUST PIPE
6. V-CLAMP
Figure 5. Exhaust System (Tier 3/Stage IIIA)
0100 SRM 1900 Remove and Install
5

EXHAUST SYSTEM (TIER 4F/STAGE IV)
WARNING
Exhaust system must be at ambient temperature
before starting disassembly or personal injury
may occur.
Wait at least 100 seconds after the engine has
been switched off then move the battery discon-
nect switch to the disconnected position. Discon-
nect the ground cable from the batteries.
Exhaust Pipes High Mount
Remove
1. Turn the steer wheels into the extreme left turn
position for better access.
2. Remove the heat shield from the exhaust pipe.
See Figure 6.
3. Remove the clamp from the Selective Catalytic
Reducer (SCR) outlet.
4. Remove the clamp from the exhaust tail pipe
and remove the exhaust tail pipe.
Install
1. Turn the steer wheels into the extreme left turn
position for better access.
2. Install the clamp on the exhaust tail pipe and
install the pipe.
3. Install the clamp on the exhaust pipe.
4. Install the exhaust pipe and flex tube assembly.
5. Install the heat shield on the exhaust pipe.
1. DILUTER
2. DILUTER BRACKET
3. EXHAUST TAIL PIPE
4. EXHAUST END PIPE WITH FLEX CONNECT-
ING PIECE
5. EXHAUST SYSTEM SUBFRAME
6. INSULATION PIPE
7. FLEX PIPE
8. END INSULATION PIPE
9. HEAT SHIELD
10. BRACKET
11. COUNTERWEIGHT
Figure 6. Exhaust Pipe Connections High Mount
(Tier 4F/Stage IV)
6

Exhaust Pipes and Diffuser Low Mount
Remove
1. Remove the clamp from the Selective Catalytic
Reducer (SCR) outlet. See Figure 7.
2. Place a support under the diffuser.
3. Remove the cap screws and washers.
4. Remove the diffuser and exhaust assembly to-
wards the back of the truck, out of the SCR out-
let.
Install
1. Install the diffuser and exhaust assembly by in-
serting the exhaust assembly in the SCR outlet.
2. Install the isolators, washer and cap screws to
the bottom side of the hydraulic tank and
tighten the cap screws to 35 N•m (26 lbf ft).
3. Tighten clamp to 54 - 81 N•m (40 - 60 lbf ft).
1. CLAMP
2. EXHAUST PIPE ASSEMBLY
3. ISOLATOR MOUNTS
4. DIFFUSER
5. CAP SCREW
6. WASHER
7. ISOLATOR
Figure 7. Exhaust Pipe Connections Low Mount
(Tier 4F/Stage IV)
Exhaust Seal Rings
In the high pressure part of the exhaust system,
the tubes and pipes are sealed by means of metal
seal rings. These seal rings deform when V-clamps
are tightened and will stick to one of the exhaust
components at disassembly. Remove the used seal
and replace by a new one at re-assembly. Pay at-
tention to the different sizes and shapes of seals at
the different locations. Pay attention to the differ-
ent torque value of the V-clamp at the connection
with the turbo. See Figure 8.
1. BAND CLAMP
2. V-CLAMP AND SEAL RING 5” – SPHERICAL
5. BAND CLAMP
8. V-CLAMP AND SEAL RING 4” – STANDARD
Figure 8. Exhaust Seal Rings
NOTE: To make repositioning possible, do not
tighten the clamps until the correct and final posi-
tion of exhaust components has been obtained.
7

A. SCR CONNECTIONS
B. DRT CONNECTIONS
C. DOC CONNECTIONS
1. NOX SENSOR
2. SELECTIVE CATALYTIC REDUCER (SCR)
3. DECOMPOSITION REACTOR TUBE (DRT)
4. DIESEL OXIDATION CATALYST (DOC)
5. ELECTRICAL CONNECTORS ON SCR
6. ELECTRICAL CONNECTOR ON DRT
7. DEF HOSE ON DRT
8. COOLING HOSES ON DRT
9. ELECTRICAL CONNECTORS ON DOC
Figure 9. Exhaust System (Tier 4F/Stage IV)
Selective Catalytic Reducer (SCR)
Remove
1. Disconnect the two 4-pin connectors from the
SCR. See Figure 9.
2. Use a forklift truck with a pallet to support the
SCR.
3. Loosen the band clamp at the exhaust pipe.
4. Remove the V-band clamp from the connection
between SCR and connection pipe to the DRT
and move the flanges apart.
5. Remove the band clamps that connect the SCR
to the exhaust sub-frame.
6. Lower the pallet and move the SCR underneath
the fuel tank, away from the truck.
Install
1. Place the SCR on a pallet and move the SCR
into its mounting position.
2. Install the SCR with the band clamps to the ex-
haust sub-frame.
3. Remove the lift truck with the pallet.
4. Insert a new seal and move the flanges of SCR
and the connection pipe to the DRT against
each other.
5. Tighten the V-band to 12 - 15 N•m (9 -
11 lbf ft).
6. Tighten the band clamp on the end-pipe to 54 -
81 N•m (40 - 60 lbf ft).
7. Connect the two 4-pin connectors to the SCR.
Decomposition Reactor Tube (DRT)
Remove
1. Disconnect and plug both coolant hoses from
the DRT. See Figure 9.
2. Disconnect and plug the DEF hose from the
DRT.
3. Disconnect the electrical connector from the
DRT.
DRT.
5. Disconnect the DEF hose from the DRT.
6. Disconnect the electrical connector from the
DRT.
8

7. Remove the V-band at the outlet of the DRT,
and separate the flanges of DRT and the con-
nection elbow to the SCR.
8. Remove the V-band at the connection between
DRT and DOC and separate the flanges to the
DOC.
9. Remove the band clamps that connect the DRT
10. Lower the pallet and move the DRT away from
the truck.
Install
1. Place the DRT on a pallet and move the DRT
2. Install the DRT with the band clamps to the ex-
haust sub-frame.
4. Insert new seals at the connection with DOC
and SCR and install the V-band clamps.
5. Tighten the V-band clamps to 12 - 15 N•m (9 -
11 lbf ft).
6. Reconnect the DEF hose and the cooling hoses
to the DRT.
7. Reconnect the electrical connector to the DRT.
Diesel Oxidation Catalyst (DOC)
Remove
1. Disconnect the two 4-pin connectors from the
DOC. See Figure 9.
Diesel Oxidation Catalyst (DOC).
3. Remove the V-band clamps from the flanges of
the insulated exhaust pipe.
4. Remove the insulation pipe from the engine
and remove the flange seals.
5. Remove the band clamps that connect the DOC
6. Lower the pallet and move the DOC away from
the truck.
Install
1. Place the DOC on a pallet and move the DOC
2. Install the DOC with the band clamps to the
exhaust sub-frame.
4. Install new seals between the DOC and on the
engine.
5. Install the insulation pipe between the DOC
and the engine.
6. Mount the V-band clamps.
7. Tighten the V-band clamp at the turbo to 6 -
8 N•m (4.5 - 6 lbf ft).
8. Tighten the V-band clamp at the DOC to 12 -
15 N•m (9 - 11 lbf ft).
HOOD ASSEMBLY
NOTE: Only for trucks with Tier 3/Stage IIIA en-
gines, the hood also carries a muffler. On trucks
with Tier 4F/Stage IV engines, the hood just holds
the air intake precleaner.
Remove
1. Tilt mast completely forward.
2. Apply parking brake.
3. Turn the engine OFF.
4. Completely tilt (raise) the cab. See the section
Operator's Cab 0100SRM1390.
5. Disconnect the battery cables from the battery.
6. Open rear cover and disconnect the two gas
springs from the counterweight. See Figure 10.
7. Remove the rear cover by sliding it sideways off
its flexible hinge.
8. Open left- and right-hand hood door.
9. On trucks with Tier 3/Stage IIIA engines, re-
move upper exhaust pipe, flex tube, and clamp
from muffler.
9

1. CENTER HOOD
2. LEFT-HAND HOOD DOOR
3. AIR INTAKE PRECLEANER
4. MUFFLER
5. REAR COVER
6. RIGHT-HAND HOOD DOOR
7. HOOD FRONT PLATE
Figure 10. Hood Assembly (Tier 3/Stage IIIA)
10. Remove the muffler.
11. Remove air filter unit. See chapter Air Filter
Assembly (Tier 3/Stage IIIA) or Air Filter As-
sembly (Tier 4F/Stage IV), Remove depending
on your lift truck.
12. Remove nuts and washers from two isolator as-
semblies on top of radiator and remove isolator
assemblies. See Figure 11.
13. Remove all tie-wraps holding electrical cables
to hood assembly.
14. Remove two cap screws, nuts, and four washers
that hold the hood support to the frame. See
Figure 11.
15. Remove four cap screws, nuts, and eight wash-
ers that hold the hood front plate to the frame.
See Figure 12.
16. Attach a lifting device to hood assembly.
1. CAP SCREW, WASHER AND NUT
2. ISOLATOR
3. COUNTERWEIGHT
4. RADIATOR
5. HOOD SUPPORT
6. EXPANSION TANK MOUNTING (TIER 3/STAGE
IIIA ONLY)
7. MUFFLER MOUNTING (TIER 3/STAGE IIIA
ONLY)
Figure 11. Hood Support
1. HARDWARE
2. HOOD FRONT PLATE
Figure 12. Hood Front Plate (Tier 3/Stage IIIA
shown)
10

CAUTION
Use caution when lifting the hood assembly to
avoid damage to the rear of the operator’s cab.
17. Slowly lift the hood assembly from the frame
and make sure all electric cables are removed
from the hood.
18. Place the hood assembly on the ground and
place a support under the rear of the hood
frame.
19. Close left- and right-hand hood door.
Install
1. Open left- and right-hand hood door. See Fig-
ure 10.
2. Attach a lifting device to hood assembly.
CAUTION
Use caution when installing the hood assembly to
avoid damage to the rear of the operator’s cab.
3. Position hood assembly on frame.
4. Install eight washers, four cap screws and four
nuts holding hood front plate to the frame. See
Figure 12.
5. Install four washers, two cap screws and nuts
holding hood support to frame. See Figure 11.
6. Position two isolator assemblies between cool-
ing system and hood support. See Figure 11.
7. Install washers and nuts to two isolator assem-
blies on top of cooling system.
8. Install air filter unit. See chapter Air Filter As-
sembly (Tier 3/Stage IIIA) or Air Filter Assem-
bly (Tier 4F/Stage IV), Install depending on
your lift truck.
9. On trucks with Tier 3/Stage IIIA engines, in-
stall upper exhaust pipe, flex tube, and clamp
to muffler.
10. Use tie wraps to hold electrical cables in origi-
nal position on hood assembly.
11. Close left- and right-hand hood door.
12. Close rear cover.
13. Completely lower the cab. See Operator's Cab
0100SRM1390.
14. Start the engine and check for leaks.
RUNNING BOARDS, STEPS AND MUD
FLAPS
The running boards and steps can be removed from
the frame for access to components. See Figure 13.
Use a lifting device to secure floor plates, handrails
and steps before loosening the fasteners that attach
them. First detach the bolt connection with other
components such as fenders and other floor plates,
before loosening the bolted connection with the
frame.
The truck can be equipped with mud flaps. The
front mud flaps are installed at the front side of the
fender. The front mud flap contains a bracket that
holds the flap in front of the drive wheel. The rear
mud flaps are installed on the counterweight. Be-
fore installation, first remove the cap screws that
are installed in the threaded holes. After removal of
the mud flaps, install the cap screws back in the
holes.
11

1. REAR MUDFLAP
2. CAP SCREW AND WASHER
3. ISOLATOR
4. FRONT FENDER
5. FRONT MUDFLAP
6. MUDFLAP BRACKET
Figure 13. Running Board, Steps and Mud Flaps
HYDRAULIC TANK
The hydraulic tank is located at the right side of
the frame between the front fender and the coun-
terweight and has a maximum capacity of:
• 151 liter (39.9 gal) for H8-12XM-6 /
H170-280HD2 lift trucks.
• 172 liter (45.4 gal) for H13-16XM-6 /
H300-360HD2, H6-7XM-12EC lift trucks.
.
Remove
WARNING
At operating temperature, the hydraulic oil is HOT.
Before draining oil, make sure hydraulic oil has
cooled down. Do not permit the oil to contact the
skin and cause a burn.
CAUTION
Make sure not to damage the hydraulic hoses and
electrical cables during tank removal.
1. Place lift truck on a solid, level surface.
2. Lower the mast completely.
3. Apply the parking brake.
4. Turn the engine OFF.
5. Remove the four cap screws and washers hold-
ing the right-hand panel on top of the hydraulic
tank and remove the right-hand panel. See Fig-
ure 14.
6. Remove the three cap screws and washers hold-
ing the right-hand extension plate and remove
the extension plate.
12

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1. RIGHT-HAND EXTENSION PLATE
2. LEVEL INDICATOR
3. HYDRAULIC TANK
4. BATTERY BOX
5. STEP
6. RIGHT-HAND PANEL
7. HYDRAULIC RETURN FILTER
Figure 14. Hydraulic Tank
7. Move the battery disconnect switch to the dis-
connected position (pointer up) and lock the
switch.
CAUTION
Disconnect the negative (ground) cable first or lift
truck damage may occur.
8. Disconnect the negative (ground) and positive
(power) cables from the batteries.
NOTE: The battery box is attached to the hydraulic
tank. To be able to remove the hydraulic tank/
battery box assembly it is necessary to disconnect
all cables which are connected to the truck. Leave
the cable gland on the cable to avoid damage to the
cable.
9. Remove the PDM box cover by removing six
screws.
10. Disconnect and remove all cables which are
connected to the truck from the battery box.
See Figure 15.
1. CAB FUSEBOX
2. PDM
3. GLAND
4. STARTER MOTOR
5. TO FUSE ALTERNATOR
6. FRAME SUPPLY
7. BATTERY NEGATIVE (GROUND)
Figure 15. Disconnect Cables from the Battery
Box
11. Close the PDM box cover to prevent the parts
from getting damaged.
12. Disconnect and remove the batteries from the
battery box.
13. Remove the step from the top of the hydraulic
tank, by removing the cap screws and washers.
14. The running board between the front fender
and the counterweight weighs 12.7 kg (28 lb),
therefore support the running board with a
hand pallet truck or forklift truck.
15. Remove the cap screws and washers from the
running board.
16. Lift the running board slightly to remove the
isolators.
17. Remove the running board from the truck.
13

NOTE: Use a drain pan to collect the oil from the
hydraulic tank and hoses. The hydraulic system
contains:
• 151 liter (39.9 gal) for H8-12XM-6 /
H170-280HD2 lift trucks.
• 172 liter (45.4 gal) for H13-16XM-6 /
H300-360HD2, H6-7XM-12EC lift trucks.
1. TANK BREATHER
2. LIFT CYLINDER DRAIN HOSE
3. WET BRAKE RETURN HOSE
4. DRAIN PLUG
5. MAIN RETURN HOSE
6. HYDRAULIC TEMPERATURE SENSOR
7. MAIN VALVE DRAIN HOSE
8. BRACKET
9. MAIN PUMP SUPPLY HOSE
10. WET BRAKE PUMP SUPPLY HOSE
11. WET BRAKE PUMP SUCTION HOSE
Figure 16. Hydraulic Tank Connections
18. Remove the hydraulic return filter. See Fig-
ure 14.
19. Use a separate pump to empty the tank by put-
ting a drain hose through the tank opening for
the return filter.
20. When the hydraulic tank is empty, put a drain
pan under the hydraulic tank.
21. Remove the drain plug at the bottom of the
tank to drain remaining oil. Reinstall the plug.
NOTE: Before disconnecting the hydraulic hoses,
place a suitable container under the hydraulic hose
connections to catch the hydraulic oil from the hy-
draulic hoses.
22. Tag all hoses and tubes connected to the hy-
draulic tank to facilitate re-installing.
23. Loosen and remove the hose clamps from the
main pump suction hose and from the wet
brake pump suction hose at the lower backside
of the hydraulic tank. See Figure 16.
24. Put caps on the suction hoses.
25. Disconnect the wet brake return, the main
valve return and the main valve drain hoses
from the hydraulic tank.
26. Disconnect the lift cylinder drain hose at the
top of the hydraulic tank.
27. Put caps on the hoses and on the connections
on the hydraulic tank.
28. Tag and disconnect the wire from the tempera-
ture sensor at the lower backside of the tank.
Remove the sensor if necessary.
29. Remove the disconnected cables from the access
hole of the hydraulic tank.
CAUTION
Support the hydraulic tank with a hand pallet lift
with blocks or a lift truck.
30. At the back side bracket, remove the cap screw
that retains the hydraulic tank to the frame.
31. Remove cap screws and washers from the top of
the hydraulic tank.
32. Lift the hydraulic tank slightly to remove the
isolators.
33. Carefully move the hydraulic tank away from
the truck.
34. Remove the hydraulic tank breather and plug
the tank opening to prevent the breather from
getting damaged.
14

Inspect
WARNING
DO NOT use tools that can make sparks, heat, or
static electricity. The vapors in the tank can cause
an explosion.
Make a visual inspection of all sides of the tank. In-
spect the welds for cracks and leakage. Check for
wet areas, accumulation of dirt, and loose or miss-
ing paint caused by leakage. Areas of the tank that
are difficult to inspect can be checked with an in-
spection mirror and a light that is approved for lo-
cations with flammable vapors.
Clean
WARNING
If the tank is cleaned inside of a building, make
sure there is enough ventilation. See the following
manuals for additional information:
• "Safe Practices for Welding and Cutting
Containers That Have Held Combustibles"
by the American Welding Society, F4.1 -
1999.
• "Safety in Welding and Cutting," American
National Standard, AWS Z 49.1 - 1999.
WARNING
When cleaning the tank, do not use solutions, that
create dangerous gases at normal temperatures
or when heated. Wear eye protection. Protect the
body from burns.
When cleaning with steam, use a hose with a mini-
mum diameter of 19 mm (0.75 in.). Control the
pressure 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 electrical connection between the nozzle
and the tank. Connect a ground wire to the tank to
prevent static electricity.
Steam Cleaning Method
1. Remove all the parts from the hydraulic tank.
2. Install the drain plug.
3. Fill the tank 1/4 full with a solution of water
and sodium bicarbonate or sodium carbonate.
Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water.
4. Mix the solution in the tank using compressed
air. Verify all the surfaces on the inside of the
tank are flushed with the solution.
5. Drain the tank.
6. Put steam into the tank until the tank does not
have odors and the metal is hot. Steam vapors
must come from all the openings.
7. Flush the inside of the tank with boiling water.
Verify all the loose material is removed from
the inside of the tank.
8. Make an inspection of the inside of the tank. If
it is not clean, repeat Step 6 and Step 7 and
make another inspection. When making inspec-
tions, use light that is approved for locations
with flammable vapors.
9. Put plugs in all the openings in the tank. Wait
15 minutes; then remove the inlet and outlet
plugs. Test a sample of the vapor with a special
indicator for gas vapors. If the amount of flam-
mable vapors is above the lower flammable
limit, repeat the cleaning procedures.
NOTE: If the tank cannot be cleaned with steam,
use the following procedure:
Chemical Solution Cleaning Method
1. Mix a solution of water and trisodium phos-
phate or a cleaning compound with an alkali
base. Follow the instructions given by the man-
ufacturer.
2. Fill the tank with the cleaning solution. Use
compressed air to mix the solution in the tank.
3. Drain the tank. Flush the inside of the tank
with hot (boiling) water. Make sure all cleaning
compound is removed.
4. Make an inspection of the inside of the tank. If
the tank is not clean, repeat Step 1 through
Step 3. Make another inspection of the tank.
When making inspections, use a light that is
approved for locations with flammable vapors.
15

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