Service repair manual sections

SERVICE REPAIR
S2.0FT S2.5FT S3.0FT S3.5FT Europe [F187]

100 SRM 1120 General
General
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The re-
moval of the following assemblies will cause
large changes in the center of gravity: mast,
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:
• Before removing the mast and drive axle, put
blocks under the counterweight so the lift
truck cannot fall backward.
• 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. See the Operating
Manual or the section Periodic Maintenance
8000 SRM 1150 for lift truck models S2.0-3.5FT
(S40-70FT, S55FTS) (F187) and H2.0-3.5FT
(H40-70FT) (L177) or Periodic Maintenance
8000 SRM 1207 for lift truck models S30FT,
S35FT, S40FTS (E010) and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) (F001).
This section contains the description of the frame
(see Figure 1) and connected parts. Procedures for re-
moving and installing the counterweight, hood, over-
head guard, engine, cooling system, exhaust system,
and LPG fuel tank and bracket are found in this sec-
tion. Checks for the operator restraint system and
procedures for the repair of tanks and installation of
safety labels are also included.
1. COWL PLATE
2. FENDERS
3. FRAME
4. HOOD MOUNTS
5. COUNTERWEIGHT MOUNTS
6. FUEL TANK (GAS OR DIESEL)
7. HYDRAULIC TANK
Figure 1. Frame
1

Hood, Seat, and Side Covers Replacement 100 SRM 1120
Description
The frame is one weldment and includes the hy-
draulic tank and fuel tank for gasoline or diesel fuel.
See Figure 1.
There is a counterweight for each capacity of lift
truck. The counterweights are similar in appear-
ance, but are different weights. See Table 1, Table 2,
Table 3, and Table 4. The muffler is fastened to the
frame inside the counterweight.
The overhead guard, cowl, and hood are installed
on the frame. The hood is connected to the frame
with hinges. Two gas-controlled springs provide as-
sistance when raising the hood and hold the hood in
the open position. The floor plate and side covers can
be removed for access to the engine, transmission,
and other components.
Hood, Seat, and Side Covers Replacement
REMOVE
1. Slide the seat to the closest position to the steer-
ing column.
2. Fully tilt the steering column forward.
3. If your truck is equipped with an LPG tank,
swing the tank off to the side. See Figure 8.
4. Raise the latch on the left, front corner of the
hood to unlatch and lift up the hood. See Fig-
ure 2.
5. Remove the floor mat and floor plate. See Fig-
ure 3 and Figure 4.
6. Remove the two capscrews holding the left and
right rear side covers to the frame. Remove the
rear side covers from the frame. See Figure 3 and
Figure 4.
7. Remove the two capscrews holding the left and
right fender covers to the front overhead guard
leg. Remove covers. See Figure 3 and Figure 4.
8. Remove the four capscrews holding the left and
right front side covers to the frame. Remove cov-
ers.
9. Fully lower the steering column.
10. Remove upper steering column cover by pulling
up on upper steering column cover to release the
latches (one on either side), and pulling cover
away from steering column. See Figure 5.
11. Remove the five fasteners (see Figure 5) securing
the dash to the top of the cowl. Remove the four
clips, located underneath dash, that attach the
dash to the kick panel. Lift to remove the dash.
12. Lift the kick panel to remove it from the truck.
See Figure 3 and Figure 4.
13. Remove the three capscrews holding the seal
plate. Remove seal plate. See Figure 6.
14. Disconnect the seat wire harness connector. See
Figure 2.
CAUTION
When removing the seat from the hood, do
not use an impact wrench to remove the cap-
screws. Damage can be caused to the threads
on the screws and in the holes.
15. If the seat is to be removed, and truck is equipped
with a non-swivel seat, remove the seat wire har-
ness from the seat wire harness brackets that
are attached to the underside of the hood. Re-
move the cable clips from the seat wire harness.
If truck is equipped with a swivel seat, remove
seat wire harness from seat wire harness bracket
attached to the underside of the hood and behind
the seat (see Figure 2).
16. Remove the four capscrews and washers holding
the seat to the hood. Lift the seat off the hood.
Pull the seat wire harness through the hood. See
Figure 2.
17. Remove the capscrews and washers at the top of
the gas springs. Remove gas springs from the
hood.
18. Remove the hinge screws, located in the rear of
the hood.
19. Lift the hood from the truck. See Figure 2.
2

100 SRM 1120 Hood, Seat, and Side Covers Replacement
NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES.
A. SIDE VIEW OF HOOD AND SEAT
B. SIDE VIEW OF HOOD
C. BOTTOM VIEW OF HOOD
D. SIDE VIEW OF VENTED HOOD WITH SWIVEL
SEAT
1. SEAT
2. HOOD
3. FRAME
4. SEAT WIRE HARNESS
5. SEAT WIRE HARNESS CONNECTOR (WITHOUT
ELECTRONIC CONTROL)
6. SEAT WIRE HARNESS CONNECTOR (WITH
ELECTRONIC CONTROL)
7. CABLE CLIPS
8. HINGE SCREWS
9. GAS SPRING
10. ATTACHMENT HOLES ATTACHING HOOD TO
SEAT (SEMI-SUSPENSION)
11. SEAT WIRE HARNESS BRACKETS
12. SEAT LINER
13. HOOD LATCH
SEAT (NON-SUSPENSION)
SEAT (FULL SUSPENSION)
16. SPACER
Figure 2. Hood and Seat Arrangement
3

1. LOWER STEERING COLUMN COVER
2. UPPER STEERING COLUMN COVER
3. INSERT
4. CLIP
5. DASHBOARD
6. CAPSCREW
7. SEAL
8. GROMMET
9. LEFT HAND REAR PANEL
10. FLOOR PLATE
11. LEFT HAND FENDER COVER
12. SCREW
13. NUT
14. LEFT HAND FRONT PANEL
15. LEFT HAND STEP PANEL
16. LEFT HAND TREAD PLATE
17. PLATE ASSEMBLY SEAL
18. RIGHT HAND FENDER COVER
19. FLOOR MAT
20. RIGHT HAND TREAD PLATE
21. RIGHT HAND FRONT PANEL
22. RIGHT HAND STEP PANEL
23. RIGHT HAND REAR PANEL
24. RADIATOR COVER
25. KICK PANEL
26. PLATE ASSEMBLY
Figure 3. Side Cover, Floor Plate, and Cowl Components, Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (F187), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001), and S30FT, S35FT,
S40FTS (E010)
4

Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models H2.0-3.5FT (H40-70FT)
(L177)
5

Legend for Figure 4
1. DASH ASSEMBLY
4. KICK PANEL
5. MUD GUARD (LH)
6. MUD GUARD (RH)
7. LOCK NUT
8. NUT
9. COVER
10. BRACKET
11. PLATE ASSEMBLY
12. GROMMET
13. LEFT FRONT PANEL
14. RIGHT FRONT PANEL
15. LEFT STEP PANEL
16. RIGHT STEP PANEL
17. LEFT STEP PLATE
18. RIGHT STEP PLATE
19. LEFT REAR PANEL
20. RIGHT REAR PANEL
21. FLOOR MAT
22. FLOOR PLATE
23. RADIATOR COVER
24. SEALS
25. CAPSCREW
26. CLIP NUT
27. INSERT
28. PLATE ASSEMBLY SEAL
NOTE: TOP VIEW OF DASH SHOWN.
A. INDICATES TO PULL UP TO UNLATCH
1. ALLEN SCREWS
2. COWL
Figure 5. Remove Dash From Cowl
6

1. CAPSCREWS 2. SEAL PLATE
Figure 6. Remove Seal Plate From Dash
INSTALL
1. Place the hood onto the lift truck frame.
2. Install the hinge screws, located in the rear of
the hood, and tighten to 38 N•m (28 lbf ft). See
Figure 2.
3. Align the top holes in the gas springs with holes
in the hood. Install capscrews and washers to at-
tach gas springs to the hood. Tighten capscrews
to 19.2 N•m (170 lbf in).
4. Install latch striker in highest slot position.
Check that latch striker is in center of jaws of
hood latch when hood closes. Open and close the
hood to ensure that the center pin strikes the
hood latch properly and that the stop screw con-
tacts the frame. A properly closed hood MUST
click twice on the hood latch. If the hood latch
does not close properly, loosen the capscrews on
the back of the center pin and adjust the center
pin up or down as required for correct alignment.
See Figure 7.
7

1. HOOD
2. HOOD LATCH
3. CENTER PIN
4. CAPSCREW
Figure 7. Hood Latch Adjustment
5. Push down until hood just touches rubber
bumper. Make sure latch striker is still in center
of hood latch. Open hood and tighten capscrews
for latch.
6. Check operation of hood latch. Have an operator
sit in the seat. Make sure hood is fully closed
(two clicks). Also check that hood touches rubber
bumper. If necessary, repeat Step 5.
CAUTION
When installing the seat to the hood, do not
use an impact wrench to install the capscrews.
Damage can be caused to the threads on the
screws and in the holes.
7. Place the seat on the hood and thread the seat
wire harness through the hole in the hood. See
Figure 2.
8. Align the holes in the seat with the holes in the
hood. Insert washers and capscrews. Tighten
capscrews to 18 N•m (159 lbf in).
9. If truck is equipped with a non-swivel seat, tie ca-
ble clips to seat wire harness and insert harness
into seat wire harness brackets under hood. If
truck is equipped with a swivel seat, secure seat
harness to bracket. See Figure 2.
10. Install seal plate using three capscrews. See Fig-
ure 6.
11. Install kick panel onto truck. See Figure 3 and
Figure 4.
12. Install dash to top of cowl. See Figure 5. Install
four clips to attach the dash to kick panel.
13. Install upper steering column cover to dash.
14. Using four capscrews, install the left and right
front side covers to frame. See Figure 3 and Fig-
ure 4.
15. Using two capscrews, install the left and right
fender covers to front of overhead guard legs.
16. Using two capscrews, install the left and right
rear side covers to frame. See Figure 3 and Fig-
ure 4.
17. Install the floor mat and floor plate.
18. If truck is equipped with an LPG tank, swing
LPG tank into position on back of counterweight.
See Figure 8.
19. Adjust the steering column and seat positions.
8

100 SRM 1120 LPG Tank and Bracket Replacement
LPG Tank and Bracket Replacement
REMOVE
LPG Tank
WARNING
LPG can cause an explosion. Do not cause
sparks or permit flammable material near the
LPG system. LPG fuel systems can be discon-
nected indoors only if the lift truck is at least
8 m (26 ft) from any open flame, motor vehicles,
electrical equipment, or ignition source.
Close the shutoff valve on the LPG tank before
any part of the engine fuel system is discon-
nected. Run the engine until the fuel in the sys-
tem is used and the engine stops.
If the engine will not run, close the shutoff
valve on the LPG tank. Loosen the fitting on
the supply hose from the LPG tank where it
enters the filter unit. Permit the pressure in
the fuel system to decrease slowly. Fuel leav-
ing the fitting removes heat. Use a cloth to
protect your hands from the cold fitting.
NOTE: The LPG tank bracket used on these trucks to
mount the LPG tank onto the counterweight come in
two styles. One style of bracket swings out to the side
of the truck and the other swings out to the side and
drops down (EZXchange™ bracket). See Figure 8.
1. Turn the shutoff valve clockwise until the valve
is completely closed.
2. Run the engine until it stops. If truck is equipped
with a key switch, turn the key switch to the
OFF position. If truck is equipped with a Power
ON/OFF button, press the Power ON/OFF but-
ton to turn engine off.
3. Disconnect the fitting on the LPG tank. See Fig-
ure 8.
4. Push in the bracket release pin, swing the tank
and bracket out to the side of the lift truck.
If your truck is equipped with a swing-out
and drop-down LPG tank bracket (EZXchange
bracket), swing the tank down to the side of the
truck for ease of removal. See Figure 8.
5. Unlatch the tank strap and remove the LPG tank
from the bracket.
9

LPG Tank and Bracket Replacement 100 SRM 1120
A. SWING-OUT LPG BRACKET B. SWING-OUT AND DROP-DOWN LPG BRACKET
(EZXCHANGE BRACKET)
1. LPG TANK
2. TANK STRAP
3. FITTING
4. HYDROSTATIC RELIEF VALVE
5. MANIFOLD BLOCK
6. ALIGNMENT PIN
7. STOP PIN
8. BRACKET HANDLE
9. BRACKET PIVOT
10. GAS SPRING (DROP-DOWN BRACKET ONLY)
11. BRACKET RELEASE PIN (BUTTON)
Figure 8. LPG Tank and Bracket
10

A. LPG REGULATOR USED ON GM 2.4L ENGINE
FUEL SYSTEMS
B. LPG REGULATOR USED ON MAZDA 2.0L AND
2.2L ENGINE FUEL SYSTEMS
1. FITTING
2. HOSE ASSEMBLY
3. CAPSCREW
4. LPG TANK
5. HOSE ASSEMBLY TO LPG
REGULATOR/LOCK-OFF
6. LPG REGULATOR CONNECTION
7. LPG REGULATOR
Figure 9. LPG Tank Hose Connections (Except 2007 Mazda Emission Compliant Engines)
11

LPG Tank and Bracket Replacement 100 SRM 1120
LPG Bracket
NOTE: The LPG tank must be removed from the lift
truck before removing the LPG bracket. See LPG
Tank.
1. For all engines except 2007 Mazda emission
compliant engines - Disconnect the hose from
the LPG fuel lock-off connection on the LPG reg-
ulator, and remove hose through hole in counter-
weight. See Figure 9.
2. 2007 Mazda emission compliant engines
only - Disconnect the hose from the LPG fuel
filter and remove hose through hole in counter-
weight. See Figure 10.
1. FITTING
2. HOSE ASSEMBLY
3. CAPSCREW
4. LPG TANK
5. HOSE ASSEMBLY TO LPG FUEL FILTER
6. LPG FUEL FILTER CONNECTION
7. HOSE ASSEMBLY TO LPG REGULATOR
8. LPG FUEL FILTER
9. LOW PRESSURE SWITCH
Figure 10. LPG Tank Hose Connections (2007
Mazda Emission Compliant Engines Only)
WARNING
When removing the capscrews for the LPG
tank bracket, only remove the capscrew (1, Fig-
ure 11) with the LPG bracket in the swing-out
or extended position. The LPG tank bracket
is heavy and difficult to handle if all the cap-
screws are removed with the bracket in the
swing-out position. Personal injury and dam-
age to the lift truck can result if the bracket is
removed and handled while in the swing-out
or extended position.
3. Push in the bracket release pin, grab the bracket
handle, and swing the bracket out to the side
of the lift truck. Remove the capscrew (1, Fig-
ure 11).
4. Pull the bracket stop pin and swing the LPG
tank bracket back into the resting position on the
counterweight. Be sure that the latch clicks shut
and locks.
5. Remove the rest of the capscrews, labeled (2, Fig-
ure 11), that attach the LPG bracket to the coun-
terweight.
6. Remove the LPG tank bracket from the lift truck.
INSTALL
LPG Bracket
compliant engines - Place the LPG bracket
onto the counterweight. Be sure to align the
holes on the counterweight with the holes on the
bracket (see Figure 11). Insert hose assembly
to LPG regulator/lock-off through the hole in
counterweight.
only - Place the LPG bracket onto the coun-
terweight. Be sure to align the holes on the
counterweight with the holes on the bracket (see
Figure 11). Insert hose assembly to LPG fuel
filter through the hole in counterweight.
3. Install and tighten three capscrews (2, Figure 11)
to 38 N•m (28 lbf ft) to secure the LPG bracket
onto the counterweight.
12

A. LPG BRACKET - SWING OUT OPTION
B. LPG BRACKET - SWING OUT AND DROP DOWN
OPTION (EZXCHANGE BRACKET)
1. CAPSCREW - REMOVE WITH BRACKET IN
SWING OUT (EXTENDED) POSITION
2. CAPSCREW - REMOVE WITH BRACKET IN
RESTING POSITION ON COUNTERWEIGHT.
Figure 11. LPG Tank Bracket Removal
4. Push the bracket release pin (button) and pull
the bracket handle to swing the bracket out to
the side of the lift truck. Install and tighten the
capscrew (1, Figure 11) to 38 N•m (28 lbf ft).
LPG Tank
NOTE: The LPG bracket must be in the swing-out po-
sition to install the LPG tank. If your lift truck has
the swing-out and drop-down bracket (EZXchange
bracket), position the bracket in the drop-down po-
sition.
WARNING
When closing the LPG tank strap, do not wrap
your fingers around the strap handle. The
strap can close quickly and with enough force
to cause injury to the fingers and hand.
1. Place the LPG tank into the bracket. Be sure
the alignment pin on the bracket (see Figure 8)
is properly aligned with the hole on the tank. Se-
cure the tank strap around the tank and close the
strap.
2. If lift truck is equipped with the swing-out and
drop-down bracket (EZXchange bracket) raise
bracket to the up position.
3. Pull the stop pin (see Figure 8) and swing the
LPG tank bracket into the resting position on the
counterweight. Be sure that the bracket locks
into position.
compliant engines - Connect the hose to the
LPG fuel lock-off connection on the LPG regula-
tor. See Figure 9.
only - Connect the hose to the LPG fuel filter.
See Figure 10.
6. Connect the fitting on the LPG tank. See Fig-
ure 8.
7. Turn the fuel valve counterclockwise to open the
fuel valve.
8. Inspect the fuel system for leaks when the fuel
valve is open. There are four methods used to
inspect the LPG fuel system for leaks:
a. Sound - Listen for sound of LPG escaping
from a tank fitting or hose connection.
b. Smell - LPG has a very distinctive odor. If
you smell LPG, DO NOT start the engine.
c. Soapy Water - This method is used in con-
junction with Step b above. If the odor of LPG
is present, but escaping fuel cannot be heard,
apply soapy water to the fittings and observe
for bubbles.
d. Frost - If the amount of LPG escaping is suf-
ficient, frost may appear on the fittings.
13

Counterweight Replacement 100 SRM 1120
Counterweight Replacement
REMOVE
WARNING
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 counter-
weight. When the lift truck is put on blocks,
(S40-70FT, S55FTS) (F187) and H2.0-3.5FT
(H40-70FT) (L177) and Periodic Maintenance
WARNING
Do not operate the lift truck if the capscrew for
the counterweight is not installed. When the
capscrew is removed, the counterweight can
fall from the lift truck.
WARNING
electrical equipment, or ignition source.
Close the shutoff valve on the LPG tank before
any part of the engine fuel system is discon-
nected. Run the engine until the fuel in the sys-
tem is used and the engine stops.
If the engine will not run, close the shutoff
valve on the LPG tank. Loosen the fitting on
the supply hose from the LPG tank where it
enters the filter unit. Permit the pressure in
the fuel system to decrease slowly. Fuel leav-
ing the fitting removes heat. Use a cloth to
protect your hands from the cold fitting.
NOTE: The counterweight is held in position on the
frame by two hooks that are part of the frame. One
M24 × 3 x 140 capscrew holds the counterweight
to the lower part of the frame on lift truck mod-
els S3.0-3.5FT (S60-70FT) (F187) and H2.5-3.5FT
(H50-70FT) (L177). One M24 × 3 x 90 capscrew
holds the counterweight to the lower part of the
frame on lift truck models S2.0-2.5FT (S40-50FT,
S55FTS) (F187), H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001), S30FT, S35FT, S40FTS
(E010), and H2.0FT (H40FT) (L177). See Figure 12.
NOTE: If lift truck is equipped with an overhead ex-
haust system, remove the overhead exhaust pipe be-
fore removing the counterweight. See the section Ex-
haust System Repair for the procedures.
1. If the lift truck has an LPG fuel system, use
the procedures in the section LPG Tank and
Bracket Replacement, to remove the LPG tank
and bracket so that the counterweight can be
removed.
Additional information on the LPG fuel system
can be found in the following sections:
• LPG Fuel System, GM 2.4L Engine 900
SRM 1124
• LPG Fuel System, Mazda 2.0L and 2.2L
Engines 900 SRM 1125
• LPG Fuel System, Mazda 2.0L and 2.2L
2007 Emission Compliant Engines 900
SRM 1326
WARNING
The counterweight is heavy. Make sure that
the eyebolt and lifting devices have enough
capacity to lift the weight. The approximate
weights of the counterweight castings are
shown in Table 1, Table 2, Table 3, and Table 4.
2. Install a lifting eye in the lift hole of the coun-
terweight. See Figure 12 and Figure 13. Con-
nect a crane to the lifting eye and raise the crane
until it holds part of the weight of the counter-
weight. Remove the tow pin and remove the cap-
screw that holds the counterweight to the frame.
See Figure 12. Use the crane to lift the counter-
weight from the lift truck. Put counterweight on
14

100 SRM 1120 Counterweight Replacement
the floor so that it has stability and will not fall
over. Take care not to damage exhaust or cooling
components.
INSTALL
1. Make sure the seals are on the counterweight.
See Figure 13. Use a crane to install the counter-
weight on the lift truck. When the counterweight
is installed, make sure the hooks on the frame
fully engage the counterweight so it is aligned
with the parts of the frame. Install and tighten
the M24 × 3 capscrew to 555 N•m (409 lbf ft).
2. Install tow pin and roll pin, see Tow Pin, Remove
and Install for procedures.
3. If the lift truck has an LPG fuel system, use
the procedures in the section LPG Tank and
Bracket Replacement, to install the LPG tank
and bracket after the counterweight has been
installed. See Figure 8.
1. FRAME HOOK
2. LOWER FRAME
MOUNT
3. TOW PIN
4. ROLL PIN
5. CAPSCREW
6. WASHERS
7. LIFT HOLE
Figure 12. Counterweight Installation
Table 1. Weight of Counterweights, Lift Truck
Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Model kg lb
S2.0FT (S40FT) 1040 2293
S2.5FT (S50FT) 1395 3075
S55FTS 1643 3622
S3.0FT (S60FT) 1819 4010
S3.5FT (S70FT) 2153 4747
Models S30FT, S35FT, S40FTS (E010)
Model kg lb
(S30FT) 772 1702
(S35FT) 963 2123
S40FTS 1131 2493
Table 3. Weight of Counterweights, Lift
Truck Models H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) (F001)
Model kg lb
H1.6FT (H30FT) 812 1790
H1.8FT (H35FT) 887 1955
H2.0FTS (H40FTS) 1047 2308
Models H2.0-3.5FT (H40-70FT) (L177)
Model kg lb
H2.0FT (H40FT) 996 2196
H2.5FT (H50FT) 1340 2954
H3.0FTS (H60FTS) 1666 3673
H3.5FTS (H70FTS) 1967 4336
15

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Overhead Guard Replacement 100 SRM 1120
1. CAPSCREW
2. LOCKWASHER
3. WASHER
4. COUNTERWEIGHT
5. LIFTING EYEBOLT
6. TOW PIN
7. ROLL PIN
8. SEAL
9. LIFT HOLE
10. LPG ACCESS
HOLE
Figure 13. Counterweight
4. If lift truck is equipped with an overhead exhaust
system, install the overhead exhaust pipe. See
the section Exhaust System Repair for the pro-
cedures.
TOW PIN, REMOVE AND INSTALL
1. Remove the tow pin from the counterweight by
driving the roll pin out. See Figure 14.
2. Install tow pin into counterweight and install roll
pin.
1. TOW PIN 2. ROLL PIN
Figure 14. Tow Pin
Overhead Guard Replacement
REMOVE AND INSTALL
WARNING
Do not operate the lift truck without the over-
head guard correctly fastened to the lift truck.
WARNING
DO NOT weld mounts for lights or accessories
to legs of the overhead guard. Changes that are
made by welding, or by drilling holes that are
too big or in the wrong location, can reduce the
strength of the overhead guard.
See your dealer for Hyster lift trucks BEFORE
performing any changes to the overhead
guard.
NOTE: The lift trucks covered in this SRM are
equipped with either a high or low overhead guard.
The removal and installation procedures for both
types of overhead guards are the same.
No welding or drilling on legs of overhead guard is
permitted as per previous WARNING.
NOTE: The lifting device can be connected to any
number of positions on the overhead guard depend-
ing upon the lifting device available. The ideal
choices are a four point sling connected to all four
corners on the top of the overhead guard, or a two
point sling connected to two opposite corners of the
overhead guard. If a single point hoist is used, make
sure that the lift point is as close to the center of the
overhead guard. If during the initial start of the lift
16

100 SRM 1120 Overhead Guard Replacement
the overhead guard is off balance lower immediately
and move the hoist to a more centered point.
1. Connect a lifting device to remove or install the
overhead guard. Loosen clamp and disconnect
the air intake hose from the elbow. Remove bolts,
elbow, retainer, and grommet from the overhead
guard rear leg. See Figure 15.
1. CLAMP
2. AIR INTAKE HOSE
3. BOLTS
4. ELBOW
5. RETAINER
6. GROMMET
Figure 15. Disconnect Air Intake Hose
2. Disconnect any wires between the frame and the
overhead guard. When the overhead guard is
lifted from the frame, make sure that any elec-
trical wires are moved through the holes in the
frame so that they are not damaged.
3. The rear legs of the overhead guard have two cap-
screws that are located under the hood inside the
engine compartment, next to the radiator. Re-
move and install the capscrews. See Figure 16.
4. Remove the fender cover, dash, and kick panel
to remove and install the three capscrews on the
front legs of the overhead guard. See Hood, Seat,
and Side Covers Replacement for the removal
procedures.
5. When installing the overhead guard, tighten the
capscrews for the overhead guard legs to 66 N•m
(49 lbf ft). See Figure 16.
1. CAPSCREWS - FRONT LEGS
2. HANDLE
3. CAPSCREWS - REAR LEGS
4. FRAME
Figure 16. Overhead Guard
LED TAIL, BACKUP, AND BRAKE LIGHTS,
REPLACE
These light assemblies are nonrepairable and must
be replaced as an assembly. See the section Elec-
trical System 2200 SRM 1142 for the procedures to
replace these lights.
17

Operator Restraint System Replacement 100 SRM 1120
Operator Restraint System Replacement
DESCRIPTION
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 good condition. See Figure 17.
Automatic Locking Retractor (ALR)
NOTE: S2.0-3.5FT (S40-70FT, S55FTS) lift trucks
produced before November 2005 are equipped with
the ALR type seat belts.
The seat belt must fasten securely. Make sure the
seat belt extends and retracts smoothly and is not
frayed or torn. If the seat belt is damaged or does not
operate properly, it must be replaced. See Figure 17.
Emergency Locking Retractor (ELR)
NOTE: Lift trucks produced after November 2005
are equipped with the Emergency Locking Retractor
(ELR) style seat belt.
When the ELR style seat belt is properly buckled
across the operator, the belt will permit slight op-
erator repositioning without activating the locking
mechanism. If the truck tips, travels off a dock, or
comes to a sudden stop, the locking mechanism will
be activated and hold the operator’s lower torso in
the seat.
A seat belt that is damaged worn or does not operate
properly will not give protection when it is needed.
The end of the belt must fasten correctly in the latch.
The seat belt must be in good condition. Replace the
seat belt if damage or wear is seen. See Figure 17.
The following seat belt operation checks must be per-
formed:
• With the hood closed and in the locked position,
pull the seat belt slowly from the retractor assem-
bly. Make sure the seat belt pulls out and retracts
smoothly. if the seat belt cannot be pulled from the
retractor assembly or the belt will not retract, re-
place the seat belt assembly.
• With the hood closed and in the locked position,
pull the seat belt with a sudden jerk. Make sure the
seat belt will not pull from the retractor assembly.
If the seat belt can be pulled from the retractor,
when it is pulled with a sudden jerk, replace the
seat belt assembly.
• With the hood in the open position, make sure the
seat belt will not pull from the retractor assembly.
If the seat belt can be pulled from the retractor,
with the hood in the open position, replace the seat
belt assembly.
Make sure the seat rails and latch striker are not
loose. The seat rails must lock securely in position
but move freely when unlocked. The seat rails must
be securely attached to the mounting surface. The
hood must be fully closed. Lift the hood to make sure
it is closed and will not move.
Adjust hood, hood latch, and latch striker when any
of the parts of the operator restraint system are in-
stalled or replaced. See the section Hood, Seat, and
Side Covers Replacement in this manual for the ad-
justment procedures for the hood.
18

100 SRM 1120 Engine Replacement
A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR
1. LATCH STRIKER
2. HOOD LATCH
3. FORWARD/BACKWARD ADJUSTMENT
4. HOOD
5. OPERATOR WEIGHT ADJUSTMENT
6. SEAT RAIL
7. ARM REST
8. SEAT BELT
9. SEAT
10. HIP RESTRAINT
11. HOOD HINGE
Figure 17. Operator Restraint System
Engine Replacement
REMOVE ENGINE ONLY
WARNING
types of maintenance and repairs. The re-
moval of the following assemblies will cause
large changes in the center of gravity: mast,
drive axle, engine and transmission, and coun-
terweight. When the lift truck is put on blocks,
(S40-70FT, S55FTS) (F187) and H2.0-3.5FT
(H40-70FT) (L177) and Periodic Maintenance
The engine can be removed with or without the trans-
mission. Follow the procedures below to remove the
engine without the transmission.
19

Engine Replacement 100 SRM 1120
WARNING
Always disconnect the cables at the battery be-
fore you make repairs to the engine. Discon-
nect the cable at the negative terminal first.
WARNING
electrical equipments, or ignition source.
1. For lift trucks equipped with an LPG fuel system,
close the shut-off valve on the tank and run en-
gine until all fuel is gone and engine stops.
2. If lift truck is equipped with an LPG fuel tank,
swing tank to the side. See the section LPG Tank
and Bracket Replacement, for the procedures.
3. Remove the floor mat and floor plate.
WARNING
DO NOT remove the radiator cap from the radi-
ator when the engine is hot. When the radiator
cap is removed, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.
4. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the capac-
ity of the cooling system under radiator. Remove
radiator cap.
NOTE: Disposal of lubricants and fluids must meet
local environmental regulations.
5. Open the drain plug or disconnect the bottom ra-
diator hose to drain coolant from radiator and en-
gine.
6. Remove the hood and seat combination and rear
side covers. See the section Hood, Seat, and Side
Covers Replacement for procedures.
NOTE: Trucks equipped with a Yanmar diesel engine
do not have an ECM.
7. On lift trucks with the GM 2.4L engine, discon-
nect the ECM from air filter and remove two bolts
holding ECM and mounting bracket to air filter,
before removing the air filter.
8. Disconnect the ground strap from the frame and
remove the power distribution module (PDM)
from the battery tray. See Figure 18.
9. Remove three capscrews from the battery tray
and remove the battery and battery tray.
1. BATTERY
2. BATTERY TRAY
3. PDM
4. BATTERY
LOCKDOWN BAR
5. GROUND STRAP
Figure 18. Power Distribution Module,
Disconnection
10. Disconnect the remaining coolant hoses from the
radiator and cap them to prevent leakage.
11. On lift trucks equipped with a Mazda engine
(except Mazda 2007 emission compliant engines)
and Basic Powershift Transmission, disconnect
the throttle linkage (see the section Powershift
Transmission, Repair 1300 SRM 1129). Dis-
connect the exhaust system.
12. Remove the radiator fan pulley, shroud, and fan
assembly. See the section Cooling System 700
SRM 1123 for the removal procedures.
20

100 SRM 1120 Engine Replacement
WARNING
All fuels are very flammable and can burn or
cause an explosion. Do not use an open flame
to check the fuel level or to check for leaks in
the fuel system.
No smoking.
Breathing fuel vapor may cause nausea, uncon-
sciousness or death. Long term exposure to
gasoline vapors may cause liver or kidney dam-
age and cancer. Avoid breathing vapor.
13. Disconnect the fuel lines at the engine. Put caps
on fuel lines to prevent fuel leakage.
NOTE: Lift trucks equipped with Yanmar diesel en-
gine do not have an ECM.
NOTE: Lift trucks equipped with 2007 Mazda emis-
sion compliant engines do not have a governor con-
troller and the ECM for these engines is mounted on
the side of the engine.
14. For all Mazda engines except 2007 Mazda
emission compliant engines - Disconnect the
electronic control module (ECM) connector and
governor controller from the side of the frame be-
fore removing the engine from the truck.
only - Disconnect the engine harness connectors
from the right hand chassis harness connectors
before removing the engine from the truck.
16. Use the access port on the side of engine and re-
move the four bolts that attach the flywheel to
the torque converter. See Figure 19.
17. Connect a lifting device to the engine. Put a block
under the transmission housing to support the
transmission.
18. Remove capscrews from transmission bell hous-
ing.
WARNING
The engine is heavy. Make sure that any lifting
device has enough capacity to lift the engine.
The engine can weigh approximately 363 kg
(800 lb).
19. Remove the flange nuts, washers, bolts, and
isolators from the engine mounts. Remove
engine adapter to transmission bolts. On trucks
equipped with a GM 2.4L engine, remove one
starter bolt.
NOTE: ACCESS PORT IN SIMILAR POSITION ON
MAZDA.
1. ACCESS PORT
2. ENGINE MOUNTING BRACKET AND
HARDWARE
Figure 19. Yanmar Diesel Engine Removal
Access Port
CAUTION
When separating the engine away from the
transmission, place a piece of plywood in front
of radiator. This will keep the engine from
damaging the radiator.
CAUTION
Keep the engine level when the engine is sepa-
rated from the transmission so the drive plate
is not damaged.
20. Use the lifting device to carefully move the en-
gine away from the torque converter. Make sure
all hoses, wires, and cables are disconnected from
the engine, then lift the engine from the frame
and place engine on blocks. See Figure 20 and
Figure 21.
21

Engine Replacement 100 SRM 1120
A. MAZDA ENGINE B. GM 2.4L ENGINE
1. FRAME
2. ENGINE MOUNT
3. NUT
Figure 20. Engine Removal
A. MAZDA AND YANMAR ENGINE MOUNT
B. GM ENGINE MOUNT
1. LEFT ENGINE MOUNT
2. RIGHT ENGINE MOUNT
3. WASHER
4. CAPSCREW
5. CROSSMEMBER
6. ISOLATOR
7. NUT
Figure 21. Engine Mounts
22

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