service repair manual

1. SERVICE REPAIR
H6.0FT H7.0FT Europe [J006]

2. 100 SRM 1321 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 Man-
ual or the section Periodic Maintenance 8000
SRM 1322.
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, exhaust system, and LPG fuel
tank and bracket are found in this section. Checks
for the operator restraint system and procedures for
the repair of tanks and installation of safety labels
are also included.
1. FENDERS
2. COWL PLATE
3. HYDRAULIC TANK
4. COUNTERWEIGHT MOUNTS
5. FUEL TANK (GAS/DIESEL)
6. FRAME
Figure 1. Frame
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3. Side Covers, Seat, Dash, and Hood Replacement 100 SRM 1321
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. The
muffler is fastened to the frame inside the counter-
weight.
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.
Side Covers, Seat, Dash, and Hood Replacement
SIDE COVERS
Remove
1. Remove front and rear floor plates.
2. Remove two screws holding the right side rear
cover to the rear overhead guard leg. See Fig-
ure 2.
3. Remove two screws holding the right side front
cover to frame. Remove right side rear cover.
4. Remove two screws holding the right side front
cover to the front overhead guard leg. Remove
right side front cover.
5. Repeat Step 2 through Step 4 to remove left side.
Install
1. Install right side front cover to front overhead
guard leg and install and tighten two screws to
the front overhead guard leg.
2. Install right side rear cover to right side front
cover and install and tighten two screws to
frame.
3. Align right side rear cover to rear overhead guard
leg and install and tighten two screws to rear
overhead guard leg.
4. Install front and rear floor mat.
5. Repeat Step 1 through Step 3 to install left side.
NOTE: RIGHT SIDE VIEW
1. RIGHT SIDE REAR COVER
2. RIGHT SIDE FRONT COVER
3. SCREWS
4. REAR FLOOR PLATE
5. FRONT FLOOR PLATE
6. CLIP NUTS
Figure 2. Side Cover Removal
SEAT AND SEAT PLATE
Remove Seat
1. Remove seat plate cover. See Figure 3.
2. Disconnect seat harness from cowl harness. See
Figure 4.
3. Remove four flange nuts holding the seat to seat
plate. Remove seat from seat plate.
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4. 100 SRM 1321 Side Covers, Seat, Dash, and Hood Replacement
Figure 3. Seat Plate Mounting
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5. Side Covers, Seat, Dash, and Hood Replacement 100 SRM 1321
Legend for Figure 3
A. REAR VIEW B. FRONT VIEW
1. CAPSCREW
2. FLANGE NUT
3. SEAT COVER
4. GRAB HANDLE
5. INSERT
6. MODULE
7. SEAT PLATE
Legend for Figure 4
A. FRONT VIEW B. REAR VIEW
1. FLANGE NUTS
2. SEAT PLATE
3. SEAT HARNESS TO COWL HARNESS
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6. 100 SRM 1321 Side Covers, Seat, Dash, and Hood Replacement
Figure 4. Seat Assembly Removal
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7. Side Covers, Seat, Dash, and Hood Replacement 100 SRM 1321
Remove Seat Plate
1. Remove side covers, see Side Cover Remove pro-
cedures.
2. Remove capscrews and inserts securing seat
plate to module. Discard inserts.
3. Remove four capscrews and flange nuts securing
seat plate to module. Remove seat plate from
module. See Figure 3.
Install Seat Plate
1. Install new inserts and install capscrews to se-
cure seat plate to module.
2. Install seat plate onto module and install four
capscrews and flange nuts to secure seat plate to
module. See Figure 3.
3. Install side covers, see side cover Install proce-
dures.
Install Seat
1. Install seat to seat plate and install four flange
nuts to secure seat to seat plate. See Figure 5 for
seat installation position.
2. Connect cowl harness to seat harness. See Fig-
ure 4.
OPERATOR RESTRAINT SYSTEM
The seat belt, hip restraint, seat, and seat plate are
all part of the operator restraint system. Each item
must be checked to make sure it is fastened correctly,
functions correctly, and is in good condition.
Emergency Locking Retractor (ELR)
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 op-
erate properly will not provide 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.
1. FULL SUSPENSION AND SWIVEL SEAT
2. NON-SUSPENSION SEAT
3. SWIVEL SEAT MOUNTING
Figure 5. Seat Installation Position
The following seat belt operation checks must be per-
formed:
• 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.
• Pull the seat belt with a sudden jerk. Make sure
the seat belt will not pull from the retractor assem-
bly. If the seat belt can be pulled from the retrac-
tor, when it is pulled with a sudden jerk, replace
the seat belt assembly.
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8. 100 SRM 1321 Side Covers, Seat, Dash, and Hood Replacement
Seat Plate and Seat Rail Check
Make sure the seat rails are not loose. The seat rails
must lock tightly in position, but move freely when
unlocked. The seat rails must be correctly fastened
to the seat plate and the seat plate must be fastened
to the frame.
STEERING COLUMN, DASH, KICK PANEL,
AND SEAL PLATE
Remove
1. Fully lower the steering column.
2. 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 6.
3. Remove the five Allen screws securing the dash
to the top of the cowl. Remove the dash from
clips, located underneath dash, that attach the
dash to the kick panel. Lift to remove the dash.
4. Lift the kick panel from seal plate and remove
from lift truck. See Figure 7.
NOTE: TOP VIEW OF DASH SHOWN.
A. INDICATES TO PULL UP TO UNLATCH
1. ALLEN SCREWS
2. COWL
3. UPPER STEERING COLUMN COVER
4. LOWER STEERING COLUMN COVER
Figure 6. Remove Dash From Cowl
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10. Side Covers, Seat, Dash, and Hood Replacement 100 SRM 1321
Figure 7. Side Covers, Floor Plate, and Cowl Components
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11. 100 SRM 1321 Side Covers, Seat, Dash, and Hood Replacement
Legend for Figure 7
1. SEAT PLATE COVER
2. COVER
3. CAPSCREW
4. LOWER STEERING COLUMN COVER
5. UPPER STEERING COLUMN COVER
6. SEAT SUPPORT
7. FRONT FLOOR PLATE
8. REAR FLOOR PLATE
9. FLOOR PLATE
10. STRIKER BOLT
11. FLOOR PLATE LATCH
12. NUT
13. COWL
14. FLOOR MAT (FRONT)
15. FLOOR MAT (REAR)
16. UPPER TREAD PLATE (LH)
17. UPPER TREAD PLATE (RH)
18. LOWER TREAD PLATE (LH)
19. LOWER TREAD PLATE (RH)
20. LEFT SIDE FRONT COVER
21. RIGHT SIDE FRONT COVER
5. Remove front floor mat and floor plate. See Fig-
ure 7.
6. Remove side covers to access the three flange
bolts securing seal plate to frame. See Side Cover
Remove procedures.
7. Remove the three capscrews securing the seal
plate to lift truck frame. Remove seal plate. See
Figure 8.
Install
1. Install seal plate and install three flange bolts
securing seal plate to lift truck frame. See Fig-
ure 8.
2. Install kick panel onto seal plate.
3. Install the dash into clips, located underneath
dash, that attach the dash to the kick panel. In-
stall the five allen screws securing the dash to
the top of the cowl. See Figure 8.
4. Install upper steering column cover by aligning
the two latches and push down until latched. See
Figure 6.
5. Install side covers. See Side Cover Install proce-
dures.
6. Install front floor plate and floor mat. See Fig-
ure 7.
7. Tilt steering column to the UP position.
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12. Side Covers, Seat, Dash, and Hood Replacement 100 SRM 1321
1. ALLEN SCREWS
2. INSERTS
3. CLIPS
4. FLANGE BOLTS
5. COWL
6. SEAL PLATE
7. SEAL
Figure 8. Dash, Kick Panel, and Seal Plate Removal
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13. 100 SRM 1321 Side Covers, Seat, Dash, and Hood Replacement
HOOD SUPPORT AND DOOR ASSEMBLY
Remove
NOTE: If pre-cleaner is dirty or damaged, perform
Step 2.
1. Remove front and rear floor mats and floor
plates. Disconnect battery. See Figure 7.
2. Remove strap clamp and pre-cleaner. See Fig-
ure 10.
3. For lift trucks equipped with GM 4.3L engine,
open right or left side door and disconnect the
air inlet hose from hood support assembly. See
Figure 9.
Figure 9. Hood Support and Component Removal Location
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14. Side Covers, Seat, Dash, and Hood Replacement 100 SRM 1321
Legend for Figure 9
NOTE: RIGHT SIDE HOOD DOOR REMOVED FOR CLARITY.
1. REAR HARNESS CONNECTOR (TO RIGHT
HAND CHASSIS HARNESS CONNECTION)
2. HINGE BRACKET
3. PIN
4. COTTER PIN
5. GAS SPRING
6. MAGNET
7. HOOD SHUT OFF SWITCH
8. IGNITION SWITCH
9. CROSSMEMBER (NON-CAB)
10. HOOD SUPPORT ASSEMBLY
11. FLANGE CAPSCREW
12. FLANGE NUT
13. CAPSCREW
14. REAR HARNESS CONNECTOR (TO LOW
COOLANT LEVEL SENSOR)
15. REAR HARNESS CONNECTOR (TO BACK UP
ALARM)
16. CONDUIT CLIPS
17. IGNITION SWITCH HARNESS
18. HOOD SUPPORT BRACKET
19. LEFT SIDE HOOD DOOR ASSEMBLY
4. For lift trucks equipped with Cummins 4.5L
diesel engine, open right or left side door and
disconnect the air inlet hose from silencer and
hood support assembly.
5. Disconnect right hand chassis harness from rear
harness. See Figure 9.
6. Disconnect ignition switch harness from rear
harness. Remove ignition switch from hood
support bracket.
7. Remove rear harness conduit clips from hood
support assembly.
8. Remove hood shut off switch and magnet from
hinge bracket.
NOTE: Before lifting the hood assembly from the lift
truck frame. Make sure to use a lifting device and
lifting straps as shown in Figure 10. The hood as-
sembly weighs approximately 45.6 kg (101 lb).
9. Remove four capscrews, washers, isolators, and
flange nuts (see Figure 11) from hood support as-
sembly (see Figure 9), and lift the hood support
and door assemblies from lift truck frame. See
Figure 10.
Install
NOTE: Before lifting the hood assembly into lift truck
frame. Make sure to use a lifting device and lifting
straps as shown in Figure 10. The hood assembly
weighs approximately 45.6 kg (101 lb).
1. Using a lifting device as shown in Figure 10 and
lift hood support and hood door assemblies into
lift truck frame.
2. If pre-cleaner was removed, install pre-cleaner
and strap clamp to hood support assembly. See
Figure 10.
3. Install four isolators, washers, capscrews, and
flange nuts. Tighten flange nuts to 19 N•m
(168 lbf in). See Figure 11.
4. Install hood shut off switch and magnet onto
hinge bracket. See Figure 9.
1. PRE-CLEANER
2. STRAP CLAMP
Figure 10. Lifting Strap Rigging
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15. 100 SRM 1321 Side Covers, Seat, Dash, and Hood Replacement
5. Install ignition switch onto hood support bracket.
Connect ignition switch harness to rear harness.
6. Connect right hand chassis harness to rear har-
ness connector.
7. Install rear harness conduit clips to hood support
assembly.
A. LEFT SIDE FRONT VIEW
B. LEFT SIDE REAR VIEW
1. CAPSCREW
2. WASHER
3. ISOLATOR
4. FLANGE NUT
Figure 11. Hood Support and Door Assembly
Removal location
8. For lift trucks equipped with GM 4.3L engine,
connect the air inlet hose to hood support assem-
bly. Close right and left side door assembly.
9. For lift trucks equipped with Cummins 4.5L en-
gine, connect the air inlet hose to silencer and
hood support assembly. Close right and left side
hood door assembly.
10. Connect battery and install front and rear floor
plates and floor mats. Figure 7.
HOOD DOOR ASSEMBLY
Remove
NOTE: Removing the right and left side hood door
assemblies, requires two people.
1. Remove front and rear floor mats and floor plates
and disconnect battery.
2. Open right side hood door assembly and discon-
nect right hand chassis harness from rear har-
ness. See Figure 9.
3. Located under right side hood door assembly, re-
move hood shut off switch and magnet from hinge
bracket.
4. Remove lock nut and gas spring from right and
left side door assemblies. See Figure 12 and re-
move right and left side hood door assembly from
lift truck frame.
1. GAS SPRING
2. LOCK NUT
Figure 12. Gas Spring Mounting Location
5. Remove cotter pin and pin from hinge bracket
and remove right hand door assembly from lift
truck frame. See Figure 9.
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16. LPG Tank and Bracket Assembly 100 SRM 1321
Install
NOTE: Installing the right and left side hood door
assemblies, requires two people.
1. Install hood door assembly onto lift truck frame
and install pin and cotter pin onto hinge bracket.
2. Install gas spring and lock nut onto door assem-
bly. See Figure 12.
3. Install hood shut off switch and magnet onto
hinge bracket located under right hand door
assembly.
4. Connect rear harness connector to right hand
chassis harness connector. See Figure 9.
5. Connect battery and Install front and rear floor
plates and floor mats.
LPG Tank and Bracket Assembly
REMOVE
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 single or dual LPG tank(s) and bracket(s)
are mounted on the right side step weldment of lift
truck frame. Procedures are for the single LPG tank
and bracket. Dual tank and bracket procedures are
similar.
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 quick-disconnect fitting on the
LPG tank. See Figure 13.
4. Unlatch the two latches and open front cover. Re-
move LPG tank from tank bracket.
DISASSEMBLE
1. Remove flange nut, washer, and capscrew hold-
ing tank bracket to step weldment. Remove tank
bracket from step weldment. See Figure 13.
2. Remove front cover from hook pins.
3. Remove pins from the two latches and remove
latches from front cover.
4. Remove nut and washer from back side of tank
bracket and remove the two hook pins.
ASSEMBLE
1. Install two hook pins into tank bracket and in-
stall washer and tighten nut. See Figure 13.
2. Install the two latches and pins into front cover.
3. Install front cover onto the two hook pins. Close
and latch front cover.
4. Place tank bracket on step weldment and install
four capscrews, washers, and flange nuts.
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