service repair manual

1. SERVICE REPAIR
H4.5FT6 H5.0FT H5.5FT Europe [N005]

2. 100 SRM 1243 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 1248.
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.
Figure 1. Frame
1

3. Hood, Seat, and Side Covers Replacement 100 SRM 1243
Legend for Figure 1
1. COWL PLATE
2. FENDERS
3. HOOD MOUNTS
4. COUNTERWEIGHT MOUNTS
5. HYDRAULIC TANK
6. FUEL TANK (GAS OR DIESEL)
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 2. 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.
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.
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.
7. Remove the two capscrews holding the left and
right fender covers to the front overhead guard
leg. Remove covers. See Figure 3.
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 4.
11. Remove the five fasteners (see Figure 4) 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.
13. Remove the three capscrews holding the seal
plate. Remove seal plate. See Figure 5.
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).
2

4. 100 SRM 1243 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
6. CABLE CLIPS
7. HINGE SCREWS
8. GAS SPRING
9. ATTACHMENT HOLES ATTACHING HOOD TO
SEAT (SEMI-SUSPENSION)
10. SEAT WIRE HARNESS BRACKETS
11. SEAT LINER
12. HOOD LATCH
13. ATTACHMENT HOLES ATTACHING HOOD TO
SEAT (NON-SUSPENSION)
14. ATTACHMENT HOLES ATTACHING HOOD TO
SEAT (FULL SUSPENSION)
15. SPACER
Figure 2. Hood and Seat Arrangement
3

5. Hood, Seat, and Side Covers Replacement 100 SRM 1243
1. UPPER STEERING COLUMN
COVER
2. LOWER STEERING COLUMN
COVER
3. CAPSCREW
4. DASH ASSEMBLY
5. INSERT
6. SCREW
7. CLIP
8. SEAL
9. GROMMET
10. KICK PANEL
11. LEFT REAR SIDE COVER
12. SEAL PLATE ASSEMBLY
13. FLOOR MAT
14. FLOOR PLATE
15. CLIP NUT
16. FOLDOVER NUT
17. LEFT FENDER COVER
18. LEFT FRONT SIDE COVER
19. LEFT PANEL
20. LEFT STEP PLATE
21. LOCK NUT
22. RIGHT FRONT SIDE COVER
23. RIGHT FENDER COVER
24. RIGHT STEP PLATE
25. RIGHT PANEL
26. RIGHT REAR SIDE COVER
27. SPLASH SHIELD
28. RADIATOR COVER S4.0,
4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004)
29. RADIATOR COVER
(H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005)
Figure 3. Side Covers, Floor Plate, and Cowl Components
4

6. 100 SRM 1243 Hood, Seat, and Side Covers Replacement
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 4. Remove Dash From Cowl
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.
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 holes in the gas springs with holes in
the hood. There are two sets of holes used to in-
stall the gas springs to the hood, based on the
type of seat the installed on the lift truck. One
set is for installing the cylinder end of the gas
springs and the other set is for attaching the rod
end of the gas springs. Install capscrews and
washers to attach gas springs to the hood. Re-
fer to Figure 6 and Table 1 for correct holes used
to connect the rod end of the cylinder, depend-
ing on the type of seat installed on the lift truck.
Tighten capscrews to 19.2 N•m (170 lbf in).
5

7. Hood, Seat, and Side Covers Replacement 100 SRM 1243
1. CAPSCREWS 2. SEAL PLATE
Figure 5. Remove Seal Plate From Dash
Legend for Figure 6
NOTE: SEE TABLE 1 FOR HOLES TO USE TO ATTACH ROD END OF GAS SPRING.
A. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004)
B. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
C. LEFT SIDE
D. RIGHT SIDE
1. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT
2. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT
6

8. 100 SRM 1243 Hood, Seat, and Side Covers Replacement
Figure 6. Gas Spring Installation
7

9. Hood, Seat, and Side Covers Replacement 100 SRM 1243
Table 1. Gas Spring Installation, Holes for Installing Rod Ends (See Figure 6)
Full or Semi Suspension Seat Non-Suspension SeatCounterweight Type
Left Side Right Side Left Side Right Side
Standard Counterweight
S4.0, 4.5, 5.5FT, (S80, 100,
120FT) (G004)
3 3 1 1
Standard Counterweight
H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT)
(N005, P005)
2 2 1 1
BCS and PRS
Counterweights
S5.5FTS
(S80, 100FTBCS; S120FTS;
S120FTPRS) (G004)
2 4 2 4
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.
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 5.
11. Install kick panel onto truck. See Figure 3.
12. Install dash to top of cowl. See Figure 4. 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.
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.
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

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11. 100 SRM 1243 LPG Tank and Bracket Replacement
Figure 7. Hood Latch Adjustment
Legend for Figure 7
1. HOOD
2. HOOD LATCH
3. CENTER PIN
4. CAPSCREW
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
9

12. LPG Tank and Bracket Replacement 100 SRM 1243
OFF position. If truck is equipped with a Power
ON/OFF button, press the Power ON/OFF but-
ton to turn power 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.
Figure 8. LPG Tank and Bracket
10

13. 100 SRM 1243 LPG Tank and Bracket Replacement
Legend for Figure 8
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)
LPG Bracket
NOTE: The LPG tank must be removed from the lift
truck before removing the LPG bracket. See LPG
Tank.
1. Disconnect the hose from the LPG fuel lock-off
connection on the LPG regulator, and remove
hose through hole in counterweight. See Fig-
ure 9.
NOTE: EZXCHANGE™ BRACKET SHOWN.
A. SIDE VIEW OF COUNTERWEIGHT AND LPG
FUEL SYSTEM
B. FRONT VIEW OF COUNTERWEIGHT AND LPG
FUEL SYSTEM
1. QUICK-DISCONNECT CONNECTION
2. HOSE ASSEMBLY
3. CAPSCREW
4. HOSE ASSEMBLY TO LPG
REGULATOR/LOCK-OFF (THROUGH
HOLE IN COUNTERWEIGHT)
5. MOUNTING BRACKET
6. LPG REGULATOR CONNECTION
7. LPG FUEL FILTER
8. LPG REGULATOR FILTER HOSE
9. LPG REGULATOR
10. HOSE TO INTAKE MANIFOLD
11. COOLANT HOSES
12. HOSE TO FUEL RAIL
13. TANK STRAP
14. LPG TANK BRACKET
Figure 9. LPG Tank Hose Connections, GM 4.3L Engine
11

14. LPG Tank and Bracket Replacement 100 SRM 1243
2. Remove capscrew (1, Figure 10) first, then re-
move rest of capscrews (2, Figure 10) that attach
the LPG bracket to counterweight.
3. Remove the LPG tank bracket from the lift truck.
INSTALL
LPG Bracket
1. Place the LPG bracket onto the counterweight.
Be sure to align the holes on the counterweight
with the holes on the bracket (see Figure 10).
Insert hose assembly to LPG regulator/lock-off
through the hole in counterweight.
2. Install and tighten three capscrews (2, Figure 10)
to 38 N•m (28 lbf ft) to secure the LPG bracket
onto the counterweight.
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 10. LPG Tank Bracket Removal
3. Install and tighten capscrew (1, Figure 10) 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.
4. Connect the hose to the LPG fuel lock-off connec-
tion on the LPG regulator. See Figure 9.
5. Connect the fitting on the LPG tank. See Fig-
ure 8.
6. Turn the fuel valve counterclockwise to open the
fuel valve.
7. 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.
12

15. 100 SRM 1243 Counterweight Replacement
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.
Counterweight Replacement
REMOVE
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine and transmission, and counter-
weight. 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 1248 for lift truck models H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005).
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
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 counterweight is held in position on the
frame by two hooks that are part of the frame. One
M30 × 3.5 x 120 capscrew holds the counterweight
to the lower part of the frame on lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005) and one
M30 x 3.5 x 160 capscrew holds the counterweight
to the lower part of the frame for lift truck models
S5.5FTS (S80, 100FTBCS; 120FTS; S120FTPRS)
(G004). For lift truck models S4.0, 4.5, 5.5FT (S80,
100, 120FT) (G004) one M30 x 3.5 x 140 capscrew
holds the counterweight to the lower part of the
frame. See Figure 11.
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 section LPG Fuel System,
GM 4.3L Engine 900 SRM 1242.
13

16. Counterweight Replacement 100 SRM 1243
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 2.
2. Install a lifting eye in the lift hole of the counter-
weight. See Figure 11. Connect a crane to the
lifting eye and raise the crane until it holds part
of the weight of the counterweight. If counter-
weight is equipped with a tow pin, remove the
tow pin and remove the capscrew that holds the
counterweight to the frame. If counterweight is
not equipped with a tow pin, remove the cap-
screw that holds the counterweight to the frame.
See Figure 11.. Use the crane to lift the counter-
weight from the lift truck. Put counterweight on
the floor so that it has stability and will not fall
over. Take care not to damage exhaust or cooling
components.
A. COUNTERWEIGHT USED ON S4.0, 4.5, 5.5FT (S80, 100, 120FT) (G004), AND H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) LIFT TRUCK MODELS
B. COUNTERWEIGHT USED ON S5.5FTS (S80FTBCS, S100FTBCS; S120FTS, AND S120FTPRS) (G004)
LIFT TRUCK MODELS
1. FRAME HOOK
2. SEAL
3. LIFT HOLE
4. TOW PIN
5. ROLL PIN
6. WASHERS
7. CAPSCREW
8. LOCKWASHER
Figure 11. Counterweight Installation
14