the best repair workshop manual

1. SERVICE REPAIR
H13.00XL H14.00XL H16.00XL Europe [C019]

2. 1
THE FRAME
GENERAL
This section has the description and repair procedures
for the frame and connected parts. Included in this sec-
tion are the frame, counterweight, fenders, hood, hy-
draulic and fuel tanks, radiator, operator compartment
and cab. The instructions for removal and installation of
the engine are included in this section.
DESCRIPTION
The frame is a one piece weldment and has mounts for
the counterweight, fenders, overhead guard, engine,
transmission, axles, hydraulic and fuel tanks, operator’s
compartment, and other parts.
COUNTERWEIGHT
WARNING
The counterweight is heavy. Make sure that the
crane and lifting devices have the capacity to lift
4600 kg (10143 lb).
Removal (See FIGURE 2.)
1. Remove the hood assembly.
2. H8.00–9.00XL (H165–210XL) units only. Remove
the cover (3) and bracket (5) from the counterweight.
3.Installliftchainsthroughtheradiatorgrillinthecoun-
terweight and attach the chains to a lifting device.
H13.00–16.00XL (H300–360XL) units. Remove the
radiator hardware. Tilt the radiator away from the
counterweight so that there is clearance when the chains
are installed through the counterweight.
4. Remove the single capscrew from the rear of the
counterweight. Raise the counterweight approximately
300 mm (12 inches). Remove the counterweight from
the frame. There can be shims between the counter-
weight and the counterweight mounts on the frame. Fas-
ten the shims to the frame with tape so they can be used
when the counterweight is installed.
Installation
WARNING
The counterweight is very heavy. Make sure that the
crane and lifting devices have the capacity to lift
4600 kg (10143 lb).
1. Put a chain through the opening in the counterweight
and attach the chains to a lifting device.
1. MAIN FRAME MEMBER
2. MOUNT, CAB SUPPORT
3. COUNTERWEIGHT MOUNT
4. STABILIZER BAR, ON
H8.00–12.00XL (H165–280XL) ONLY
5. MOUNT, STEERING AXLE
6. MOUNT, DRIVE AXLE
7. MOUNT, MAST
8. MOUNT, TILT CYLINDERS
FIGURE 1. FRAME
12460
1
2
3
8
7 6
4
5
2

3. 2
FIGURE 2. COUNTERWEIGHT MOUNTS
SIDE VIEW
TOP VIEW
1. COUNTERWEIGHT
2. CAPSCREW
3. COVER
4. NUT
5. BRACKET
6. SIDE COUNTERWEIGHT*
7. CAPSCREW
8. FRAME
9. COUNTERWEIGHT
10. FENDER, COUNTERWEIGHT
11. CAPSCREW AND WASHER
12. TOW PIN
13. CAPSCREW, WASHER AND NUT
14. SHIM
* SIDE COUNTERWEIGHTS (WHEN INSTALLED) ARE WELDED TO
FRAME EXCEPT ON H13.00–16.00XL (H300–360XL) UNITS.
H13.00–16.00XL (H300–360XL) SHOWN
H8.00–12.00XL (H165–280XL) ARE SIMILAR
12461
H8.00–12.00XL
(H165–280XL) ONLY
H13.00–16.00XL (H300–360XL) units. Install the ra-
diator hardware. Tilt the radiator ahead so there is clear-
ance for the chains that are installed through the coun-
terweight.
2. Install the counterweight on the frame. Install the
capscrew, lockwasher and flat washer to fasten the
counterweight to the frame. Tighten the capscrew to
1140 N.m (840 lbf ft).
Fenders. Removal
WARNING
The fenders are part of the lift truck counterweight
and are very heavy. Make sure any lifting devices
have the capacity to lift 1 750 kg (3 860 lb). Make sure
the fender is balanced and supported by the chain.
The fenders are not of a regular shape and can be dif-
ficult to handle.
1. Remove the capscrews washers and nuts that fasten
the fender to the frame mount. Install eyebolts in the
mount holes. Use a smaller washer on the bottom side to
clear the hole in the fender mount.
2.Fastenaliftingdevicetotheeyebolts.Operatethelift-
ing device and lift the fender away from the frame.
Fenders, Installation
1. Install eyebolts in the fenders as described in Re-
moval, step 1. Fasten a lifting device to the eyebolts.
2. Raise the fender to the lift truck. Align the eyebolts in
the fender with the holes in the fender mount on the
frame. Lower the fender to the fender mount, remove
the lifting device and the eyebolts.
3. Install the capscrews, washers and nuts that hold the
fender to the frame. Tighten the nuts to 320 N.m (240 lbf
ft).

4. 3
Side Counterweights
H13.00–16.00XL (H330–360XL)
The counterweights located on either side of the lift
truck are fastened to the frame by large capscrews. Nor-
mally these counterweights will never have to be re-
moved or replaced on the lift truck.
Side Counterweights, Replacement
If replacement of the side counterweight is required, do
the following procedure:
WARNING
The side counterweights are heavy. Each side
counterweight weighs approximately 560 kg (1235
lb). Make sure that the crane and lifting devices have
the capacity to lift 908 kg (2000 lb).
1. Remove the engine. See the paragraph ENGINE and
TRANSMISSION in this section for the correct re-
moval and installation procedure.
2. Remove each counterweight capscrew and replace it
in turn with a long stud. The studs must protrude about
152 mm (6 in) beyond the counterweight.
3. Use a pry bar and carefully move the counterweight
away from the frame about 50 mm (2 in). Install a nylon
lifting sling securely around the counterweight and at-
tach it to a lifting device.
WARNING
Make sure the counterweight is balanced and cannot
fall from the sling, when the sling is raised.
4. Carefully lift the counterweight away from the lift
truck frame and lower the counterweight to the floor.
5. For installation of the side counterweights, follow the
above procedure in reverse order. Tighten the counter-
weight capscrews to 655 N.m (485 lbf ft).
HOOD AND AIR CLEANER
The hood and air cleaner assembly, which includes the
pre–cleaner and inlet pipe, can be removed from the
frame as a single unit.
2. Remove the nuts, washers and bar washers that fasten
the hood crossmember to the counterweight. Remove
the two capscrews from the front of the hood assembly
at the center bracket. These two capscrews are mounted
to the cab. Attach a lifting device and sling. Lift the hood
from the frame. See FIGURE 3.
Installation
Install the hood and air cleaner assembly in the reverse
procedure of removal and align the hood as necessary
duringinstallation.Makesurethehoodsidepanelsclose
completely and that the cushioned screw stops (bump-
ers) are located correctly.
Removal
1. Raise both hood side panels and disconnect the air in-
take hose (9) at the engine. Disconnect the small hose,
that goes to the air compressor, at the air cleaner. On
trucks with a cab, disconnect the hose from the rear win-
dow washer.

5. 4
FIGURE 3. HOOD AND AIR CLEANER ASSEMBLY
1. HOOD, TRANSMISSION –
H13.00–16.00XL (H300–360XL) ONLY
2. HOOD, ENGINE
3. GAS SPRING (2)
4. PRE–CLEANER
5. AIR INLET PIPE
6. SHIM
7. AIR RESTRICTION INDICATOR
8. AIR CLEANER
9. HOSE, AIR INTAKE
10. CLAMP
11. ENGINE (REFERENCE)
12. FRAME, RIGHT SIDE
13. HANDLE (2)
14. STOP SCREW
15. HOOD, RH PANEL
16. ROD, HINGE
17. CENTER BRACKET
18. CAPSCREW
19. LOCKWASHER
20. SPRING
21. SPACER
22. WASHER
23. CAPSCREW, WASHER AND NUT
24. HOOD CROSSMEMBER
1 2

6. 5
FIGURE 4. HYDRAULIC TANK AND BATTERY BOX
1. HYDRAULIC
TANK
2. BATTERY BOX
3. FRAME
4. SIDE COVER
5. NUT AND WASHER
12463
1
3
4
2
5 5
5
HYDRAULIC TANK
The hydraulic tank is installed on the right side of the
frame between the front and rear fenders.
Removal
1. Remove the side cover between the bottom of the op-
erator compartment and the top of the hydraulic tank. If
necessary, remove the drain plug at the bottom of the
tank to drain the oil.
2. Disconnect the hoses at the top elbow connection and
at the side connection to the tank located on the inside of
the frame. Use a pan to catch the oil that is in the hydrau-
lic lines. Put tags on the lines for identification. Put caps
on the open lines and the fittings.
3. Support the fuel tank with blocks from beneath. First,
remove the three capscrews that fasten the bottom of the
tank to the running board. Remove the three nuts and
washers that hold the top of the tank to the frame. Install
two lifting eyes at the outer holes. Attach a lifting device
and support the tank. Lift the tank from the frame.
WARNING
Make sure that the tank is supported by blocks be-
fore removing the nuts and washers from the top of
the tank.
Repairs, All Units
SMALL LEAKS
Use the following procedures to repair small leaks:
1. Use steam to clean the area around the leak. Remove
all paint and dirt around the leak.
WARNING
Do not use tools that can make sparks, heat or static
electricity. The vapors in the tank can cause an ex-
plosion.
2. Apply Loctite 290 to the leak. Follow the instruc-
tions of the manufacturer.
LARGE LEAKS
1. Use one of the procedures described under Cleaning
to clean and prepare the tank for repairs.
2. Use acceptable welding practices to repair the tank.
See the American National Standard Safety in Welding
and Cutting ANSI Z49.1–1973.
Cleaning
WARNING
Special procedures must be followed when large
leaks or other repairs need welding or cutting. All
work must be done by authorized personnel. 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 Con-
tainers That Have Held Combustibles” by the Ameri-
can Welding Society, A6.0–65.
• “Safety In Welding and Cutting”, American Na-
tional Standard, ANSI Z 49.1 – 1973.

7. 6
1
2
12
6
7
4
5
11
8
10
9
16
15
14
3
13
FIGURE 5. HYDRAULIC TANK
1 WASHER (3)
2 NUT (3)
3 BREATHER
4 FILTER HEAD
5 O–RING
6 DIPSTICK
7 O–RING
8 SEAL
9 SPRING
10 WASHER
11 FILTER
12 FITTING
13 LOCKWASHER (3)
14 FITTING
15 FITTING
16 HYDRAULIC TANK
When cleaning the tank, do not use solutions that make
dangerous gases at normal temperatures or when
heated. Wear eye and face protection. Protect the body
from burns.
When cleaning with steam, use a hose with a minimum
diameter of 19 mm (0.75 inch). 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
doesnotmakesparks.Makeanelectricalconnectionbe-
tween the nozzle and the tank. Connect a ground wire to
the tank to prevent static electricity.
Steam Method of Cleaning
Use the following procedure to clean the tank with
steam:
1. Remove all the parts from the tank. Install the drain
plug.
2. Fill the tank 1/4 full with a solution of water and so-
diumbicarbonateorsodiumcarbonate.Mix0.5kg(1lb)
per 4 litres (1 gal) of water.
3. Mix the solution in the tank using air pressure. Make
sure all the surfaces on the inside of the tank are flushed
with the solution. Drain the tank.
4. 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.
5. Flush the inside of the tank with boiling water. Make
sure all the loose material is removed from the inside of
the tank.
6. Make an inspection of the inside of the tank. If it is not
clean, repeat steps 4. and 5. and make another inspec-
tion. When making inspections, use light that is ap-
proved for locations with flammable vapors.
7. Put plugs in all the openings in the tank. Wait 15 min-
utes, then remove the inlet and outlet plugs. Test a sam-
pleofthevaporwithaspecialindicatorforgasvapors.If
the amount of flammable vapors is above the lower
flammable limit, repeat the cleaning procedures.
Chemical Solution Method of Cleaning
If the tank cannot be cleaned with steam, use the follow-
ing procedure:
1. Mix a solution of water and trisodium phosphate or a
cleaning compound with an alkali base. Follow the in-
structions given by the manufacturer.
2. Fill the tank with the cleaning solution. Use com-
pressed 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 the cleaning compound is
removed.
4. Make an inspection of the inside of the tank. If the
tank is not clean, repeat steps 1 through 3. Make another
inspection of the tank. When making inspections, use a
light that is approved for locations with flammable va-
pors.

8. 7
5. Check the tank for flammable vapors using special in-
dicator for gas vapors. If the amount of flammable va-
pors is not below the lower flammable limit, repeat the
cleaning procedures.
Other Methods Of Preparation For Repair
If nitrogen gas or carbon dioxide gas is available, pre-
pare the tank for welding using these gases. See the
manual Safe Practices For Welding and Cutting Con-
tainers That Have Held Combustibles by the American
Welding Society, A6.0–65. If these gases are not avail-
able, another method using water can be used as fol-
lows:
1. Fill the tank with water to just below the point where
the work will be done. Make sure the space above the
level of the water has a vent.
2. Use acceptable welding practices to repair the tank.
See the American National Standard Safety In Welding
And Cutting ANSI Z 49.1–1973.
Installation
1. Connect a lifting device to the outer holes in the top of
the hydraulic tank. Put the hydraulic tank in position on
the frame. Put blocks under the tank to provide support.
Installthelowerthreecapscrewsandwashersthatfasten
the top of the hydraulic tank to the frame.
2. Make sure the tank is supported by the upper
capscrews. Install the three nuts and washers that fasten
the bottom of the hydraulic tank to the running board.
3. Connect the hydraulic return line to the upper elbow
connection of the hydraulic tank. Attach the suction
hose to the side tank connection on the inside of the
frame member.
4. Fill the hydraulic tank to the correct level with the oil
specified in the maintenance table. See the section PE-
RIODIC MAINTENANCE, 8000 SRM 433.
FUEL TANK
The fuel tank is installed on the left–hand frame chan-
nel.
Removal
1. If necessary, remove the drain plug to drain the fuel
from the tank.
WARNING
If the fuel is drained from the fuel tank, put the fuel
in a can or barrel that has a protected seal cap.
2. Disconnect the fuel lines at the tank.
3. Support the fuel tank with blocks from beneath the
tank. First, remove the three capscrews that fasten the
bottom of the tank to the running board. Remove the
three nuts and washers that hold the top of the tank to the
frame. Install two lifting eyes at the outer holes. Attach a
lifting device and support the tank. Lift the tank from the
frame.
WARNING
Make sure that the tank is supported by blocks be-
fore removing the nuts and washers from the top of
the tank.
Repairs
Repair the fuel tank as described in the repair proce-
dures for the hydraulic tank.
WARNING
Do not use tools that can make sparks, heat or static
electricity. The vapors in the tank can cause an ex-
plosion.
Installation
1. Connect a lifting device to the outer holes in the top of
the fuel tank. Put the fuel tank in position on the frame.
Put blocks under the tank to provide support. Install the
lower three capscrews and washers that fasten the top of
the fuel tank to the frame.
2. Make sure the tank is held by the upper capscrews,
then install the three nuts and washers that fasten the
bottom of the fuel tank to the running board.
3. Connect the fuel lines to the tank.

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10. 8
TOP VIEW
FIGURE 6. FUEL TANK
1
2
3
4
5
6
7
8
1
3
4
5
6
7
8
1. FUEL TANK
2. FRAME
3. DRAIN PLUG (ON BOTTOM)
4. FILLER CAP
5. CAPSCREWS, TOP (3)
6. FUEL LINE, SUPPLY
7. FUEL LINE, RETURN
8. SENDER, FUEL LEVEL

11. 9
FIGURE 7. RADIATOR
1. TANK, COOLANT
RECOVERY
2. CAP, RADIATOR
3. RADIATOR
4. HOSE, TOP
5. SEAL, RADIATOR
6. SHROUD WELDMENT
7. BRACKET ON FRAME
8. FRAME
9. HOSE, LOWER
10. BRACKET AND PIN
11. ISOLATOR
12. DRAIN VALVE
13. FAN
14. V–BELT
15. CAPSCREW
16. WASHER (2)
17. GROMMET
18. NUT
12465
16
RADIATOR (See FIGURE 7.)
Removal
1. Remove the hood. See the paragraphs Hood And Air
Cleaner.
2. Drain the radiator. Disconnect the coolant hoses at the
radiator.
3. Disconnect the transmission oil lines at the radiator.
4. Remove the fan from the drive pulley.
5. Remove the capscrews between the fan shroud and
the radiator.
6. Remove the two capscrew and grommet assemblies
that hold the radiator shroud to the bracket on the frame.
Remove the radiator and shroud.
Installation
1. Install the brackets on the radiator. Install the radiator
and shroud in the frame. Install the two capscrew and
grommet assemblies that fasten the shroud weldment to
the bracket on the frame. Install the capscrews between
the fan shroud and the radiator.
2. Connect the coolant hoses to the radiator.
3. Connect the transmission oil lines to the bottom of the
radiator.
4. Install the counterweight and hood assembly.
5. Fill the radiator with coolant. See Maintenance
Schedule in the section PERIODIC MAINTE-
NANCE, 8000 SRM 433 for quantity and anti–freeze
requirements.
ENGINE and TRANSMISSION
See the sections PERKINS ENGINE, 600 SRM 412
for repair of the engine. See the transmission section,
POWERSHIFT TRANSMISSION, 1300 SRM 438
for earlier production lift trucks.
Later production lift trucks use the Hyster T–50 power-
shift transmission. An installation kit is available that
enables the installation of the T–50 transmission in ear-
lier production lift trucks. See the section, THREE–
SPEED POWERSHIFT TRANSMISSION, RE-
PAIRS, 1300 SRM 518 for lift trucks with this trans-
mission. The removal of this transmission is described
later in this section. See HYSTER T–50 TRANSMIS-
SION, REMOVAL.
Removal (Earlier Production Lift Trucks)
1. Disconnect the cables at the battery. (Remove the
ground cable first.) Remove the bracket for the battery
cables.
2. H13.00–16.00XL (H300–360XL) units. Remove
the operator compartment. See the paragraph Operator
Compartment.
3. H8.00–12.00XL (H165–280XL) units. Removal of
the operator compartment is not required. Tilt the opera-

12. 10
tor compartment forward to remove the engine and
transmission.
4. Remove the hood and air cleaner assembly. See the
paragraph Hood And Air Cleaner.
5. Drain the coolant from the cooling system. Remove
the radiator. See the paragraph Radiator.
6. Disconnect the exhaust system. Remove the header
pipe at the exhaust manifold.
FIGURE 8. EXHAUST SYSTEM
1. CAB (REFERENCE)
2. STACK, EXHAUST
3. EXHAUST SHIELD
4. CLAMP
5. FRAME
6. NUT AND WASHER
7. MUFFLER
8. FLEX TUBE, EXHAUST
9. SEAL CLAMP
10. EXHAUST PIPE
11. GASKET
12. ENGINE
12466
H13.00–16.00XL (H300–360XL) SHOWN
7. Disconnect the air lines at the air compressor. Loosen
the fittings slowly to vent any compressed air.
8. Disconnect fuel lines at the fuel tank. Disconnect
throttle linkage.
FIGURE 9. ENGINE INSTALLATION
FRONT VIEW
1. MOTOR MOUNT
2. MOUNT, ENGINE
3. WASHER
4. CAPSCREW
5. NUT
6. FRAME,
H10.00–12.00XL
(H230–280XL)
7. FRAME,
H8.00–9.00XL
(H165–210XL) and
H13.00–16.00XL
(H300–360XL)
8. ENGINE
12469
9. Disconnect wires and wiring harnesses at the engine.
Disconnect the heater hoses at the engine.
10. Disconnect the drive shaft.
11. Connect a lifting device to the engine and transmis-
sion. Make sure the lifting device has a capacity of at
least 1135 kg (2500 lb).
12. Remove the capscrews that hold the engine and
transmission mount brackets to the frame mounts.
13. Make sure all the connections have been removed.
Carefully lift the engine and transmission assembly
from the frame.
WARNING
Put blocks under the engine and transmission to
make sure the assembly has good support while re-
moving components.
14. Remove the bracket and linkage for the transmis-
sion.

13. 11
FIGURE 10. TRANSMISSION INSTALLATION (EARLIER PRODUCTION)
1. TRANSMISSION
2. FRAME
3. PLATE, MOUNT
4. CAPSCREW
5. MOUNT
6. WASHER
7. NUT
8. DRIVE AXLE
SIDE VIEW FRONT VIEW
12467
Installation (Earlier Production Lift Trucks)
1. Connect a lifting device to the engine and transmis-
sion. Make sure the lifting device has a capacity of at
least 1200 kg (2500 lb).
2. Install the engine and transmission assembly in the
frame. Install and tighten the nuts and capscrews for the
engine and transmission mounts.
3. Connect the drive shaft to transmission. Tighten the
bolts for the universal joint to 68 N.m (50 lbf ft).
4. Install the hydraulic lines to the pump.
5. Connect the exhaust pipes to the engine and muffler.
6. Connect the heater hoses, air lines, wiring harnesses,
wires and throttle cable to the engine.
7. Install the radiator. Connect the coolant hoses to the
radiator. Connect the oil cooler lines to the transmission.
8. Connect the fuel lines between the fuel filter on the
engine assembly and fuel tank and primary.
9. Install and connect the hood and air cleaner assembly.
10. Connect the battery cables to the battery (Connect
thepositivecablefirst,thenthegroundcable.).Fillcool-
ing system with coolant. Check all oil levels. Start the
engine and check for leaks and correct operation.
Hyster T–50 Transmission, Removal
NOTE: On H8.00–12.00XL (H165–280XL) lift trucks,
the transmission can be removed through the operator’s
compartment or from under the lift truck. On
H13.00–16.00XL (H300–360XL) lift trucks, the trans-
mission can be removed from the engine compartment
or from under the lift truck.
1. Remove the forks. Put the lift truck on blocks so that
there is access under the lift truck. See “How To Put The
Lift Truck On Blocks” in the OPERATINGMANUAL
orthe PERIODICMAINTENANCE,8000SRM433,
section. Tilt the mast fully forward to release hydraulic
pressure in the system.
1. Disconnect the cables at the battery. (Remove the
ground cable first.) Remove the bracket for the battery
cables.
2. H13.00–16.00XL (H300–360XL) units. Remove
the operator compartment. See the paragraph Operator
Compartment.
3. H8.00–12.00XL (H165–280XL) units. Removal of
the operator compartment is not required. Tilt the opera-
tor compartment forward to remove the engine and
transmission.

14. 12
FIGURE 11. HYSTER T–50 TRANSMISSION ARRANGEMENT [H8.00–12.00XL (H165–280XL) SHOWN]
1 1
2
2
3
4
5
5
6
7
1. FRAME (REFERENCE)
2. DIPSTICK ASSEMBLY
3. DRIVE SHAFT
4. OUTPUT YOKE
5. TRANSMISSION MOUNT
6. TRANSMISSION
7. TORQUE CONVERTER
4. Remove the hood and air cleaner assembly. See the
paragraph Hood And Air Cleaner.
5. Drain the coolant from the cooling system. Remove
the radiator. See the paragraph Radiator.
6. Disconnect the exhaust system. Remove the header
pipe at the exhaust manifold.
7. Disconnect the air lines at the air compressor. Loosen
the fittings slowly to vent any compressed air.
8. Disconnect fuel lines at the fuel tank. Disconnect
throttle linkage.
9. Disconnect wires and wiring harnesses at the engine.
Disconnect the heater hoses at the engine.
10. Disconnect the drive shaft at the yokes. Remove the
drive shaft between the transmission and the differen-
tial.
11. Disconnect the wiring harnesses on top of the trans-
mission. Disconnect the wires at the solenoids on the
transmission control valve. Disconnect the wires at the
pressure sending unit and the temperature sending unit
on the transmission. Put identification tags on the wires
so that they can be correctly connected again.
12. Apply the service brakes repeatedly until the air
pressure in the air tank decreases to 0 kPa (0 psi). Dis-
connect the air brake hose from the air tank so that there
is clearance at the transmission.
13. Disconnect the wire to the starter solenoid.
14. Disconnect the cables at the spools on the transmis-
sion control valve. Remove the linkage bracket from the
transmission housing.
15. Remove the drain plug from the transmission sump
to drain the oil from the transmission [approximately 28
litres (29 qt)]. Disconnect the oil lines to the oil cooler at
the transmission. Drain the oil lines into the drain pan.
Put plugs and caps in the open fittings.
16. Disconnect the oil hoses at the hydraulic pump. Dis-
connect the hose from the hydraulic pump to the steer-
ing system. Put plugs and caps on the open fittings.
17. The hydraulic pump is fastened to the transmission
cover with four capscrews. The hydraulic pump weighs
approximately 45 kg (100 lb). Use a lifting device to
hold and lift the hydraulic pump. Remove the hydraulic
pump. The drive shaft of the hydraulic pump is engaged
insplinesinthedrivegear.Thedriveshaftofthehydrau-
lic pump will slide from the drive gear when the hydrau-
lic pump is removed.

15. 13
18. Disconnect and remove the dipstick assembly from
the transmission.
19. The temperature sender for the transmission oil can
be easily damaged. Remove the temperature sender
from the transmission sump.
20. Install blocks and a jack under the flywheel end of
the engine as a support. If the support is put under the
engine oil sump, make sure the support is across the
width of the oil sump so that the weight of the engine
does not damage the oil sump.
21. A 5/8 inch machined hole with UNC threads is in the
top of the transmission housing. Install an eyebolt in the
5/8 inchUNChole.Connectaliftingdevicetotheengine
and transmission. Make sure the lifting device has a ca-
pacity of at least 1200 kg (2500 lb).
22. Remove the two 3/4 x 31/2 inch bolts that fasten the
transmission mounts to the frame. These bolts have
been tightened to 270 N.m (200 lbf ft).
23. Remove the capscrews that hold the engine mount
brackets to the frame mounts.
24. Make sure all the connections have been removed.
Carefully lift the engine and transmission assembly
from the frame.
Hyster T–50 Transmission, Installation
1. If the mounts were removed from the sides of the
transmission housing, install them and tighten the cap-
screws to 270 N.m (200 lbf ft).
2. Connect a lifting device to the engine and transmis-
sion. Make sure the lifting device has a capacity of at
least 1200 kg (2500 lb).
3. Install the engine and transmission assembly in the
frame. Install and tighten the nuts and capscrews for the
engine and transmission mounts. Install the two 3/4 x
31/2 inch bolts (item 5, FIGURE 12.) for the transmis-
sion mounts. Tighten the locknuts to 270 N.m (200 lbf
ft).
4. Connect the drive shaft to the yoke on the transmis-
sion. Make sure the slip joint is installed as shown in
FIGURE 12. Tighten the capscrews at the yoke to 50
N.m (35 lbf ft).
1. FRAME (REFERENCE)
2. DIPSTICK ASSEMBLY
3. DRIVE SHAFT
(Make sure the slip joint is installed as shown)
FIGURE 12. INSTALLATION OF THE HYSTER T–50 TRANSMISSION
1327720
368 to 394 mm
(14.5 to 15.5 in)
1 1
2 2
3
5
4
5
7
6
4. OUTPUT YOKE
5. TRANSMISSION MOUNT
6. STARTER SOLENOID
7. TORQUE CONVERTER

16. 14
5. Install the dipstick assembly on the transmission. Ad-
just the handle of the dipstick so that it is 368 to 394 mm
(14.5 to 15.5 in) from the centerline of the transmission
as shown in FIGURE 12.
6. Use a lifting device to hold and lift the hydraulic
pump. Install the hydraulic pump. The drive shaft of the
hydraulic pump is engaged in splines in the drive gear.
The drive shaft of the hydraulic pump will slide into the
drive gear when the hydraulic pump is installed.
7. Connect the hose from the hydraulic pump to the
steering system. Connect the hydraulic hoses to the hy-
draulic pump.
8. Install the temperature sender for the transmission oil
into the transmission sump.
9. Connect the wiring harnesses on the top of the trans-
mission. Connect the wires to the solenoids on the con-
trol valve. Make sure the yellow wire is connected to the
reverse solenoid and the black wire is connected to the
forward solenoid. Connect the wires at the temperature
sending unit and the pressure sending unit on the trans-
mission. Use the straps and clamps to hold the wires in
position.
10. Install the starter solenoid shown in item 6,
FIGURE 12.
11. Connect the air brake hose to the air tank.
12. Fasten the bracket (item 7, FIGURE 13.) to the
transmission housing. Connect the cables to the control
spools in the transmission control valve. See the adjust-
ment procedure in the section, THREE–SPEED
POWERSHIFT TRANSMISSION, REPAIRS, 1300
SRM 518.
FIGURE 13. CONNECT THE CONTROL CABLES
1. SLEEVE
2. SNAP RING
3. BUSHING
4. SPRING GUIDE
5. INCHING CABLE
1
2 3 4
5 6 7
8
9
10
6. SPRING
7. BRACKET
8. INCHING SPOOL
9. RANGE SPOOL
10. RANGE CABLE
13. Connect the exhaust pipes to the engine and muffler.
14. Connect the heater hoses, air lines, wiringharnesses,
wires and throttle cable to the engine.
15. Install the radiator. Connect the coolant hoses to the
radiator. Connect the oil cooler lines to the transmission
The hose from the upper fitting on the transmission goes
to the right–hand fitting (as seen from the operator’s
position) on the oil cooler. The hose from the lower fit-
ting on the transmission goes to the left–hand fitting on
the oil cooler.
16. Connect the fuel lines between the fuel filter on the
engine assembly and fuel tank and primary.
17. Install and connect the hood and air cleaner assem-
bly.
18. Fill the transmission with the correct transmission
oil [29 liters (31 qt)]. Transmission oil is available in the
following sizes:
Hyster Part No. 336830 in one quart containers
Hyster Part No. 336831 in eight quart containers
Hyster Part No. 336832 in 20 quart containers.
19. Connect the battery cables to the battery (Connect
thepositivecablefirst,thenthegroundcable.).Fillcool-
ing system with coolant. Add oil to the engine. Check all
oil levels. Check that all connections have been made.
Start the engine and check for leaks and correct opera-
tion.
20. When the lift truck can be operated, check the for-
ward and reverse clutch pressures as described in the
“Checks And Adjustments” in the section, THREE–
SPEED POWERSHIFT TRANSMISSION, RE-
PAIRS, 1300 SRM 518.
21. Install the floor plates and seat and doors or the hood
as necessary.