This document provides instructions for servicing and repairing various components of a lift truck, including:
- Side covers, floor plates, seats, dashes, and hoods. Removal and installation steps are provided.
- Counterweights, mufflers, overhead guards, engines, exhaust systems, and LPG fuel tanks. Procedures for checks, repairs, and safety label installation are included.
- Frames, fuel tanks, hydraulic tanks, and counterweight mounts. Component descriptions and identification are given.
- Operator restraint systems including seat belts and hip restraints. Inspection and function checks are outlined.
- Hood support assemblies, hood doors, pre-cleaners, and related components
Hyster h006 (h155 ft) forklift service repair manualfujdfjjskkkemw
This document provides instructions for servicing various components of a lift truck, including:
1) Removing and installing side covers, the seat, dash, kick panel, and seal plate.
2) Removing and installing the hood support and door assembly, including disconnecting related components.
3) Removing and installing the hood door assembly on each side of the lift truck.
4) Instructions are provided for each component with detailed steps and diagrams to guide the process. Safety warnings are included for working with certain systems like the LPG tank.
Hyster f187 (s3.5 ft europe) forklift service repair manualfjskefkksem
The document provides instructions for servicing and repairing a lift truck. It contains warnings about stability and safety when putting the truck on blocks for maintenance. It describes the frame components and locations for removing parts like the counterweight, hood, engine, and fuel tank. Step-by-step instructions are given for removing and replacing the hood, seat, side covers and floor plates. The process for removing and installing the LPG fuel tank and bracket is also outlined.
Hyster f187 (s2.0 ft europe) forklift service repair manualfjjkskekfsmem
The document provides instructions for servicing and repairing a lift truck. It warns that the lift truck must be stabilized with blocks when removing parts that change the center of gravity, such as the mast, drive axle, engine, and counterweight. It then details how to remove and replace parts like the hood, seat, side covers, and floor plate to access other components for maintenance and repair. Diagrams show the frame and locations of parts.
Hyster f187 (s2.5 ft europe) forklift service repair manualjfjkskekfsmem
The document provides instructions for servicing and repairing a lift truck. It warns that the lift truck must be properly supported on blocks during maintenance that involves removing heavy components to prevent instability. It then details how to remove and replace the hood, seat, side covers, and LPG tank and bracket. Removal involves disconnecting wiring, removing fasteners, and swinging or lifting parts off. Replacement is the reverse of removal, making sure to properly align, position, and secure all parts. Safety precautions are provided for working with the LPG system.
The document provides instructions for repairing various components of a lift truck including the counterweight, hood, overhead guard, LED lights, operator restraint system, radiator, and exhaust system. The counterweight repair section describes how to safely remove and install the counterweight using lifting eyebolts and a lifting device. The radiator repair section explains how to drain the coolant before removing the radiator, and notes the need to add coolant after installation. Safety warnings are provided throughout regarding putting the lift truck on blocks and adding additional blocks when removing heavy components to maintain stability.
Hyster n005 (h4.5 ft6 europe) forklift service repair manualfudjsjfekskkem
This document provides instructions for servicing various components on a lift truck, including removing and installing the counterweight, hood, overhead guard, engine, and fuel tank. It warns that the lift truck must be stabilized on blocks when heavy components are removed to prevent tipping. The specific section summarized here provides step-by-step instructions for removing and installing the hood, seat, floor plate, side covers, and dash. Proper installation of the gas springs and hood latch mechanism are emphasized to ensure safe and secure closing of the hood.
1991 toyota celica service repair manualhfjsejdkemmn
The document provides information about front axle shafts for various 1988 Toyota models. It describes the components and purpose of axle shafts. Common problems include grease leaks from damaged boots, clicking or clunking noises indicating damaged CV joints, and vibration or shudder from issues like sticking or worn CV joints. Troubleshooting tips and procedures for removing and installing axle shafts on different models are provided. Inspection and disassembly/reassembly of the CV joints are also outlined.
1987 toyota celica service repair manualjjfksekdmejik
The document provides information about front axle shafts for various 1988 Toyota models. It describes the components and purpose of axle shafts, including the constant velocity joints and boots. The document outlines troubleshooting tips for common axle shaft issues and provides detailed steps for removing and installing axle shafts on different Toyota models, including the Celica, Camry, Corolla, Pickup, Van, 4Runner, and Tercel. Removal and installation procedures involve draining fluids, marking components, loosening nuts, and using specialty tools to separate shafts.
Hyster h006 (h155 ft) forklift service repair manualfujdfjjskkkemw
This document provides instructions for servicing various components of a lift truck, including:
1) Removing and installing side covers, the seat, dash, kick panel, and seal plate.
2) Removing and installing the hood support and door assembly, including disconnecting related components.
3) Removing and installing the hood door assembly on each side of the lift truck.
4) Instructions are provided for each component with detailed steps and diagrams to guide the process. Safety warnings are included for working with certain systems like the LPG tank.
Hyster f187 (s3.5 ft europe) forklift service repair manualfjskefkksem
The document provides instructions for servicing and repairing a lift truck. It contains warnings about stability and safety when putting the truck on blocks for maintenance. It describes the frame components and locations for removing parts like the counterweight, hood, engine, and fuel tank. Step-by-step instructions are given for removing and replacing the hood, seat, side covers and floor plates. The process for removing and installing the LPG fuel tank and bracket is also outlined.
Hyster f187 (s2.0 ft europe) forklift service repair manualfjjkskekfsmem
The document provides instructions for servicing and repairing a lift truck. It warns that the lift truck must be stabilized with blocks when removing parts that change the center of gravity, such as the mast, drive axle, engine, and counterweight. It then details how to remove and replace parts like the hood, seat, side covers, and floor plate to access other components for maintenance and repair. Diagrams show the frame and locations of parts.
Hyster f187 (s2.5 ft europe) forklift service repair manualjfjkskekfsmem
The document provides instructions for servicing and repairing a lift truck. It warns that the lift truck must be properly supported on blocks during maintenance that involves removing heavy components to prevent instability. It then details how to remove and replace the hood, seat, side covers, and LPG tank and bracket. Removal involves disconnecting wiring, removing fasteners, and swinging or lifting parts off. Replacement is the reverse of removal, making sure to properly align, position, and secure all parts. Safety precautions are provided for working with the LPG system.
The document provides instructions for repairing various components of a lift truck including the counterweight, hood, overhead guard, LED lights, operator restraint system, radiator, and exhaust system. The counterweight repair section describes how to safely remove and install the counterweight using lifting eyebolts and a lifting device. The radiator repair section explains how to drain the coolant before removing the radiator, and notes the need to add coolant after installation. Safety warnings are provided throughout regarding putting the lift truck on blocks and adding additional blocks when removing heavy components to maintain stability.
Hyster n005 (h4.5 ft6 europe) forklift service repair manualfudjsjfekskkem
This document provides instructions for servicing various components on a lift truck, including removing and installing the counterweight, hood, overhead guard, engine, and fuel tank. It warns that the lift truck must be stabilized on blocks when heavy components are removed to prevent tipping. The specific section summarized here provides step-by-step instructions for removing and installing the hood, seat, floor plate, side covers, and dash. Proper installation of the gas springs and hood latch mechanism are emphasized to ensure safe and secure closing of the hood.
1991 toyota celica service repair manualhfjsejdkemmn
The document provides information about front axle shafts for various 1988 Toyota models. It describes the components and purpose of axle shafts. Common problems include grease leaks from damaged boots, clicking or clunking noises indicating damaged CV joints, and vibration or shudder from issues like sticking or worn CV joints. Troubleshooting tips and procedures for removing and installing axle shafts on different models are provided. Inspection and disassembly/reassembly of the CV joints are also outlined.
1987 toyota celica service repair manualjjfksekdmejik
The document provides information about front axle shafts for various 1988 Toyota models. It describes the components and purpose of axle shafts, including the constant velocity joints and boots. The document outlines troubleshooting tips for common axle shaft issues and provides detailed steps for removing and installing axle shafts on different Toyota models, including the Celica, Camry, Corolla, Pickup, Van, 4Runner, and Tercel. Removal and installation procedures involve draining fluids, marking components, loosening nuts, and using specialty tools to separate shafts.
Hyster f187 (s2.0 ft europe) forklift service repair manualfjjkskekfsxswamem
The document provides instructions for servicing and repairing a lift truck. It warns that the lift truck must be stabilized using blocks when removing parts that change the center of gravity, such as the mast, drive axle, engine, and counterweight. It then describes the lift truck frame and lists the counterweight specifications. The remainder of the document provides step-by-step instructions for removing and replacing the hood, seat, side covers, and other components to access parts for maintenance and repair.
Hyster n005 (h5.0 ft europe) forklift service repair manualfjsjfjskeksmem
This document provides instructions for servicing various components of a lift truck, including:
- Removing and installing the counterweight, hood, overhead guard, engine, exhaust system, and LPG fuel tank and bracket.
- Removing and installing the hood, seat, floor plate, side covers, dash, kick panel, and steering column covers to access internal components.
- Adjusting the hood latch and gas springs to properly secure the hood.
- Removing and installing the LPG fuel tank and bracket, including warnings about working with pressurized fuel systems.
Hyster n005 (h4.5 ft6 europe) forklift service repair manualfjskeazqkkdmme
This document provides instructions for servicing various components on a lift truck, including removing and replacing the hood, seat, side covers, and other parts. It contains the following key details:
- Warnings about putting the lift truck on blocks and maintaining stability when removing heavy components that shift the center of gravity, such as the mast, drive axle, engine, and counterweight.
- Descriptions of the frame components and locations of the hydraulic and fuel tanks.
- Step-by-step instructions for removing and installing the hood, seat, side covers, floor plate, cowl, and other parts, including proper attachment points for gas springs on the hood.
- Figures illustrating the
Hyster n005 (h5.5 ft europe) forklift service repair manualufjjsjefkskekmme
This document provides instructions for servicing various components of a lift truck, including:
1) Warnings about stability and safety when the lift truck is on blocks for maintenance or repairs.
2) Descriptions and removal/installation steps for the hood, seat, side covers, and LPG tank bracket.
3) Details on adjusting the hood latch and installing gas springs on the hood. Safety precautions are provided for working with the LPG tank and fuel system.
Hyster n005 (h5.5 ft europe) forklift service repair manualfjskekdmmem
This document provides instructions for servicing various components on a lift truck, including removing and replacing the hood, seat, side covers, and other parts. It contains the following key points:
1) Warnings about putting the lift truck on blocks and maintaining stability when removing heavy components that change the center of gravity, such as the mast, drive axle, engine, and counterweight.
2) Descriptions of the frame and connected parts like the counterweight, overhead guard, and fuel tank.
3) Step-by-step instructions for removing and replacing the hood, seat, side covers, and other exterior body panels to access internal components. Proper installation of items like the gas springs and hood
Hyster n005 (h5.0 ft europe) forklift service repair manualfjsekkdmeik
This document provides instructions for servicing various components on a lift truck, including removing and replacing the hood, seat, side covers, and other parts. It contains the following key details:
1) Warnings about putting the lift truck on blocks and maintaining stability when removing heavy components that change the center of gravity, such as the mast, drive axle, engine, and counterweight.
2) Descriptions of the frame components and locations of the hydraulic and fuel tanks.
3) Step-by-step instructions for removing and replacing the hood, seat, side covers, floor plate, and other exterior body parts, including proper installation of gas springs and ensuring the hood latch closes correctly.
4
Hyster n005 (h5.5 ft europe) forklift service repair manualfjsqazkekdmme
This document provides instructions for servicing various components on a lift truck, including removing and replacing the hood, seat, side covers, and other parts. It contains the following key details:
- Warnings about stability when removing heavy components and putting the truck on blocks.
- Descriptions of the frame and connected parts like the counterweight and fuel tank.
- Step-by-step instructions for removing the hood, seat, side covers, and other parts for access during maintenance and repairs.
- Instructions for reinstalling these components in the reverse order and ensuring proper operation of parts like the hood latch.
Hyster n005 (h5.0 ft europe) forklift service repair manualfjskkesmdmm
This document provides instructions for servicing various components on a lift truck, including removing and replacing the hood, seat, side covers, and other parts. It contains warnings about maintaining stability when removing heavy assemblies that affect the vehicle's center of gravity. Figures and tables are included to illustrate the proper installation of gas springs and identify the correct fastener holes to use depending on the seat and counterweight type. The steps describe removing parts like the hood, seat, covers, and dash, and reinstalling them in reverse order.
Hyster n005 (h5.0 ft europe) forklift service repair manualfujsjejfkskemm
This document provides instructions for servicing various components of a lift truck, including:
- Removing and installing the counterweight, hood, overhead guard, engine, exhaust system, and LPG fuel tank and bracket.
- Removing and installing the hood, seat, floor plate, side covers, dash, and kick panel for access to internal components.
- Adjusting the hood latch if it does not close properly.
- Properly removing the LPG fuel tank and disconnecting fuel lines before maintenance to avoid sparks or flames near the fuel system.
- Two styles of LPG tank brackets are described - one that swings out to the side and another that both swings and drops down.
Yale a967 glc050 lx lift truck service repair manualfjskefksemer
This document provides instructions for removing and installing various components on a lift truck, including the hood, seat, side covers, and dash panel. Key steps include removing screws and nuts to detach parts, sliding seats, tilting steering columns, removing gas springs from the hood, and lifting parts off the truck. Proper order and attachment points are specified to correctly remove and replace the parts. Safety warnings are also provided about supporting the truck during maintenance.
Yale a974 gdp20 lx lift truck service repair manualfjsjjdkemmde
This document provides a service manual for a GLP/GDP20-25LX (A974) lift truck. It contains sections covering various parts and systems of the truck, including the frame, engines, cooling system, transmission, axles, brakes, hydraulics, electrical systems, and repairs. The document provides part numbers, section numbers, and revision dates for the content. It also contains a section on steering column repair that describes removing and installing the steering column, which attaches the steering wheel to the cowl inside the operator compartment.
Yale a974 gdp25 lx lift truck service repair manualdueikdkmem
This document provides a service manual for a GLP/GDP20-25LX (A974) lift truck. It contains sections covering various parts and systems of the truck, including the frame, engines, transmission, axles, brakes, hydraulics, electrical systems, and repairs. The document provides part numbers, section numbers, and revision dates for the content. It also includes summaries of procedures for tasks like removing and installing hoods, seats, side covers, and steering columns.
Yale a974 glp20 lx lift truck service repair manualfhjsjkdmemm
This document provides a service manual for a GLP/GDP20-25LX (A974) lift truck. It contains sections on various parts and systems of the truck, including the frame, engines, transmission, axles, brakes, hydraulics, electrical systems, and repairs. The document outlines removal and installation procedures, component descriptions, and safety warnings for working on the lift truck.
Yale a974 glp25 lx lift truck service repair manualfhjskemme
This document provides a service manual for a GLP/GDP20-25LX (A974) lift truck. It contains sections on various parts and systems of the truck, including the frame, engines, transmission, axles, brakes, hydraulics, electrical systems, and repairs. The document provides part numbers, section contents, and revision dates for the manual. It also includes a section summarizing procedures for removing and installing components like the hood, seat, side covers, and steering column on the truck.
Hyster d470 (n35 zr) forklift service repair manualfujfjjjskekemm
- The document provides repair instructions for various components on a forklift truck frame, including the overhead guard, front frame panels, operator compartment cover, drive unit compartment door, and load wheels.
- To remove the overhead guard, detach it from the mast using six capscrews and lower it to the floor. To install, lift it back into place and secure with the six capscrews.
- Front frame panels are removed by pulling out lower tabs and loosening upper and lower screws. The operator compartment cover is removed by loosening two retaining screws and pulling it up and off retaining clips.
Hyster d470 (n35 zr) forklift service repair manualfujsjfjkskekmm
- The document provides repair instructions for various components on a forklift truck frame, including the front frame panels, operator compartment cover, drive unit compartment door, operator pads, caster wheel cover, load wheels, and overhead guard.
- To repair the frame components, screws, bolts, and other fasteners must be removed to access the components. The specific procedures for each component are described.
- Welding repairs require following safety precautions and may require factory approval for structural members like base arms and mast components. Only properly trained technicians should perform welding repairs.
Hyster d470 (n30 zdr) forklift service repair manualfusjejfjsekksem
- The document provides repair instructions for various components on a forklift truck frame, including covers, panels, and plates, load wheels, and general safety warnings.
- Key components that can be repaired include the front frame panels, operator compartment cover, drive unit compartment door, various pads, and caster wheel cover. Instructions are provided for removing and installing these parts.
- Load wheel removal instructions include removing the nut, washers, axle bolt, and then pressing or tapping the bearings and axle sleeves from the load wheels using a soft punch and hammer to avoid damage.
Mc cormick f e line restyling (2010- ) - rp56 - f90gexl tractor service repai...fjjskekdmmem
This document contains parts listings and component information for engine and tractor parts. It includes item numbers, part names and numbers, quantities, and other identifying information. Replacement kits and shims are indicated by color coding. Measurement specifications are provided for some items.
Mc cormick f e line restyling (2010- ) - rp56 - f70ge tractor service repair ...fjjskekdmmem
This document contains parts listings and diagrams for components of an engine and tractor assembly. It lists 27 individual parts with identification numbers, descriptions, quantities and other technical specifications. It indicates that this represents a component of a larger assembly and parts are not serviced individually, but instead the entire assembly is replaced.
Mc cormick cx l series (2004-2007) - rp21 - cx-l 85 tractor service repair ma...fjjskekdmmem
This document contains parts lists and diagrams for engine components of CX-L tractors from 2004-2007. It includes lists of replacement parts needed for the engine, cylinder head, crankshaft, valves, pistons, and other internal engine parts. Each part is accompanied by an identification number, description, and quantity. Diagrams are provided to identify the location and relationship between parts.
Komatsu d61 px 12 dozer bulldozer service repair manual sn b16001 and upfjjskekdmmem
- This document provides specifications for Komatsu D61EX-12 and D61PX-12 dozers, including:
- Operating weights ranging from 13,130-17,790 kg depending on attachments.
- A 6-cylinder, 114 mm bore x 135 mm stroke engine producing 112 kW at 1,850 rpm.
- A 3-speed forward and reverse transmission and hydraulic steering system.
- Track widths of 1,900 mm for the D61EX-12 and 2,140 mm for the D61PX-12.
Komatsu d61 px 12 dozer bulldozer service repair manual sn 1001 and upfjjskekdmmem
- This document provides specifications for Komatsu D61EX-12 and D61PX-12 dozers, including operating weights, dimensions, performance, engine details, and other technical specifications.
- Standard operating weights range from 13,130kg for the bare D61PX-12 tractor to 17,790kg for the D61EX-12 with angle tiltdozer, cab, and ROPS.
- Both models have a 6-cylinder, 114mm bore x 135mm stroke, 8,270cc water-cooled turbocharged diesel engine producing 150HP at 1,850rpm.
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Komatsu d61 ex 12 dozer bulldozer service repair manual sn b1001 and upfjjskekdmmem
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- Operating weights ranging from 13,130-17,790 kg depending on attachments.
- A 6-cylinder, 114 mm bore x 135 mm stroke engine producing 112 kW at 1,850 rpm.
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Komatsu d61 ex 12 dozer bulldozer service repair manual sn 1001 and upfjjskekdmmem
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- Operating weights ranging from 13,130-17,790 kg depending on attachments.
- A 6-cylinder, 114 mm bore x 135 mm stroke engine producing 112 kW at 1,850 rpm.
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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
1
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.
2
4. 100 SRM 1321 Side Covers, Seat, Dash, and Hood Replacement
Figure 3. Seat Plate Mounting
3
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
4
6. 100 SRM 1321 Side Covers, Seat, Dash, and Hood Replacement
Figure 4. Seat Assembly Removal
5
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.
6
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
7
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10. Side Covers, Seat, Dash, and Hood Replacement 100 SRM 1321
Figure 7. Side Covers, Floor Plate, and Cowl Components
8
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.
9
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
10
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
11
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
12
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.
13
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.
14