service repair manual

1. SERVICE REPAIR
H13.00XM H14.00XM H16.00XM Europe [E019]

2. 100 SRM 927 Counterweight Repair
General
This section has the description and repair procedures for the frame and connected parts. Included in this
section are the frame, counterweight, fenders, hood, hydraulic and fuel tanks, radiator/cooling section, operator
compartment, and cab. The instructions for removal and installation of the engine are included in this section.
If the lift truck is fitted with a battery disconnect
switch, open the switch if welding on the engine and
remove the ECM (Engine Control Module). If weld-
ing on the lift truck chassis, verify the ground clamp
is placed as close to the welding point as possible and
NOT near the ECM. If it is necessary to weld near
the ECM, remove the ECM from the engine to avoid
damage from welding arc radiation.
Description
The frame is a one-piece weldment and has mounts
for the counterweight, fenders, engine, transmission,
axles, hydraulic and fuel tanks, operator’s compart-
ment, and other parts. See Figure 1.
1. MAIN MOUNT
2. COUNTERWEIGHT MOUNT
3. STEERING MOUNT
4. DRIVE AXLE MOUNT
5. TILT CYLINDERS MOUNT
6. CAB CYLINDER MOUNT
7. CAB HINGE
8. MAST MOUNT
9. SIDE COUNTERWEIGHT MOUNT
10. FENDERS
11. CAB LATCH MOUNT
Figure 1. Frame
Counterweight Repair
REMOVE
WARNING
The counterweight is heavy. Make sure that
the crane and lifting devices have the capacity
to lift 4600 kg (10,141 lb).
1. Remove the hood spine assembly. See Hood and
Air Cleaner Repair.
2. H8.00-12.00XM (H170-280HD) units only. Re-
move the counterweight by placing an eyebolt
through the hole in the top of the counterweight.
See Figure 2. The eyebolt must be able to sup-
port the weight of the counterweight. Attach a
lifting device to eyebolt.
1

3. Counterweight Repair 100 SRM 927
H13.00-16.00XM (H300-360HD) and H10.00-
12.00XM-12EC (H330-360HD-EC) units. Re-
move the fenders, noting shims used and location
of shims. Remove the radiator fan, shroud, and
hardware. Tilt the radiator away from the coun-
terweight so there is clearance when removing
the counterweight. See Figure 2. Install eyebolt
into the top of the counterweight. The eyebolt
must be able to support the weight of the coun-
terweight. Attach lifting device.
3. Remove the single capscrew from the rear of the
counterweight. Remove the counterweight from
the frame.
1. LH FENDER
COUNTERWEIGHT
2. RH FENDER
COUNTERWEIGHT
3. CAPSCREW
4. WASHER
5. NUT
6. WASHER
7. TOW PIN
8. GRIP
9. PIN
10. PIN
11. SHIM
12. WASHER
13. LOCKWASHER
14. WASHER
15. SHIM
16. SHIM
17. SHIM
18. COUNTERWEIGHT
19. CAPSCREW
20. SLAB COUNTERWEIGHT
21. PLATE
22. LOCKWASHER
23. CAPSCREW
24. RH SLAB COUNTERWEIGHT
25. LH SLAB COUNTERWEIGHT
26. CAPSCREW
27. WASHER
28. WASHER
29. NUT
30. ISOLATOR
31. LOCKWASHER
32. NUT
33. RUBBER STOP
Figure 2. Counterweight Mounts
2

4. 100 SRM 927 Counterweight Repair
INSTALL
WARNING
The counterweight is heavy. Make sure that
the crane and lifting devices have the capacity
to lift 4600 kg (10,141 lb).
1. Put a chain into top opening of the counterweight
and attach chain to a lifting device. See Figure 2.
2. H13.00-16.00XM (H300-360HD) and H10.00-
12.00XM-12EC (H330-360HD-EC) units only.
Install the radiator hardware. Tilt the radiator
ahead so there is clearance for the chain that is
installed through the counterweight.
3. Install the counterweight on the frame. Install
the capscrew, lockwasher, and flat washer to fas-
ten the counterweight to the frame. Tighten the
capscrew to 1140 N•m (841 lbf ft).
FENDERS
Remove
WARNING
The fenders are part of the lift truck counter-
weight and are very heavy. Make sure any lift-
ing devices have the capacity to lift 1750 kg
(3858 lb). Make sure the fender is balanced and
supported by the chain. The fenders are not of
a regular shape and can be difficult to handle.
1. Remove the capscrews, washers, and nuts that
fasten the fender to the frame mount. Install
eyebolts in the mount holes. Use mount holes to
pick up fender from frame.
2. Fasten a lifting device to the eyebolts. Operate
the lifting device and lift the fender away from
the frame.
Install
1. Install eyebolts in the fenders as described in Re-
move, Step 1. Fasten a lifting device to the eye-
bolts.
2. Raise the fender to the lift truck. Align the eye-
bolts in the fender with the holes in the fender
mount on the frame. Shim fenders to correct
height. Lower the fender to the fender mount
and 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 (236 lbf ft).
SIDE COUNTERWEIGHTS H13.00-16.00XM
(H300-360HD)
The counterweights located on either side of the lift
truck are fastened to the frame by large capscrews.
Normally these counterweights will never have to be
removed or replaced on the lift truck.
SIDE COUNTERWEIGHT, REPLACE
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 lift-
ing devices have the capacity to lift 908 kg
(2433 lb).
1. Remove the extension covers from both side
tanks.
2. Remove each counterweight capscrew and re-
place 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 counter-
weight away from the frame about 50 mm (2 in.).
Install a nylon lifting sling securely around the
counterweight and attach 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 or-
der. Tighten the counterweight capscrews to
655 N•m (483 lbf ft).
3

5. Hood and Air Cleaner Repair 100 SRM 927
Hood and Air Cleaner Repair
The hood and air cleaner assembly, which includes
the rain cap or optional precleaner and inlet pipe,
can be removed from the frame as a single unit, or
pivoted out of the way for access.
REMOVE
NOTE: The hood and air cleaner assembly can be piv-
oted out of the way to gain access to many compo-
nents. In order to pivot hood and air cleaner assem-
bly, remove 2 bolts, nuts, and washers at one side
connecting hood to hood spine support and loosen the
2 bolts at opposite side.
1. Unlock hood with an allen wrench.
2. Open hood panel until gas spring locks hood
panel in open position.
3. Attach a lifting device and sling to support hood
spine and attaching components. See Figure 3
and Figure 4.
1. HOOD SPINE HARDWARE
2. HOOD SPINE
3. COUNTERWEIGHT
4. HOOD SPINE SUPPORT
5. AIR INTAKE HOSE
6. EXHAUST STACK CLAMP
7. RAIN CAP
8. GAS SPRING
9. HOOD PANEL
10. EXHAUST STACK
Figure 3. Hood and Air Cleaner Assembly (E019 and F007)
4

6. 100 SRM 927 Hood and Air Cleaner Repair
1. HOOD SPINE HARDWARE
2. HOOD SPINE
3. COUNTERWEIGHT
4. HOOD SPINE SUPPORT
5. AIR INTAKE HOSE
6. EXHAUST STACK CLAMP
7. RAINCAP
8. HOOD PANEL
9. EXHAUST STACK
Figure 4. Hood and Air Cleaner (F019 and G007)
4. Loosen air intake hose to turbocharger at inlet
side of turbocharger.
5. Loosen clamps at upper exhaust stack.
6. Remove bolts, nuts, washers, and bar washers
that fasten hood spine to counterweight and hood
support.
7. Disconnect washer hoses from washer container
and mark for reconnecting.
8. Disconnect the washer hoses from hood and air
cleaner assembly.
9. Using lifting device, lift hood assembly from
frame. Air filter assembly and exhaust stack
will remain attached to hood and spine assembly.
5

7. Hydraulic Tank Repair 100 SRM 927
INSTALL
Install the hood and air cleaner assembly in the re-
verse procedure of removal and align the hood as
necessary during installation. Make sure the hood
side panels close completely and that the cushioned
screw stops (bumpers) are located correctly.
Hydraulic Tank Repair
The hydraulic tank is installed on the right side of
the frame between the front and rear fenders.
REMOVE
1. Remove the side cover between the bottom of
the operator compartment and the top of the hy-
draulic tank. See Figure 5. If necessary, remove
the drain plug at the bottom of the tank to drain
the oil. See Figure 6 and Figure 7.
2. Remove the extension panel.
NOTE: Do not remove items 14, 15, 16, and 17 from
the tank.
3. 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 hydraulic lines. Put tags on the
lines for identification. Put caps on the open lines
and the fittings.
WARNING
Make sure that the tank is supported by blocks
before removing the nuts and washers from the
top of the tank.
4. 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.
1. HYDRAULIC TANK
2. BATTERY BOX
3. FRAME
4. SIDE COVER
5. NUT AND WASHER
6. EXTENSION PANEL
Figure 5. Hydraulic Tank and Battery Box
6

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9. 100 SRM 927 Hydraulic Tank Repair
1. WASHER (3)
2. LOCKWASHER (3)
3. BREATHER
4. FILTER HEAD
5. O-RING
6. DIPSTICK
7. O-RING
8. SEAL
9. SPRING
10. WASHER
11. FILTER
12. DRAIN PLUG
13. NUT (3)
14. ADAPTER
15. ADAPTER
16. HYDRAULIC TANK
17. O-RING
18. RETAINING RING
19. FITTING
20. FITTING
21. PLUG
Figure 6. Hydraulic Tank (F007 and E019)
1. SIGHT GLASS
2. FILTER
3. FILTER HEAD
4. SPRING
5. O-RING
6. CAPSCREW
7. PLUG
8. BREATHER
9. WASHER
10. NUT
11. DRAIN PLUG
12. O-RING
13. HYDRAULIC TANK
14. COVER
15. SEAL
16. WASHER
17. CAPSCREW
Figure 7. Hydraulic Tank (G007 and F019)
REPAIRS, ALL UNITS
Small Leaks
Use the following procedures to repair small leaks:
1. Use steam to clean the area around the leak. Re-
move 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 explosion.
2. Apply Loctite® 290 to the leak. Follow the in-
structions of the manufacturer.
7

10. Hydraulic Tank Repair 100 SRM 927
Large Leaks
1. Use one of the procedures described under Clean-
ing to clean and prepare the tank for repairs.
CAUTION
Welding on the truck may cause damage to the
engine, transmission, and/or hydraulic elec-
tronic control units if proper precautions are
not taken. Disconnect the negative battery ter-
minal from the battery. Disconnect all ECM’s.
If welding must be done in a close proximity
of an ECM, that ECM must be removed. When
welding to the chassis, attach the ground cable
as close to the weld as possible.
2. Use acceptable welding practices to repair the
tank. See the American National Standard
Safety in Welding and Cutting AWS Z 49.1 -
1999.
CLEAN
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 ventila-
tion. See the following manuals for additional
information:
CAUTION
Welding on the truck may cause damage to the
engine, transmission, and/or hydraulic elec-
tronic control units if proper precautions are
not taken. Disconnect the negative battery ter-
minal from the battery. Disconnect all ECM’s.
If welding must be done in a close proximity
of an ECM, that ECM must be removed. When
welding to the chassis, attach the ground cable
as close the weld as possible.
• Safe Practices for Welding and Cutting Contain-
ers That Have Held Combustibles by the American
Welding Society, F4.1 - 1999.
• Safety in Welding and Cutting, American National
Standard, AWS Z 49.1 - 1999.
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 mini-
mum diameter of 19 mm (0.75 in.). Control the pres-
sure 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 does not make sparks. Make an elec-
trical connection between the nozzle and the tank.
Connect a ground wire to the tank to prevent static
electricity.
Steam Method
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
sodium bicarbonate or sodium carbonate. Mix
0.5 kg (1 lb) per 4 liter (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.
WARNING
When making inspections, use light that is ap-
proved for locations with flammable vapors.
6. Make an inspection of the inside of the tank. If it
is not clean, repeat Step 4 and Step 5 and make
another inspection.
7. Put plugs in all the openings in the tank. Wait 15
minutes, then remove the inlet and outlet plugs.
Test a sample of the vapor with a special indi-
cator for gas vapors. If the amount of flammable
vapors is above the lower flammable limit, repeat
the cleaning procedures.
8

11. 100 SRM 927 Hydraulic Tank Repair
Chemical Solution Method
If the tank cannot be cleaned with steam, use the
following procedure:
1. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Fol-
low the instructions 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.
WARNING
When making inspections, use a light that is ap-
proved for locations with flammable vapors.
4. Make an inspection of the inside of the tank.
If the tank is not clean, repeat Step 1 through
Step 3. Make another inspection of the tank.
5. Check the tank for flammable vapors using
special indicator for gas vapors. If the amount
of flammable vapors 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 Ameri-
can Welding Society, F4.1 - 1999. If these gases are
not available, another method using water can be
used as follows:
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.
CAUTION
Welding on the truck may cause damage to the
engine, transmission, and/or hydraulic elec-
tronic control units if proper precautions are
not taken. Disconnect the negative battery ter-
minal from the battery. Disconnect all ECM’s.
If welding must be done in a close proximity
of an ECM, that ECM must be removed. When
welding to the chassis, attach the ground cable
as close the weld as possible.
2. Use acceptable welding practices to repair the
tank. See the American National Standard
Safety in Welding and Cutting AWS Z 49.1 -
1999.
INSTALL
NOTE: When installing the filter after cleaning, it is
important that you grease the O-ring before installa-
tion.
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. Install the lower three
capscrews and washers that fasten 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. Install the extension piece and side cover. See
Figure 5.
5. Fill the hydraulic tank to the correct level with
the oil specified in the maintenance table. See
the section Periodic Maintenance 8000 SRM
934 for E019 and F007 trucks or Periodic
Maintenance 8000 SRM 1099 for F019 and
G007 trucks.
9

12. Fuel Tank Repair 100 SRM 927
Fuel Tank Repair
The fuel tank is installed on the left-hand frame
channel. See Figure 8.
REMOVE
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. Remove the extension piece between fuel tank
and frame.
3. Disconnect the fuel lines at the tank.
WARNING
Make sure that the tank is supported by blocks
before removing the nuts and washers from the
top of the tank.
4. 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.
REPAIRS
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
Repair the fuel tank as described in the repair proce-
dures for the hydraulic tank.
INSTALL
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 pro-
vide 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 cap-
screws, then install the three nuts and washers
that fasten the bottom of the fuel tank to the run-
ning board.
3. Connect the fuel lines to the tank.
4. Install extension piece between fuel tank and
frame.
5. Fill fuel tank to the correct level per specifica-
tions. See the section Periodic Maintenance
8000 SRM 934 for E019 and F007 trucks or Pe-
riodic Maintenance 8000 SRM 1099 for F019
and G007 trucks.
Legend for Figure 8
1. HOSE
2. HOSE
3. CLAMP STRAP
4. FUEL TANK
5. PLUG
6. OIL SEAL
7. FITTING
8. TUBE
9. FITTING
10. TUBE
11. CLAMP
12. TUBE
13. FITTING
14. FITTING
15. TUBE
16. FITTING
17. FITTING
18. CLAMP
19. BRACKET
20. CAPSCREW
21. WASHER
22. FILTER
23. CAPSCREW
24. WASHER
25. NUT
26. WASHER
27. NUT
28. O-RING
29. PIPE PLUG
30. WASHER
31. STRAP
32. CLAMP
33. TUBE
34. FITTING
35. FITTING
36. FUEL CAP
10

13. 100 SRM 927 Fuel Tank Repair
Figure 8. Fuel Tank
11

14. Cooling System and Radiator Repair 100 SRM 927
Cooling System and Radiator Repair
REMOVE
1. Disconnect the cables at the battery. (Remove the
ground cable first.) Remove the bracket for the
battery cables.
2. Pivot hood and spine assembly to right side. See
Hood and Air Cleaner Repair.
3. Let the coolant cool to room temperature. Put
drain pan under radiator. Remove radiator cap.
Open the drain valve and drain the radiator. Dis-
connect the coolant hoses at the radiator. See
Figure 9 and Figure 10.
4. Disconnect charged air cooler hoses from the
charged air cooler (F019/G007 Perkins engine
only).
5. Remove four capscrews and washers mounting
the charged air cooler (F019/G007 Perkins en-
gine only).
6. Disconnect the transmission oil lines at the radi-
ator.
7. Cap an plug all open lines.
8. Remove the fan from the drive pulley (Perkins
engine only).
9. Remove the capscrews between the fan shroud
and the radiator.
10. Remove the two capscrew and grommet assem-
blies that hold the radiator shroud to the bracket
on the frame. Remove the radiator and shroud.
1. COOLANT RECOVERY TANK
2. RADIATOR CAP
3. RADIATOR
4. TOP HOSE
5. RADIATOR SHROUD
6. CHARGED AIR COOLER
7. BRACKET ON FRAME
8. FRAME
9. LOWER HOSE
10. BRACKET
11. ISOLATOR PIN
12. DRAIN VALVE
13. FAN
14. V-BELT
15. CAPSCREW
16. WASHER (2)
17. GROMMET
18. NUT
19. TRANSMISSION OIL COOLER IN/OUT
Figure 9. Cooling System/Radiator (E019/F007)
12

15. 100 SRM 927 Cooling System and Radiator Repair
1. COOLANT RECOVERY TANK
2. RADIATOR CAP
3. RADIATOR
4. TOP HOSE
5. RADIATOR SHROUD
6. CHARGED AIR COOLER
7. BRACKET ON FRAME
8. FRAME
9. LOWER HOSE
10. BRACKET
11. ISOLATOR AND/WITH PIN
12. DRAIN VALVE
13. FAN
14. CAPSCREW
15. LOCKWASHER
16. WASHER
17. NUT
18. TRANSMISSION OIL COOLER IN/OUT
19. WASHER
20. CAPSCREW
21. GROMMET
Figure 10. Cooling System/Radiator (F019/G007 Perkins Engine Shown)
INSTALL
1. Install the radiator and shroud in the frame. In-
stall 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. Install the fan on the drive pulley.
3. Connect the coolant hoses to the radiator.
4. Connect the transmission oil lines to the bottom
of the radiator.
5. Install four capscrews and washers mounting the
charged air cooler (Perkins engine only).
6. Connect charged air cooler hoses to the charged
air cooler (Perkins engine only).
7. Pivot hood and spine assembly back into position
and tighten mounting hardware.
13

16. Engine and Transmission Repair 100 SRM 927
8. Fill the radiator with coolant. See Maintenance
Schedule in the section Periodic Maintenance
8000 SRM 934 for E019 and F007 trucks or Pe-
riodic Maintenance 8000 SRM 1099 for F019
and G007 trucks, for quantity and antifreeze re-
quirements.
Engine and Transmission Repair
See engine manufacturer’s repair manual for repair
of the engine. See the section Three-Speed Pow-
ershift Transmission, Repairs (Hyster Model
T-50) 1300 SRM 931 for transmission repairs.
The removal of this transmission is described later in
this section. See Hyster T-50 Transmission, Remove.
HYSTER T-50 TRANSMISSION, REMOVE
NOTE: The transmission can be removed from above
or under the lift truck. See Figure 11.
1. Remove the forks. Put the lift truck on blocks
so that there is access under the lift truck. See
"How to Put Lift Truck on Blocks" in the section
Operating Manual or the section Periodic
Maintenance 8000 SRM 934 for E019 and F007
trucks or Periodic Maintenance 8000 SRM
1099 for F019 and G007 trucks. Tilt the mast
fully forward to release hydraulic pressure in
the system.
2. Disconnect the cables at the battery. (Remove the
ground cable first.) Remove the bracket for the
battery cables.
3. Tilt the operator compartment up to remove the
engine and transmission.
4. Drain the coolant from the cooling system. See
Cooling System and Radiator Repair.
5. Disconnect the exhaust system. Remove the
header pipe at the exhaust manifold.
6. Disconnect the air lines at the air compressor.
Loosen the fittings slowly to vent any compressed
air.
7. Disconnect fuel lines at the fuel tank. Disconnect
throttle linkage.
8. Disconnect wires and wiring harnesses at the en-
gine. Disconnect the heater hoses at the engine.
9. Disconnect the drive shaft at the yokes. Remove
the drive shaft between the transmission and the
differential.
10. Disconnect the wiring harnesses on top of the
transmission. Disconnect the wires at the
solenoids on the transmission control valve. Dis-
connect the wires at the pressure sending unit
and the temperature sending unit on the trans-
mission. Put identification tags on the wires so
that they can be correctly connected again.
11. Apply the service brakes repeatedly until the air
pressure in the air tank decreases to 0 kPa (0 psi)
or pressure is removed from hydraulic system
on wet brakes. Disconnect the air brake hose
from the air tank so that there is clearance at the
transmission.
12. Disconnect the wire to the starter solenoid.
13. Disconnect the cables at the spools on the trans-
mission control valve. Remove the linkage
bracket from the transmission housing.
14. Remove the drain plug from the transmission
sump to drain the oil from the transmission [ap-
proximately 28 liter (30 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.
15. Disconnect the oil hoses at the hydraulic pump.
Disconnect the hose from the hydraulic pump to
the steering system. Put plugs and caps on the
open fittings.
16. The hydraulic pump is fastened to the transmis-
sion 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 in splines in the
drive gear. The drive shaft of the hydraulic pump
will slide from the drive gear when the hydraulic
pump is removed.
17. Disconnect and remove the dipstick assembly
from the transmission.
14

17. 100 SRM 927 Engine and Transmission Repair
1. FRAME (REFERENCE)
2. DIPSTICK ASSEMBLY
3. DRIVE SHAFT
4. OUTPUT YOKE
5. TRANSMISSION MOUNT
6. STARTER SOLENOID
7. TORQUE CONVERTER
Figure 11. Hyster T-50 Transmission Arrangement
18. The temperature sender for the transmission oil
can be easily damaged. Remove the temperature
sender from the transmission sump.
19. 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 sup-
port is across the width of the oil sump so that
the weight of the engine does not damage the oil
sump.
20. A 5/8" machined hole with UNC (United National
Course) threads is in the top of the transmission
housing. Install an eyebolt in the 5/8" UNC hole.
Connect a lifting device to the engine and trans-
mission. Make sure the lifting device has a ca-
pacity of at least 1200 kg (2650 lb).
21. Remove the two 3/4 × 3 1/2 inch bolts that fas-
ten the transmission mounts to the frame. These
bolts have been tightened to 270 N•m (199 lbf ft).
22. Remove the capscrews that hold the engine
mount brackets to the frame mounts.
23. Make sure all the connections have been re-
moved. Carefully lift the engine and transmis-
sion assembly from the frame.
HYSTER T-50 TRANSMISSION, INSTALL
1. If the mounts were removed from the sides of the
transmission housing, install them and tighten
the capscrews to 270 N•m (199 lbf ft).
2. Connect a lifting device to the engine and trans-
mission. Make sure the lifting device has a ca-
pacity of at least 1200 kg (2650 lb).
3. Install the engine and transmission assembly in
the frame. Install and tighten the nuts and cap-
screws for the engine and transmission mounts.
Install the two 3/4 × 3 1/2 inch bolts (Figure 11)
for the transmission mounts. Tighten the lock
nuts to 270 N•m (199 lbf ft).
4. Connect the drive shaft to the yoke on the trans-
mission. Make sure the slip joint is installed as
shown in Figure 11. Tighten the capscrews at the
yoke to 50 N•m (37 lbf ft).
5. Install the dipstick assembly on the transmis-
sion.
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
15