100 SRM 545 Operator Module Repair
General
This section has the description of the frame and
some connected parts. See Figure 1. Procedures for
the removal and installation of the counterweight,
hood, overhead guard, and engine (including the
transmission) are under Counterweight Repair,
Hood and Side Covers Repair, Overhead Guard
Repair, and Engine Repair. Checks for the operator
restraint system, repair procedures for the tanks,
and replacement procedures for the safety labels are
also included.
Description
The frame is one weldment and includes the hy-
draulic tank and the fuel tank for gasoline or diesel
fuel. (Diesel fuel is not used on the S25-35XM or
S40XMS.)
There is a counterweight for each capacity of lift
truck. The counterweights are similar, but are
different weights. The muffler is fastened to the
frame inside the counterweight.
An operator module is installed on the frame with
rubber mounts. The overhead guard, steering con-
trols, hydraulic control valve, instrument panel, and
the hood and seat are installed on the operator mod-
ule.
Thehoodisconnectedtotheoperatormodulewith
hinges. Two torsion springs assist in raising the
hood. A support rod holds the hood in the open
position. The floor plates and side covers can be
removed for access to the engine, transmission, and
other components.
Operator Module Repair
REMOVE
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine, transmission, and the counter-
weight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
•Before removing the mast and drive axle, put
blocks under the counterweight so the lift
truck cannot fall backward.
•Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that
anyblocksusedtosupportthelifttruckare
solid, one-piece units. See the Operating Man-
ual or the section Periodic Maintenance 8000
SRM 531.
1. Remove hood and side covers.
2. Remove three capscrews that hold hydraulic con-
trol valve to mounting bracket.
3. Remove steering housing and instrument cluster
from cowl. Remove capscrews that hold parking
brake lever to cowl.
4. Remove nuts at mounts for operator module.
5. Connect lifting device to overhead guard. Over-
head guard and module weigh approximately
385 kg (850 lb). Lift operator module from frame.
SeeFigure1.
NOTE: The module is supported by two different
types of rubber mounts. Mark the mounts for proper
installation.
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