Hyster H70XM User manual

Hyster L005 (H70XM-H120XM) Forklift

FRAME
H3.50-5.50XM (H70-120XM) [K005, L005]
PART NO. 1467898 100 SRM 726

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
•Keep the unit clean and the working area clean and orderly.
•Use the correct tools for the job.
•Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Frame Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Counterweight Repair ....................................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Install ............................................................................................................................................................. 2
Hood Repair........................................................................................................................................................ 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 2
Overhead Guard Repair .................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Inspect ............................................................................................................................................................ 4
Install ............................................................................................................................................................. 4
LED Backup and Brake Lights, Replace...................................................................................................... 4
Remove....................................................................................................................................................... 4
Install......................................................................................................................................................... 4
Operator Restraint System Repair ................................................................................................................... 5
Radiator Repair.................................................................................................................................................. 6
Remove ........................................................................................................................................................... 6
Install ............................................................................................................................................................. 6
Exhaust System Repair ..................................................................................................................................... 8
Muffler............................................................................................................................................................ 8
Remove....................................................................................................................................................... 8
Install......................................................................................................................................................... 8
LPG/Gas Engine Exhaust Pipe - Lift Trucks Without Low Emissions....................................................... 8
Remove....................................................................................................................................................... 8
Install......................................................................................................................................................... 11
EPA Compliant LPG/Gas Engine Exhaust System ..................................................................................... 11
Remove....................................................................................................................................................... 11
Install......................................................................................................................................................... 13
Diesel Engine Exhaust Pipe.......................................................................................................................... 13
Remove....................................................................................................................................................... 13
Install......................................................................................................................................................... 15
Engine Repair .................................................................................................................................................... 15
Remove ........................................................................................................................................................... 15
Install ............................................................................................................................................................. 17
Throttle Pedal Adjustment................................................................................................................................ 19
Perkins 1104C-44(RE) Diesel Engine........................................................................................................... 19
Lift Trucks With an Accelerator Pedal..................................................................................................... 19
Lift Trucks With a MONOTROL Pedal....................................................................................................20
Fuel and Hydraulic Tanks Repair..................................................................................................................... 22
Inspect ............................................................................................................................................................ 22
Small Leaks, Repair ...................................................................................................................................... 22
Large Leaks, Repair ...................................................................................................................................... 22
Clean .............................................................................................................................................................. 22
Steam Method............................................................................................................................................ 22
Chemical Solution Method........................................................................................................................ 23
Other Preparation Methods for Repair ........................................................................................................ 23
Safety Labels...................................................................................................................................................... 23
©2004 HYSTER COMPANY i

Table of Contents Frame
TABLE OF CONTENTS (Continued)
This section is for the following models:
H3.50-5.50XM (H70-120XM) [K005, L005]
ii

100 SRM 726 Counterweight Repair
General
This section has the description and repair procedures for the frame and connected parts. Included in this sec-
tion are the frame, counterweight, hood, hydraulic and fuel tanks, radiator, exhaust system, and cab assembly.
Also included are the instructions for removal and installation of the engine.
Description
The frame is a one-piece weldment and has mounts for the counterweight, overhead guard, operator’s module,
engine and transmission, axles, and other parts. The hydraulic tank and fuel tank are part of the frame.
Counterweight 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 and transmission, and counter-
weight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. 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.
WARNING
Make sure that the lifting device used has the
correct lift capacity for the counterweight be-
ing removed. See Table 1.
1. If installed, remove the overhead exhaust pipe
from the counterweight. See Figure 1.
2. Remove cover between counterweight and hood.
Remove tow pin.
Table 1. Weight of Counterweights
Weight
Lift Truck (kg) (lb)
H3.50XM
(H70XM)
1787 to 1843 3931 to 4055
H4.00XM
(H80XM)
2068 to 2132 4550 to 4690
H4.00XM
(H90XM)
2245 to 2315 4939 to 5093
H4.50XM
(H100XM)
2610 to 2690 5742 to 5918
H5.00XM
(H110XM)
2906 to 29946393 to 6587
H5.50XM
(H120XM)
3102 to 3198 6824 to 7036
3. Install two eyebolts into the counterweight lift-
ing holes and attach a lifting device to the eye-
bolts.
CAUTION
When lifting the counterweight from the lift
truck, be careful not to bend the exhaust pipe.
4. Remove two capscrews, washers, and lockwash-
ers. Remove counterweight from lift truck.
1

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Hood Repair 100 SRM 726
1. COUNTERWEIGHT
2. LIFTING DEVICE
3. LIFTING EYE
4. WASHER
5. LOCKWASHER
6. MOUNTING BOLT
Figure 1. Counterweight
INSTALL
1. Install counterweight in place on the lift truck.
See Figure 1. Install two lockwashers, washers,
and capscrews. Tighten capscrews to 555 N•m
(409 lbf ft).
2. Remove eyebolts from counterweight lifting
holes.
3. Install tow pin. Install cover between hood and
counterweight.
4. If removed, install the overhead exhaust pipe
in the counterweight. Tighten the capscrews to
38 N•m (28 lbf ft).
Hood 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 counterweight.
Whenthelifttruckisputonblocks,putad-
ditional blocks in the following positions to
maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. 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.
1. Raise the hood and disconnect the two gas-assist
cylinders at the hood. Disconnect the park brake
alert wiring harness.
2. Remove the pins that hold the hood hinges to
the operator’s module crossmember. Remove the
hood.
INSTALL
1. Install the hood in position on the lift truck. In-
stall the pins that hold the hood hinges to the op-
erator’s module crossmember.
2. Connect the two gas-assist cylinders to the hood.
Connect the park brake alert wiring harness.
2

100 SRM 726 Hood Repair
WARNING
The hood, hood latch, and hood striker must be
correctly adjusted for the correct operation of
the operator restraint system.
3. Adjust the hood latch (see Figure 2) as follows:
a. Center the latch striker in the slot located in
the rear crossmember. Check that the latch
striker is in the center of the jaws of the hood
latch and tighten.
b. Loosen the capscrews for the hood latch just
enough to let the latch move. Position the
latch. Tighten the capscrews for the latch.
c. Check the operation of the hood latch. Have
an operator sit in the seat. Make sure that
the hood is fully closed (two clicks). Also,
check that the hood touches the rubber
bumpers. If necessary, repeat Step b.
1. LATCH STRIKER
2. HOOD LATCH
3. LATCH LEVER
4. SEAT
5. SEAT BELT LATCH
6. HIP RESTRAINT
7. SEAT RAIL
8. HOOD
9. HINGE
10. OPERATOR WEIGHT ADJUSTMENT
11. FORWARD/BACKWARD ADJUSTMENT
Figure 2. Hood and Seat Latches Check
3

Overhead Guard Repair 100 SRM 726
Overhead Guard 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 and transmission, and counter-
weight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so that
the lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the mast assembly so that the
lifttruckcannotfallforward.
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.
WARNING
Donotoperatethelifttruckwithouttheover-
head guard correctly fastened to the lift truck.
Do not make changes to the overhead guard by
welding. Changes that are made by welding, or
by drilling holes that are too big in the wrong
location, can reduce the strength of the over-
head guard. See the instructions for Changes
to the Overhead Guard in the Periodic Mainte-
nance section included with this lift truck.
Connect a lifting device to the top of the overhead
guard. Remove the capscrews that hold the overhead
guard to the frame. Remove the capscrews that hold
the overhead guard to the cowl and module. Lift the
overhead guard from the lift truck.
INSPECT
Inspect the condition of the mount isolators located
at the rear legs of the overhead guard for any dam-
age. Replace if damaged.
INSTALL
1. Connect a lifting device to the top of the overhead
guard.Puttheoverheadguardinpositiononthe
lift truck.
2. Install the capscrews at the rear of the over-
head guard. Tighten the capscrews to 90 N•m
(67 lbf ft). Install the capscrews that hold the
overhead guard to the cowl. Tighten the cap-
screws to 90 N•m (67 lbf ft).
LED BACKUP AND BRAKE LIGHTS,
REPLACE
NOTE: Newer models of lift trucks are equipped
with LED (Light Emitting Diode) backup and brake
tail lights. These light assemblies are non-repairable
and must be replaced as a complete unit. See the
Parts Manual for replacement LED lights.
Remove
1. Disconnect negative terminal of battery and, re-
move the key.
2. Disconnect the LED light from the chassis light
harness.
3. Remove LED light assembly and harness from
mounting bracket. See Figure 3.
4. If the LED mounting bracket must be removed
from the overhead guard leg, remove the plug,
screw and bracket from the overhead guard leg.
Install
1. If the mounting bracket was removed, install it
onto the overhead guard leg. Insert the plug and
screw to attach mounting bracket to overhead
guard leg. See Figure 3.
2. Install the LED light assembly and harness on
the mounting bracket.
3. Connect the LED light to the chassis light har-
ness.
4. Connect the negative terminal of battery and
close the hood.
4

100 SRM 726 Operator Restraint System Repair
Figure 3. LED Backup and Brake Lights
Assembly
Legend for Figure 3
A. LED ASSEMBLY WITH STANDARD EXHAUST
B. LED ASSEMBLY WITH OVERHEAD EXHAUST
1. LED LIGHT
2. SCREW
3. WASHER
4. LOCKNUT
5. MOUNTING BRACKET
6. GROMMET
7. PLUG
8. SCREW
9. OVERHEAD GUARD LEG
Operator Restraint System Repair
WARNING
The lifttruckmustbeputonblocksforsome
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine and transmission, and counter-
weight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the mast assembly so the lift
truckcannotfallforward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that
any blocksusedtosupportthelifttruckare
solid, one-piece units.
The seat belt, hip restraint brackets, seat and mount-
ing, hood, and latches are all part of the operator re-
straint system. Each item must be checked to make
sure it is attached securely, functions correctly, and
is in good condition. See Figure 2.
The seat belt must fasten securely. Make sure the
seat belt extends and retracts smoothly and is not
frayed or torn. If the seat belt is damaged or does
notoperateproperly,itmustbereplaced.
Make sure the seat rails and latch striker are not
loose. The seat rails must lock securely in position,
but move freely when unlocked. The seat rails must
be securely attached to the mounting surface. The
hood must be fully closed. Lift on the hood to make
sure it is closed and will not move.
Adjust the hood, hood latch, and latch striker when
any of the parts of the operator restraint system are
installed or replaced. See the Hood Repair proce-
dures.
5

Radiator Repair 100 SRM 726
Radiator 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 and transmission, and counter-
weight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. 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.
1. Remove the cover between the hood and counter-
weight. SeeFigure4.
WARNING
Disposal of coolant must be in accordance with
local regulations.
NOTE: To aid in the draining of coolant from the ra-
diator, remove the radiator cap.
2. Drain the coolant from the radiator.
3. Disconnect the upper and lower coolant hoses
from the radiator.
4. Disconnect the hydraulic hoses from the radiator
and install plugs in the hoses.
5. On the GM-powered lift truck, remove the clamp
and hose from the bottom of the radiator.
6. Remove the top radiator support plate.
7. Disconnect the coolant recovery reservoir hose
from the radiator.
8. Remove the coolant recovery reservoir from the
overhead guard leg.
9. Remove the upper and lower fan shroud halves
from the radiator.
10. Remove the radiator from the lower radiator
mounting plate.
INSTALL
1. Install the rubber isolators on the lower radiator
locating studs. See Figure 4.
2. Install the radiator on the lower radiator mount-
ing plate.
3. Install the upper and lower fan shroud halves on
the radiator.
4. Install the coolant recovery reservoir on the over-
head guard leg.
5. Connect the coolant recovery reservoir hose to
the radiator.
6. Install the rubber isolators on the upper radiator
locating studs.
7. Install the top radiator support plate. Tighten
the outer screws to 66 N•m (49 lbf ft). Tighten
the inner screws to 38 N•m (28 lbf ft).
8. On the GM-powered lift truck, install the hose
and clamp on the bottom of the radiator.
9. Connect the upper and lower coolant hoses to the
radiator.
10. Connect the hydraulic hoses to the radiator.
CAUTION
To prevent possible damage to the engine,
make sure the engine is running at idle speed
while performing Step 11.
11. Add coolant to the system until the entire cooling
system is full.
12. Install the cover between the hood and counter-
weight.
6

100 SRM 726 Radiator Repair
Figure 4. Radiator
7

Exhaust System Repair 100 SRM 726
Legend for Figure 4
A. PERKINS DIESEL 1004.42 B. GM 4.3L V-6
1. COVER
2. HOOD
3. COUNTERWEIGHT
4. RADIATOR
5. HOSE
6. HOSE
7. CLAMP
8. RADIATOR SUPPORT PLATE
9. COOLANT RECOVERY RESERVOIR HOSE
10. COOLANT RECOVERY RESERVOIR
11. OVERHEAD GUARD LEG
12. LOWER RADIATOR MOUNTING PLATE
Exhaust System Repair
MUFFLER
Remove
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine and transmission, and counter-
weight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. 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.
1. Remove the overhead exhaust pipe from the
counterweight. See Figure 5 or Figure 6.
2. Remove the counterweight. See Counterweight
Repair, Remove in this SRM.
3. Remove the lower exhaust pipe from the muffler
and disconnect the upper exhaust pipe from the
muffler.
4. Remove the muffler from the mounting bracket.
Install
1. Install the muffler on the mounting bracket.
Tighten bolts until all clearance has been re-
moved; then tighten one additional turn. See
Figure 5 or Figure 6.
2. Connect the upper exhaust pipe to the muffler
and install the lower exhaust pipe on the muffler.
3. Install the counterweight on the lift truck. See
Counterweight Repair, Install in this SRM.
4. Install the overhead exhaust pipe in the coun-
terweight. Tighten the capscrews to 38 N•m
(28 lbf ft).
LPG/GAS ENGINE EXHAUST PIPE - LIFT
TRUCKS WITHOUT LOW EMISSIONS
Remove
NOTE: If the lift truck does not have an overhead
exhaust, perform Step 2 and Step 4 through Step 8.
If the lift truck has an overhead exhaust, perform
Step 1 through Step 3 and Step 5 through Step 8.
1. Remove the overhead exhaust pipe from the
counterweight.SeeFigure5andFigure6.
2. Remove the counterweight. See Counterweight
Repair, Remove in this SRM.
3. Remove the lower exhaust pipe from the right
side of the muffler and disconnect the upper ex-
haust pipe from the left side of the muffler.
4. Remove the counterweight exhaust pipe from the
right side of the muffler and disconnect the upper
exhaust pipe from the left side of the muffler.
8

100 SRM 726 Exhaust System Repair
1. LEFT ENGINE EXHAUST PIPE
2. RIGHT ENGINE EXHAUST PIPE
3. UPPER EXHAUST PIPE
4. MUFFLER
5. SEAL
6. FLANGE
7. HEX HEAD BOLT
8. SPRING
9. CLAMP
10. OVERHEAD EXHAUST
11. LOWER EXHAUST PIPE
12. COUNTERWEIGHT EXHAUST PIPE
13. HEAT SHIELD
14. CLAMP
15. HEAT SHIELD SLEEVE
16. HEAT SHIELD SLEEVE
17. INTERMEDIATE UPPER EXHAUST PIPE
18. MUFFLER MOUNTING BRACKET
19. ISOLATOR
20. WASHER
21. HEX HEAD BOLT
22. WASHER
23. NUT
24. HEX HEAD BOLT
25. LOCKWASHER
26. RIGHT-SIDE EXHAUST MANIFOLD
27. LEFT-SIDE EXHAUST MANIFOLD
Figure 5. LPG/GAS Exhaust System (Without Low Emissions) Early Model Lift Trucks
9

Exhaust System Repair 100 SRM 726
Figure 6. LPG/GAS Exhaust System (Without Low Emissions) Later Model Lift Trucks
10

100 SRM 726 Exhaust System Repair
Legend for Figure 6
1. LEFT ENGINE EXHAUST PIPE
2. RIGHT ENGINE EXHAUST PIPE
3. UPPER EXHAUST PIPE
4. MUFFLER
5. COUNTERWEIGHT EXHAUST PIPE
6. SEAL
7. FLANGE
8. HEX HEAD BOLT
9. SPRING
10. CLAMP
11. OVERHEAD EXHAUST PIPE
12. LOWER EXHAUST PIPE
13. HEAT SHIELD
14. HEAT SHIELD SLEEVE
15. LOCKWASHER
16. INTERMEDIATE UPPER EXHAUST PIPE
17. NUT
18. MUFFLER MOUNTING BRACKET
19. ISOLATOR
20. WASHER
21. PLUG
5. Disconnect upper exhaust pipe from the interme-
diate upper exhaust pipe and disconnect the in-
termediate upper exhaust pipe from the left-side
engine exhaust pipe.
6. On early model lift trucks only, remove the metal
heat shield from the left and right engine exhaust
pipes.
7. Disconnect the left and right engine exhaust
pipes from each other.
8. Removetheleftandrightengineexhaustpipes
from the engine exhaust manifolds.
Install
NOTE: If the lift truck does not have an overhead
exhaust perform Step 1 through Step 5, and Step 7. If
the lift truck has an overhead exhaust perform Step 1
through Step 4 and Step 6 through Step 8.
1. Install the left and right engine exhaust pipes on
the engine exhaust manifolds. See Figure 5.
2. Connect the left and right engine exhaust pipes
to each other.
3. On early model lift trucks only, install the metal
heat shield on the left and right engine exhaust
pipes.
4. Connect the intermediate upper exhaust pipe to
the left-side engine exhaust pipe and connect the
upper exhaust pipe to the intermediate upper ex-
haust pipe.
5. Connect the upper exhaust pipe to the left side
of the muffler and install the counterweight ex-
haust pipe on the right side of the muffler.
6. Connect the upper exhaust pipe to the left side of
the muffler and connect the lower exhaust pipe
to the right side of the muffler.
7. Install the counterweight. See Counterweight
Repair, Install in this SRM.
8. Install the overhead exhaust pipe in the coun-
terweight. Tighten the capscrews to 38 N•m
(28 lbf ft).
EPA COMPLIANT LPG/GAS ENGINE
EXHAUST SYSTEM
Remove
NOTE: If the lift truck does not have an overhead
exhaust, perform Step 2 and Step 4 through Step 8.
If the lift truck has an overhead exhaust, perform
Step 1 through Step 3 and Step 5 through Step 8.
1. Remove the overhead exhaust pipe from the
counterweight. See Figure 7.
2. Remove the counterweight. See Counterweight
Repair, Remove in this SRM.
3. Remove the lower exhaust pipe from the right
side of the muffler and the upper exhaust pipe
from the left side of the muffler.
4. Remove the counterweight exhaust pipe from the
right side of the muffler and the upper exhaust
pipe from the left side of the muffler.
5. Disconnect upper exhaust pipe from the left and
right-side engine exhaust pipes.
11

Exhaust System Repair 100 SRM 726
Figure 7. EPA Compliant LPG/GAS Exhaust System
12

100 SRM 726 Exhaust System Repair
Legend for Figure 7
1. GASKET
2. HEX HEAD BOLT
3. SPRING
4. SEAL
5. UPPER EXHAUST PIPE
6. LEFT ENGINE EXHAUST PIPE
7. CLAMP
8. RIGHT ENGINE EXHAUST PIPE
9. HEAT SHIELD SLEEVE
10. WIRE HARNESS (CLOSED LOOP)
11. HEAT SHIELD
12. MUFFLER
13. WASHER
14. NUT
15. MUFFLER MOUNTING BRACKET
16. COUNTERWEIGHT EXHAUST PIPE
17. ISOLATOR
18. PLUG
19. OXYGEN SENSOR
20. LOWER EXHAUST PIPE
21. OVERHEAD EXHAUSTPIPE
22. CAPSCREW
6. Remove the metal heat shield from the left and
right engine exhaust pipes.
7. Disconnect the electrical connector from the oxy-
gen sensor. Remove oxygen sensor from the en-
gine exhaust pipes. Inspect oxygen sensor and if
it is damaged or broken, replace with new sensor.
8. Removetheleftandrightengineexhaustpipes
from the engine exhaust manifolds. See Figure 7.
Install
NOTE: If the lift truck does not have an overhead
exhaust, perform Step 1 through Step 5 and Step 7.
If the lift truck has an overhead exhaust, perform
Step 1 through Step 4 and Step 6 through Step 8.
1. Install the left and right engine exhaust pipes to
the engine exhaust manifolds. See Figure 7.
2. Before installing the oxygen sensor, apply a small
amount of antiseize compound. Install the oxy-
gen sensor to the engine exhaust pipes. Tighten
sensor to 39 N•m (29 lbf ft). Connect the electri-
cal connector to the oxygen sensor.
3. Install the metal heat shield to the engine ex-
haust pipes.
4. Connect upper exhaust pipe to the left and right-
side engine exhaust pipes.
5. Connect the upper exhaust pipe to the left side
of the muffler and install the counterweight ex-
haust pipe on the right side of the muffler.
6. Connect the lower exhaust pipe from the right
side of the muffler and the upper exhaust pipe
from the left side of the muffler.
7. Install the counterweight. See Counterweight
Repair, Install in this SRM.
8. Install the overhead exhaust pipe in the coun-
terweight. Tighten the capscrews to 38 N•m
(28 lbf ft).
DIESEL ENGINE EXHAUST PIPE
Remove
NOTE: If the lift truck does not have an overhead
exhaust, perform Step 2 and Step 4 through Step 7.
If the lift truck has an overhead exhaust, perform
Step 1 through Step 3 and Step 5 through Step 7.
1. Remove the overhead exhaust pipe from the
counterweight. See Figure 8.
2. Remove the counterweight. See Counterweight
Repair, Remove in this SRM.
3. Remove the lower exhaust pipe from the right
side of the muffler and disconnect the upper ex-
haust pipe from the left side of the muffler.
4. Remove the counterweight exhaust pipe from the
right side of the muffler and disconnect the upper
exhaust pipe from the left side of the muffler.
5. Remove the heat shield from the upper exhaust
pipe and intermediate upper exhaust pipe. Re-
move the upper exhaust pipe from the interme-
diate exhaust pipe.
6. Remove the intermediate exhaust pipe from the
engine exhaust pipe.
7. Remove the engine exhaust pipe from the ex-
haust manifold.
13

Exhaust System Repair 100 SRM 726
1. MUFFLER
2. LOWER EXHAUST PIPE
3. CLAMP
4. UPPER EXHAUST PIPE
5. INTERMEDIATE EXHAUST PIPE
6. ENGINE EXHAUST PIPE
7. ADAPTER
8. OVERHEAD EXHAUST PIPE
9. HEX HEAD BOLT
10. SPRING
11. SEAL
12. HEAT SHIELD SLEEVE
13. COUNTERWEIGHT EXHAUST PIPE
14. BRACKET
15. HEX HEAD BOLT
16. WASHER
17. ISOLATOR
18. NUT
19. WASHER
20. HEX HEAD BOLT
21. WASHER
22. ENGINE EXHAUST MANIFOLD
Figure 8. Diesel Exhaust System
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