HMM010001

Frame
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

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 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 Maintenance 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), 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!

—1—
 GENERAL

WARNING
The lift truck must be put on blocks for some types of maintenance and repairs. The removal
of the following assemblies will cause large changes in the center of gravity: mast, drive
axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put
additional blocks in the following positions 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 Operator
Manual or the section Periodic Maintenance for lift truck models H2.0-3.5TX [B466] or
Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS [B475].

This section contains the description of the frame (see Figure 1) and some connected parts.
Procedures for removing and installing the counterweight, hood, overhead guard, engine, cooling
system, 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.

DESCRIPTION
The frame is one weldment and includes the hydraulic tank and the fuel tank for gasoline or
diesel fuel. See Figure 1.
There is a counterweight for each capacity of lift truck. The counterweights are similar, but
are different weights (see Table 1 and Table 2). The muffler is fastened to the frame inside the
counterweight.
The overhead guard, cowl, and hood are installed on the frame. The hood is connected to the
frame with hinges. The gas-controlled spring provides assistance 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.

—2—
1. FRAME SIDE WLDMNT LH 10. PLATE REAR XMBR
2. FRAME SIDE WLDMNT RH 11. BRACKET PUMP
3. FRAME REAR WLDMT 12. BRACKET FLOOR PLATE LH
4. DA - MOUNT - L.H 13. BRACKET FLOOR PLATE RH
5. DA - MOUNT - R.H 16. BRACKET RADIATOR
6. PLATE STIFFNER 18. BRACKET MUFFLER LH
7. ENGINE BRACKET WLDMT 19. BRACKET MUFFLER RH
8. CROSS MEMBER 20. BRACKET TAIL PIPE
9. GUSSET REAR

Figure 1. Frame

—3—
 HOOD, SEAT, AND SIDE COVERS REPLACEMENT

[1] Remove

1. Slide the seat to the closest position to the steering column.

2. Fully tilt the steering column forward.
3. If your truck is equipped with an LPG tank, swing the tank off to the side. See Figure 8.
4. Raise the latch on the left, front corner of the hood to unlatch and lift up the hood. See Figure 2.
5. Remove the floor mat and floor plate. See Figure 4.

1. HOOD
2. GROMMET
3. HINGE ASSY
4. HEXAGON FLANGE NUT
5. WA HEX HEAD BOLT
6. COVER HOOD LOCK
7. HOOD LOCK ASSY
8. HOOK
9. WA HEX HEAD BOLT
10. STRIP
11. GAS SPRING
12. WASHER

Figure 2. Hood and Seat Arrangement

—4—
 6. Remove the two capscrews holding the left and right rear side panels to the frame. Remove
the covers from the frame. See Figure 3 and Figure 4.
7. Remove the four capscrews holding the left and right front side covers to the frame. Remove
covers.
8. Fully lower the steering column.
9. Remove back side steering column cover by loosening the retention screws, then remove the
front column cover by loosening the screws.
10. Remove the fasteners securing the dash panels to the top of the cowl. Lift to remove the
dash panels.
11. Lift the kick panel to remove it from the truck. See Figure 3.
12. Disconnect the seat harness connector.

CAUTION
When removing the seat from the hood, do not use an impact wrench to remove the
capscrews. Damage can be caused to the threads on the screws and in the holes.

13. If the seat is to be removed and truck is equipped with a non-swivel seat, remove the seat
harness from the brackets that are attached to the underside of the hood. Remove the cable
clips from the seat harness.
14. Remove the four nuts and washers holding the seat to the hood. Lift the seat off the hood.
Pull the seat harness through the hood.
15. Remove the capscrews and washers at the top of the gas spring to disconnect the gas spring
from the hood. Lay gas spring off to the side.
16. Remove the hinge screws, located in the rear of the hood.
17. Lift the hood from the truck. See Figure 2.

1. PANEL FRONT WLDMT LH

5. WA HEX HEAD BOLT
8. SPLASH GUARD
9. PACKING FUEL
18. KICK PANEL
19. WA HEX HEAD BOLT
20. PUSH RIVET
28. COVER COLUMN BACK

Figure 3. Side Cover, Floor Plate, and Cowl Components

—5—
 2. PANEL FRONT WLDMT RH
3. PANEL REAR WLDMT LH
4. PANEL REAR WLDMT RH
5. WA HEX HEAD BOLT
6. COVER RADIATOR
7. BOLT SPECIAL
10. STEP WLDMT
11. STEP WLDMT
12. WA HEX HEAD BOLT
13. DASH PANEL LH
14. DASH PANEL RH
15. COVER PARKING LEVER
16. COVER RESERVE TANK
17. HOLDER CUP
19. WA HEX HEAD BOLT
21. PLATE C/V LEVER
22. TAPPING SCREW
23. FLOOR PLATE WLDMT
24. MAT FLOOR CENTER
25. MAT FLOOR RH
26. MAT FLOOR LH
27. COVER COLUMN FRONT
30. SCREW

Figure 4. Side Covers, Floor Plate, and Cowl Components

—6—
[2] Install

1. Place the hood onto the lift truck frame.

2. Install the hinge screws, located in the rear of the hood, and tighten them to 38 N·m (28
lbf ft). See Figure 2.
3. Align the top holes in the gas spring to the hole in the hood. Install the capscrews and
washers to attach the gas spring to the hood. Tighten the capscrew to 19.2 N·m (170 lbf in).
4. Install hook weldment to the frame. Check that hood lock is in center of the hook bar when
hood closes. Open and close the hood to ensure that the hood lock catches the hook bar
properly. If the hood lock and hook bar do not close properly, loosen the capscrews on the
hood lock or hook weldment, and adjust the alignment. See Figure 7.
5. Push down until hood just touches rubber bumper. Make sure hood lock is still in center of
hook bar. Open hood and tighten capscrews for hood lock and/or hook weld’t.
6. Check operation of hood lock. Have an operator sit in the seat. Make sure hood is fully
closed. Also check that hood touches rubber bumper. If necessary, repeat Step 5.

CAUTION
When installing the seat to the hood, do not use an impact wrench to install the capscrews.
Damage can be caused to the threads on the screws and in the holes.

7. Place the seat on the hood and thread the

seat harness through the hole in the hood.
See Figure 2.
8. Tighten the nuts and washers to attach
seat to hood.
9. Tie seat harness with cable clips and
insert harness into brackets under hood.
10. Install kick panel onto truck. See Figure 3
and Figure 4.
11. Install dash panels to top of cowl.
12. Install steering column covers to column
support.
13. Insert four capscrews and install the left
and right front side covers to frame. See
Figure 3 and Figure 4.
14. Install the left and right rear side covers to
frame using two capscrews. See Figure 3
and Figure 4.
15. Install the floor mat and floor plate.
16. If truck is equipped with an LPG tank, 1. LOCK ASS’Y
swing LPG tank into position on back of 2. HOOK WELD’T
counterweight. See Figure 8. 3. CAPSCREW
17. Adjust the steering column and seat
positions.

Figure 7. Hood Lock Adjustment

—7—
 LPG TANK AND BRACKET REPLACEMENT

[1] Remove

(1) LPG Tank

WARNING
LPG can cause an explosion. Do not cause sparks or permit flammable material near the
LPG system. LPG fuel systems can be disconnected 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
disconnected. Run the engine until the fuel in the system 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 leaving the fitting removes heat. Use a cloth to protect your
hands from the cold fitting.

NOTE: The LPG tank bracket used on this line of trucks to mount the LPG tank onto the counterweight is
the swings out to the side and drops down (EZXchange Bracket). See Figure 8.

1. LPG tanks can be removed and replaced indoors only if the lift truck is at least 8 m (26 ft)
from any flame or ignition source. Move the lift truck to an the area where LPG tanks are
changed.
2. Turn the shutoff valve clockwise until the valve is completely closed.
3. Run the engine until it stops. Turn the key switch to the OFF position.
4. Disconnect the quick-disconnect fitting on the LPG tank. See Figure 8.
5. Pull the bracket release pin, push the latch release button and swing the tank and bracket
out to the side of the lift truck. Then swing the tank down to the side of the truck for ease of
removal. See Figure 8.
6. Unlatch the tank straps and remove the LPG tank from the bracket.

(2) LPG Bracket

NOTE: The LPG tank must be removed from the lift truck before removing the LPG bracket. See LPG Tank.

1. Disconnect the hose from the LPG fuel adapter on the overhead guard leg and remove the
hose from the lift truck. See Figure 9

WARNING
When removing the capscrews for the LPG tank bracket, only remove the capscrew (Figure
10) with the LPG bracket in the swing-out or drop-down position. The LPG tank bracket
is heavy and difficult to handle if all the capscrews are removed with the bracket in the
swing-out position. Personal injury and damage to the lift truck can result if the bracket is
removed and handled while in the swing-out or drop-down position.

2. Pull the bracket release pin, grab the bracket handle, and swing the bracket out to the side of
the lift truck. Remove the capscrew (Figure 10).
3. Pull the bracket release pin and swing the LPG tank bracket back into the resting position on
the counterweight. Be sure that the latch clicks shut and locks.

—8—
 1. HOSE LPG LINE
2. ELBOW
3. COUNTER WEIGHT

Figure 8. LPG Tank and Bracket

Figure 9. LPG Tank Hose Connections

—9—
 1. CAPSCREW
2. RELEASE PIN
3. LATCH RELEASE BUTTON
4. HANDLE

Figure 10. LPG Tank Bracket Removal

4. Remove the rest of the capscrews, labeled (Figure 10), that attach the LPG bracket to the
counterweight.
5. Remove the LPG tank bracket from the lift truck.

[2] Install

(1) LPG Bracket

1. Place the LPG bracket onto the counterweight. Be sure to align the holes on the counter-
weight with the holes on the bracket. See Figure 9 and Figure 10.
2. Install and tighten the capscrews (Figure 10) to secure the LPG bracket onto the counter-
weight.
3. Pull the bracket release pin, push the latch release button and pull the bracket handle to
swing the bracket out to the side of the lift truck. Install and tighten the capscrew (Figure 10).

(2) LPG Tank

NOTE: The LPG bracket must be in the swing-out position to install the LPG tank. Since your lift truck has
the swing-out and drop-down bracket (EZX change Bracket), position the bracket in the drop-down position.

— 10 —
 WARNING
When closing the LPG tank strap, do not wrap your fingers around the strap handle. The
strap can close quickly and with enough force to cause injury to the fingers and hand.

1. Place the LPG tank into the bracket. Secure the tank straps around the tank and close the
straps.
2. Pull the release pin (see Figure 10) and swing the LPG tank bracket into the resting position
on the counterweight. Be sure that the bracket locks into position.
3. Connect the hose to the LPG fuel adapter on the overhead guard leg. See Figure 9.
4. Connect the quick-disconnect fitting on the LPG tank. See Figure 9.
5. Turn the fuel valve counterclockwise to open the fuel valve.
6. Inspect the fuel system for leaks when the fuel valve is open. There are four methods used to
inspect the fuel system for leaks:
a. Sound - Listen for sound of LPG escaping from a tank fitting or hose connection.
b. Smell - LPG has a very distinctive odor. If you smell LPG, DO NOT start the engine.
c. Soapy Water - This method is used in conjunction with Step b above. If the odor of LPG is
present, but escaping fuel cannot be heard, apply soapy water to the fittings and observe
for bubbles.
d. Frost - If the amount of LPG escaping is sufficient, frost may appear on the fittings.

— 11 —
 COUNTERWEIGHT REPLACEMENT

[1] 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 counterweight. When the lift truck is put on blocks, put
additional blocks in the following positions 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
Manual or the section Periodic Maintenance for lift truck models H2.0-3.5TX [B466] and
Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS [B475].

WARNING
Do not operate the lift truck if the capscrew for the counterweight is not installed. When the
capscrew is removed, the counterweight can fall from the lift truck.

WARNING
LPG can cause an explosion. Do not cause sparks or permit flammable material near the
LPG system. LPG fuel systems can be disconnected 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
disconnected. Run the engine until the fuel in the system 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 leaving the fitting removes heat. Use a cloth to protect your
hands from the cold fitting.

NOTE: The counterweight is held in position on the frame by two hooks that are part of the frame. One M24
× 3 × 140 capscrew holds the counterweight to the lower part of the frame on lift truck models H2.0-3.5TX
[B466]. One M24 × 3 × 90 capscrew holds the counterweight to the lower part of the frame on lift truck
models H1.5-1.8TX, H2.0TXS [B475]. See Figure 11.
NOTE: If lift truck is equipped with an overhead exhaust system, remove the overhead exhaust pipe before
removing the counterweight. See the section Exhaust System Repair for the procedures.

1. If the lift truck has an LPG fuel system, use the procedures in the section LPG Tank and
Bracket Replacement, to remove the LPG tank and bracket so that the counterweight can be
removed.

Additional information on the LPG fuel system can be found in the following sections:
• LPG Fuel System, Mazda M4-2.0G and M4-2.2G Engines

— 12 —
 WARNING
The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough
capacity to lift the weight. The approximate weights of the counterweight castings are
shown in Table 1 and Table 2.

2. Install a lifting eye in the lift hole of the counterweight. See Figure 11 and Figure 12.
Connect a crane to the lifting eye and raise the crane until it holds part of the weight of the
counterweight. Remove the capscrew that holds the counterweight to the frame. Use the
crane to lift the counterweight from the lift truck. Put counterweight on the floor so that it has
stability and will not fall over. Take care not to damage exhaust or cooling components.

1. FRAME HOOK
2. LOWER FRAME MOUNT
3. TOW PIN
4. ROLL PIN
5. CAPSCREW

Figure 11. Counterweight Installation

— 13 —
[2] Install

1. Make sure the seals are on the counterweight. See Figure 12. Use a crane to install the
counterweight on the lift truck. When the counterweight is installed, make sure the hooks on
the frame fully engage the counterweight so it is aligned with the parts of the frame. Install
and tighten the M24 × 3 capscrew to 555 N·m (409 lbf ft).

Table 1. Weight of Counterweights, Lift Truck Models H1.5-1.8TX, H2.0TXS [B475]

Model kg
H1.5TX 811
H1.8TX 1014
H2.0TXS 1200

Table 2. Weight of Counterweights, Lift Truck Models H2.0-3.5TX [B466]

Model kg
H2.0TX 1188
H2.5TX 1529
H3.0TX 1917
H3.5TX 2216

1. COUNTERWEIGHT

Figure 12. Counterweight

— 14 —
 2. If the lift truck has an LPG fuel system,
use the procedures in the section LPG
Tank and Bracket Replacement, to install
the LPG tank and bracket after the
counterweight has been installed. See
Figure 8.
3. If lift truck is equipped with an overhead
exhaust system, install the overhead
exhaust pipe. See the section Exhaust
System Repair for the procedures.
1. TOW PIN

[3] Tow Pin, Remove and Install

1. Remove the tow pin from the counterweight

by pulling the extended wire. See Figure
13.
2. Install tow pin into counterweight. Figure 13. Tow Pin

— 15 —
 OVERHEAD GUARD REPLACEMENT

[1] Remove and Install

WARNING
Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.

WARNING
DO NOT weld mounts for lights or accessories to legs of the overhead guard. Changes
that are made by welding, or by drilling holes that are too big or in the wrong location, can
reduce the strength of the overhead guard.
See your dealer for Hyster lift trucks BEFORE performing any changes to the overhead
guard.

NOTE: The lift trucks covered in this manual are equipped with either a high or low overhead guard. The
removal and installation procedures for both types of overhead guards are the same.

No welding or drilling on legs of overhead guard is permitted as per previous WARNING.

NOTE: The lifting device can be connected to any number of positions on the overhead guard depending
upon the lifting device available. The ideal choices are a four point sling connected to all four corners on the
top of the overhead guard, or a two point sling connected to two opposite corners of the overhead guard. If
a single point hoist is used, make sure that the lift point is as close to the center of the overhead guard. If
during the initial start of the lift the overhead guard is off balance lower immediately and move the hoist to a
more centered point.

1. Connect a lifting device to remove or install the overhead guard. Loosen clamp and
disconnect the air intake hose from the tube on the left hand rear leg. Remove capscrew

1. CLAMP
2. AIR INTAKE HOSE
3. CAPSCREW
4. NUT

Figure 14. Disconnect Air Intake Hose

— 16 —
 retaining the exhaust pipe on the right hand rear leg. See Figure 14.
2. Disconnect any wires between the frame and the overhead guard. When the overhead guard
is lifted from the frame, make sure that any electrical wires are moved through the holes in
the frame so that they are not damaged.
3. The rear legs of the overhead guard have two capscrews that are located under the hood
inside the engine compartment, next to the radiator. Remove and install the capscrews. See
Figure 15.
4. Remove and install the four capscrews on the front legs of the overhead guard.
5. When installing the overhead guard, tighten the capscrews for the overhead guard legs to 66
N·m (49 lbf ft). See Figure 15.

[2] Tail, Backup, and Brake Lights, Replace

See the section Electrical System for the procedures to replace these lights.

1. OHG WLDMT
3. CAPSCREWS
9. JOIT TUBE
10. VINYL TUBE
11. VINYL TUBE
12. MIRROR BACK
13. GRILL AIR INLET
14. CAP OHG

Figure 15. Overhead Guard

— 17 —
 OPERATOR RESTRAINT SYSTEM REPLACEMENT
The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of the
operator restraint system. Each item must be checked to make sure it is attached securely,
functions correctly, and is in good condition. See Figure 16.
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 not operate properly, it must be replaced.
Make sure the seat rails and hood latch hook 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 the hood to make sure it is closed and will not move.
Adjust hood, hood latch, and hook weldment when any of the parts of the operator restraint
system are installed or replaced. See the section Hood, Seat, and Side Covers Replacement in
this manual for the adjustment procedures for the hood.

1. SEAT
2. FLANGE NUT

Figure 16. Operator Restraint System

— 18 —
 ENGINE REPLACEMENT

[1] Remove Engine Only

WARNING
The lift truck must be put on blocks for some types of maintenance and repairs. The removal
of the following assemblies will cause large changes in the center of gravity: mast, drive
axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put
additional blocks in the following positions 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 Manual or the section Periodic Maintenance for lift truck models H2.0-3.5TX [B466]
and Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS [B475].

The engine can be removed with or without the transmission. Follow the procedures below to
remove the engine without the transmission.

WARNING
Always disconnect the cables at the battery before you make repairs to the engine.
Disconnect the cable at the negative terminal first.

1. Run engine until all fuel is gone and engine stops.

2. If lift truck is equipped with an LPG fuel tank, swing tank to the side. See the section LPG
Tank and Bracket Replacement, for the procedures. Remove the floor plates. Remove the
hood and rear side covers. See the section Hood, Seat, and Side Covers Replacement for
the procedures.
3. Remove the air filter and bracket assembly, disconnect the battery cables. Remove the
battery and battery tray. Remove the hydraulic hose between the pump and the tank. Put a
cap on the tank fitting. Remove the supply line from pump to the main control valve.
4. Disconnect the coolant hoses from the radiator. Remove the radiator and fan shroud. See the
section Cooling System for the removal procedures.
5. Disconnect the throttle linkage (see the section Powershift Transmission, Repair).
Disconnect the exhaust system.
6. Disconnect the wires and wiring harness at the engine. Disconnect the fuel lines at the
engine.
7. Use the access port on the side of engine and remove the four bolts that attach the flywheel
to the torque converter. See Figure 17.
8. Connect a lifting device to the engine. Put a block under the transmission housing to support
the transmission.

WARNING
The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine.
The engine can weigh approximately 340 kg (750 lb).

— 19 —
10. Remove the nuts and bolts from the engine mounts. Remove engine end plate to
transmission bolts. Separate engine from transmission.
11. Use the lifting device to carefully move the engine away from the torque converter. Make sure
all hoses, wires, and cables are disconnected from the engine, then lift the engine from the
frame. See Figure 18.

1. ACCESS PORT
2. TRANSMISSION ASSEMBLY
3. ENGINE ASSEMBLY

Figure 17. Yanmar Diesel Engine Removal

MAZDA ENGINE
1. FRAME
2. ENGINE MOUNT
3. NUT

Figure 18. Engine Removal

— 20 —
[2] Remove Engine and Transmission

The engine can be removed with or without the transmission. Follow the procedures below to
remove the engine with the transmission.

1. Perform Step 1 through Step 6 from the section Remove Engine Only.
2. Remove the brake and throttle pedals. See Figure 6. Disconnect the inching cable at the
transmission control valve.
3. Disconnect the wiring harness from transmission. Disconnect transmission cooling lines.
4. Drain the oil from the transmission. Connect a device to support the transmission.
5. Remove the capscrews that hold the transmission mount to the transmission.

WARNING
The engine and transmission are heavy. Make sure that any lifting device has enough
capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500
lb).

6. Connect a lifting device to the engine and transmission. Make sure the engine and
transmission assembly can be raised at an angle so they will clear the frame. Remove the
nuts and bolts from the engine mounts (Figure 17). Use the lifting device to carefully lift the
engine and transmission from the frame. Slip the universal joint yoke out of the drive axle.
Make sure to not damage the seal.

[3] Install Engine Only

The engine can be installed with or without the transmission. Follow the procedures below to
install the engine without the transmission.

WARNING
The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine.
The engine can weigh approximately 340 kg (750 lb).

1. Connect lifting device to engine and lift engine into frame. Install engine to transmission.
2. Install the torque converter to the transmission and install the engine end plate to
transmission bolts.
3. If isolators fell from engine mounts during removal, install isolators to engine mounts. Install
the nuts and bolts for the engine mounts to secure engine to frame. See Figure 18. Tighten
the nuts to 150 N·m (110 lbf ft).
4. Use access port on side of engine and install four bolts to hold torque converter to flywheel.
Tighten nuts to 41 N·m (417 kg/cm). See Figure 17.
5. Install exhaust pipe to exhaust manifold.
6. Connect the wires and wiring harnesses at the engine. Connect the fuel lines at the engine.
7. Connect the throttle linkage (see the section Powershift Transmission, Repair). Install the
air filter assembly.
8. Install the hydraulic hose between the pump and the tank. Install the hydraulic filter and
hoses. Connect the supply line to the main control valve.
9. Install the radiator and fan shroud. See the section Cooling System for the installation
procedures. Connect the coolant hoses and lines to the transmission.
10. Connect the battery cables to battery. Install the battery and battery tray. Install the rear side

— 21 —
 covers, floor plates, and hood. See the section Hood, Seat, and Side Covers Replacement
for the procedures. If lift truck is equipped with an LPG tank, swing tank into position on truck.
See the section LPG Tank and Bracket Replacement, for the procedures.
11. Check all fluid levels as described in the section Periodic Maintenance for lift truck models
H2.0-3.5TX [B466] and Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS
[B475].

[4] Install Engine and Transmission

The engine can be installed with or without the transmission. Follow the procedures below to
install the engine with the transmission.

1. Put the lift truck on blocks so that you have access under the lift truck. See the Operating
Manual or the section Periodic Maintenance for lift truck models H2.0-3.5TX [B466] and
Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS [B475] for the procedures.
Connect a lifting device to the engine and transmission. Lift the engine and transmission into
the frame.

WARNING
The engine and transmission are heavy. Make sure that any lifting device has enough
capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500
lb).

2. Install the universal joint yoke into the drive axle. Be sure to not damage the seal.
3. Install the nuts and bolts for the engine mounts (see Figure 18) and transmission mount.
Ensure that the engine is properly set on the mounts. Tighten the nuts to 150 N·m (110 lbf ft).
4. Connect the transmission wiring harness to transmission. Connect transmission cooling lines.
Connect the inching cable.
5. Install the brake and throttle pedals. See Figure 6.
6. Perform Step 7 through Step 11 from section Install Engine Only.

— 22 —
 THROTTLE PEDAL AND CABLE ADJUSTMENT

CAUTION
The adjustment of the throttle cable must be correct or it can break during operation.
The accelerator pedal or the MONOTROL pedal must reach the pedal stop by the time the
throttle plate in the carburetor is fully open.

[1] Standard Throttle Pedal (See Figure 20.)

NOTE: Care about interference between kick panel and accel pedal at operating pedal.
1. THROTTLE PEDAL
2. WA HEX HEAD BOLT
3. CUP SQUARE NECK B
4. NUT

Figure 20. Throttle Pedal and Cable Adjustment

— 23 —
 Table 3. Accel Pedal Adjustment (Ref.)

Stopper bolt height Adjust the idle Pedal set angle at

Model Engine (Hmm) stroke (Xmm) full stroke (Y°)
B475/B466 GAS/LPG 53 9±2 24
B475 DSL 2.7L 68 12.5 ± 2 31
B466 DSL 2.7L 57 12.5 ± 2 25
B466 DSL 3.0L 53 12.5 ± 2 24

NOTE: Each time the throttle system is disassembled, it is important to adjust the throttle cable.

Adjust the throttle pedal when the engine is running at idle and at the normal operating
temperature.
With the engine at idle and the throttle pedal released, adjust the up-position pedal stop until the
tension is removed from the throttle cable.

1. Adjust the idle speed to 725 ± 25 rpm for Gasoline/LPG, 775 ± 25 rpm for Diesel.
2. Make sure the throttle linkage at the pedal assembly is in the correct position.
3. Push the throttle pedal until it stops against the pedal stop. Adjust the throttle cable so that
the pedal stops on the pedal stop just as the throttle plate reaches the wide open position.
Use the nuts at the pedal end of the cable housing to change the adjustment of the cable.
4. Adjust the pedal stop so that the pedal and throttle lever reach the full return positions at the
same time.

[2] Monotrol Pedal

1. Remove floor plate and disconnect throttle cable from the bellcrank and engine. See Figure
21.
2. Fully depress throttle pedal and verify that the dimension of stopper bolt height is correct.
3. If dimension is not correct, adjust the stopper bolt. After adjusting the stopper, tighten jam
nuts to 8 to 15 N·m.
4. Connect throttle cable to bellcrank and engine.
5. With throttle pedal in full up position, adjust throttle cable, to provide the pedal free play
specified.
6. Install floor plate. Fully depress the pedal and adjust pedal stop so that it touches the stop
plate. Tighten jam nuts to 8 to 15 N·m.

— 24 —
NOTE: Confirm pedal switch is turned on before lever assy pull the accel cable.
1. THROTTLE PEDAL
2. WA HEX HEAD BOLT
3. CUP SQUARE NECK B
4. NUT

Figure 21. Monotrol Pedal and Cable Adjustment

Table 4. Pedal Adjustment (Ref.)

Stopper bolt height Adjust the idle Pedal set angle at

Model Engine (Hmm) stroke (Xmm) full stroke (Y°)
B475/B466 GAS/LPG 30 12 ± 2 62.8
B475 DSL 2.7L 40 16 ± 2 60.0
B466 DSL 2.7L 34 16 ± 2 61.5
B466 DSL 3.0L 30 16 ± 2 62.8

— 25 —
 EXHAUST SYSTEM REPAIR

[1] Lift Trucks With Counterweight Exhaust System

(1) Mazda Gas and LPG Engines

NOTE: Remove the counterweight before removing the muffler and other parts of the exhaust system. See
the section Counterweight Replacement for the removal procedures for the counterweight.

Remove and Disassemble

The muffler is installed inside the cavity of the counterweight. An exhaust tail pipe sends the
exhaust gases out of the lift truck under the counterweight.

WARNING
Exhaust system components are hot to touch. Be sure exhaust system components are
cool before starting disassembly, or personal injury may occur.

1. Disconnect the exhaust pipe from the exhaust manifold and remove and discard the gaskets.
2. Remove the exhaust pipe from the engine exhaust manifold.
3. Remove the clamps that hold the two exhaust pipes to the muffler. Remove the exhaust pipes
from the muffler.
4. Remove the washers, isolators, nuts, and capscrews that fasten the muffler to the frame of
the lift truck. Remove the muffler from the lift truck.

Inspect
Inspect the following items in the exhaust system:
• Inspect all exhaust pipes for damage, corrosion, and rust and replace as needed.
• Inspect all exhaust pipe heat shields for damage and replace as needed.
• Inspect the muffler for damage, corrosion, and rust. Replace as needed.

Assemble and Install

1. Place the muffler onto the frame of the truck and install the washers, isolators, nuts, and
capscrews. Tighten the nuts to 21−25 N·m.
2. Install the exhaust pipes onto the muffler. Install the clamps on the pipes to hold them onto
the muffler.
3. Install the exhaust pipe onto the engine exhaust manifold with a new gasket. Tighten lock
nuts to 16−23 N·m.
4. Install the counterweight. See the section Counterweight Replacement for the installation
procedures for the counterweight.

(2) Yanmar Diesel Engine

Remove and Disassemble

WARNING
Exhaust system components are hot to touch. Be sure exhaust system components are
cool before starting disassembly, or personal injury may occur.

— 26 —
 1. Remove the counterweight. See the section Counterweight Replacement for the removal
procedures for the counterweight.
2. Remove clamp that attaches exhaust pipe to muffler. Remove exhaust pipe.
3. Remove clamp that attaches the exhaust tail pipe to muffler. The muffler is positioned
horizontally and the lower exhaust pipe protrudes from the side.
4. Remove the washers, isolators, nuts, and capscrews that fasten the muffler to the lift truck
frame and remove muffler from lift truck.
5. Remove four lock nuts attaching engine exhaust pipe to engine exhaust manifold and remove
engine exhaust pipe from engine manifold.

Inspect
Inspect the following items in the exhaust system:
• Inspect all exhaust pipes for damage, corrosion, and rust and replace as needed.
• Inspect all exhaust pipe heat shields for damage and replace as needed.
• Inspect the muffler for damage, corrosion, and rust. Replace as needed.

Assemble and Install

1. Install engine exhaust pipe to engine exhaust manifold. Tighten lock nuts to 16−23 N·m.
2. Place muffler onto the frame of lift truck and install the washers, isolators, nuts, and
capscrews to secure muffler to lift truck. Tighten nuts to 21−25 N·m.
3. Install engine exhaust tail pipe to muffler with clamp.
4. Install exhaust pipe on muffler with clamp.
5. Install the counterweight. See the section Counterweight Replacement for the removal
procedures for the counterweight.

[2] Lift Trucks With Overhead Exhaust System

The muffler is installed inside the cavity of the counterweight. A long exhaust pipe, located above
the overhead guard, sends the exhaust gases out of the lift truck.

(1) Remove and Disassemble

WARNING
Exhaust system components are hot to touch. Be sure exhaust system components are
cool before starting disassembly, or personal injury may occur.

1. On trucks equipped with overhead exhaust system, remove four capscrews that attach the
overhead exhaust pipe to overhand guard leg. Remove clamp between overhead exhaust
pipe and exhaust pipe and remove overhead exhaust pipe.
2. Remove the counterweight. See the section Counterweight Replacement for the removal
procedures for the counterweight.
3. On lift trucks with overhead exhaust system, remove clamp that attaches exhaust pipe
to muffler. On lift trucks with counterweight exhaust system, remove clamp that attaches
exhaust pipe to muffler Remove exhaust pipe.
4. Remove clamp that attaches the exhaust pipe to muffler. The muffler is positioned
horizontally.
5. Remove the washers, isolators, nuts, and capscrews that fasten the muffler to the lift truck
frame and remove muffler from lift truck.

— 27 —
(2) Inspect

Inspect the following items in the exhaust system:

• Inspect all exhaust pipes for damage, corrosion, and rust and replace as needed.
• Inspect all exhaust pipe heat shields for damage and replace as needed.
• Inspect the muffler for damage, corrosion, and rust. Replace as needed.

(3) Assemble and Install

1. Install engine exhaust pipe to engine exhaust manifold with a new gasket. Tighten lock nuts
to 16−23 N·m.
2. Place muffler onto the frame of lift truck and install the washers, isolators, nuts, and
capscrews to secure muffler to lift truck. Tighten nuts to 21−25 N·m.
3. Install engine exhaust pipe to muffler with clamp.
4. Install exhaust tail pipe (for overhead exhaust or for counterweight exhaust) to muffler with
clamp.
5. Install the counterweight. See the section Counterweight Replacement for the removal
procedures for the counterweight.
6. On trucks equipped with overhead exhaust system, insert overhead exhaust pipe in hole of
counterweight. Attach overhead exhaust pipe to exhaust pipe and secure with clamp. Install
and tighten four capscrews to 21−25 N·m to secure overhead exhaust pipe to overhand
guard leg.

— 28 —
 COOLING SYSTEM

[1] Description

WARNING
DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator
cap is removed, the pressure is released from the system. If the system is hot, the steam
and boiling coolant can cause burns. DO NOT remove the cover for the radiator when the
engine is running.

CAUTION
Additives may damage the cooling system. Before using additives, contact your local Hyster
dealer.

The cooling system is used to cool the engine and keep it at the correct operating temperature.
The cooling system is comprised of the following main components:
• Radiator
• Fan and belt
• Fan shroud and radiator duct
• Coolant hoses and lines
• Coolant reservoir
• Water pump

For the procedures to repair, clean, inspect, and install the radiator and cooling system
components, refer to the section Cooling System.

— 29 —
 FUEL AND HYDRAULIC TANKS REPAIR

[1] Inspect

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 a
building, make sure there is enough ventilation. See the following manuals for additional
information:
• Safe Practices for Welding and Cutting Containers 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.

WARNING
Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can
cause an explosion.

CAUTION
Additives may damage the hydraulic system. Before using additives, contact your local
Hyster dealer.

Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage.
Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas
of the tank that are not easily seen can be checked with an inspection mirror and a light that is
approved for locations with flammable vapors.

[2] Clean

WARNING
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.

WARNING
Compressed air can move particles so that they cause injury to the user or to other
personnel. Make sure that the path of the compressed air is away from all personnel. Wear
protective goggles or a face shield to prevent injury to the eyes.

When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control the
pressure of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it
must be made of a material that does not make sparks. Make an electrical connection between
the nozzle and the tank.
Connect a ground wire to the tank to prevent static electricity.

— 30 —
(1) Steam Method of Cleaning

WARNING
Compressed air can move particles so that they cause injury to the user or to other
personnel. Make sure that the path of the compressed air is away from all personnel. Wear
protective goggles or a face shield to prevent injury to the eyes.

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.
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. When making inspections, use a light that is approved for locations
with flammable vapors.
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 indicator for gas vapors. If the amount of
flammable vapors is above the lower flammable limit, repeat the cleaning procedures.

(2) Chemical Solution Method of Cleaning

WARNING
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.

WARNING
Compressed air can move particles so that they cause injury to the user or to other
personnel. Make sure that the path of the compressed air is away from all personnel. Wear
protective goggles or a face shield to prevent injury to the eyes.

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 alkaline
base. Follow the instructions given by the manufacturer.
2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank.
3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning
compound is removed.
4. Make an inspection of the inside of the tank. If the tank is not clean, repeat Step 1 through
Step 3. Make another inspection of the tank. When making inspections, use a light that is
approved for locations with flammable vapors.
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.

— 31 —
[3] Additional Preparations for Repair

If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases.
See the manual Safe Practices for Welding and Cutting Containers That Have Held Combustibles
by the American 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.
2. Use acceptable welding practices to repair the tank. See the American National Standard
Safety in Welding and Cutting, AWS Z 49.1 - 1999.

[4] Small Leaks, Repair

Use the following procedure to repair small leaks:

1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.
2. Apply Loctite® 290 to the leak. Follow the instructions of the manufacturer.

[5] Large Leaks, Repair

1. Use one of the procedures described under Clean to clean and prepare the tank for repairs.
2. Contact your dealer for Hyster lift trucks for welding instructions.
3. Use acceptable welding practices to repair the tank. See the American National Standard
Safety in Welding and Cutting, AWS Z 49.1 - 1999.

[6] Preparations for Usage After Repair

1. Add more water to the tank so that the water goes above the point of where the work was
done. Check to see if there are any leaks coming from tank.
2. If there are no leaks coming from the tank, remove all the water from the tank.

— 32 —
 SAFETY LABELS

WARNING
Safety labels are installed on the lift truck to give information about operation and possible
hazards. It is important that all safety labels are installed on the lift truck and can be read.
DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its
equipment can change the lifting capacity. The lift truck must be rated as equipped, and the
nameplate must show the new capacity rating. Contact your dealer for a new nameplate.

WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using
cleaning solvents, always follow the recommendations of the manufacturer.

NOTE: Not all labels that are used on the lift trucks covered in this manual are shown in Figure 26. See the
Parts Manual for a complete listing of all labels used on these lift trucks and their part numbers.

If a new label must be installed, use the following procedure to install a new label. See Figure 26.

1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint.
Clean the surface of old paint with a cleaning solvent.
2. Remove the paper from the back of the label. Do not touch the adhesive surface.
3. Carefully hold the label in the correct position above the surface. The label cannot be moved
after it touches the surface. Put the label on the surface. Make sure that all air is removed
from under the label, and the corners and edges are tight.

— 33 —
1. MAST WARNING LABEL 11. LABEL-FAN WARNING
2. LABEL-OPERATOR RESTRAINT 13. LABEL-PARKBRAKE WARNING
5. LABEL-CAUTION BATTERY 14. LABEL-MAST WARNING
6. LABEL CERTIFICATE 15. LABEL-OPERATOR WARNING
7. LABEL-LOCKING GAS SPRING 30. LABEL-FLAMMABLE LP GAS
CAUTION NON-U.S. 31. LABEL-HOOD OPENING
8. LABEL-PINCH POINT CAUTION NON-U.S.
9. LABEL-NO RIDERS 41. LABEL ETHER WARNING
10. DECAL-FAN WARNING 51. LABEL FLAMMABLE LP GAS
PICTORIAL 64. LABEL NAMEPLATE

Figure 26. Safety Label Positions

— 34 —