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• 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.
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100 SRM 545 Operator Module Repair General This section has the description of the frame and Hood and Side Covers Repair, Overhead Guard some connected parts. See Figure 1. Procedures for Repair, and Engine Repair. Checks for the operator the removal and installation of the counterweight, restraint system, repair procedures for the tanks, hood, overhead guard, and engine (including the and replacement procedures for the safety labels are...
Operator Module Repair 100 SRM 545 1. OPERATOR MODULE 5. STEERING AXLE MOUNT 9. FLOOR PLATE 2. FRAME 6. DRIVE AXLE MOUNT 10. RUBBER MOUNT 3. HYDRAULIC TANK 7. LOCK NUT ASSEMBLY 11. PLATE 4. FUEL TANK 8. WASHER Figure 1. Frame and Operator Module INSTALL does not have any marking is installed at right rear postion of module.
100 SRM 545 Hood and Side Covers Repair 1. RIGHT REAR RUBBER MOUNT 4. BOTTOM LOCK NUT 2. LEFT REAR AND FRONT RUBBER MOUNT 5. WASHER 3. TOP LOCK NUT Figure 2. Module Mounts 3. Install large flat washers and lock nuts. Use fol- 4.
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Hood and Side Covers Repair 100 SRM 545 1. HOOD 5. HOOD LATCH 9. PIN 13. SEAL 2. SEAT PAN 6. SIDE COVER 10. COVER 3. HINGE 7. TORSION SPRING 11. LATCH STRIKER 4. PIVOT PIN 8. WASHER 12. BRACKET Figure 3.
100 SRM 545 Overhead Guard Repair e. Check operation of hood latch. See Figure 4. WARNING Have operator sit in seat. Make sure hood is The hood, the hood latch, and the latch striker fully closed (two clicks). Also check that hood must be correctly adjusted for the operator re- touches rubber bumpers.
2183 to 2227 S35XM Fuel leaving the fitting is cold. Use a cloth to 1167 to 1191 2573 to 2626 H2.00XMS protect your hands from the cold fitting. (H40XMS) If engine will not run, close shutoff valve on S40XMS 1179 to 1203 2599 to 2652 LPG tank.
100 SRM 545 Counterweight Repair b. Put tank in tank bracket. Make sure tank is aligned with alignment pin. c. Close latch. d. Connect quick-disconnect fitting to shutoff valve on tank. Use your hand to tighten fitting. Do not open shutoff valve until quick-disconnect fitting is completely tight- ened.
Exhaust System Repair 100 SRM 545 Exhaust System Repair The muffler is installed inside the cavity of the coun- see Figure 7, Figure 8, or Figure 9. When connecting terweight. A short exhaust pipe sends the exhaust the exhaust pipe to the engine, do the following: gases out of the lift truck through the grille in the •...
Radiator and Cooling System Repair 100 SRM 545 Radiator and Cooling System Repair REMOVE 3. Disconnect top coolant hose at radiator. Discon- nect lines to oil cooler in side of radiator. Put caps on open lines and ports. Remove capscrews that WARNING hold radiator to frame.
100 SRM 545 Operator Restraint System Repair Operator Restraint System Repair The seat belt, hip restraint, seat and mount, hood, belt must be in good condition. A seat belt that is and latch are all part of the operator restraint sys- damaged or worn will not give protection when it is tem.
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