100 SRM 449
Exhaust System Repair
2.
Use acceptable welding practices to repair the
tank.
See the American National Standard
Safety In Welding and Cutting AWS Z 49.1 -
1999.
Radiator Repair
REMOVE
NOTE:
To make radiator removal easier, remove
the counterweight as described in Counterweight
Repair, Remove.
1.
Open the access door between the hood and the
counterweight. Remove the cover plate over the
radiator. If installed, remove the LPG tank and
bracket.
2.
Drain the coolant from the radiator. Remove the
radiator hoses. Disconnect the oil lines at the
radiator. Put caps on the open lines.
3.
Remove the remote fill assembly and radiator
hoses to the engine. Disconnect the hose to the
auxiliary coolant reservoir.
4.
Remove the hood and transition plate as de-
scribed in Hood Repair, Remove. Remove the
fan shroud and fan. Loosen the exhaust band
clamp on the gasoline and LPG units. Remove
the engine water outlet on diesel units.
5.
Remove the muffler and inlet exhaust pipe to the
muffler. Remove the capscrews that fasten the
radiator. Move the exhaust pipe for clearance of
the radiator flange.
6.
Tip the radiator forward over the engine as you
lift and remove the radiator.
INSTALL
NOTE:
The installation of the radiator is easier if the
counterweight is removed. See Counterweight Re-
pair, Remove in this section.
1.
Tip the radiator forward over the engine as you
install the radiator in the lift truck. Move the
exhaust pipe for clearance to the radiator flange.
2.
Install the capscrews that fasten the radiator. In-
stall the muffler and inlet exhaust pipe at the
muffler.
3.
Install the engine water outlet on diesel units.
Tighten the exhaust band clamp on gasoline or
LPG units. Install the fan and fan shroud. In-
stall the hood and transition plate as described
in the Hood Repair, Install section.
4.
Connect the hose to the auxiliary coolant reser-
voir. Install the remote fill assembly and radiator
hoses to the engine. Make sure the hose clamp
screws have an access at the wheel wells.
5.
Connect the oil lines at the radiator. Install the
cover plate over the radiator and fill the radiator
with the coolant specified in the table in the Pe-
riodic Maintenance 8000 SRM 393.
6.
If removed, install the counterweight as de-
scribed in the Counterweight Repair, Install
section. If the LPG tank and bracket were re-
moved, install them.
Exhaust System Repair
MUFFLER, REMOVE
1.
Remove the grill by removing the retaining plate
at the top of the grill. See Figure 5, Figure 6, and
Figure 7.
2.
Disconnect the exhaust pipes and remove the
clamps.
3.
Remove the clamp from the muffler outlet and
remove the muffler.
INSTALL
1.
On overhead exhaust units, install the counter-
weight exhaust pipe on the muffler, but do NOT
tighten. See Figure 5, Figure 6, and Figure 7.
2.
Install the muffler and, on units with the over-
head exhaust, rotate the muffler so the outlet is
at the top. Install the other exhaust pipes and
tighten the clamps. Rotate the counterweight
exhaust pipe so that it points straight back and
down at a 45 angle.
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