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Hyster C004 (S60-120E) Service Manual – PDF DOWNLOAD
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Description
Hyster C004 (S60-120E) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C004 (S60-120E) Service Manual – PDF DOWNLOAD
Language : English
Pages : 569
Downloadable : Yes
File Type : PDF
Size: 15.8 MB
TABLE OF CONTENTS:
Hyster C004 (S60-120E) Service Manual – PDF DOWNLOAD
2 Speed Manual Transmission.................................................................................. 1 INTRODUCTION............................................................................................. 1 General.............................................................................................. 1 Description.......................................................................................... 1 Operation............................................................................................ 2 REPAIRS.................................................................................................. 3 Removal.............................................................................................. 3 Installation......................................................................................... 3 Disassembly.......................................................................................... 4 Cleaning............................................................................................. 5 Inspection........................................................................................... 5 Assembly............................................................................................. 5 DIFFERENTIAL............................................................................................. 10 Removal.............................................................................................. 10 Disassembly.......................................................................................... 11 Cleaning and Inspection.............................................................................. 11 Assembly............................................................................................. 11 Adjusting the Differential........................................................................... 12 Installation......................................................................................... 14 TROUBLESHOOTING.......................................................................................... 14 Alternator................................................................................................... 18 INTRODUCTION............................................................................................. 18 GENERAL.............................................................................................. 18 DESCRIPTION.......................................................................................... 18 REPAIRS.................................................................................................. 20 GENERAL.............................................................................................. 20 REMOVAL AND DISASSEMBLY (Type A)..................................................................... 20 CLEANING............................................................................................. 20 ASSEMBLY (Type A).................................................................................... 21 REMOVAL AND DISAASSEMBLY (Type B).................................................................... 23 CLEANING............................................................................................. 25 ASSEMBLY (Type B).................................................................................... 25 INSTALLATION (Type A and Type B)..................................................................... 26 CHECKS AND ADJUSTMENTS................................................................................... 26 GENERAL.............................................................................................. 26 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)............................................... 27 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B).............................................. 28 CHECK THE CIRCUIT FOR THE BRUSHES.................................................................... 30 Delco Alternators................................................................................ 30 Motorola Alternators............................................................................. 30 CHECK THE DIODES..................................................................................... 30 CHECK THE DIODE BRIDGE............................................................................... 30 Delco and Leece–Neville Alternators.............................................................. 30 Motorola Alternators............................................................................. 30 CHECK THE FIELD WINDING FOR THE ROTOR................................................................ 31 CHECK THE WINDINGS IN THE STATOR..................................................................... 31 CHECK THE VOLTAGE REGULATOR.......................................................................... 32 TROUBLESHOOTING.......................................................................................... 32 Brake System................................................................................................. 33 INTRODUCTION............................................................................................. 33 GENERAL.............................................................................................. 33 DESCRIPTION AND OPERATION............................................................................ 33 REPAIRS.................................................................................................. 37 CLEANING PROCEDURES.................................................................................. 37 REMOVAL AND DISASSEMBLY.............................................................................. 37 INSPECTION........................................................................................... 38 ASSEMBLY............................................................................................. 39 CHECKS AND ADJUSTMENTS................................................................................... 41 ADJUSTING THE SERVICE BRAKES......................................................................... 41 ADJUSTING THE PARKING BRAKE.......................................................................... 41 REMOVING THE AIR FROM THE BRAKE SYSTEM............................................................... 41 ADJUSTING THE SERVICE BRAKE PEDAL.................................................................... 42 TROUBLESHOOTING.......................................................................................... 43 Capacities & Specfications................................................................................... 45 Cooling System............................................................................................... 48 INTRODUCTION............................................................................................. 48 GENERAL.............................................................................................. 48 DESCRIPTION.......................................................................................... 48 REPAIRS.................................................................................................. 51 FAN ASSEMBLY......................................................................................... 51 Removal (S30–120E)............................................................................... 51 Removal (H60–110E)............................................................................... 51 Disassembly (S30–120E)........................................................................... 51 Disassembly (H60–110E)........................................................................... 52 Assembly (Both Series)........................................................................... 52 Fan Belt Adjustment.............................................................................. 55 Installation..................................................................................... 55 RADIATOR............................................................................................. 56 Removal.......................................................................................... 56 Installation..................................................................................... 56 Cleaning and Inspection.......................................................................... 57 TROUBLESHOOTING.......................................................................................... 58 Diagrams..................................................................................................... 59 Drive Axle................................................................................................... 65 INTRODUCTION............................................................................................. 65 General.............................................................................................. 65 Description.......................................................................................... 65 REPAIRS.................................................................................................. 66 Removal.............................................................................................. 66 Installation......................................................................................... 67 Axle Housing For S30-100E And S40-50F Lift Trucks.................................................... 68 Wheels And Tires..................................................................................... 70 TROUBLESHOOTING.......................................................................................... 72 SPECIFICATIONS........................................................................................... 73 Electrical System Troubleshooting............................................................................ 75 ELECTRICAL SYSTEM COMPLETELY DEAD........................................................................ 75 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN .................................................... 76 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER.............................................. 78 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK............................................. 79 STARTER CRANKS SLOWLY.................................................................................... 81 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START................................................ 82 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND.............................................................. 84 CHARGING SYSTEM DOES NOT FUNCTION........................................................................ 85 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW..................................................... 88 BATTERY IS BEING OVERCHARGED............................................................................. 91 ONE OR MORE DASH GAUGES DO NOT WORK...................................................................... 92 HORN DOES NOT BLOW....................................................................................... 96 POWERSHIFT TRANSMISSION WILL NOT ENGAGE.................................................................. 97 ELECTRICAL SCHEMATIC S20-30A, H20-30E.................................................................... 98 ELECTRICAL S30-50C....................................................................................... 99 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG..............................................................100 ELECTRICAL SCHEMATIC H30-60H DIESEL......................................................................102 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG..............................................................104 ELECTRICAL SCHEMATIC H60-90C DIESEL......................................................................105 ELECTRICAL SCHEMATIC S30-60ES............................................................................106 ELECTRICAL SCHEMATIC S60-120E............................................................................107 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG............................................................108 ELECTRICAL SCHEMATIC S125-150A DIESEL....................................................................109 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG............................................................110 ELECTRICAL SCHEMATIC H110-150F DIESEL....................................................................111 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG..................................................112 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL.........................................................113 ELECTRICAL SCHEMATIC H300A...............................................................................114 ELECTRICAL SCHEMATIC H300-350B...........................................................................115 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL............................................................116 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL............................................................117 ELECTRICAL SCHEMATIC H700-800A...........................................................................118 ELECTRICAL SCHEMATIC P40-50A GASOLINE....................................................................120 ELECTRICAL SCHEMATIC P40-50A DIESEL......................................................................121 ELECTRICAL SCHEMATIC P60-80A GASOLINE....................................................................122 ELECTRICAL SCHEMATIC P60-80A DIESEL......................................................................123 ELECTRICAL SCHEMATIC KE GAS GASOLINE.....................................................................124 ELECTRICAL SCHEMATIC KE DIESEL...........................................................................125 ELECTRICAL SCHEMATIC M200-400H GASOLINE..................................................................126 ELECTRICAL SCHEMATIC M200-400H DIESEL....................................................................128 ELECTRICAL SCHEMATIC M600A...............................................................................130 Electrical Warning Devices...................................................................................132 ELECTRICAL WARNING DEVICES...............................................................................132 GENERAL..............................................................................................132 DESCRIPTION..........................................................................................132 Operator Controlled Horns........................................................................132 System Warning Lights, Buzzers and Bells.........................................................132 Reverse Warning Horns............................................................................133 Warning Lights...................................................................................133 REPLACEMENT..........................................................................................134 General..........................................................................................134 Replacing Horns or Bells.........................................................................134 Replacing Horn Relay or Buzzer...................................................................134 Replacing Warning Lights.........................................................................134 Light Assemblies.................................................................................135 Replacing Flashing Units.........................................................................135 Flow Control Valve...........................................................................................136 INTRODUCTION.............................................................................................136 General..............................................................................................136 Description..........................................................................................136 Operation............................................................................................136 Flow Regulator Valve.............................................................................137 Steering Relief Valve............................................................................138 Relief Valve for Cold Oil........................................................................139 REPAIRS..................................................................................................139 Removal..............................................................................................139 Disassembly..........................................................................................139 Cleaning and Inspection..............................................................................139 Assembly and Installation............................................................................139 CHECKS AND ADJUSTMENTS...................................................................................140 Removing air from the Hydraulic System...............................................................140 Adjusting the Setting of the Relief Valve............................................................140 Frame........................................................................................................142 INTRODUCTION.............................................................................................142 General..............................................................................................142 Description..........................................................................................142 DISASSEMBLY AND ASSEMBLY.................................................................................143 Counterweight........................................................................................143 Hood and Seat........................................................................................145 Operator Restraint System............................................................................146 Exhaust System.......................................................................................147 Overhead Guard.......................................................................................147 Engine (Removal and Installation)....................................................................150 REPAIRS..................................................................................................152 Fuel and Hydraulic Tanks.............................................................................152 Decal Replacement....................................................................................153 GM Engine 6-250..............................................................................................155 INTRODUCTION.............................................................................................155 GENERAL..............................................................................................155 DESCRIPTION..........................................................................................156 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................156 CYLINDER HEAD AND MECHANISM..........................................................................156 Cylinder Head, Removal...........................................................................156 Cylinder Head, Disassembly.......................................................................157 Cleaning And Inspection..........................................................................158 Valve And Valve Seats............................................................................159 Studs For The Rocker Arms........................................................................159 Hydraulic Valve Lifters, Replacement.............................................................159 Hydraulic Valve Lifters, Cleaning And Inspection.................................................160 Cylinder Head, Assembly..........................................................................160 Cylinder Head, Installation......................................................................160 Rocker Arm Cover, Installation...................................................................161 TIMING GEAR COVER....................................................................................162 Removal..........................................................................................162 Installation.....................................................................................162 CAMSHAFT.............................................................................................163 Removal..........................................................................................163 Inspection.......................................................................................164 Camshaft Bearings, Removal.......................................................................164 Camshaft Bearings, Installation..................................................................164 DISTRIBUTOR..........................................................................................165 Removal..........................................................................................165 Installation.....................................................................................165 LUBRICATION SYSTEM...................................................................................166 Oil Sump, Removal................................................................................166 Oil Sump, Installation...........................................................................166 Oil Pump, Removal................................................................................166 Oil Pump, Disassembly and Repair.................................................................166 Oil Pump, Assembly...............................................................................167 Oil Pump, Installation...........................................................................167 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................167 Connecting Rod Bearings, Replacement.............................................................167 Piston And Connecting Rod Assemblies, Removal....................................................168 Disassembly......................................................................................169 Piston, Cleaning And Inspection..................................................................169 Cylinder Bores, Inspection And Repair............................................................169 Piston Rings.....................................................................................170 Assembly.........................................................................................171 Piston And Connecting Rod Assemblies, Installation...............................................171 CRANKSHAFT...........................................................................................172 Main Bearings, Replacement.......................................................................172 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................173 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........173 Crankshaft, Removal..............................................................................174 Inspection and Repair............................................................................175 How To Check The Clearance Between The Main Bearings And Their Journals..........................175 Installation.....................................................................................176 FLYWHEEL AND FLYWHEEL HOUSING........................................................................177 Flywheel, Removal................................................................................177 Ring Gear, Replacement...........................................................................178 Flywheel, Installation...........................................................................178 COOLING SYSTEM.......................................................................................178 Coolant Pump.....................................................................................178 Fan Drive........................................................................................179 Viscous Fan Drive................................................................................179 ENGINE SPECIFICATIONS....................................................................................180 ENGINE DATA..........................................................................................180 CYLINDER HEAD........................................................................................180 HYDRAULIC VALVE LIFTER...............................................................................181 CAMSHAFT.............................................................................................181 PISTONS..............................................................................................181 CYLINDER BORE........................................................................................182 CRANKSHAFT...........................................................................................182 CONNECTING RODS......................................................................................182 COOLING SYSTEM.......................................................................................183 LUBRICATION SYSTEM...................................................................................183 TORQUE SPECIFICATIONS....................................................................................183 High Engery Ignition System (HEI)............................................................................186 HIGH ENERGY IGNITION (HEI)...............................................................................186 DESCRIPTION..........................................................................................186 REPAIRS..................................................................................................188 DISTRIBUTOR..........................................................................................188 Removal..........................................................................................188 Disassembly......................................................................................188 Assembly.........................................................................................193 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................194 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................195 IGNITION COIL........................................................................................195 Removal, Some 4 And 6 Cylinder Models............................................................195 Installation, Some 4 And 6 Cylinder Models.......................................................196 Removal, V8, Some 4 And 6 Cylinder Models........................................................196 Installation, V8, Some 4 And 6 Cylinder Models...................................................197 ELECTRONIC MODULE....................................................................................198 Removal..........................................................................................198 Installation.....................................................................................198 SENSING COIL.........................................................................................199 Removal..........................................................................................199 Installation.....................................................................................199 SPARK PLUGS..........................................................................................199 Removal..........................................................................................199 Installation.....................................................................................200 CHECKS AND ADJUSTMENTS...............................................................................200 Visual Checks....................................................................................200 Check The High Voltage Wires.....................................................................200 Checking The Ignition Coil.......................................................................200 Coil In Distributor Cap Design...................................................................200 Separate Coil Design.............................................................................201 Checking The Sensing Coil........................................................................201 Check The Electronic Module......................................................................202 Ignition Timing Adjustment.......................................................................202 Ignition System, GM V8-366 (6-litre).............................................................203 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................203 SPECIFICATIONS...........................................................................................203 TROUBLESHOOTING..........................................................................................204 Hydraulic Gear Pumps.........................................................................................205 INTRODUCTION.............................................................................................205 DESCRIPTION..........................................................................................205 OPERATION............................................................................................205 Flow Control Valve...............................................................................207 Relief Valve.....................................................................................207 REPAIRS..................................................................................................208 REMOVAL..............................................................................................208 DISASSEMBLY..........................................................................................208 CLEANING.............................................................................................210 INSPECTION...........................................................................................210 ASSEMBLY.............................................................................................211 INSTALLATION.........................................................................................212 CHECKS AND ADUSTMENTS....................................................................................213 CHECK THE OUTPUT OF THE PUMP.........................................................................213 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................213 TROUBLESHOOTING..........................................................................................215 Hydraulic Pump Drive Assembly................................................................................218 INTRODUCTION.............................................................................................218 GENERAL..............................................................................................218 DESCRIPTION..........................................................................................218 REPAIRS..................................................................................................218 REMOVAL AND DISASSEMBLY..............................................................................218 CLEANING.............................................................................................220 INSPECTION...........................................................................................220 ASSEMBLY AND INSTALLATION............................................................................220 TROUBLESHOOTING..........................................................................................222 GENERAL..............................................................................................222 INCH (SAE) & Metric Fasteners................................................................................223 INTRODUCTION.............................................................................................223 NOMENCLATURE, THREADS................................................................................223 STRENGTH IDENTIFICATION..............................................................................224 TABLE 1. BOLTS AND SCREWS................................................................................224 TABLE 2. STUDS AND NUTS..................................................................................225 TABLE 3. TORQUE NUTS.....................................................................................226 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................227 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................228 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................229 Instrument Pannel Indicators & Senders.......................................................................232 INTRODUCTION.............................................................................................232 GENERAL..............................................................................................232 DESCRIPTION..............................................................................................232 GENERAL..............................................................................................232 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................235 LED DISPLAY PANEL....................................................................................235 Battery Discharge Indicators.....................................................................235 Brush Wear Indicators............................................................................236 Motor Temperature Indicators.....................................................................237 "LX" SERIES DISPLAY PANEL............................................................................238 Hourmeter Functions..............................................................................239 Battery Indicator Function.......................................................................239 Status Code Function.............................................................................239 "ZX" SERIES DISPLAY PANELS...........................................................................239 Display Panel....................................................................................240 Basic Display Panels.............................................................................240 Performance Display..............................................................................242 Brush Wear Indicators............................................................................245 CHECKS AND ADJUSTMENTS...................................................................................245 GENERAL..............................................................................................245 REPLACEMENT..............................................................................................246 GENERAL..............................................................................................246 METER REPLACEMENT....................................................................................246 SENDER REPLACEMENT...................................................................................247 Fuel Level Sender................................................................................247 Pressure And Temperature Sender..................................................................247 I.T.W. DISPLAY PANEL.................................................................................248 Removal..........................................................................................248 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................249 Removal..........................................................................................249 Replacing Display Panel Assembly.................................................................249 Indicator LEDs...................................................................................249 Battery Indicators...............................................................................249 Digital Display (Performance Disply Panel Only)..................................................249 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....249 Replacing Parts Of The Basic Display Panel.......................................................250 Replacing Parts Of The Performance Display Panel.................................................252 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................252 Removal And Replacement..........................................................................252 SPECIFICATIONS...........................................................................................253 TROUBLESHOOTING..........................................................................................254 Lift Cylinders...............................................................................................255 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................255 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................255 LIFT CYLINDERS...........................................................................................258 GENERAL..............................................................................................258 DESCRIPTION..........................................................................................258 Lowering Control Valve...........................................................................258 Cylinders (General)..............................................................................261 Cylinders (H520-620B,H700-800A)..................................................................263 Cylinders (H360-460B)............................................................................264 Cylinders (Two-Speed)............................................................................264 REPAIRS..................................................................................................265 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................265 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........265 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................269 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................267 DISASSEMBLY..........................................................................................267 ASSEMBLY.............................................................................................269 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................269 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........269 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................269 CHEVRON PACKING......................................................................................270 LIFT CYLINDERS FOR VISTA MASTS...........................................................................273 DESCRIPTION..........................................................................................273 Lowering Control Valve...........................................................................275 REMOVAL..............................................................................................276 DISASSEMBLY..........................................................................................276 ASSEMBLY.............................................................................................276 INSTALLATION.........................................................................................277 Main Lift Cylinders..............................................................................277 Free-Lift Cylinders..............................................................................277 CHECKS AND ADJUSTMENTS...................................................................................278 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................278 TROUBLESHOOTING..........................................................................................279 SPECIFICATIONS...........................................................................................280 LPG Fuel System..............................................................................................281 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................281 GENERAL..............................................................................................281 DESCRIPTION..........................................................................................281 Fuel Tank........................................................................................282 Fuel Filter And Fuel Valve Unit..................................................................283 Vaporizer........................................................................................283 The IMPCO CA 100 Carbureto.......................................................................285 IMPCO CA 50 Carburetor...........................................................................287 The Governor (GM Engines Only)...................................................................288 Governor With Electronic Controller..............................................................289 REPAIRS..................................................................................................290 LPG TANK.............................................................................................290 Removal..........................................................................................290 Installation.....................................................................................291 REPLACE THE HOSES....................................................................................291 HYDROSTATIC RELIEF VALVE.............................................................................291 Removal and Installation.........................................................................291 FILTER UNIT..........................................................................................292 Replacement Of the Fuel Filter Element...........................................................292 Replacement of the Diaphragm and Fuel Valve......................................................293 VAPORIZER............................................................................................293 Removal..........................................................................................293 Disassembly......................................................................................293 Cleaning.........................................................................................293 Inspection.......................................................................................293 Assembly.........................................................................................295 Installation.....................................................................................295 CARBURETOR (IMPCO CA 100)............................................................................297 Removal..........................................................................................297 Disassembly......................................................................................297 Cleaning.........................................................................................297 Assembly.........................................................................................297 Installation.....................................................................................300 CARBURETER (IMPCO CA 50).............................................................................299 Removal..........................................................................................299 Disassembly......................................................................................299 Cleaning.........................................................................................300 Inspection.......................................................................................300 Assembly (See FIGURE 26.)........................................................................300 Installation.....................................................................................300 CHECKS AND ADJUSTMENTS...................................................................................301 CHECK THE FILTER UNIT................................................................................301 CHECK THE VAPORIZER..................................................................................301 Pressure Reducer Valve...........................................................................301 Vapor Valve......................................................................................301 ADJUST THE CARBURETOR................................................................................301 Idle Mixture.....................................................................................301 Idle Speed.......................................................................................301 Power Mixture....................................................................................301 ADJUST THE GOVERNOR (GM Engines Only)................................................................302 Checks...........................................................................................302 Main Adjusting Screw.............................................................................302 Secondary Adjusting Screw........................................................................302 AISAN Governor...................................................................................303 Adjustment, AISAN Governor.......................................................................303 TROUBLESHOOTING..........................................................................................304 Main Control Valve...........................................................................................308 INTRODUCTION.............................................................................................308 GENERAL..............................................................................................308 DESCRIPTION..........................................................................................308 OPERATION............................................................................................310 Lift Spool.......................................................................................310 Tilt Spool.......................................................................................310 Relief Valve, Single–Stage.......................................................................313 Relief Valve, Two–Stage..........................................................................314 REPAIRS..................................................................................................314 REMOVAL AND DISASSEMBLY..............................................................................314 CLEANING AND INSPECTION..............................................................................315 ASSEMBLY.............................................................................................315 INSTALLATION.........................................................................................315 CHECKS AND ADJUSTMENTS...................................................................................315 ADJUST THE SINGLE–STAGE RELIEF VALVE.................................................................315 ADJUST THE TWO–STAGE RELIEF VALVE....................................................................316 ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY................................317 TROUBLESHOOTING..........................................................................................317 Mast Description.............................................................................................319 INTRODUCTION.............................................................................................319 GENERAL..............................................................................................319 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................321 FULL FREE-LIFT MASTS.................................................................................321 THREE-STAGE MASTS....................................................................................323 FOUR-STAGE MASTS.....................................................................................324 SEQUENCE VALVE.......................................................................................324 Mast Repair..................................................................................................326 INTRODUCTION.............................................................................................326 GENERAL..............................................................................................326 REPAIRS..................................................................................................326 FORKS................................................................................................326 CARRIAGE.............................................................................................326 Removal..........................................................................................326 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................327 Installation.....................................................................................328 MASTS................................................................................................330 Removal..........................................................................................330 Disassembly......................................................................................332 Cleaning and Inspection..........................................................................336 Assembly.........................................................................................337 INSTALLATION.........................................................................................338 CHECKS AND ADJUSTMENTS...................................................................................338 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................338 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................339 LIFT CHAIN ADJUSTMENTS...............................................................................339 MAST ADJUSTMENTS.....................................................................................340 Guide Shoe Adjustment............................................................................341 CARRIAGE ADJUSTMENT..................................................................................343 TROUBLESHOOTING..........................................................................................345 Master Cylinder..............................................................................................346 INTRODUCTION.............................................................................................346 GENERAL..............................................................................................346 DESCRIPTION..........................................................................................346 REPAIRS..................................................................................................346 REMOVAL AND DISASSEMBLY..............................................................................346 CLEANING ............................................................................................347 ASSEMBLY.............................................................................................347 CHECKS AND ADJUSTMENTS...................................................................................347 CHECKS...............................................................................................347 Oil Clutch...................................................................................................348 INTRODUCTION.............................................................................................348 General..............................................................................................348 Description..........................................................................................348 REAPAIRS.................................................................................................350 Removal..............................................................................................350 Cleaning.............................................................................................350 Inspection...........................................................................................350 Installation.........................................................................................350 CHECKS AND ADJUSTMENTS...................................................................................352 Adjusting the Clutch Pedal Height....................................................................352 Adjusting the Clearance of the Release Mechanism.....................................................352 TROUBLESHOOTING..........................................................................................353 Periodic Maintenance.........................................................................................355 INTRODUCTION.............................................................................................355 General..............................................................................................355 MAINTENANCE SCHEDULE.....................................................................................355 MAINTENANCE PROCEDURES Every 8 Hours or Daily............................................................358 Checks with the Engine Stopped.......................................................................358 Hydraulic System.................................................................................358 Air Cleaner......................................................................................358 Engine Oil.......................................................................................358 Fuel Filter (Diesel).............................................................................358 Battery..........................................................................................359 Cooling System...................................................................................359 Drive Belts......................................................................................359 Tires and Wheels.................................................................................360 Lift Mechanism...................................................................................361 Forks............................................................................................361 Lift Chains......................................................................................361 Upright..........................................................................................362 Carriage.........................................................................................362 Load Backrest Extension..........................................................................362 Powershift Transmission..........................................................................362 Checks with the Engine Running.......................................................................362 Guages and Lights................................................................................363 Powershift Transmission..........................................................................363 Brakes...........................................................................................363 Steering System..................................................................................363 Hydraulic System.................................................................................365 Uprights.........................................................................................365 Attachments......................................................................................365 Every 350 Hours or Two Months........................................................................366 Engine Oil and Filter............................................................................366 Brake Fluid......................................................................................366 Hydraulic Tank Breather..........................................................................366 Forks............................................................................................366 Uprights.........................................................................................367 Other Lubrication Points.........................................................................368 Every 1000 Hours or Six Months.......................................................................368 Final Fuel Filter (Diesel).......................................................................368 Removing Air From The Diesel Fuel System.........................................................368 Ignition System (Gas Engine......................................................................369 PCV Valve (Gas Engine)...........................................................................369 Every 2000 Hours or Yearly...........................................................................370 PCV Valve (Gas Engine)...........................................................................370 PCV Valve (Diesel Engine)........................................................................370 Differential.....................................................................................371 Adjusting The Oil Clutch Pedal...................................................................371 Hydraulic System.................................................................................371 Changing The Gasoline Fuel System................................................................372 Changing The Fuel Filter for LPG.................................................................372 WHEELS AND TIRES.........................................................................................373 Drive Tires..........................................................................................373 Steering Tires.......................................................................................376 Perkins Engine 4.236.........................................................................................377 INTRODUCTION.............................................................................................377 GENERAL..............................................................................................377 DESCRIPTION..........................................................................................377 ENGINE SERIAL NUMBER CODES...........................................................................378 REMOVAL AND INSTALLATION.............................................................................378 ENGINE...................................................................................................378 CYLINDER HEAD........................................................................................378 Removal..........................................................................................378 Installation.....................................................................................379 Cylinder Head Repairs............................................................................380 OIL PUMP.............................................................................................382 Removal..........................................................................................382 Disassembly......................................................................................382 Inspection.......................................................................................382 Assembly.........................................................................................383 Installation.....................................................................................383 RELIEF VALVE.........................................................................................384 TIMING GEAR CASE AND TIMING GEARS....................................................................384 Removal..........................................................................................384 Installation.....................................................................................385 PISTONS AND CONNECTING RODS..........................................................................386 Removal..........................................................................................386 Disassembly......................................................................................386 Inspection.......................................................................................387 Assembly.........................................................................................388 Installation.....................................................................................388 CRANKSHAFT AND MAIN BEARINGS.........................................................................389 Removal..........................................................................................389 Inspection.......................................................................................389 Assembly.........................................................................................390 CAMSHAFT AND CAM FOLLOWERS...........................................................................391 Removal..........................................................................................391 Inspection.......................................................................................392 Assembly.........................................................................................392 FLYWHEEL AND FLYWHEEL HOUSING........................................................................393 Removal..........................................................................................393 Repairs..........................................................................................393 Installation.....................................................................................393 STEERING PUMP DRIVE..................................................................................393 Removal..........................................................................................393 Installation.....................................................................................394 PCV VALVE............................................................................................394 FUEL SYSTEM..............................................................................................394 FUEL PUMP............................................................................................394 Removal..........................................................................................394 Disassembly......................................................................................394 Assembly.........................................................................................394 Installation.....................................................................................395 FUEL INJECTION PUMP..................................................................................395 Removal..........................................................................................395 Repairs..........................................................................................395 Installation.....................................................................................395 FUEL INJECTORS.......................................................................................395 Removal..........................................................................................395 Repairs..........................................................................................396 Installation.....................................................................................396 COLD START AID.......................................................................................396 Description......................................................................................396 Removal..........................................................................................396 Installation.....................................................................................396 COOLING SYSTEM...........................................................................................397 THERMOSTAT...........................................................................................397 Removal..........................................................................................397 Inspection.......................................................................................397 Installation.....................................................................................397 WATER PUMP...........................................................................................397 Removal..........................................................................................397 Disassembly......................................................................................397 Assembly.........................................................................................397 Installation.....................................................................................397 CHECKS AND ADJUSTMENTS...................................................................................397 CHECKING THE INJECTORS...............................................................................397 Repairs..........................................................................................398 Installation.....................................................................................398 REMOVING AIR FROM THE FUEL SYSTEM....................................................................398 CHECKING THE TIMING MARKS............................................................................399 Method A.........................................................................................399 Method B.........................................................................................400 CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL...........................401 VALVE CLEARANCE ADJUSTMENT...........................................................................402 ADJUSTING THE THROTTLE LINKAGE.......................................................................402 TROUBLESHOOTING..........................................................................................404 SPECIFICATIONS...........................................................................................405 TORQUE SPECIFICATIONS....................................................................................408 Rochester Carburetor.........................................................................................409 INTRODUCTION.............................................................................................409 GENERAL..............................................................................................409 DESCRIPTION..........................................................................................409 OPERATION............................................................................................410 The Float System.................................................................................410 The Idle System..................................................................................410 The Main Metering System (GM 6-250)..............................................................411 The Power System (GM 6-250)......................................................................412 The Accelerator Pump System......................................................................412 Choke System.....................................................................................412 REPAIRS..................................................................................................413 REMOVAL..............................................................................................413 DISASSEMBLY..........................................................................................413 Cleaning.............................................................................................413 ASSEMBLY.............................................................................................413 INSTALLATION.........................................................................................413 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)......................................................418 GOVERNOR (PNEUMATIC) (Early Units)...................................................................419 CHECKS AND ADJUSTMENTS...................................................................................420 GENERAL..............................................................................................420 ADJUST THE CHOKE CONTROL.............................................................................420 ADJUST THE IDLE SPEED................................................................................420 ADJSUT THE IDLE MIXTURE..............................................................................421 ADJUST THE FAST IDLE.................................................................................421 ADJUST THE THROTTLE LINKAGE,(Later Models)...........................................................422 ADJUST THE THROTTLE LINKAGE,(Early Models)...........................................................423 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)........................................423 Check the Governor...............................................................................423 GOVERNOR (AISAN Type) (Early GM Engines Only)........................................................424 Checks...........................................................................................425 Adjustments......................................................................................425 GOVERNOR (HOOF Type) (Early GM Engines Only).........................................................425 Adjust the Governor..............................................................................425 TROUBLESHOOTING..........................................................................................427 Single-SPD PS Trans-Description & Operation..................................................................428 INTRODUCTION.............................................................................................428 GENERAL..............................................................................................428 DESCRIPTION..............................................................................................428 OPERATION................................................................................................430 THE TORQUE CONVERTER.................................................................................430 THE PLANETARY GEAR SET...............................................................................432 CLUTCHES.............................................................................................434 HYDRAULIC SYSTEM.....................................................................................434 H60-110E.........................................................................................434 S40-50F, S30-120E................................................................................435 CONTROL VALVE........................................................................................436 Monotrol Regulator...............................................................................436 Clutch Regulator.................................................................................436 Torque Converter Regulator.......................................................................437 Direction Spool..................................................................................438 Modulation Spool, All Models Except S100-120E....................................................438 Modulation Spool and Accumulator Valve, S100-120E................................................438 The Valve For The Parking Brake Solenoid.........................................................439 The Inching Valve................................................................................439 THE ELECTRICAL CIRCUIT...............................................................................440 Electrical Circuit For the Direction.............................................................440 OIL FLOW DIAGRAMS....................................................................................441 PARK or NEUTRAL..................................................................................441 "1" Circuit Monotrol.............................................................................441 "2" Circuit - Clutch Apply.......................................................................441 "3" Circuit - Torque Converter...................................................................441 FORWARD..............................................................................................441 "1" Circuit - Monotrol...........................................................................441 "2" Circuit......................................................................................442 FORWARD - INCHING....................................................................................442 REVERSE..............................................................................................442 TROUBLESHOOTING..........................................................................................451 Single-SPD PS Trans-Repair...................................................................................452 INTRODUCTION.............................................................................................452 General..............................................................................................452 REPAIRS..................................................................................................453 Removal..............................................................................................453 Disassembly..........................................................................................453 Inspection...........................................................................................457 Transmission.....................................................................................457 Torque Converter.................................................................................457 Repairing the Control Valve..........................................................................457 DIFFERENTIAL.............................................................................................460 Removal..............................................................................................460 Disassembly..........................................................................................462 Cleaning and Inspection..............................................................................462 Assembly.............................................................................................462 Adjusting the Differential...........................................................................463 Installation.........................................................................................465 Assembly of Transmission.............................................................................465 Installation of the Transmission.....................................................................471 Monotrol Pedal.......................................................................................472 Removal and Disassembly..............................................................................472 Assembly and Installation............................................................................472 CHECKS AND ADJUSTMENTS...................................................................................472 Checking the Monotrol Pedal for Leakage..............................................................472 Monotrol Linkage.....................................................................................472 Stall Test...........................................................................................473 Checking the Oil Pressures...........................................................................474 Monotrol Pressure................................................................................474 Clutch Pressure..................................................................................476 Inching Pressure.................................................................................476 Torque Converter Pressure........................................................................477 Modulator Spool/Clutch Engage Pressure...........................................................477 Checking the Powershift Electrical Circuit...........................................................477 Checking the Circuit for the Direction Control Lever.................................................478 TROUBLESHOOTING..........................................................................................479 Starter......................................................................................................486 INTRODUCTION.............................................................................................486 GENERAL..............................................................................................486 DESCRIPTION AND OPERATION............................................................................486 REPAIRS..................................................................................................488 REMOVAL..............................................................................................488 DISSASEMBLY..........................................................................................488 CLEANING.............................................................................................489 ASSEMBLY.............................................................................................489 INSTALLATION.........................................................................................489 CHECKS AND ADJUSTMENTS...................................................................................490 GENERAL..............................................................................................490 TROUBLESHOOTING..........................................................................................492 Steer Axle...................................................................................................494 INTRODUCTION.............................................................................................494 GENERAL..............................................................................................494 DESCRIPTION..........................................................................................494 REPAIRS..................................................................................................495 STEERING AXLES WITH STUB SHAFT MOUNTS................................................................495 Removal..........................................................................................496 Installation.....................................................................................496 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS...............................................................497 Removal..........................................................................................497 Installation.....................................................................................498 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)............................499 Removal..........................................................................................499 Installation.....................................................................................500 WHEELS AND HUBS......................................................................................500 Removal and Disassembly..........................................................................500 Cleaning.........................................................................................500 Assembly And Installation........................................................................500 SPINDLES, BEARING AND TIE RODS.......................................................................500 Removal And Disassembly..........................................................................500 Cleaning.........................................................................................500 Assembly And Installation........................................................................500 STEERING CYLINDER....................................................................................502 Removal And Disassembly..........................................................................502 Cleaning.........................................................................................503 Assembly And Installation........................................................................503 CHECKS AND ADJUSTMENTS...................................................................................505 STEERING CYLINDER....................................................................................505 CENTER PIVOT OR RUBBER MOUNTS........................................................................505 SPINDLE AND HUB......................................................................................505 TROUBLESHOOTING..........................................................................................506 Steer Control Unit...........................................................................................507 INTRODUCTION.............................................................................................507 GENERAL..............................................................................................507 DESCRIPTION..........................................................................................507 OPERATION............................................................................................507 REPAIRS..................................................................................................507 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................507 TYPE "A" STEERING COLUMN ASSEMBLY....................................................................509 Removal And Disassembly..........................................................................509 Assembly And Installation........................................................................509 TYPE "A" STEERING COLUMN.............................................................................510 TYPE "A" STEERING COLUMN.............................................................................511 TYPE "B" STEERING COLUMN.............................................................................512 Removal And Disassembly..........................................................................512 Assembly And Installation........................................................................512 TYPE "B" STEERING COLUMN.............................................................................513 Disassembly of Steering Control Unit.............................................................514 Cleaning of Steering Control Unit................................................................514 Assembly of Steering Control Unit................................................................516 CHECKS AND ADJUSTMENTS...................................................................................519 REMOVE AIR FROM THE SYSTEM...........................................................................519 TROUBLESHOOTING..........................................................................................520 Tilt Cylinders...............................................................................................521 INTRODUCTION.............................................................................................521 GENERAL..............................................................................................521 DESCRIPTION..........................................................................................521 REPAIRS..................................................................................................521 REMOVAL..............................................................................................521 DISASSEMBLY..........................................................................................521 CLEANING.............................................................................................521 ASSEMBLY.............................................................................................521 Tilt Cylinders with O-Rings or Single Lip Seals..................................................521 Tilt Cylinders for the XM and XMS Models.........................................................522 Tilt Cylinders for H700 800A and Early Model H700 920B...........................................524 INSTALLATION.........................................................................................524 Tilt Cylinders Using Chevron Packing.............................................................525 CHECKS AND ADJUSTMENTS...................................................................................527 CHECK THE TILT CYLINDERS FOR LEAKS...................................................................527 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..............................................527 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.................................................528 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS................................................529 TROUBLESHOOTING..........................................................................................531 Vista Uprights Description & Operation.......................................................................532 INTRODUCTION.............................................................................................532 GENERAL..............................................................................................532 VISTA TWO-STAGE MASTS....................................................................................534 DESCRIPTION..........................................................................................534 OPERATION............................................................................................537 VISTA THREE-STAGE MASTS..................................................................................537 DESCRIPTION..........................................................................................537 OPERATION............................................................................................539 SEQUENCE VALVE.......................................................................................541 Vista Uprights -Repair.......................................................................................544 INTRODUCTION.............................................................................................544 GENERAL..............................................................................................544 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................544 REPAIRS..................................................................................................545 FORKS................................................................................................545 Removal..........................................................................................545 CARRIAGE.............................................................................................545 Removal (Two-Stage and Later Production Three-Stage Carriages)...................................545 Removal (Carriages with Removable Stop Block)....................................................546 Installation (Two-Stage and Later Production Three-Stage Carriages)..............................547 Installation (Carriages With Removable Stop Block)...............................................547 TWO-STAGE MASTS..........................................................................................549 REMOVAL..............................................................................................549 DISASSEMBLY..........................................................................................550 CLEANING AND INSPECTION..............................................................................551 ASSEMBLY.............................................................................................552 INSTALLATION.........................................................................................553 THREE-STAGE MASTS........................................................................................553 REMOVAL..............................................................................................553 DISASSEMBLY..........................................................................................553 CLEANING AND INSPECTION..............................................................................555 ASSEMBLY.............................................................................................555 INSTALLATION.........................................................................................556 LIFT AND TILT CYLINDERS..............................................................................557 SIDE SHIFT CARRIAGE..................................................................................557 Removal..........................................................................................557 Repairs..........................................................................................557 Installation.....................................................................................557 SEQUENCE VALVE.......................................................................................558 Removal and Disassembly..........................................................................561 Cleaning.........................................................................................561 Assembly and Installation........................................................................561 CHECKS AND ADJUSTMENTS...................................................................................562 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................562 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................562 LIFTING CHAIN ADJUSTMENTS............................................................................563 MAST ADJUSTMENTS.....................................................................................564 CARRIAGE ADJUSTMENT..................................................................................565 HEADER HOSE ROLLER ADJUSTMENT, 2-STAGE...............................................................566 TROUBLESHOOTING..........................................................................................567 TORQUE SPECIFICATIONS....................................................................................568 VISTA MASTS..............................................................................................569
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