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Hyster C007 (H150-275HP150-200B) Service Manual – PDF DOWNLOAD
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Description
Hyster C007 (H150-275HP150-200B) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C007 (H150-275HP150-200B) Service Manual – PDF DOWNLOAD
Language : English
Pages : 550
Downloadable : Yes
File Type : PDF
Size: 19.2 MB
TABLE OF CONTENTS:
Hyster C007 (H150-275HP150-200B) Service Manual – PDF DOWNLOAD
6007............................................................................................................. 1 INTRODUCTION................................................................................................. 1 GENERAL.................................................................................................. 1 DESCRIPTION.............................................................................................. 1 CYLINDER HEAD AND VALVE MECHANISM............................................................................ 2 CYLINDER HEAD............................................................................................ 2 Removal.............................................................................................. 2 Repairs.............................................................................................. 3 Installation......................................................................................... 3 VALVE MECHANISM.......................................................................................... 5 Repairs.............................................................................................. 5 LUBRICATION SYSTEM........................................................................................... 6 OIL PUMP................................................................................................. 6 Removal And Disassembly.............................................................................. 6 Repairs.............................................................................................. 6 Assembly And Installation............................................................................ 6 Relief Valve For The Oil Pressure.................................................................... 7 Oil Cooler (T6.3544 Engine Only)..................................................................... 7 Cooling Jets For The Pistons......................................................................... 8 TIMING GEARS AND CAMSHAFT.................................................................................... 9 TIMING GEAR CASE......................................................................................... 9 Removal.............................................................................................. 9 Installation......................................................................................... 9 Idler Gears And Hubs Removal......................................................................... 12 Camshaft And Cam Followers........................................................................... 12 Auxiliary Drive Shaft And The Drive Shaft For The Fuel Injection Pump................................ 13 CRANKSHAFT................................................................................................... 15 REMOVAL.................................................................................................. 15 REPAIR................................................................................................... 16 INSTALLATION............................................................................................. 16 PISTONS AND PISTON RODS...................................................................................... 18 REMOVAL.................................................................................................. 18 DISASSEMBLY.............................................................................................. 18 REPAIRS.................................................................................................. 19 ASSEMBLY................................................................................................. 19 INSTALLATION............................................................................................. 20 CYLINDER LINERS.............................................................................................. 21 REMOVAL AND INSTALLATION................................................................................. 21 FLYWHEEL AND FLYWHEEL HOUSING................................................................................ 21 REPAIRS.................................................................................................. 21 INSTALLATION............................................................................................. 21 TURBOCHARGER................................................................................................. 22 REMOVAL.................................................................................................. 22 DISASSEMBLY.............................................................................................. 22 INSPECTION............................................................................................... 22 ASSEMBLY................................................................................................. 22 INSTALLATION............................................................................................. 23 FUEL SYSTEM.................................................................................................. 23 FUEL PUMP................................................................................................ 24 Removal.............................................................................................. 24 Disassembly.......................................................................................... 24 Assembly............................................................................................. 24 Installation......................................................................................... 24 FUEL INJECTION PUMP...................................................................................... 24 Removal.............................................................................................. 24 Repairs.............................................................................................. 25 Installation......................................................................................... 25 FUEL INJECTORS........................................................................................... 25 Checks............................................................................................... 25 Removal.............................................................................................. 25 Repairs.............................................................................................. 25 Installation......................................................................................... 25 COLD START AID........................................................................................... 26 Description.......................................................................................... 26 Removal.............................................................................................. 26 Installation......................................................................................... 26 COOLING SYSTEM............................................................................................... 26 THERMOSTATS.............................................................................................. 26 Removal.............................................................................................. 26 Installation......................................................................................... 26 WATER PUMP............................................................................................... 26 Removal.............................................................................................. 26 Disassembly.......................................................................................... 26 Assembly............................................................................................. 27 Installation......................................................................................... 28 CHECKS AND ADJUSTMENTS....................................................................................... 28 REMOVING AIR FROM FUEL SYSTEM............................................................................ 28 TIMING................................................................................................... 29 Fuel Injection Pump.................................................................................. 29 Checking The Timing Angle For The Fuel Injection Pump (Using The Timing Tool)........................ 31 VALVE CLEARANCE ADJUSTMENT............................................................................... 32 ADJUSTING THE THROTTLE LINKAGE........................................................................... 33 CHECKING THE FUEL INJECTORS.............................................................................. 34 TROUBLESHOOTING.............................................................................................. 35 SPECIFICATIONS............................................................................................... 36 TORQUE SPECIFICATIONS........................................................................................ 40 22002............................................................................................................ 41 General...................................................................................................... 43 Description.................................................................................................. 43 Alternator Repair............................................................................................ 45 Alternator Type A........................................................................................ 45 Remove and Disassemble............................................................................... 45 Clean................................................................................................ 46 Assemble............................................................................................. 46 Install.............................................................................................. 47 Alternator Type B........................................................................................ 50 Remove and Disassemble............................................................................... 50 Clean................................................................................................ 50 Assemble............................................................................................. 51 Install.............................................................................................. 52 General Check and Adjustment................................................................................. 53 Low Output Check (Type A or Type B).......................................................................... 53 High Output Check (Type A or Type B)......................................................................... 55 Brushes Circuit Check........................................................................................ 56 Delco Alternators........................................................................................ 56 Motorola Alternators..................................................................................... 57 Diodes Check................................................................................................. 58 Diodes Bridge Check.......................................................................................... 58 Delco and Leece-Neville Alternators...................................................................... 58 Motorola Alternators..................................................................................... 58 Rotor Field Winding Check.................................................................................... 59 Stator Windings Check........................................................................................ 60 Voltage Regulator Check...................................................................................... 60 Troubleshooting.............................................................................................. 61 90012............................................................................................................ 63 INTRODUCTION................................................................................................. 63 GENERAL.................................................................................................. 63 DESCRIPTION.............................................................................................. 63 CARBURETOR........................................................................................... 63 GOVERNOR............................................................................................. 63 REPAIRS...................................................................................................... 63 CARBURETOR............................................................................................... 63 REMOVAL AND DISASSEMBLY.............................................................................. 63 CLEANING............................................................................................. 63 ASSEMBLY............................................................................................. 63 INSTALLATION......................................................................................... 65 GOVENOR.................................................................................................. 65 CHECKS AND ADJUSTMENTS....................................................................................... 65 ADJUSTING THE CARBURETOR................................................................................. 65 ADJUSTING THE GOVERNOR................................................................................... 66 ADJUSTING THE THROTTLE LINKAGE........................................................................... 66 TROUBLESHOOTING.............................................................................................. 67 90016............................................................................................................ 68 INTRODUCTION................................................................................................. 68 GENERAL.................................................................................................. 68 DESCRIPTION.............................................................................................. 68 PROCEDURES FOR LPG FUEL TANKS............................................................................ 69 Installation......................................................................................... 69 HYDROSTATIC RELIEF VALVE................................................................................. 69 Removal and Installation............................................................................. 69 CARBURETOR............................................................................................... 70 Removal and Dissembly................................................................................ 70 Cleaning............................................................................................. 70 Assembly and Installation............................................................................ 70 GOVERNOR................................................................................................. 71 FUEL FILTER AND SHUT-OFF VALVE........................................................................... 71 Replace The Filter Element........................................................................... 71 Install A New Diaphragm and Fuel Valve............................................................... 71 Check The Filter Unit................................................................................ 72 VAPORIZER................................................................................................ 73 Description.......................................................................................... 73 Removal.............................................................................................. 74 Disassembly.......................................................................................... 74 Cleaning............................................................................................. 76 Inspection........................................................................................... 76 Assembly............................................................................................. 76 Installation......................................................................................... 76 Check The Pressure Reducer Valve..................................................................... 76 Check The Vapor Valve................................................................................ 76 INSTALLATION OF NEW HOSES................................................................................ 76 CHECKS AND ADJUSTMENTS....................................................................................... 79 CHECK THE FILTER AND SHUT-OFF VALVE...................................................................... 79 CHECK THE VAPORIZER/REGULATOR............................................................................ 79 Pressure Reducer Valve............................................................................... 79 Check the Low Pressure Valve......................................................................... 79 Check the Low Pressure Diaphragm..................................................................... 79 ADJUST THE CARBURETOR.................................................................................... 79 Idle Mixture......................................................................................... 79 Idle Speed........................................................................................... 79 Power Mixture........................................................................................ 79 ADJUST THE GOVERNOR...................................................................................... 80 ADJUST THE THROTTLE LINKAGE.............................................................................. 80 TROUBLESHOOTING.............................................................................................. 81 100141........................................................................................................... 85 INTRODUCTION................................................................................................. 85 General.................................................................................................. 85 Description.............................................................................................. 85 Frame................................................................................................ 85 Fuel Tank............................................................................................ 85 Hydraulic tank....................................................................................... 85 REPAIRS...................................................................................................... 86 Counterweight............................................................................................ 86 Removal.............................................................................................. 86 Installation......................................................................................... 86 Fenders.................................................................................................. 87 Removal.............................................................................................. 87 Installation......................................................................................... 87 Seat..................................................................................................... 87 Removal.............................................................................................. 87 Installation......................................................................................... 87 Hood..................................................................................................... 87 Hydraulic Tank........................................................................................... 88 Removal.............................................................................................. 88 Service Procedures................................................................................... 88 Installation......................................................................................... 89 Fuel Tank................................................................................................ 89 Removal.............................................................................................. 89 Service Procedures................................................................................... 89 Installation......................................................................................... 89 Housing (Steering Control Unit).......................................................................... 89 Removal.............................................................................................. 89 Installation......................................................................................... 89 Painting Instructions.................................................................................... 90 Decal Installation....................................................................................... 90 Cab...................................................................................................... 90 120022........................................................................................................... 94 INTRODUCTION................................................................................................. 94 GENERAL.................................................................................................. 94 DESCRIPTION.............................................................................................. 94 Oil Clutch........................................................................................... 94 Jet Pump............................................................................................. 94 REPAIRS...................................................................................................... 95 OIL CLUTCH ASSEMBLY...................................................................................... 95 Removal And Disassembly.............................................................................. 95 Cleaning............................................................................................. 95 Inspection........................................................................................... 95 Assembly And Installation............................................................................ 96 JET PUMP................................................................................................. 96 Removal And Disassembly.............................................................................. 96 CLEANING............................................................................................. 96 Assembly And Installation............................................................................ 96 CHECKS AND ADJUSTMENTS....................................................................................... 96 ADJUSTING THE LINKAGE FOR THE CLUTCH PEDAL............................................................... 96 CHECKING THE ALIGNMENT OF THE CLUTCH DISC................................................................ 97 TROUBLESHOOTING.............................................................................................. 98 130033........................................................................................................... 99 INTRODUCTION.................................................................................................100 MECHANICAL SECTION...........................................................................................101 TORQUE CONVERTER.........................................................................................102 FORWARD-REVERSE SECTION..................................................................................102 PLANETARY GEARS: HOW THEY WORK...........................................................................104 WHEN THE SUN GEAR IS DRIVEN..............................................................................104 WHEN PLANET PINION CARRIER IS DRIVEN.....................................................................104 DOUBLE PLANET PINION SET.................................................................................104 REVERSE..................................................................................................105 FORWARD..................................................................................................105 RANGE SECTION............................................................................................106 LOW......................................................................................................106 MEDIUM...................................................................................................106 HIGH.....................................................................................................109 HYDRAULIC SYSTEM.............................................................................................110 INTRODUCTION TO HYDRAULIC SYSTEM.........................................................................110 PUMP AND SUMP............................................................................................111 OIL FILTER...............................................................................................111 MONOTROL ASSEMBLY........................................................................................112 OIL COOLERS..............................................................................................113 CONTROL VALVE ASSEMBLY.......................................................................................114 RANGE SPOOL..............................................................................................114 INCHING VALVE............................................................................................114 DIRECTIONAL SPOOL........................................................................................117 PRESSURE REGULATORS......................................................................................119 CUSHION VALVE............................................................................................119 SCHEMATIC AND FLOW DIAGRAMS..................................................................................121 NEUTRAL-REVERSE..........................................................................................121 DRIVE-HIGH-REVERSE.......................................................................................124 DRIVE-MEDIUM-FORWARD.....................................................................................125 INCHING-LOW-FORWARD......................................................................................126 130039...........................................................................................................127 INTRODUCTION.................................................................................................127 General..................................................................................................127 Description..............................................................................................127 REPAIRS......................................................................................................128 Removal..................................................................................................128 Disassembly..............................................................................................128 Cleaning.................................................................................................128 Installation.............................................................................................128 CHECKS AND ADJUSTMENTS.......................................................................................138 Forward/Reverse Linkage..................................................................................138 TROUBLESHOOTING..............................................................................................138 130044...........................................................................................................140 INTRODUCTION.................................................................................................140 GENERAL..................................................................................................140 DESCRIPTION..............................................................................................140 REPAIRS......................................................................................................140 REMOVAL..................................................................................................140 DISASSEMBLY..............................................................................................141 CLEANING.................................................................................................141 ASSEMBLY AND INSTALLATION................................................................................141 TROUBLESHOOTING..............................................................................................141 140046...........................................................................................................142 General......................................................................................................144 Description..................................................................................................144 Differential Repair..........................................................................................144 Remove...................................................................................................144 Disassemble..............................................................................................144 Assemble.................................................................................................144 Pinion, Bearings, and Pinion Carrier, Assemble.......................................................144 Pinion Bearings, Adjust Preload......................................................................146 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)..........................................146 Differential and Ring Gear, Assemble.................................................................148 Differential Pinion and Side Gear Assembly, Assemble.................................................150 Differential Gears Rotating Torque, Check............................................................151 Differential and Ring Gear Assembly, Install.........................................................152 Differential Bearings, Preload Adjust................................................................153 Ring Gear, Runout Check..............................................................................153 Gear Clearance, Adjust...............................................................................154 Gear Set, Tooth Contact Pattern Check................................................................154 Install into Axle Housing............................................................................154 Specifications...............................................................................................157 General Specifications...................................................................................157 Rivet Installation Pressure..............................................................................157 Pinion Preload Pressure..................................................................................157 Pinion Adjustment........................................................................................157 Troubleshooting..............................................................................................160 160054...........................................................................................................162 INTRODUCTION.................................................................................................162 GENERAL..................................................................................................162 DESCRIPTION..............................................................................................162 OPERATION................................................................................................162 REPAIRS......................................................................................................162 STEERING WHEEL AND COLUMN ASSEMBLY.......................................................................162 TYPE "A" STEERING COLUMN ASSEMBLY........................................................................164 Removal And Disassembly..............................................................................164 Assembly And Installation............................................................................164 TYPE "A" STEERING COLUMN.................................................................................165 TYPE "A" STEERING COLUMN.................................................................................166 TYPE "B" STEERING COLUMN.................................................................................167 Removal And Disassembly..............................................................................167 Assembly And Installation............................................................................167 TYPE "B" STEERING COLUMN.................................................................................168 Disassembly of Steering Control Unit.................................................................169 Cleaning of Steering Control Unit....................................................................169 Assembly of Steering Control Unit....................................................................171 CHECKS AND ADJUSTMENTS.......................................................................................174 REMOVE AIR FROM THE SYSTEM...............................................................................174 TROUBLESHOOTING..............................................................................................175 160071...........................................................................................................176 INTRODUCTION.................................................................................................176 GENERAL .................................................................................................176 DESCRIPTION..............................................................................................176 REPAIRS......................................................................................................177 STEERING AXLE............................................................................................177 Removal..............................................................................................177 Installation.........................................................................................177 STEERING CYLINDER........................................................................................177 Removal..............................................................................................177 Inspection...........................................................................................179 Assembly.............................................................................................179 Installation.........................................................................................179 HUBS, H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B (P150-200B).......................180 Removal..............................................................................................180 Installation.........................................................................................180 HUBS, H360-620B, H16.00-30.00C, H17.00-32.00C, H700-800A, H36.00-44.00B, H36.00-48.00C, H20.00-32.00F....181 Removal..............................................................................................181 Installation.........................................................................................181 SPINDLES.................................................................................................181 Removal..............................................................................................181 Installation.........................................................................................181 CHECKS AND ADJUSTMENTS.......................................................................................183 REMOVE THE AIR FROM THE STEERING SYSTEM..................................................................183 ADJUST THE CYLINDER STOPS................................................................................183 180083...........................................................................................................184 INTRODUCTION.................................................................................................184 GENERAL..................................................................................................184 DESCRIPTION..............................................................................................184 CONTROL VALVE OPERATION..................................................................................185 REPAIRS......................................................................................................185 BRAKE SHOE ASSEMBLIES....................................................................................185 Removal..............................................................................................185 Cleaning.............................................................................................185 Inspection...........................................................................................186 Installation.........................................................................................186 AIR CHAMBER..............................................................................................187 Removal and Disassembly..............................................................................187 Assembly and Installation............................................................................187 CONTROL VALVE............................................................................................187 Removal..............................................................................................187 Disassembly..........................................................................................188 Assembly.............................................................................................189 Installation.........................................................................................189 AIR TANK.................................................................................................189 CHECKS AND ADJUSTMENTS.......................................................................................190 ADJUSTING THE BRAKES.....................................................................................190 RELIEF VALVE.............................................................................................190 TROUBLESHOOTING..............................................................................................191 180084...........................................................................................................193 INTRODUCTION.................................................................................................193 General..................................................................................................193 Description..............................................................................................193 Brake Valve..........................................................................................193 Service Brake Assembly...............................................................................196 REPAIRS......................................................................................................197 Brake Shoe Assemblies....................................................................................197 Removal..............................................................................................197 Cleaning.............................................................................................198 Assembly.............................................................................................198 Brake Valve Assemblies...................................................................................199 Master Cylinder......................................................................................200 Removal..............................................................................................200 Disassembly..........................................................................................201 Assembly.............................................................................................201 Relief Valve Assembly....................................................................................202 Disassembly..............................................................................................202 Assembly.............................................................................................202 Actuator.............................................................................................203 Disassembly..........................................................................................204 Assembly.............................................................................................204 CHECKS AND ADJUSTMENTS.......................................................................................205 Adjust the Brake Shoes...................................................................................205 Adjust the Brake Pedal...................................................................................205 Remove Air from the Brake System.........................................................................206 Adjust the Relief Valve In The Actuator..................................................................206 SPECIFICATIONS...............................................................................................207 TROUBLESHOOTING..............................................................................................207 190097...........................................................................................................210 INTRODUCTION.................................................................................................210 DESCRIPTION..............................................................................................210 OPERATION................................................................................................210 Flow Control Valve...................................................................................212 Relief Valve.........................................................................................212 REPAIRS......................................................................................................213 REMOVAL..................................................................................................213 DISASSEMBLY..............................................................................................213 CLEANING.................................................................................................215 INSPECTION...............................................................................................215 ASSEMBLY.................................................................................................216 INSTALLATION.............................................................................................217 CHECKS AND ADUSTMENTS........................................................................................218 CHECK THE OUTPUT OF THE PUMP.............................................................................218 CHECK FOR AIR IN THE HYDRAULIC SYSTEM....................................................................218 TROUBLESHOOTING..............................................................................................220 200099...........................................................................................................223 INTRODUCTION.................................................................................................223 GENERAL..................................................................................................223 DESCRIPTION..............................................................................................223 OPERATION....................................................................................................224 LIFTING, NO LOAD OR LIGHT LOAD...........................................................................224 LIFTING, CAPACITY LOAD...................................................................................224 LOWERING.................................................................................................224 TILTING..................................................................................................225 RELIEF VALVE.............................................................................................225 BY-PASS FITTING..........................................................................................225 FLOW CONTROL FITTING.....................................................................................226 REPAIRS......................................................................................................226 REMOVAL AND DISASSEMBLY..................................................................................226 CLEANING.................................................................................................227 ASSEMBLY.................................................................................................227 INSTALLATION.............................................................................................228 CHECKS AND ADJUSTMENTS.......................................................................................228 ADJUSTING THE PRESSURE OF THE RELIEF VALVE...............................................................228 SETTINGS FOR THE PRESSURE OF THE RELIEF VALVE................................................................228 CHECKING AND ADJUSTING THE PRESSURE OF THE TWO SPEED VALVE...............................................228 TROUBLESHOOTING..............................................................................................230 600104...........................................................................................................231 GM 4.3 LITRE V-6 AND 5.7 LITRE V-8 ENGINES...................................................................231 DESCRIPTION..............................................................................................231 ENGINE, REMOVAL AND INSTALLATION.........................................................................231 CYLINDER HEAD............................................................................................231 Removal And Disassembly..............................................................................231 Cleaning And Inspection..............................................................................231 Repairs, Valve Guides and Seats......................................................................231 Studs For The Rocker Arms............................................................................232 Valve Springs........................................................................................232 ASSEMBLY AND INSTALLATION................................................................................233 CYLINDER BLOCK, CLEANING AND INSPECTION..................................................................234 PISTON BORE PREPARTION...................................................................................234 ENGINE MOUNTS............................................................................................234 LUBRICATION SYSTEM.......................................................................................234 Oil Pump, Removal and Disassembly....................................................................234 Cleaning and Inspection..............................................................................234 Oil Pump, Assembly and Installation..................................................................234 TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS...............................................235 Timing Cover, Removal................................................................................235 Installation.........................................................................................235 Timing Sprockets, Removal............................................................................236 Timing Sprockets, Installation.......................................................................236 Camshaft, Removal....................................................................................236 Camshaft, Inspection.................................................................................236 Camshaft, Installation...............................................................................237 Hydraulic Valve Lifters, Removal.....................................................................237 Hydraulic Valve Lifters, Disassembly.................................................................237 Hydraulic Valve Lifters, Cleaning And Inspection.....................................................237 Hydraulic Valve Lifters, Assembly....................................................................238 CRANKSHAFT...............................................................................................238 Removal..............................................................................................238 Inspection and Repair................................................................................239 How To Check The Clearance Between The Main Bearings And Their Journals..............................239 Installation.........................................................................................240 PISTON AND CONNECTING ROD ASSEMBLIES.....................................................................241 Connecting Rod Bearings, Replacement.................................................................241 Piston And Connecting Rod Assemblies, Removal........................................................242 Disassembly..........................................................................................242 Piston, Cleaning And Inspection......................................................................243 Cylinder Bores, Inspection And Repair................................................................243 Piston Rings.........................................................................................244 Assembly.............................................................................................244 Piston And Connecting Rod Assemblies, Installation...................................................245 FLYWHEEL AND FLYWEEL HOUSING.............................................................................245 Flywheel Repair For V-6 Engines......................................................................245 Flywheel For V-6 Engines, Installation...............................................................245 Flywheel Housing, H3.5-5.00XL (H70-110XL)............................................................245 Engine Adapter, H6.00-7.00XL (H135-155XL)............................................................245 Ring Gear Replacement (Flywheel) For V-8 Engines.....................................................246 Flywheel For V-8 Engines, Flywheel Housing...........................................................246 COOLANT PUMP.............................................................................................247 FAN MOUNT................................................................................................247 CHECKS AND ADJUSTEMENTS..................................................................................248 Valve Clearance Adjustment...........................................................................248 ENGINE SPECIFICATIONS........................................................................................248 ENGINE SPECIFICATIONS....................................................................................248 Engine Data..........................................................................................248 Cylinder head........................................................................................248 Hydraulic Valve Lifter...............................................................................249 Camshaft.............................................................................................249 Pistons..............................................................................................249 Crankshaft...........................................................................................250 Connecting Rods......................................................................................250 Cooling System.......................................................................................250 Lubrication System...................................................................................250 TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS............................................................251 TROUBLESHOOTING..........................................................................................252 700626...........................................................................................................254 General......................................................................................................256 Description..................................................................................................257 Radiator.................................................................................................257 Radiator Cap.............................................................................................257 Thermostat...............................................................................................257 Water Pump...............................................................................................258 Fan and Fan Shroud.......................................................................................258 Cooling System Checks........................................................................................258 Radiator.................................................................................................258 Thermostat...............................................................................................258 Water Pump...............................................................................................259 Exhaust Leaks............................................................................................259 Fan and Fan Shroud.......................................................................................259 Radiator Cleaning............................................................................................259 Drain....................................................................................................259 Clean....................................................................................................259 Fill.....................................................................................................260 Troubleshooting..............................................................................................261 900347...........................................................................................................263 WEBER CARBURETOR WITH GOVERNOR...............................................................................263 GENERAL..................................................................................................263 DESCRIPTION..............................................................................................263 Carburetor...........................................................................................263 Governor.............................................................................................263 OPERATION................................................................................................264 Carburetor, Float System.............................................................................264 Carburetor, Idle System..............................................................................264 Carburetor, Main Metering System.....................................................................264 Carburetor, Power System.............................................................................265 Carburetor, Accelerator Pump System..................................................................265 Carburetor, Choke System.............................................................................266 GOVERNOR.................................................................................................267 REPAIRS......................................................................................................268 CARBURETOR...............................................................................................268 Removal..............................................................................................268 Disassembly..........................................................................................268 Cleaning.............................................................................................268 Assembly.............................................................................................268 Installation.........................................................................................269 GOVERNOR.................................................................................................269 CHECKS AND ADJUSTMENTS.......................................................................................270 GENERAL..................................................................................................270 CHOKE SYSTEM.............................................................................................270 ELECTRIC CHOKE...........................................................................................270 IDLE MIXTURE ADJUSTMENT..................................................................................271 IDLE SPEED ADJUSTMENT....................................................................................271 THROTTLE LINKAGE ADJUSTMENT..............................................................................272 TROUBLESHOOTING..........................................................................................273 1300142..........................................................................................................274 INTRODUCTION.................................................................................................274 General..................................................................................................274 REPAIRS......................................................................................................274 Torque Converter.........................................................................................274 Transmission.............................................................................................274 Control Valve............................................................................................289 Monotrol Pedal...........................................................................................291 CHECKS AND ADJUSTMENTS.......................................................................................292 Stall Speed of the Torque Converter......................................................................292 Leakage in the Monotrol Pedal............................................................................292 Oil Pressure of the Transmission.........................................................................292 Linkages.................................................................................................295 TROUBLESHOOTING..............................................................................................297 SPECIFICATIONS...............................................................................................300 1800146..........................................................................................................302 INTRODUCTION.................................................................................................302 General..................................................................................................302 Description..............................................................................................302 REPAIRS......................................................................................................302 Removal and Disassembly..................................................................................302 Cleaning.................................................................................................303 Assembly and Installation................................................................................303 1800150..........................................................................................................305 INTRODUCTION.................................................................................................305 General..................................................................................................305 Description..............................................................................................305 Operation................................................................................................305 REPAIRS......................................................................................................305 Removal..................................................................................................305 Disassembly..............................................................................................305 Cleaning.................................................................................................306 Assembly.................................................................................................306 Installation.............................................................................................308 TROUBLESHOOTING..............................................................................................309 1900147..........................................................................................................311 2000100..........................................................................................................313 INTRODUCTION.................................................................................................313 GENERAL..................................................................................................313 DESCRIPTION..............................................................................................313 OPERATION................................................................................................314 Lifting, No Load or Light Load...........................................................................314 Lifting, Capacity Load...................................................................................314 Lowering.................................................................................................315 Tilting..................................................................................................316 Relief Valve.............................................................................................316 By-Pass Fitting..........................................................................................316 Flow Control Fitting.....................................................................................316 REPAIRS......................................................................................................317 REMOVAL AND DISASSEMBLY..................................................................................317 CLEANING.................................................................................................317 ASSEMBLY.................................................................................................317 INSTALLATION.............................................................................................318 CHECKS AND ADJUSTMENTS.......................................................................................318 ADJUSTING THE PRESSURE OF THE RELIEF VALVE...............................................................318 CHECK AND ADJUST THE PRESSURE OF THE TWO SPEED VALVE.....................................................319 TROUBLESHOOTING..............................................................................................319 2100102..........................................................................................................320 INTRODUCTION.................................................................................................320 GENERAL..................................................................................................320 DESCRIPTION AND OPERATION................................................................................320 Tilt Forward.........................................................................................320 Tilt Backward........................................................................................321 REPAIRS......................................................................................................323 REMOVAL..................................................................................................323 DISASSEMBLY..............................................................................................323 CLEANING.................................................................................................323 ASSEMBLY.................................................................................................323 INSTILLATION.............................................................................................324 TROUBLESHOOTING..............................................................................................324 2100103..........................................................................................................325 General......................................................................................................327 Description..................................................................................................327 Tilt Cylinder................................................................................................327 Remove...................................................................................................327 Disassemble..............................................................................................327 Clean....................................................................................................327 Assemble.................................................................................................327 Tilt Cylinders with O-Ring or Single-Lip Seals.......................................................327 Tilt Cylinders for XM and XMS Models.................................................................329 Tilt Cylinders for H700-800A and Early Model H700-920B...............................................330 Install..................................................................................................331 Tilt Cylinders Using Chevron Packing.................................................................332 Install..........................................................................................333 Tilt Cylinder Leak Check.....................................................................................335 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment..........................................................336 Torque Specifications........................................................................................336 Piston Rod Nut...........................................................................................336 Retainer.................................................................................................338 Troubleshooting..............................................................................................339 2200106..........................................................................................................342 General......................................................................................................344 Description and Operation....................................................................................344 Starter Repair...............................................................................................346 Remove...................................................................................................346 Disassemble..............................................................................................346 Clean....................................................................................................347 Assemble.................................................................................................347 Install..................................................................................................348 General Checks and Adjustments...............................................................................348 Troubleshooting..............................................................................................351 2200143..........................................................................................................355 INTRODUCTION.................................................................................................355 GENERAL..................................................................................................355 DESCRIPTION..................................................................................................355 GENERAL..................................................................................................355 STEERING COLUMN GAUGES, METERS AND INDICATORS............................................................358 LED DISPLAY PANEL........................................................................................358 Battery Discharge Indicators.........................................................................358 Brush Wear Indicators................................................................................359 Motor Temperature Indicators.........................................................................360 "LX" SERIES DISPLAY PANEL................................................................................361 Hourmeter Functions..................................................................................362 Battery Indicator Function...........................................................................362 Status Code Function.................................................................................362 "ZX" SERIES DISPLAY PANELS...............................................................................362 Display Panel........................................................................................363 Basic Display Panels.................................................................................363 Performance Display..................................................................................365 Brush Wear Indicators................................................................................368 CHECKS AND ADJUSTMENTS.......................................................................................368 GENERAL..................................................................................................368 REPLACEMENT..................................................................................................369 GENERAL..................................................................................................369 METER REPLACEMENT........................................................................................369 SENDER REPLACEMENT.......................................................................................370 Fuel Level Sender....................................................................................370 Pressure And Temperature Sender......................................................................370 I.T.W. DISPLAY PANEL.....................................................................................371 Removal..............................................................................................371 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT....................................372 Removal..............................................................................................372 Replacing Display Panel Assembly.....................................................................372 Indicator LEDs.......................................................................................372 Battery Indicators...................................................................................372 Digital Display (Performance Disply Panel Only)......................................................372 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)........372 Replacing Parts Of The Basic Display Panel...........................................................373 Replacing Parts Of The Performance Display Panel.....................................................375 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT........................................375 Removal And Replacement..............................................................................375 SPECIFICATIONS...............................................................................................376 TROUBLESHOOTING..............................................................................................377 2200144..........................................................................................................378 ELECTRICAL WARNING DEVICES...................................................................................378 GENERAL..................................................................................................378 DESCRIPTION..............................................................................................378 Operator Controlled Horns............................................................................378 System Warning Lights, Buzzers and Bells.............................................................378 Reverse Warning Horns................................................................................379 Warning Lights.......................................................................................379 REPLACEMENT..............................................................................................380 General..............................................................................................380 Replacing Horns or Bells.............................................................................380 Replacing Horn Relay or Buzzer.......................................................................380 Replacing Warning Lights.............................................................................380 Light Assemblies.....................................................................................381 Replacing Flashing Units.............................................................................381 2200153..........................................................................................................382 ELECTRICAL SYSTEM COMPLETELY DEAD............................................................................382 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN ........................................................383 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER..................................................385 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK.................................................386 STARTER CRANKS SLOWLY........................................................................................388 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START....................................................389 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND..................................................................391 CHARGING SYSTEM DOES NOT FUNCTION............................................................................392 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW.........................................................395 BATTERY IS BEING OVERCHARGED.................................................................................398 ONE OR MORE DASH GAUGES DO NOT WORK..........................................................................399 HORN DOES NOT BLOW...........................................................................................403 POWERSHIFT TRANSMISSION WILL NOT ENGAGE......................................................................404 ELECTRICAL SCHEMATIC S20-30A, H20-30E........................................................................405 ELECTRICAL S30-50C...........................................................................................406 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG..................................................................407 ELECTRICAL SCHEMATIC H30-60H DIESEL..........................................................................409 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG..................................................................411 ELECTRICAL SCHEMATIC H60-90C DIESEL..........................................................................412 ELECTRICAL SCHEMATIC S30-60ES................................................................................413 ELECTRICAL SCHEMATIC S60-120E................................................................................414 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG................................................................415 ELECTRICAL SCHEMATIC S125-150A DIESEL........................................................................416 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG................................................................417 ELECTRICAL SCHEMATIC H110-150F DIESEL........................................................................418 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG......................................................419 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL.............................................................420 ELECTRICAL SCHEMATIC H300A...................................................................................421 ELECTRICAL SCHEMATIC H300-350B...............................................................................422 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL................................................................423 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL................................................................424 ELECTRICAL SCHEMATIC H700-800A...............................................................................425 ELECTRICAL SCHEMATIC P40-50A GASOLINE........................................................................427 ELECTRICAL SCHEMATIC P40-50A DIESEL..........................................................................428 ELECTRICAL SCHEMATIC P60-80A GASOLINE........................................................................429 ELECTRICAL SCHEMATIC P60-80A DIESEL..........................................................................430 ELECTRICAL SCHEMATIC KE GAS GASOLINE.........................................................................431 ELECTRICAL SCHEMATIC KE DIESEL...............................................................................432 ELECTRICAL SCHEMATIC M200-400H GASOLINE......................................................................433 ELECTRICAL SCHEMATIC M200-400H DIESEL........................................................................435 ELECTRICAL SCHEMATIC M600A...................................................................................437 4000127..........................................................................................................439 INTRODUCTION.................................................................................................439 General..................................................................................................439 Description..............................................................................................439 Upright..............................................................................................439 Carriage.............................................................................................439 Lift Cylinder........................................................................................439 REPAIRS......................................................................................................440 Upright..................................................................................................440 Removal..............................................................................................440 Disassembly..........................................................................................441 Cleaning.............................................................................................441 Assembly.............................................................................................441 Installation.........................................................................................442 Carriage.................................................................................................443 Removal..............................................................................................443 Installation.........................................................................................443 Lift Cylinder............................................................................................444 Removal..............................................................................................444 Disassembly..........................................................................................445 Assembly.............................................................................................445 Installation.........................................................................................446 Forks....................................................................................................447 Removal..............................................................................................447 Intallation..........................................................................................447 LAYDOWN TILT.................................................................................................447 General..................................................................................................447 Lowering Procedure.......................................................................................447 Transportation...........................................................................................449 Raising Procedure........................................................................................449 Special Equipment........................................................................................450 CHECKS AND ADJUSTMENTS.......................................................................................452 Lift Chains..............................................................................................452 Checking and Adjusting the Side Rollers..................................................................452 Checking and Adjusting the Back Rollers..................................................................453 SPECIFICATIONS...............................................................................................454 5000154..........................................................................................................456 INTRODUCTION.................................................................................................456 General..................................................................................................456 Description..............................................................................................456 REPAIRS......................................................................................................459 Removal..................................................................................................459 Disassembly..............................................................................................459 Cleaning.................................................................................................459 Assembly.................................................................................................459 Installation.............................................................................................459 CHECKS AND ADJUSTMENTS.......................................................................................459 The Lifting Chains.......................................................................................459 Checking and Adjusting The Side Rollers..................................................................460 Checking and Adjusting The Bumper Roller.................................................................460 8000148..........................................................................................................461 FIGURE 1. GRAPHIC SYMBOLS (Sheet 1 of 2).....................................................................461 FIGURE 1. GRAPHIC SYMBOLS (Sheet 2 of 2).....................................................................462 FIGURE 2. HYDRAULIC SYSTEM SCHEMATIC.........................................................................463 FIGURE 3. POWERSHIFT TRANSMISSION............................................................................464 FIGURE 4. ELECTRICAL WIRING DIAGRAM..........................................................................465 FIGURE 5. INSTRUMENT PANEL ELECTRICAL CONNECTIONS............................................................466 FIGURE 6. ENGINE CABLING DIAGRAM.............................................................................468 FIGURE 7. CAB ELETRICAL AND HEATER CONNECTIONS...............................................................469 8000151..........................................................................................................470 INTRODUCTION.................................................................................................470 General..................................................................................................470 How To Move A Disabled Lift Truck........................................................................470 How To Put A Lift Truck On Blocks........................................................................471 MAINTENANCE SCHEDULE.........................................................................................472 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY................................................................476 How To Make Checks With The Engine Stopped...............................................................476 Engine Oil ..........................................................................................476 Fuel System..........................................................................................476 Drive Belts..........................................................................................477 Battery..............................................................................................477 Primary Fuel Filter, Diesel..........................................................................478 Upright, Forks, And Lift Chains......................................................................478 Lift Chain Adjustments...............................................................................478 Tires And Wheels.....................................................................................480 Operator Restraint System............................................................................481 How To Make Checks With The Engine Running...............................................................482 Guages, Lights, Horn And Fuses.......................................................................482 Control Levers And Pedals............................................................................482 Lift System Operation................................................................................482 Service Brakes.......................................................................................482 Parking Brake........................................................................................483 Steering System......................................................................................483 FIRST 100 HOURS ON NEW LIFT TRUCKS...........................................................................483 EVERY 150 HOURS OR MONTHLY...................................................................................484 Engine Oil And Filter....................................................................................484 Lift Chains..............................................................................................484 Lubrication..............................................................................................484 Air Cleaner..............................................................................................485 EVERY 350 HOURS OR 2 MONTHS..................................................................................485 Forks....................................................................................................485 Brake Fluid..............................................................................................485 Pedal Adjustment.........................................................................................485 Engine Speed.............................................................................................488 Accelerator Linkage Adjustment, Diesel...................................................................488 Governor Adjustment, Gasoline And LPG Engines............................................................490 Accelerator Linkage Adjustment, Gasoline And LPG Engines.................................................490 Battery..................................................................................................490 Wheel Nuts...............................................................................................491 Upright Lubrication......................................................................................491 Fork Pins And Fork Guides................................................................................491 Other Lubrication........................................................................................492 Fuel Filters, Diesel.....................................................................................492 EVERY 1000 HOURS OR 6 MONTHS.................................................................................494 Checks For Leaks In The Lift And Tilt System.............................................................494 Ignition System, GM V8-350...............................................................................494 Timing, Diesel Engines...................................................................................495 Oil Level, Manual Transmission...........................................................................495 Oil Level, Final Drives..................................................................................496 Valve Clearance Adjustment...............................................................................496 Check The PCV Valve, GM V8-350...........................................................................496 Primary Fuel Filter, Diesel..............................................................................497 EVERY 2000 HOURS OR YEARLY...................................................................................497 Fuel Filter, Gasoline And LPG............................................................................497 Changing The Coolant In The Coolant System...............................................................497 Changing The Hydraulic Oil, Hydraulic Filter, And The Hydraulic Tank Breather............................498 Changing The Oil In The Final Drive......................................................................498 Changing The Oil And Filter In The Powershift Transmission...............................................498 Change The Oil In the Manual Transmission................................................................499 Lubricate the Wheel Bearings, Steering Axle..............................................................499 Lubricate The Wheel Bearings, Hypoid Drive Axle..........................................................499 GENERAL PROCEDURES...........................................................................................501 Checking The Fuel Injectors..............................................................................501 Wheels And Tires.........................................................................................501 8000152..........................................................................................................506 8000231..........................................................................................................512 General......................................................................................................514 Nomenclature, Threads....................................................................................514 Strength Identification..................................................................................515 Fastener Torque Tables...................................................................................519 Conversion Table.........................................................................................521 Unlock-2200107...................................................................................................523
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