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Hyster C019 (H13.00-16.00XL Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster C019 (H13.00-16.00XL Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C019 (H13.00-16.00XL Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 544
Downloadable : Yes
File Type : PDF
Size: 23.1 MB
TABLE OF CONTENTS:
Hyster C019 (H13.00-16.00XL Europe) Service Manual – PDF DOWNLOAD
22002................................................................................................................. 1 INTRODUCTION...................................................................................................... 1 GENERAL....................................................................................................... 1 DESCRIPTION................................................................................................... 1 REPAIRS........................................................................................................... 3 GENERAL....................................................................................................... 3 REMOVAL AND DISASSEMBLY (Type A).............................................................................. 3 CLEANING...................................................................................................... 3 ASSEMBLY (Type A)............................................................................................. 4 REMOVAL AND DISAASSEMBLY (Type B)............................................................................. 6 CLEANING...................................................................................................... 8 ASSEMBLY (Type B)............................................................................................. 8 INSTALLATION (Type A and Type B).............................................................................. 9 CHECKS AND ADJUSTMENTS............................................................................................ 9 GENERAL....................................................................................................... 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)........................................................ 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)....................................................... 11 CHECK THE CIRCUIT FOR THE BRUSHES............................................................................. 13 Delco Alternators......................................................................................... 13 Motorola Alternators...................................................................................... 13 CHECK THE DIODES.............................................................................................. 13 CHECK THE DIODE BRIDGE........................................................................................ 13 Delco and Leece–Neville Alternators....................................................................... 13 Motorola Alternators...................................................................................... 13 CHECK THE FIELD WINDING FOR THE ROTOR......................................................................... 14 CHECK THE WINDINGS IN THE STATOR.............................................................................. 14 CHECK THE VOLTAGE REGULATOR................................................................................... 15 TROUBLESHOOTING................................................................................................... 15 100436................................................................................................................ 16 THE FRAME......................................................................................................... 16 GENERAL....................................................................................................... 16 DESCRIPTION................................................................................................... 16 COUNTERWEIGHT................................................................................................. 16 Removal................................................................................................... 16 Installation.............................................................................................. 16 Fenders. Removal.......................................................................................... 17 Fenders, Installation..................................................................................... 17 Side Counterweights H13.00–16.00XL (H330–360XL)........................................................... 18 Side Counterweights, Replacement.......................................................................... 18 HOOD AND AIR CLEANER.......................................................................................... 18 Installation.............................................................................................. 18 Removal................................................................................................... 18 HYDRAULIC TANK................................................................................................ 20 Removal................................................................................................... 20 Repairs, All Units........................................................................................ 20 Cleaning.................................................................................................. 20 Steam Method of Cleaning.................................................................................. 21 Chemical Solution Method of Cleaning...................................................................... 21 Other Methods Of Preparation For Repair................................................................... 22 Installation.............................................................................................. 22 FUEL TANK..................................................................................................... 22 Removal................................................................................................... 22 Repairs................................................................................................... 22 Installation.............................................................................................. 22 RADIATOR...................................................................................................... 24 Removal................................................................................................... 24 Installation.............................................................................................. 24 ENGINE and TRANSMISSION....................................................................................... 24 Removal (Earlier Production Lift Trucks).................................................................. 24 Installation (Earlier Production Lift Trucks)............................................................. 26 Hyster T–50 Transmission, Removal......................................................................... 26 Hyster T–50 Transmission, Installation.................................................................... 28 OPERATOR COMPARTMENT.......................................................................................... 30 General................................................................................................... 30 Removal................................................................................................... 35 Installation.............................................................................................. 36 Gauges and Switches....................................................................................... 36 Window Wipers............................................................................................. 36 Window Washer Motor And Pump.............................................................................. 37 Fuse Panel................................................................................................ 37 Heater Control Panel Assembly............................................................................. 38 Blower and Core Assemblies................................................................................ 38 Door Handle Assembly...................................................................................... 41 Door Retainer Assemblies.................................................................................. 41 Window Replacement........................................................................................ 42 Operator Restraint System................................................................................. 44 LABEL REPLACEMENT............................................................................................. 44 140046................................................................................................................ 46 DIFFERENTIAL...................................................................................................... 46 GENERAL....................................................................................................... 46 DESCRIPTION................................................................................................... 46 REPAIRS........................................................................................................... 47 REMOVAL....................................................................................................... 47 DISASSEMBLY................................................................................................... 47 ASSEMBLY...................................................................................................... 47 Assemble The Pinion, Bearings And Pinion Carrier.......................................................... 47 Adjust Preload For Pinion Bearings........................................................................ 47 Adjust Thickness Of Shim Set For The Pinion Carrier (Depth Of Pinion)..................................... 48 Assemble The Differential And Ring Gear................................................................... 50 Assemble Differential Pinion And Side Gear Assembly....................................................... 51 Check The Rotating Torque Of Differential Gears........................................................... 52 Install The Differential And Ring Gear Assembly........................................................... 53 Adjust Preload Of The Differential Bearings............................................................... 54 Check Runout Of Ring Gear................................................................................. 54 Adjust The Gear Clearance................................................................................. 54 Check Tooth Contact Pattern Of The Gear Set............................................................... 55 Installation Into The Axle Housing........................................................................ 55 SPECIFICATIONS.................................................................................................... 58 TABLE 1. GENERAL SPECIFICATIONS............................................................................... 58 TABLE 2. RIVET INSTALLATION PRESSURE.......................................................................... 58 TABLE 3. PINION PRELOAD PRESSURE.............................................................................. 58 TABLE 4. PINION ADJUSTMENT.................................................................................... 58 TABLE 5. TORQUE SPECIFICATIONS................................................................................ 59 TROUBLESHOOTING................................................................................................... 60 160054................................................................................................................ 61 INTRODUCTION...................................................................................................... 61 GENERAL....................................................................................................... 61 DESCRIPTION................................................................................................... 61 OPERATION..................................................................................................... 61 REPAIRS........................................................................................................... 61 STEERING WHEEL AND COLUMN ASSEMBLY............................................................................ 61 TYPE "A" STEERING COLUMN ASSEMBLY............................................................................. 63 Removal And Disassembly................................................................................... 63 Assembly And Installation................................................................................. 63 TYPE "A" STEERING COLUMN...................................................................................... 64 TYPE "A" STEERING COLUMN...................................................................................... 65 TYPE "B" STEERING COLUMN...................................................................................... 66 Removal And Disassembly................................................................................... 66 Assembly And Installation................................................................................. 66 TYPE "B" STEERING COLUMN...................................................................................... 67 Disassembly of Steering Control Unit...................................................................... 68 Cleaning of Steering Control Unit......................................................................... 68 Assembly of Steering Control Unit......................................................................... 70 CHECKS AND ADJUSTMENTS............................................................................................ 73 REMOVE AIR FROM THE SYSTEM.................................................................................... 73 TROUBLESHOOTING................................................................................................... 74 600412................................................................................................................ 75 PERKINS DIESEL ENGINES, SERIES 1000............................................................................... 75 1.1 GENERAL................................................................................................... 75 GENERAL SAFETY RULES.......................................................................................... 75 Viton Seals............................................................................................... 75 1.2 DESCRIPTION............................................................................................... 78 1.3 Engine Serial Number Codes............................................................................ 78 1.4 Engine Data........................................................................................... 78 1.5 1004–4 ENGINE......................................................................................... 79 1.6 1004–4T ENGINE........................................................................................ 79 1.7 1006–6 ENGINE......................................................................................... 79 1.8 1006–6T ENGINE........................................................................................ 79 1.9 REMOVAL AND INSTALLATION.................................................................................. 79 CYLINDER HEAD ASSEMBLY............................................................................................ 80 1.10 VALVE COVER.............................................................................................. 80 1.11 Removal.............................................................................................. 80 1.12 Installation......................................................................................... 80 1.13 ROCKER ARM ASSEMBLY...................................................................................... 80 1.14 Removal.............................................................................................. 80 1.15 Installation......................................................................................... 80 1.16 Disassembly.......................................................................................... 81 1.17 Inspection........................................................................................... 81 1.18 Assembly............................................................................................. 81 1.19 VALVE CLEARANCE ADJUSTMENTS.............................................................................. 81 1.20 Four Cylinder Engines................................................................................ 82 1.21 Six Cylinder Engines................................................................................. 82 1.22 VALVE SPRINGS............................................................................................ 82 1.23 CYLINDER HEAD ASSEMBLY................................................................................... 84 1.24 Removal.............................................................................................. 84 1.25 Installation......................................................................................... 85 1.26 VALVES AND VALVE SPRINGS................................................................................. 88 1.27 Removal.............................................................................................. 88 1.28 Inspection........................................................................................... 89 1.29 Installation......................................................................................... 89 1.30 VALVE GUIDES............................................................................................. 89 1.31 Inspection........................................................................................... 89 1.32 Removal.............................................................................................. 90 1.33 Installation......................................................................................... 90 1.34 CYLINDER HEAD AND VALVE SEATS............................................................................ 90 1.35 Inspection........................................................................................... 90 1.36 Repair............................................................................................... 91 1.37 Installation Of New Valve Seats...................................................................... 91 PISTON AND CONNECTING ROD ASSEMBLIES.............................................................................. 92 1.38 ROD BEARINGS............................................................................................. 92 1.39 Removal.............................................................................................. 92 1.40 Installation......................................................................................... 93 1.41 PISTON AND CONNECTING ROD ASSEMBLY....................................................................... 93 1.42 Service Note......................................................................................... 93 1.43 Removal.............................................................................................. 93 1.44 Installation......................................................................................... 94 1.45 PISTON RINGS............................................................................................. 95 1.46 Removal.............................................................................................. 95 1.47 Inspection........................................................................................... 95 1.48 Installation......................................................................................... 96 1.49 PISTON AND CONNECTING ROD................................................................................ 97 1.50 Disassembly.......................................................................................... 97 1.51 Inspection........................................................................................... 97 1.52 Installation......................................................................................... 97 1.53 PISTON COOLING JETS...................................................................................... 98 1.54 Removal.............................................................................................. 98 1.55 Installation......................................................................................... 98 CRANKSHAFT ASSEMBLY............................................................................................... 99 1.56 GENERAL.................................................................................................. 99 1.57 CRANKSHAFT PULLEY........................................................................................ 99 1.58 Removal, Engines AA and AB........................................................................... 99 1.59 Installation, Engines AA and AB...................................................................... 99 1.60 Removal, Engines YA and YB........................................................................... 99 1.61 Installation, Engines YA and YB...................................................................... 99 1.62 REAR OIL SEAL............................................................................................100 1.63 Replacement..........................................................................................100 1.64 MAIN BEARINGS............................................................................................101 1.65 Removal..............................................................................................101 1.66 Installation.........................................................................................101 1.67 THRUST WASHERS...........................................................................................102 1.68 Check The Axial Movement Of The Crankshaft...........................................................102 1.69 Removal..............................................................................................103 1.70 Installation.........................................................................................103 1.71 CRANKSHAFT...............................................................................................103 1.72 Removal..............................................................................................103 1.73 Inspection...........................................................................................104 1.74 Installation.........................................................................................104 TIMING CASE AND TIMING GEARS......................................................................................106 1.75 GENERAL..................................................................................................106 1.76 TIMING CASE COVER........................................................................................106 1.77 Removal..............................................................................................106 1.78 Installation.........................................................................................106 1.79 FRONT OIL SEAL...........................................................................................107 1.80 Removal..............................................................................................107 1.81 Installation.........................................................................................107 1.82 IDLER GEAR AND HUB.......................................................................................107 1.83 Removal..............................................................................................107 1.84 Installation.........................................................................................108 1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR....................................................109 1.86 Removal..............................................................................................109 1.87 Installation.........................................................................................109 1.88 CRANKSHAFT GEAR..........................................................................................110 1.89 Removal..............................................................................................110 1.90 Installation.........................................................................................110 1.91 TIMING CASE..............................................................................................110 1.92 Removal..............................................................................................110 1.93 Installation.........................................................................................110 1.94 CAMSHAFT AND TAPPETS.....................................................................................111 1.95 Removal..............................................................................................112 1.96 Installation.........................................................................................112 ENGINE BLOCK ASSEMBLY.............................................................................................113 1.97 DESCRIPTION..............................................................................................113 1.98 ENGINE BLOCK.............................................................................................113 1.99 Disassembly..........................................................................................113 1.100 Inspection..........................................................................................114 1.101 Assembly............................................................................................114 1.102 CYLINDER LINER..........................................................................................114 1.103 Inspection..........................................................................................114 1.104 Hone................................................................................................115 1.105 Removal.............................................................................................115 1.106 Installation........................................................................................116 TURBOCHARGER, ENGINES AB AND YB...................................................................................117 1.107 GENERAL.................................................................................................117 1.108 Removal.............................................................................................117 1.109 Installation........................................................................................118 1.110 Clean The Impeller And Compressor Housing...........................................................118 LUBRICATION SYSTEM................................................................................................119 1.111 GENERAL.................................................................................................119 1.112 OIL FILTER, REPLACEMENT.................................................................................119 1.113 OIL SUMP................................................................................................120 1.114 Removal.............................................................................................120 1.115 Installation........................................................................................120 1.116 OIL PUMP................................................................................................120 1.117 Removal.............................................................................................120 1.118 Inspection..........................................................................................121 1.119 Installation........................................................................................121 1.120 RELIEF VALVE............................................................................................122 1.121 Removal.............................................................................................122 1.122 Disassembly.........................................................................................122 1.123 Inspection..........................................................................................123 1.124 Installation........................................................................................123 FUEL SYSTEM.......................................................................................................123 1.125 DESCRIPTION.............................................................................................123 1.126 CAV FUEL INJECTION PUMP.................................................................................124 1.127 Removal.............................................................................................124 1.128 Installation........................................................................................124 1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS.........................................................125 1.130 Timing Gear Marks...................................................................................125 1.131 How To Set Number 1 Piston To TDC On The Compression Stroke.........................................126 1.132 Check The Valve Timing..............................................................................126 1.133 Check The Timing Of The Fuel Injection Pump.........................................................127 1.134 Check The Timing Mark Of The Fuel Injection Pump....................................................127 1.135 Check The Engine Timing Mark........................................................................128 1.136 REMOVE AIR FROM THE FUEL SYSTEM.........................................................................129 1.137 Fuel Injection Pump With Vent Tube..................................................................129 1.138 Fuel Injection Pump With Vent Screw.................................................................130 1.139 FUEL FILTER (REPLACEMENT)...............................................................................131 1.140 FUEL INJECTORS..........................................................................................131 1.141 Removal.............................................................................................131 1.142 Inspection..........................................................................................132 1.143 Installation........................................................................................133 1.144 FUEL PUMP...............................................................................................133 1.145 Removal.............................................................................................133 1.146 Disassembly.........................................................................................133 1.147 Assembly............................................................................................134 1.148 Installation........................................................................................134 1.149 Test................................................................................................135 COOLING SYSTEM....................................................................................................135 1.150 GENERAL.................................................................................................135 1.151 THERMOSTAT..............................................................................................135 1.152 Replacement.........................................................................................135 1.153 COOLANT PUMP............................................................................................136 1.154 Removal.............................................................................................136 1.155 Disassembly.........................................................................................136 1.156 Assembly............................................................................................137 1.157 Installation........................................................................................137 1.158 FAN AND FAN DRIVE.......................................................................................137 1.159 Removal.............................................................................................137 1.160 Disassembly.........................................................................................137 1.161 Assembly............................................................................................138 1.162 Installation........................................................................................138 1.163 OIL COOLER..............................................................................................138 1.164 Removal, Engine AB..................................................................................138 1.165 Removal, Engines YA and YB..........................................................................138 1.166 Disassembly And Assembly............................................................................139 1.167 Installation, Engine AB.............................................................................139 1.168 Installation, Engines YA and YB.....................................................................140 1.169 By–Pass Valve, Oil Cooler...........................................................................140 FLYWHEEL AND FLYWHEEL HOUSING.....................................................................................140 1.170 GENERAL.................................................................................................140 1.171 FLYWHEEL................................................................................................140 1.172 Removal.............................................................................................140 1.173 Ring Gear (Replacement).............................................................................140 1.174 Installation........................................................................................140 1.175 FLYWHEEL HOUSING........................................................................................141 1.176 Removal.............................................................................................141 1.177 Installation........................................................................................141 ELECTRICAL EQUIPMENT..............................................................................................142 1.178 DRIVE BELTS.............................................................................................142 1.179 ALTERNATOR..............................................................................................143 1.180 STARTER MOTOR...........................................................................................143 1.181 Removal.............................................................................................143 1.182 Installation........................................................................................143 1.183 COLD START AID..........................................................................................143 AIR COMPRESSOR, ENGINES YA AND YB.................................................................................143 1.184 GENERAL.................................................................................................143 1.185 Air Compressor, Removal, WABCO......................................................................143 1.186 Compressor Drive, Inspection........................................................................144 1.187 Air Compressor, Installation, WABCO.................................................................144 1.188 Compressor Drive, Disassembly, WABCO................................................................144 1.189 Compressor Drive, Assembly, WABCO...................................................................145 1.190 Air Compressor, Removal, BENDIX.....................................................................145 1.191 Air Compressor, Installation, BENDIX................................................................146 1.192 Compressor Drive, Disassembly, BENDIX...............................................................147 1.193 Compressor Drive, Assembly, BENDIX..................................................................147 ENGINE SPECIFICATIONS.............................................................................................149 1.194 CYLINDER HEAD ASSEMBLY..................................................................................149 1.195 Cylinder Head.......................................................................................149 1.196 Valve Guides........................................................................................149 1.197 Inlet Valves........................................................................................150 1.198 Exhaust Valves......................................................................................150 1.199 Double Valve Springs To Outer.......................................................................150 1.200 Double Valve Springs To Inner.......................................................................150 1.201 Single Valve Springs................................................................................150 1.202 Tappets.............................................................................................150 1.203 Rocker Arm Shaft....................................................................................150 1.204 Rocker Arms And Bushings............................................................................151 1.205 PISTON AND CONNECTING RODS..............................................................................151 1.206 Pistons, Engines AA And YA..........................................................................151 1.207 Pistons, Engines AB And YB..........................................................................151 1.208 Piston Rings, Engines AA And YA.....................................................................151 1.209 Piston Rings, Engines AB And YB.....................................................................151 1.210 Connecting Rods, Engines AB And YB..................................................................152 1.211 Connecting Rods, Engines AB And YB..................................................................152 1.212 Piston Pins, Engines AA And YA......................................................................152 1.213 Piston Pins, Engines AB and YB......................................................................152 1.214 Small End Bushings, Engines AA And YA...............................................................152 1.215 Small End Bushings, Engines AB And YB...............................................................152 1.216 Connecting Rod Bearings, Engines AA And YA..........................................................153 1.217 Connecting Rod Bearings, Engines AB And YB..........................................................153 1.218 Piston Cooling Jets, Engines AB And YB..............................................................153 1.219 CRANKSHAFT ASSEMBLY.....................................................................................153 1.220 Crankshaft..........................................................................................153 1.221 Crankshaft Heat Treatment...........................................................................153 1.222 Crankshaft Overhaul.................................................................................153 1.223 Main Bearings.......................................................................................155 1.224 Crankshaft Thrust Washers...........................................................................155 1.225 TIMING CASE AND DRIVE ASSEMBLY..........................................................................155 1.226 Camshaft............................................................................................155 1.227 Camshaft Thrust Washer..............................................................................155 1.228 Camshaft Gear.......................................................................................156 1.229 Gear For Fuel Injection Pump........................................................................156 1.230 Crankshaft Gear.....................................................................................156 1.231 Idler Gear And Hub..................................................................................156 1.232 ENGINE BLOCK ASSEMBLY...................................................................................156 1.233 Engine Block........................................................................................156 1.234 Cylinder Liners.....................................................................................156 1.235 TURBOCHARGER............................................................................................157 1.236 LUBRICATION SYSTEM......................................................................................157 1.237 Oil Pump, Engines AA And AB.........................................................................157 1.238 Oil Pump, Engines YA And YB.........................................................................157 1.239 Relief Valve........................................................................................157 1.240 Oil Filter..........................................................................................157 1.241 FUEL SYSTEM.............................................................................................157 1.242 Cav Fuel Injection Pump.............................................................................157 1.243 FUEL INJECTORS......................................................................................158 1.244 Fuel Pump, Engines AA And AB........................................................................159 1.245 Fuel Pump, Engines YA And YB........................................................................159 1.246 Fuel Filter.........................................................................................159 1.247 COOLING SYSTEM..........................................................................................159 1.248 Coolant Pump........................................................................................159 1.249 Thermostat..........................................................................................160 1.250 Fan Drive Housing...................................................................................160 1.251 FLYWHEEL AND HOUSING....................................................................................160 1.252 Limits for flywheel ''run out'' and alignment (total indicator reading).............................160 1.253 ELECTRICAL EQUIPMENT....................................................................................160 1.254 Alternator..........................................................................................160 1.255 Starter Motor.......................................................................................160 1.256 Cold Start Aid......................................................................................160 TORQUE SPECIFICATIONS.............................................................................................161 SPECIAL TOOLS.....................................................................................................162 700626................................................................................................................166 COOLING SYSTEM....................................................................................................166 INTRODUCTION..................................................................................................166 DESCRIPTION...................................................................................................166 RADIATOR......................................................................................................166 RADIATOR CAP..................................................................................................166 THERMOSTAT....................................................................................................166 WATER PUMP....................................................................................................167 FAN AND FAN SHROUD ...........................................................................................167 REPAIRS...........................................................................................................167 COOLING SYSTEM CHECKS.........................................................................................167 Exhaust Leaks.............................................................................................167 RADIATOR......................................................................................................167 Checks....................................................................................................167 Cleaning The Radiator.....................................................................................167 Drain The Cooling System..................................................................................169 Fill The Cooling System...................................................................................169 WATER PUMP....................................................................................................169 Checks....................................................................................................169 THERMOSTAT....................................................................................................170 Checks....................................................................................................170 FAN AND FAN SHROUD ...........................................................................................170 TROUBLESHOOTING...................................................................................................171 1300437...............................................................................................................172 INTRODUCTION......................................................................................................172 GENERAL.......................................................................................................172 MECHANICAL DESCRIPTION............................................................................................173 GENERAL.......................................................................................................173 TORQUE CONVERTER..............................................................................................173 Description...............................................................................................173 Operation.................................................................................................173 CLUTCH ASSEMBLIES.............................................................................................173 Description...............................................................................................173 Operation.................................................................................................175 HYDRAULIC OPERATION...............................................................................................175 SUMP, FILTER, AND PUMP........................................................................................175 CONTROL VALVE.................................................................................................175 Solenoid Valves...........................................................................................176 Inching Spool.............................................................................................176 Direction Spools..........................................................................................177 Range Spool...............................................................................................177 MODULATOR VALVE...............................................................................................177 Operation.................................................................................................178 TRANSMISSION CONTROL SYSTEM...................................................................................178 Monotrol Pedal............................................................................................178 HYDRAULIC CIRCUITS............................................................................................178 Cooling and Lubrication...................................................................................178 NEUTRAL...................................................................................................179 FORWARD-First.............................................................................................179 REVERSE-First.............................................................................................181 Shift From First To Second Speed..........................................................................182 INCHING...................................................................................................183 1300438...............................................................................................................185 INTRODUCTION......................................................................................................185 General ......................................................................................................185 Transmission..................................................................................................185 Removal...................................................................................................185 Disassembly...............................................................................................185 Cleaning..................................................................................................211 Inspection................................................................................................211 Assembly..................................................................................................211 Installation..............................................................................................244 Control Valve.................................................................................................244 Removal...................................................................................................244 Disassembly...............................................................................................245 Cleaning and Inspection...................................................................................245 Assembly..................................................................................................245 Installation..............................................................................................246 Modulator Valve...............................................................................................246 Removal...................................................................................................246 Disassembly...............................................................................................246 Cleaning and Inspection...................................................................................247 Assembly..................................................................................................247 Installation..............................................................................................247 Oil Pump......................................................................................................247 Removal...................................................................................................247 Disassembly...............................................................................................247 Cleaning and Inspection...................................................................................247 Assembly..................................................................................................247 Installation..............................................................................................247 Monotrol Pedal................................................................................................247 Removal and Disassembly...................................................................................247 Assembly and Installation.................................................................................247 CHECKS AND ADJUSTMENTS............................................................................................250 Stall Test....................................................................................................250 Check the Oil Pressure of the Transmission....................................................................250 Adjust the Linkages for the Transmission......................................................................252 Linkage for the Inching/Brake Pedal.......................................................................252 Linkage for the Range Lever...............................................................................253 TROUBLESHOOTING...................................................................................................254 1400439...............................................................................................................256 INTRODUCTION......................................................................................................256 GENERAL.......................................................................................................256 DESCRIPTION...................................................................................................256 OPERATION.....................................................................................................256 REPAIRS...........................................................................................................256 REMOVAL.......................................................................................................256 DISASSEMBLY...................................................................................................259 ASSEMBLY AND INSTALLATION.....................................................................................259 TROUBLESHOOTING...................................................................................................265 1600326...............................................................................................................267 INTRODUCTION......................................................................................................267 GENERAL.......................................................................................................267 DESCRIPTION...................................................................................................267 REPAIRS...........................................................................................................268 STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)....................................268 Removal...................................................................................................268 Installation..............................................................................................268 STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL)...........................................269 Removal...................................................................................................269 Installation..............................................................................................270 WHEELS AND HUBS, ALL UNITS....................................................................................270 Removal and Disassembly...................................................................................270 Cleaning..................................................................................................270 Assembly and Installation.................................................................................270 SPINDLES AND BEARINGS, ALL UNITS..............................................................................271 Removal...................................................................................................271 Cleaning..................................................................................................272 Assembly and Installation.................................................................................272 TIE RODS, ALL UNITS...........................................................................................272 Removal...................................................................................................272 Cleaning..................................................................................................272 Installation..............................................................................................273 STEERING CYLINDER.............................................................................................274 Removal and Disassembly...................................................................................274 Cleaning and Inspection...................................................................................274 Assembly and Installation.................................................................................274 TROUBLESHOOTING...................................................................................................275 1600564...............................................................................................................276 INTRODUCTION......................................................................................................276 GENERAL.......................................................................................................276 DESCRIPTION...................................................................................................276 STEERING WHEEL AND COLUMN ASSEMBLY................................................................................277 GENERAL.......................................................................................................277 STEERING WHEEL AND HORN...................................................................................278 Removal...................................................................................................278 Installation..............................................................................................279 STEERING CONTROL UNIT.............................................................................................279 GENERAL.......................................................................................................279 DESCRIPTION...................................................................................................279 OPERATION.....................................................................................................280 Load Sensing Steering.....................................................................................280 REMOVAL.......................................................................................................280 DISASSEMBLY...................................................................................................280 CLEANING......................................................................................................280 ASSEMBLY AND INSTALLATION.....................................................................................280 CHECKS AND ADJUSTMENTS............................................................................................286 REMOVE AIR FROM THE SYSTEM....................................................................................286 CHECK THE STEERING RELIEF PRESSURE............................................................................286 TROUBLESHOOTING...................................................................................................287 1800441...............................................................................................................289 INTRODUCTION......................................................................................................289 GENERAL.......................................................................................................289 DESCRIPTION...................................................................................................289 OPERATION.....................................................................................................290 Service Brakes............................................................................................290 Parking Brake.............................................................................................291 REPAIRS...........................................................................................................292 AIR TANK......................................................................................................292 Relief Valve..............................................................................................292 Drain Valve...............................................................................................292 BRAKE PEDAL VALVE.............................................................................................293 Removal...................................................................................................293 Disassembly, Inspection and Assembly......................................................................293 Installation..............................................................................................294 PARKING BRAKE VALVE...........................................................................................295 Removal...................................................................................................295 Disassembly And Repair....................................................................................295 Assembly..................................................................................................295 Installation..............................................................................................295 AIR CHAMBERS..................................................................................................295 Removal...................................................................................................295 Disassembly...............................................................................................295 Inspection................................................................................................297 Assembly..................................................................................................297 Installation..............................................................................................297 ACTUATOR ATMS.................................................................................................297 Removal...................................................................................................297 Inspection................................................................................................298 Installation..............................................................................................298 BRAKE ASSEMBLIES..............................................................................................298 Brake Shoe Removal........................................................................................298 Camshaft Removal..........................................................................................300 Cleaning..................................................................................................301 Inspection................................................................................................301 Camshaft Installation.....................................................................................301 Brake Shoe Installation...................................................................................302 QUICK-RELEASE VALVE...........................................................................................303 CHECKS AND ADJUSTMENTS............................................................................................303 CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR..........................................................303 ADJUST THE BRAKE SHOES........................................................................................303 TROUBLESHOOTING...................................................................................................304 SPECIFICATIONS....................................................................................................306 1800442...............................................................................................................308 INTRODUCTION......................................................................................................308 GENERAL.......................................................................................................308 DESCRIPTION...................................................................................................308 OPERATION.....................................................................................................308 REPAIRS...........................................................................................................308 REMOVAL.......................................................................................................308 DISASSEMBLY...................................................................................................308 Cylinder Head.............................................................................................308 Crankcase.................................................................................................309 CLEANING......................................................................................................310 INSPECTION....................................................................................................310 Crankshaft................................................................................................310 Connecting Rod............................................................................................310 Crankshaft Bushings.......................................................................................310 ASSEMBLY......................................................................................................310 TROUBLESHOOTING...................................................................................................312 1900443...............................................................................................................313 INTRODUCTION......................................................................................................313 GENERAL.......................................................................................................313 DESCRIPTION AND OPERATION.....................................................................................313 Hydraulic Pump............................................................................................316 Hydraulic Pump, Units with Empty Container Attachment.....................................................316 Main Control Valve........................................................................................316 Steering Control Unit.....................................................................................317 REPAIRS...........................................................................................................317 HYDRAULIC PUMP................................................................................................317 Removal...................................................................................................317 Disassemby................................................................................................318 Cleaning and Inspection...................................................................................319 Assembly..................................................................................................319 Installation..............................................................................................320 PRIORITY VALVE................................................................................................320 Removal...................................................................................................320 Disassembly...............................................................................................321 Cleaning and Inspection...................................................................................321 Assembly..................................................................................................321 Installation..............................................................................................321 CHECKS AND ADJUSTMENTS............................................................................................322 CHECK THE OUTPUT OF THE PUMP..................................................................................322 CHECK THE STEERING RELIEF PRESSURE............................................................................322 TROUBLESHOOTING...................................................................................................322 SPECIFICATIONS....................................................................................................324 2000444...............................................................................................................326 INTRODUCTION......................................................................................................326 GENERAL.......................................................................................................326 DESCRIPTION...................................................................................................326 OPERATION.....................................................................................................327 Lift Section..............................................................................................328 Tilt Section..............................................................................................330 Relief Valves.............................................................................................330 REPAIRS...........................................................................................................331 REMOVAL AND DIASSEMBLY........................................................................................331 CLEANING AND INSPECTION.......................................................................................331 ASSEMBLY......................................................................................................332 INSTALLATION..................................................................................................332 CHECKS AND ADJUSTMENTS............................................................................................332 PRESSURE RELIEF VALVES........................................................................................332 Primary Relief Valve......................................................................................332 Secondary Relief Valve....................................................................................333 Relief Valves for Extend/Retract Circuit..................................................................333 ADJUST THE CONTROL LEVERS.....................................................................................334 TROUBLESHOOTING...................................................................................................335 SPECIFICATIONS....................................................................................................336 2100102...............................................................................................................337 INTRODUCTION......................................................................................................337 GENERAL.......................................................................................................337 DESCRIPTION AND OPERATION.....................................................................................337 Tilt Forward..............................................................................................337 Tilt Backward.............................................................................................338 REPAIRS...........................................................................................................340 REMOVAL.......................................................................................................340 DISASSEMBLY...................................................................................................340 CLEANING......................................................................................................340 ASSEMBLY......................................................................................................340 INSTILLATION..................................................................................................341 TROUBLESHOOTING...................................................................................................341 2100103...............................................................................................................342 INTRODUCTION......................................................................................................345 GENERAL.......................................................................................................345 DESCRIPTION...................................................................................................345 REPAIRS...........................................................................................................345 REMOVAL.......................................................................................................345 DISASSEMBLY...................................................................................................345 CLEANING......................................................................................................345 ASSEMBLY......................................................................................................345 Tilt Cylinders for the XM and XMS Models..................................................................345 Tilt Cylinders with O-Ring or Single Lip Seals............................................................347 Tilt Cylinders for H700-800A and Early Model H700-920B....................................................347 INSTALLATION..................................................................................................347 Tilt Cylinders with Chevron Packing.......................................................................347 CHECKS AND ADJUSTMENTS............................................................................................351 CHECK THE TILT CYLINDERS FOR LEAKS............................................................................351 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.......................................................351 TROUBLESHOOTING...................................................................................................354 2200106...............................................................................................................357 INTRODUCTION......................................................................................................357 GENERAL.......................................................................................................357 DESCRIPTION AND OPERATION.....................................................................................357 REPAIRS...........................................................................................................359 REMOVAL.......................................................................................................359 DISSASEMBLY...................................................................................................359 CLEANING......................................................................................................360 ASSEMBLY......................................................................................................360 INSTALLATION..................................................................................................360 CHECKS AND ADJUSTMENTS............................................................................................361 GENERAL.......................................................................................................361 TROUBLESHOOTING...................................................................................................363 2200143...............................................................................................................365 INTRODUCTION......................................................................................................365 GENERAL.......................................................................................................365 DESCRIPTION.......................................................................................................365 GENERAL.......................................................................................................365 STEERING COLUMN GAUGES, METERS AND INDICATORS.................................................................368 LED DISPLAY PANEL.............................................................................................368 Battery Discharge Indicators .............................................................................368 Brush Wear Indicators.....................................................................................369 Motor Temperature Indicators..............................................................................370 "LX" SERIES INSTRUMENT PANEL DISPLAY..........................................................................371 Hourmeter Functions.......................................................................................372 Battery Indicator Function................................................................................372 Status Code Function......................................................................................372 CHECKS AND ADJUSTMENTS............................................................................................372 GENERAL.......................................................................................................372 REPLACEMENT.......................................................................................................373 GENERAL.......................................................................................................373 METER REPLACEMENT.............................................................................................373 SENDER REPLACEMENT............................................................................................374 Fuel Level Sender.........................................................................................374 Pressure And Temperature Sender...........................................................................375 I.T.W. DISPLAY PANEL..........................................................................................375 Removal...................................................................................................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 4000135...............................................................................................................382 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................382 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................382 LIFT CYLINDERS....................................................................................................385 GENERAL.......................................................................................................385 DESCRIPTION...................................................................................................385 Lowering Control Valve....................................................................................385 Cylinders (General).......................................................................................388 Cylinders (H520-620B,H700-800A)...........................................................................390 Cylinders (H360-460B).....................................................................................391 Cylinders (Two-Speed).....................................................................................391 REPAIRS...........................................................................................................392 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST........................................................392 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..................392 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...................................396 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.............................394 DISASSEMBLY...................................................................................................394 ASSEMBLY......................................................................................................396 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.................................................................396 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..................396 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead..........................396 CHEVRON PACKING...............................................................................................397 LIFT CYLINDERS FOR VISTA MASTS....................................................................................400 DESCRIPTION...................................................................................................400 Lowering Control Valve....................................................................................402 REMOVAL.......................................................................................................403 DISASSEMBLY...................................................................................................403 ASSEMBLY......................................................................................................403 INSTALLATION..................................................................................................404 Main Lift Cylinders.......................................................................................404 Free-Lift Cylinders.......................................................................................404 CHECKS AND ADJUSTMENTS............................................................................................405 CHECK FOR LEAKS IN LIFT SYSTEM................................................................................405 TROUBLESHOOTING...................................................................................................406 SPECIFICATIONS....................................................................................................407 4000445...............................................................................................................408 INTRODUCTION......................................................................................................408 GENERAL.......................................................................................................408 DESCRIPTION...................................................................................................408 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................409 OPERATION.........................................................................................................410 TWO-STAGE MAST................................................................................................410 THREE-STAGE MAST..............................................................................................411 REPAIRS...........................................................................................................413 FORKS.........................................................................................................413 Removal...................................................................................................413 Installation..............................................................................................413 CARRIAGE......................................................................................................413 Removal...................................................................................................413 Disassembly, Side-Shift Carriage..........................................................................415 Assembly, Side-Shift Carriage.............................................................................416 Side-Shift Cylinder Disassembly...........................................................................417 Side-Shift Cylinder Asembly...............................................................................417 Fork Positioner Cylinder Disassembly......................................................................418 Fork Positioner Cylinder Assembly.........................................................................418 Installation..............................................................................................419 MAST..........................................................................................................420 Removal...................................................................................................420 Disassembly-Two Stage Mast................................................................................420 Disassembly-Three Stage Mast..............................................................................423 Cleaning and Inspection...................................................................................426 Assembly-Two Stage Mast...................................................................................427 Assembly-Three Stage Mast.................................................................................427 Installation..............................................................................................432 LIFT CYLINDERS................................................................................................433 Description...............................................................................................433 PISTON TYPE CYLINDERS.........................................................................................433 DISPLACEMENT TYPE CYLINDERS...................................................................................433 ALL LIFT CYLINDERS............................................................................................433 Removal...................................................................................................434 Disassembly...............................................................................................434 Cleaning and Inspection...................................................................................435 Assembly..................................................................................................436 Installation..............................................................................................436 CHECKS AND ADJUSTMENTS............................................................................................437 CHECK THE OPERATION OF THE MAST...............................................................................437 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...................................................................437 Lift System...............................................................................................437 Tilt System...............................................................................................437 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...................................................438 LIFT CHAIN ADJUSTMENTS........................................................................................438 MAST ADJUSTMENTS..............................................................................................439 Bearing Blocks............................................................................................439 Wear Plates...............................................................................................439 Load Roller Adjustments...................................................................................439 CARRIAGE ADJUSTMENT...........................................................................................441 TROUBLESHOOTING...................................................................................................443 4500465...............................................................................................................444 INTRODUCTION......................................................................................................444 GENERAL.......................................................................................................444 DESCRIPTION...................................................................................................444 OPERATION.....................................................................................................445 Side-Shift Circuit........................................................................................445 Extend/Retract Circuit....................................................................................445 Lock Pin Circuit..........................................................................................446 REPAIRS...........................................................................................................448 ADJUST AND INSTALL THE BEARING BLOCKS.........................................................................448 CONTAINER ATTACHMENT..........................................................................................450 Removal...................................................................................................450 Disassembly...............................................................................................450 Cleaning and Inspection...................................................................................450 Assembly..................................................................................................451 Installation..............................................................................................452 SIDE-SHIFT CYLINDER...........................................................................................454 Removal...................................................................................................454 Disassembly...............................................................................................454 Cleaning and Inspection...................................................................................454 Assembly..................................................................................................454 Installation..............................................................................................454 EXTENSION CYLINDER............................................................................................454 Removal...................................................................................................454 Disassembly...............................................................................................454 Cleaning and Inspection...................................................................................455 Assembly..................................................................................................455 Installation..............................................................................................455 END BEAMS.....................................................................................................456 Removal and Disassembly...................................................................................456 Cleaning and Inspection...................................................................................456 Assembly..................................................................................................456 OPERATOR CONTROLS.............................................................................................457 Repairs...................................................................................................457 CHECKS AND ADJUSTMENTS............................................................................................462 CHECK AND ADJUST THE END BEAM SWITCHES........................................................................462 LIFT CHAIN ADJUSTMENTS........................................................................................462 CARRIAGE ADJUSTMENTS..........................................................................................462 CHECK AND ADJUST THE WIDTH OF THE ATTACHMENT..................................................................463 TROUBLESHOOTING...................................................................................................464 8000231...............................................................................................................467 INTRODUCTION......................................................................................................467 NOMENCLATURE, THREADS.........................................................................................467 STRENGTH IDENTIFICATION.......................................................................................468 TABLE 1. BOLTS AND SCREWS.........................................................................................468 TABLE 2. STUDS AND NUTS...........................................................................................469 TABLE 3. TORQUE NUTS..............................................................................................470 TABLE 4. TORQUE NUTS WITH NYLON INSERT............................................................................471 TABLE 5. TORQUE VALUES FOR INCH FASTENERS.........................................................................472 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.......................................................................473 8000433...............................................................................................................476 INTRODUCTION......................................................................................................476 GENERAL.......................................................................................................476 HOW TO MOVE A DISABLED LIFT TRUCK.............................................................................476 How to Tow the Lift Truck.................................................................................476 HOW TO PUT A LIFT TRUCK ON BLOCKS.............................................................................477 How to Raise the Drive Tires..............................................................................477 How to Raise the Steering Tires...........................................................................477 TABLE 1. MAINTENANCE SCHEDULE.................................................................................479 MAINTENANCE SCHEDULE, EMPTY CONTAINER ATTACHMENT..............................................................481 MAINTENANCE PROCEDURES............................................................................................482 EVERY 8 HOURS OR DAILY............................................................................................482 HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED................................................................482 Tires and Wheels..........................................................................................482 Forks.....................................................................................................483 Forks, Adjustment.........................................................................................483 Forks, Removal............................................................................................483 Forks, Installation.......................................................................................483 Inspection of Forks, Mast and Lift Chains.................................................................484 SAFETY LABELS.................................................................................................484 Operator Restraint System.................................................................................485 Steering Column Latch.....................................................................................485 Drive Belts...............................................................................................485 Cooling System............................................................................................485 Check For Fuel, Oil Or Coolant Leaks......................................................................485 Hydraulic System..........................................................................................486 Engine Oil................................................................................................486 Fuel System...............................................................................................486 Primary Fuel Filter.......................................................................................487 Battery...................................................................................................487 Pre–Cleaner for Air Filter................................................................................487 Air Filter................................................................................................487 HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING................................................................487 Gauges, Lights, Horn and Fuses,...........................................................................488 Control Levers and Pedals.................................................................................489 Transmission Oil..........................................................................................489 Lift System Operation.....................................................................................489 Brakes....................................................................................................489 Steering System...........................................................................................489 EVERY 150 HOURS OR MONTHLY........................................................................................490 LIFT CHAINS, LUBRICATION......................................................................................490 LIFT CHAIN ADJUSTMENTS........................................................................................490 AIR TANKS.....................................................................................................490 DRIVE SHAFT...................................................................................................490 STEERING AXLE.................................................................................................491 WHEEL NUTS....................................................................................................491 SHAFTS FOR BRAKE ACTUATORS....................................................................................491 DRIVE AXLE AND DIFFERENTIAL...................................................................................491 HYDRAULIC TANK BREATHER.......................................................................................491 AIR FILTER, HEATER............................................................................................491 EVERY 350 HOURS OR TWO MONTHS.....................................................................................491 ENGINE OIL AND FILTER.........................................................................................491 BRAKE ACTUATOR ARMS...........................................................................................491 DRIVE BELTS...................................................................................................491 MAST..........................................................................................................492 EMPTY CONTAINER ATTACHMENT....................................................................................493 GENERAL LUBRICATION...........................................................................................493 FORKS, CHECK FOR WEAR AND DAMAGE..............................................................................493 LIFT CHAINS, CHECK FOR WEAR...................................................................................493 FUEL SYSTEM...................................................................................................494 Idle Speed................................................................................................494 Governor Speed (Diesel)...................................................................................494 Governor Speed (GM V8)....................................................................................495 Carburetor Adjustments (GM V8)............................................................................495 Power Mixture Adjustment..................................................................................496 EVERY 1000 HOURS OR SIX MONTHS....................................................................................496 CHANGE THE TRANSMISSION OIL AND FILTER........................................................................496 FINAL FUEL FILTERS, DIESEL....................................................................................496 Remove Air from the Diesel Fuel System....................................................................496 Fuel Injection Pump With Vent Tube........................................................................496 Fuel Injection Pump Without Vent Tube.....................................................................497 FUEL INJECTION PUMP TIMING....................................................................................498 VALVE ADJUSTMENT..............................................................................................498 IGNITION SYSTEM, GM V8........................................................................................498 EVERY 2000 HOURS OR YEARLY........................................................................................499 HYDRAULIC SYSTEM..............................................................................................499 Change the Hydraulic Oil Filter...........................................................................499 Change the Hydraulic Oil..................................................................................499 DIFFERENTIAL AND DRIVE AXLE...................................................................................499 EMPTY CONTAINER ATTACHMENT....................................................................................500 WHEEL BEARINGS................................................................................................500 Steer Wheels..............................................................................................500 Drive Wheels..............................................................................................500 SERVICE BRAKES................................................................................................500 Cleaning Procedures:......................................................................................500 GENERAL PROCEDURES................................................................................................501 CHECK THE FUEL INJECTORS......................................................................................501 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................502 TABLE 2. ALLOWABLE MAST MOVEMENT FROM INTERNAL LEAKAGE........................................................503 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...................................................................503 Lift System...............................................................................................503 Tilt System...............................................................................................503 WELDING REPAIRS...............................................................................................504 TIRES AND WHEELS..................................................................................................504 REMOVE THE WHEELS FROM THE LIFT TRUCK.........................................................................504 PNEUMATIC TIRES...............................................................................................504 Remove the Tire from the Wheel............................................................................504 Install the Tire on the Wheel.............................................................................505 ADD AIR TO THE TIRES..........................................................................................506 SOLID RUBBER TIRES............................................................................................507 Remove the Tire from the Wheel............................................................................507 Install the Tire on the Wheel.............................................................................508 INSTALL THE WHEELS............................................................................................509 8000447...............................................................................................................510 LIFT TRUCK WEIGHTS................................................................................................510 CAPACITIES........................................................................................................510 ENGINE SPECIFICATIONS, PERKINS DIESEL.............................................................................511 ENGINE SPECIFICATIONS, GM V8......................................................................................511 HYDRAULIC SYSTEM..................................................................................................512 ELECTRICAL SYSTEM.................................................................................................512 TIRE SIZES........................................................................................................512 MAST SPEEDS, PERKINS DIESEL.......................................................................................513 MAST SPEEDS, GM V8................................................................................................513 TORQUE SPECIFICATIONS, PERKINS DIESEL.............................................................................514 TORQUE SPECIFICATIONS GM V8.......................................................................................515 TORQUE SPECIFICATIONS.............................................................................................516 TRANSMISSION PRESSURES............................................................................................518 HYSTER T-50 TRANSMISSION PRESSURES................................................................................519 8000448...............................................................................................................520 INTRODUCTION......................................................................................................520 GENERAL.......................................................................................................520 DESCRIPTION...................................................................................................520 FIGURE 1. AIR SYSTEM SCHEMATIC (WITHOUTH AUTOSHIFT)...........................................................521 FIGURE 2. AIR SYSTEM SCHEMATIC (WITH AUTOSHIFT)...............................................................522 FIGURE 3. ELECTRICAL SYSTEM SCHEMATIC, DIESEL (WITHOUTH AUTOSHIFT OR SSFP OPTIONS)............................524 FIGURE 4. ELECTRICAL SYSTEM SCHEMATIC, H165-360, DIESEL (WITH AUTOSHIFT AND SSFP OPTIONS).....................526 FIGURE 5. ELECTRICAL SYSTEM SCHEMATIC, H165-360, DIESEL (AUTOSHIFT OPTION ONLY)...............................528 FIGURE 6. ENGINE COMPARTMENT HARNESS H165-360, DIESEL (WITH AUTOSHIFT)........................................529 FIGURE 7. ENGINE COMPARTMENT HARNESS, H165-360, DIESEL (WITHOUT AUTOSHIFT)....................................530 FIGURE 8. ELECTRICAL SYSTEM SCHEMATIC, GM V8..................................................................532 FIGURE 9. ELECTRICAL SCHEMATIC FOR THE EMPTY CONTAINER ATTACHMENT (H330-360XL-EC).............................534 FIGURE 10. ELECTRICAL SCHEMATIC FOR LIGHTS (U.S.).............................................................535 FIGURE 11. ELECTRICAL SCHEMATIC FOR LIGHTS (EUROPE)...........................................................536 FIGURE 12. ELECTRICAL SYSTEM SCHEMATIC, H165-360 (DUAL FUNCTION SIDE SHIFT FORK POSITION OPTION)..............537 FIGURE 13. HYDRAULIC SYSTEM SCHEMATIC - U.S., WITHOUT LOAD SENSING CIRCUIT....................................539 FIGURE 14. HYDRAULIC SYSTEM SCHEMATIC - U.S., WITH LOAD SENSING CIRCUIT.......................................540 FIGURE 15. HYDRAULIC SYSTEM SCHEMATIC - EC; WITHOUT LOAD SENSING CIRCUIT, WITH TWO SPEED HOIST................541 FIGURE 16. HYDRAULIC SYSTEM SCHEMATIC - EC; WITH LOAD SENSING CIRCUIT, WITHOUT TWO SPEED HOIST................542 FIGURE 17. TRANSMISSION HYDRAULIC SCHEMATIC ..................................................................543 FIGURE 18. TRANSMISSION SCHEMATIC, HYSTER T-50 (INSTALLED IN LIFT TRUCKS MANUFACTURED AFTER FEBRUARY 1993)....544
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