Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster D001 (H1.50-1.75XM, H2.00XMS Europe) Service Manual – PDF DOWNLOAD
Original price was: $89.95.$29.95Current price is: $29.95.
Hyster D001 (H1.50-1.75XM, H2.00XMS Europe) Service Manual – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster D001 (H1.50-1.75XM, H2.00XMS Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster D001 (H1.50-1.75XM, H2.00XMS Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 518
Downloadable : Yes
File Type : PDF
Size: 14.2 MB
TABLE OF CONTENTS:
Hyster D001 (H1.50-1.75XM, H2.00XMS Europe) Service Manual – PDF DOWNLOAD
100545.................................................................................................. 1
INTRODUCTION........................................................................................ 1
GENERAL......................................................................................... 1
DESCRIPTION..................................................................................... 1
REPAIRS............................................................................................. 2
OPERATOR MODULE................................................................................. 2
Removal..................................................................................... 2
Installation................................................................................ 2
HOOD AND SIDE COVERS............................................................................ 3
Removal..................................................................................... 3
Installation................................................................................ 3
OVERHEAD GUARD.................................................................................. 5
Removal and Installation.................................................................... 5
COUNTERWEIGHT................................................................................... 5
Removal..................................................................................... 5
Installation................................................................................ 6
EXHAUST SYSTEM.................................................................................. 7
Muffler Replacement......................................................................... 7
RADIATOR AND COOLING SYSTEM..................................................................... 7
Removal..................................................................................... 7
Installation................................................................................ 7
OPERATOR RESTRAINT SYSTEM....................................................................... 10
ENGINE.......................................................................................... 10
Removal..................................................................................... 10
Installation................................................................................ 11
FUEL AND HYDRAULIC TANKS........................................................................ 12
Inspection.................................................................................. 12
Repairs, Small Leaks........................................................................ 12
Repairs, Large Leaks........................................................................ 12
Cleaning.................................................................................... 12
Steam Method Of Cleaning.................................................................... 13
Chemical Solution Method of Cleaning....................................................... 13
Additional Preparations For Repair.......................................................... 13
SAFETY LABELS................................................................................... 14
600496.................................................................................................. 18
INTRODUCTION ....................................................................................... 18
GENERAL ........................................................................................ 18
DESCRIPTION .................................................................................... 18
REPAIRS ............................................................................................ 18
REMOVAL AND INSTALLATION OF THE ENGINE ......................................................... 18
CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM .................................................... 18
Removal .................................................................................... 18
Cleaning ................................................................................... 20
Inspection And Repairs ..................................................................... 20
Cylinder Head, Installation ................................................................ 23
CRANKSHAFT AND MAIN BEARINGS ................................................................... 25
Removal .................................................................................... 25
Inspection And Repair ...................................................................... 26
Installation ............................................................................... 27
PISTONS AND CONNECTING RODS .................................................................... 27
Removal And Disassembly .................................................................... 27
Cleaning ................................................................................... 28
Inspection And Repair ...................................................................... 28
Assembly And Installation .................................................................. 29
CYLINDER BLOCK ................................................................................. 30
Repairs .................................................................................... 30
OIL PUMP ....................................................................................... 30
Removal .................................................................................... 30
Disassembly ................................................................................ 30
Cleaning ................................................................................... 31
Inspection ................................................................................. 31
Assembly ................................................................................... 32
Installation ............................................................................... 32
COOLING SYSTEM ................................................................................. 32
Thermostat ................................................................................. 32
Fan Assembly ............................................................................... 32
Water Pump ................................................................................. 33
DISTRIBUTOR .................................................................................... 34
Removal .................................................................................... 34
Installation ............................................................................... 34
FLYWHEEL AND RING GEAR, S/H2.00–3.20XM (S/H40–65XM) ............................................ 34
Flywheel, Removal .......................................................................... 34
Ring Gear, Replacement ..................................................................... 35
Flywheel, Installation ..................................................................... 35
FLYWHEEL, S/H1.50–1.75XM, S/H2.00XMS (S/H25–35XM, S/H40XMS) .................................... 35
Removal .................................................................................... 35
Installation ............................................................................... 35
CHECKS AND ADJUSTMENTS ......................................................................... 37
ADJUST THE VALVES .............................................................................. 37
CHECK THE COMPRESSION PRESSURE ................................................................. 37
ENGINE SPECIFICATIONS .............................................................................. 38
TORQUE SPECIFICATIONS .............................................................................. 41
600537.................................................................................................. 44
INTRODUCTION........................................................................................ 44
DESCRIPTION..................................................................................... 44
REPAIRS............................................................................................. 45
CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM..................................................... 45
Removal..................................................................................... 45
Cleaning.................................................................................... 46
Inspection And Repairs...................................................................... 46
Installation................................................................................ 49
CRANKSHAFT AND MAIN BEARINGS.................................................................... 52
Removal..................................................................................... 52
Inspection And Repair....................................................................... 52
Installation................................................................................ 53
PISTONS AND CONNECTING RODS..................................................................... 54
Removal and Disassembly..................................................................... 54
Cleaning.................................................................................... 54
Inspection and Repair....................................................................... 54
Assembly and Installation................................................................... 56
CYLINDER BLOCK.................................................................................. 57
Repairs..................................................................................... 57
FLYWHEEL AND RING GEAR.......................................................................... 57
Flywheel , Removal.......................................................................... 57
Ring Gear................................................................................... 57
Flywheel, Installation...................................................................... 57
CHECKS AND ADJUSTMENTS.............................................................................. 58
ADJUST THE VALVES............................................................................... 58
CHECK THE COMPRESSION PRESSURE.................................................................. 58
ENGINE SPECIFICATIONS............................................................................... 60
TORQUE SPECIFICATIONS............................................................................... 62
TROUBLESHOOTING..................................................................................... 63
600538.................................................................................................. 65
INTRODUCTION........................................................................................ 65
GENERAL......................................................................................... 65
DESCRIPTION..................................................................................... 65
REPAIRS............................................................................................. 66
REMOVAL AND INSTALLATION OF THE ENGINE.......................................................... 66
CYLINDER HEAD AND VALVE MECHANISM............................................................... 66
Removal..................................................................................... 66
Cleaning.................................................................................... 67
Inspection And Repairs...................................................................... 67
Cylinder Head, Assembly..................................................................... 70
Cylinder Head, Installation................................................................. 71
TIMING GEARS.................................................................................... 71
Removal..................................................................................... 71
Cleaning And Inspection..................................................................... 72
Installation................................................................................ 72
CAMSHAFT........................................................................................ 73
Removal..................................................................................... 73
Inspection And Repairs...................................................................... 73
Installation................................................................................ 74
CRANKSHAFT AND MAIN BEARINGS.................................................................... 74
Removal..................................................................................... 74
Inspection And Repair....................................................................... 74
Installation................................................................................ 75
PISTONS AND CONNECTING RODS..................................................................... 76
Removal And Disassembly..................................................................... 76
Cleaning.................................................................................... 76
Inspection And Repair....................................................................... 76
Assembly And Installation................................................................... 77
CYLINDER BLOCK AND LINERS....................................................................... 78
Inspection and Repairs...................................................................... 78
LUBRICATION SYSTEM.............................................................................. 79
Oil Pump, Removal........................................................................... 79
Oil Pump, Disassembly....................................................................... 79
Oil Pump, Cleaning.......................................................................... 80
Inspection.................................................................................. 80
Assembly.................................................................................... 81
Installation................................................................................ 81
Oil Filter Mount, Removal................................................................... 81
Oil Filter Mount, Installation.............................................................. 82
COOLING SYSTEM.................................................................................. 82
Thermostat, Installation.................................................................... 82
Water Pump, Removal......................................................................... 82
Water Pump, Disassembly..................................................................... 83
Water Pump, Inspection...................................................................... 84
Water Pump, Assembly........................................................................ 84
Water Pump, Installation.................................................................... 84
FUEL SYSTEM..................................................................................... 85
Description And Operation................................................................... 85
FUEL INJECTION PUMP............................................................................. 87
Removal..................................................................................... 87
Installation................................................................................ 87
FUEL FILTER..................................................................................... 87
Install a New Filter........................................................................ 87
Check the Water Sensor...................................................................... 88
REMOVE AIR FROM THE FUEL SYSTEM................................................................. 88
FUEL INJECTORS.................................................................................. 89
Removal And Disassembly..................................................................... 89
Assembly.................................................................................... 89
Inspection And Adjustment................................................................... 89
Installation................................................................................ 90
FLYWHEEL........................................................................................ 90
Removal .................................................................................... 90
Insallation................................................................................. 90
CHECKS AND ADJUSTMENTS.............................................................................. 91
ADJUST THE VALVES............................................................................... 91
CHECK THE COMPRESSION PRESSURE.................................................................. 91
ADJUST THE THROTTLE LINKAGE..................................................................... 91
CHECK THE TIMING OF THE FUEL INJECTION PUMP..................................................... 92
ENGINE SPECIFICATIONS............................................................................... 93
TORQUE SPECIFICATIONS............................................................................... 95
TROUBLESHOOTING..................................................................................... 95
700626..................................................................................................100
COOLING SYSTEM......................................................................................100
INTRODUCTION....................................................................................100
DESCRIPTION.....................................................................................100
RADIATOR........................................................................................100
RADIATOR CAP....................................................................................100
THERMOSTAT......................................................................................100
WATER PUMP......................................................................................101
FAN AND FAN SHROUD .............................................................................101
REPAIRS.............................................................................................101
COOLING SYSTEM CHECKS...........................................................................101
Exhaust Leaks...............................................................................101
RADIATOR........................................................................................101
Checks......................................................................................101
Cleaning The Radiator.......................................................................101
Drain The Cooling System....................................................................103
Fill The Cooling System.....................................................................103
WATER PUMP......................................................................................103
Checks......................................................................................103
THERMOSTAT......................................................................................104
Checks......................................................................................104
FAN AND FAN SHROUD .............................................................................104
TROUBLESHOOTING.....................................................................................105
900523..................................................................................................106
INTRODUCTION .......................................................................................106
GENERAL ........................................................................................106
DESCRIPTION AND OPERATION. .....................................................................106
Fuel Tank ..................................................................................107
Fuel Filter and Fuel Valve Unit ............................................................108
Vaporizer ..................................................................................109
Carburetor .................................................................................110
Solenoid Valve .............................................................................111
Idle Control Actuator ......................................................................111
Governor ...................................................................................112
REPAIRS ............................................................................................112
REPLACEMENT OF THE HOSES .......................................................................112
LPG TANK .......................................................................................112
Removal ....................................................................................112
Installation ...............................................................................113
HYDROSTATIC RELIEF VALVE .......................................................................113
Removal and Installation ...................................................................113
FILTER UNIT ....................................................................................113
Replacement Of The Fuel Filter Element .....................................................113
Replacement of the Diaphragm and Fuel Valve ................................................114
VAPORIZER ......................................................................................115
Removal ....................................................................................115
Disassembly ................................................................................115
Cleaning ...................................................................................115
Inspection .................................................................................115
Assembly ...................................................................................117
Installation ...............................................................................117
CARBURETOR .....................................................................................119
Removal ....................................................................................119
Disassembly ................................................................................119
Cleaning ...................................................................................120
Assembly ...................................................................................121
Installation ...............................................................................121
SOLENOID VALVE .................................................................................122
GOVERNOR .......................................................................................122
CHECK THE VAPORIZER ............................................................................122
CHECKS AND ADJUSTMENTS .............................................................................106
CHECK THE FILTER UNIT ..........................................................................122
Pressure Reducer Valve .....................................................................122
Vapor Valve ................................................................................122
ADJUST THE CARBURETOR ..........................................................................123
Idle Mixture ...............................................................................123
Idle Adjustments ...........................................................................123
Power Mixture Adjustment ...................................................................123
GOVERNOR .......................................................................................124
Checks .....................................................................................124
Adjustments ...............................................................................124
ADJUST THE THROTTLE LINKAGE, S/H2.00–3.20XM (S/H40–65XM) .......................................125
ADJUST THE THROTTLE LINKAGE, S/H1.50–1.75XM, S/H2.00XMS (S/H25–35XM, H40XMS) ...................125
CHECK THE MONOTROL PEDAL .......................................................................126
TROUBLESHOOTING ....................................................................................126
900547..................................................................................................129
INTRODUCTION........................................................................................129
DESCRIPTION.....................................................................................129
GOVERNOR........................................................................................129
REPAIRS.............................................................................................130
CARBURETOR......................................................................................130
Removal.....................................................................................130
Disassembly.................................................................................131
Cleaning....................................................................................131
Inspection..................................................................................134
Assembly....................................................................................135
Installation................................................................................136
CHECKS AND ADJUSTMENTS..............................................................................136
CARBURETOR......................................................................................136
Idle Speed And Mixture Adjustment...........................................................136
Throttle Linkage Adjustment.................................................................137
GOVERNOR........................................................................................138
TROUBLESHOOTING.....................................................................................139
900548..................................................................................................142
INTRODUCTION........................................................................................142
DESCRIPTION.....................................................................................142
FUEL TANK.......................................................................................142
Description.................................................................................142
Removal.....................................................................................143
Installation................................................................................143
HYDROSTATIC RELIEF VALVE........................................................................144
Removal and Installation....................................................................144
FUEL FILTER AND FUEL VALVE UNIT.................................................................144
Description.................................................................................144
Install A New Fuel Filter Element...........................................................145
Install A New Diaphragm and Fuel Valve......................................................145
Check The Filter Unit.......................................................................145
VAPORIZER.......................................................................................146
Description.................................................................................146
Removal.....................................................................................149
Disassembly.................................................................................149
Cleaning....................................................................................149
Inspection..................................................................................149
Assembly....................................................................................149
Installation................................................................................149
Check The Pressure Reducer Valve............................................................149
Check The Vapor Valve.......................................................................149
CARBURETOR......................................................................................151
Description.................................................................................151
Removal.....................................................................................153
Disassembly.................................................................................153
Cleaning....................................................................................154
Assembly....................................................................................154
Installation................................................................................154
GOVERNOR........................................................................................154
INSTALLING NEW HOSES............................................................................154
CHECKS AND ADJUSTMENTS..............................................................................155
CARBURETOR......................................................................................155
Adjustments.................................................................................155
GOVERNOR........................................................................................155
Checks......................................................................................155
Adjustments.................................................................................155
ADJUST THE THROTTLE LINKAGE.....................................................................156
TROUBLESHOOTING.....................................................................................157
1300543.................................................................................................160
INTRODUCTION........................................................................................160
GENERAL.........................................................................................160
Description.................................................................................160
TORQUE CONVERTER................................................................................160
Description.................................................................................160
Operation...................................................................................161
CLUTCH ASSEMBLIES...............................................................................162
Description.................................................................................162
Operation...................................................................................164
HYDRAULIC SYSTEM................................................................................164
General.....................................................................................164
CONTROL VALVE...................................................................................165
Regulator for Clutch Pressure...............................................................165
Inching Spool Assembly......................................................................165
Direction Spool.............................................................................165
Modulator Circuit...........................................................................165
Regulator for the Torque Converter..........................................................165
MONOTROL PEDAL..................................................................................166
DIRECTION CONTROL LEVER.........................................................................166
DIFFERENTIAL....................................................................................166
REPAIRS.............................................................................................167
TORQUE CONVERTER AND TRANSMISSION PUMP..........................................................167
Removal And Disassembly.....................................................................167
Inspection..................................................................................168
Assembly And Installation...................................................................168
CLUTCH ASSEMBLIES...............................................................................168
Removal And Disassembly.....................................................................168
Inspection..................................................................................171
Assembly....................................................................................171
Installation................................................................................172
DIFFERENTIAL....................................................................................172
Removal And Disassembly.....................................................................172
Inspection..................................................................................172
Assembly And Installation...................................................................172
CONTROL VALVE...................................................................................177
Removal and Disassembly.....................................................................177
Inspection..................................................................................177
Assembly and Installation...................................................................177
MONOTROL PEDAL..................................................................................178
Removal and Disassembly.....................................................................178
Assembly and Installation...................................................................178
DIRECTION CONTROL LEVER.........................................................................181
Removal and Disassembly.....................................................................181
Assembly and Installation...................................................................181
CHECKS AND ADJUSTMENTS..............................................................................182
TORQUE CONVERTER STALL TEST.....................................................................182
TRANSMISSION PRESSURE TESTS.....................................................................183
Check The Transmission Pump Pressure, TEST PORT NO. 1.......................................183
Check The Torque Converter Inlet Pressure, TEST PORT NO. 2..................................183
Check The Clutch Pressure, TEST PORT NO. 3..................................................183
ADJUST THE INCHING/BRAKE PEDAL..................................................................184
TROUBLESHOOTING.....................................................................................186
1400542.................................................................................................192
INTRODUCTION........................................................................................192
GENERAL.........................................................................................192
DESCRIPTION.....................................................................................192
REPAIRS.............................................................................................193
REMOVAL AND DISASSEMBLY.........................................................................193
CLEANING AND INSPECTION.........................................................................193
ASSEMBLY AND INSTALLATION.......................................................................194
TROUBLESHOOTING.....................................................................................196
TORQUE SPECIFICATIONS...............................................................................196
1600257.................................................................................................198
INTRODUCTION........................................................................................198
DESCRIPTION.....................................................................................198
Control Valve Section.......................................................................198
Metering Section............................................................................198
DISASSEMBLY AND INSPECTION......................................................................200
ASSEMBLY........................................................................................210
TROUBLESHOOTING.................................................................................222
1600532.................................................................................................223
INTRODUCTION........................................................................................223
GENERAL.........................................................................................223
DESCRIPTION.....................................................................................223
REPAIRS.............................................................................................224
HOW TO PUT THE LIFT TRUCK ON BLOCKS.............................................................224
STEERING AXLE ASSEMBLY..........................................................................224
Removal.....................................................................................224
Installation................................................................................224
WHEELS AND HUBS.................................................................................224
Removal and Disassembly H1.50-1.75XM,H2.00XMS (H25-35XM, H40XMS)............................224
Removal and Disaasembly S25-35XM, S40XMS....................................................226
Cleaning....................................................................................226
Assembly And Installation H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS).........................226
Assembly And Installation S25-35XM, S40XMS..................................................226
SPINDLES, BEARINGS, AND TIE RODS................................................................227
Removal H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS)...........................................227
Installation................................................................................227
Removal S25-35XM, S40XMS....................................................................227
Installation................................................................................227
STEERING CYLINDER...............................................................................228
Removal And Disassembly.....................................................................228
Cleaning and Inspection.....................................................................228
Assembly and Installation...................................................................228
TROUBLESHOOTING.....................................................................................230
TORQUE SPECIFICATIONS...............................................................................230
1600565.................................................................................................232
INTRODUCTION........................................................................................232
GENERAL.........................................................................................232
DESCRIPTION.....................................................................................232
REPAIRS.............................................................................................233
STEERING HOUSING ...............................................................................233
Removal And Disassembly.....................................................................233
Assembly And Installation...................................................................233
1800540.................................................................................................236
INTRODUCTION........................................................................................236
GENERAL.........................................................................................236
DESCRIPTION AND OPERATION.......................................................................236
Service Brake...............................................................................236
Parking Brake...............................................................................236
SERVICE BRAKES..................................................................................237
Removal And Disassembly.....................................................................237
Cleaning....................................................................................240
Inspection..................................................................................241
Assembly And Installation...................................................................241
Adjustments.................................................................................243
PARKING BRAKE...................................................................................243
Removal And Disassembly.....................................................................243
Assembly And Installation...................................................................244
Adjust The Parking Brake....................................................................244
MASTER CYLINDER.................................................................................246
Removal.....................................................................................246
Repair......................................................................................246
Disassembly.................................................................................246
Cleaning And Inspection.....................................................................246
Assembly....................................................................................246
Installation................................................................................246
CHECKS AND ADJUSTMENTS..............................................................................248
ADJUST THE SERVICE BRAKES ......................................................................248
REMOVE THE AIR FROM THE BRAKE SYSTEM............................................................248
TEST THE "PARKING BRAKE NOT APPLIED" SWITCH.....................................................248
TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY).............................................248
ADJUST THE INCHING/BRAKE PEDAL..................................................................249
TROUBLESHOOTING.....................................................................................251
TORQUE SPECIFICATIONS...............................................................................253
1900539.................................................................................................255
INTRODUCTION........................................................................................255
GENERAL.........................................................................................255
DESCRIPTION.....................................................................................255
Hydraulic System............................................................................255
Gear Pump Assembly..........................................................................255
Pump Drive Shaft............................................................................259
Steering Flow Divider.......................................................................259
Relief Valve (Steering).....................................................................259
Relief Valve (Main Hydraulic)...............................................................259
OPERATION.......................................................................................259
Hydraulic System............................................................................259
Gear Pump...................................................................................259
Steering Flow Divider.......................................................................260
Relief Valve (Steering).....................................................................260
Relief Valve (Main Hydraulic)...............................................................260
REPAIR..............................................................................................260
GEAR PUMP ASSEMBLY..............................................................................260
Removal and Disassembly.....................................................................260
Assembly and Installation...................................................................260
PUMP DRIVE SHAFT................................................................................261
Disassembly.................................................................................261
Assembly and Installation...................................................................261
CHECK AND ADJUST STEERING RELIEF PRESSURE.......................................................261
CHECK GEAR PUMP FOR CORRECT FLOW................................................................261
TROUBLESHOOTING.....................................................................................262
2000541.................................................................................................264
INTRODUCTION........................................................................................264
GENERAL.........................................................................................264
DESCRIPTION.....................................................................................264
OPERATION.......................................................................................265
Lift Section................................................................................266
Tilt Section................................................................................267
Steering Flow Divider.......................................................................268
Relief Valve (Steering).....................................................................268
Relief Valve (Main Hydraulic)...............................................................268
REPAIRS.............................................................................................269
MAIN CONTROL VALVE..............................................................................269
Removal.....................................................................................269
Disassembly.................................................................................269
Cleaning And Inspection.....................................................................269
Assembly....................................................................................273
Installation................................................................................273
CHECKS AND ADJUSTMENTS..............................................................................274
PRESSURE RELIEF VALVES..........................................................................274
Steering Relief Valve.......................................................................274
Main Hydraulic Relief Valve.................................................................274
TROUBLESHOOTING.....................................................................................275
2100103.................................................................................................278
INTRODUCTION........................................................................................281
GENERAL.........................................................................................281
DESCRIPTION.....................................................................................281
REPAIRS.............................................................................................281
REMOVAL.........................................................................................281
DISASSEMBLY.....................................................................................281
CLEANING........................................................................................281
ASSEMBLY........................................................................................281
Tilt Cylinders for the XM and XMS Models....................................................281
Tilt Cylinders with O-Ring or Single Lip Seals..............................................283
Tilt Cylinders for H700-800A and Early Model H700-920B......................................283
INSTALLATION....................................................................................283
Tilt Cylinders with Chevron Packing.........................................................283
CHECKS AND ADJUSTMENTS..............................................................................287
CHECK THE TILT CYLINDERS FOR LEAKS..............................................................287
ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.........................................287
TROUBLESHOOTING.....................................................................................290
2200144.................................................................................................293
ELECTRICAL WARNING DEVICES..........................................................................293
GENERAL.........................................................................................293
DESCRIPTION.....................................................................................293
Operator Controlled Horns...................................................................293
System Warning Lights, Buzzers and Bells....................................................293
Reverse Warning Horns.......................................................................294
Warning Lights..............................................................................294
REPLACEMENT.....................................................................................295
General.....................................................................................295
Replacing Horns or Bells....................................................................295
Replacing Horn Relay or Buzzer..............................................................295
Replacing Warning Lights....................................................................295
Light Assemblies............................................................................296
Replacing Flashing Units....................................................................296
2200514.................................................................................................297
INTRODUCTION........................................................................................297
GENERAL.........................................................................................297
DESCRIPTION.....................................................................................297
REPAIRS.............................................................................................301
REMOVAL AND DISASSEMBLY.........................................................................301
ASSEMBLY AND INSTALLATION.......................................................................301
2200524.................................................................................................304
INTRODUCTION........................................................................................304
GENERAL ........................................................................................304
DESCRIPTION ....................................................................................304
Starting System ............................................................................304
Ignition System ............................................................................304
Charging System ............................................................................305
REPAIRS ............................................................................................306
GENERAL ........................................................................................306
STARTER ........................................................................................306
Removal and Disassembly ....................................................................306
Assembly and Installation ..................................................................307
COIL REPLACEMENT ...............................................................................308
DISTRIBUTOR, H1.50–1.75XM, H2.00XMS (S/H25–35XM, S/H40XMS) .....................................308
Removal And Disassembly ....................................................................308
Assembly and Installation ..................................................................309
DISTRIBUTOR, S/H2.00–3.20XM (S/H40–65XM) .......................................................310
Removal and Disassembly ....................................................................310
Assembly and Installation .................................................................311
ALTERNATOR .....................................................................................312
Removal And Disassembly ....................................................................312
Assembly and Installation ..................................................................313
CHECKS AND ADJUSTMENTS .............................................................................314
GENERAL ........................................................................................314
STARTER ........................................................................................314
Check Operation ............................................................................314
Check Brush Holder .........................................................................315
Check Armature .............................................................................315
Check Field Windings .......................................................................315
Check Clutch And Bearing ...................................................................315
IGNITION SYSTEM ................................................................................315
Adjust Engine Timing .......................................................................315
Spark Plugs ................................................................................316
CHARGING CIRCUIT ...............................................................................316
Check For Low Output .......................................................................317
Check For High Output ......................................................................317
Check The Diodes ...........................................................................318
Check Field Winding For The Rotor ..........................................................318
Check Windings In The Stator................................................................319
Brushes And Bearings........................................................................319
Check The Voltage Regulator ................................................................319
TROUBLESHOOTING.....................................................................................320
2200549.................................................................................................322
INTRODUCTION........................................................................................322
GENERAL.........................................................................................322
DESCRIPTION.....................................................................................322
Starting System.............................................................................322
Ignition System.............................................................................322
Charging System.............................................................................323
REPAIRS.............................................................................................324
GENERAL.........................................................................................324
STARTER.........................................................................................324
Removal And Disassembly.....................................................................324
Assembly And Installation...................................................................325
COIL REPLACEMENT................................................................................326
DISTRIBUTOR.....................................................................................326
Removal And Disassembly.....................................................................326
Assembly and Installation...................................................................326
ALTERNATOR......................................................................................328
Removal And Disassembly.....................................................................328
Assembly And Installation...................................................................329
CHECKS AND ADJUSTMENTS..............................................................................329
GENERAL.........................................................................................329
STARTER.........................................................................................329
Check Operation.............................................................................329
Check Brush Holder..........................................................................330
Check Armature..............................................................................330
Check Field Windings........................................................................330
Check Clutch And Bearing....................................................................331
IGNITION SYSTEM.................................................................................331
Adjust Engine Timing........................................................................331
Spark Plugs.................................................................................331
CHARGING CIRCUIT................................................................................331
Check For Low Output........................................................................331
Check For High Output.......................................................................331
Check The Diodes............................................................................332
Check Field Winding For The Rotor...........................................................333
Check Windings In The Stator................................................................333
Brushes And Bearings........................................................................334
Check The Voltage Regulator.................................................................334
TROUBLESHOOTING.....................................................................................334
2200550.................................................................................................336
INTRODUCTION........................................................................................336
GENERAL.........................................................................................336
DESCRIPTION.................................................................................336
Starting Circuit........................................................................336
Charging System.........................................................................337
REPAIRS.............................................................................................338
GENERAL.........................................................................................338
STARTER.....................................................................................338
Removal And Disassembly.................................................................338
Assembly And Installation...............................................................338
ALTERNATOR..................................................................................340
Removal And Disassembly.................................................................340
Assembly And Installation...............................................................341
CHECKS AND ADJUSTMENTS..............................................................................341
GENERAL.........................................................................................341
STARTER.........................................................................................341
Check Operation.............................................................................341
Solenoid Coil Checks........................................................................342
Check Brush Holder..........................................................................342
Check Armature..............................................................................342
Check Field Windings........................................................................343
Check Clutch And Bearing....................................................................343
COLD START AID..................................................................................343
Glow Plugs..................................................................................343
Check The Glow Plugs .......................................................................343
Fuse........................................................................................343
Relay And Controller........................................................................343
CHARGING CIRCUIT................................................................................344
Check For Low Output........................................................................345
Check For High Output.......................................................................345
Check The Diodes............................................................................345
Check Field Windings For The Rotor..........................................................346
Check Windings In The Stator................................................................346
Brushes And Bearings........................................................................347
Check The Voltage Regulator.................................................................347
TROUBLESHOOTING.....................................................................................347
4000135.................................................................................................350
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................350
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................350
LIFT CYLINDERS......................................................................................353
GENERAL.........................................................................................353
DESCRIPTION.....................................................................................353
Lowering Control Valve......................................................................353
Cylinders (General).........................................................................356
Cylinders (H520-620B,H700-800A).............................................................358
Cylinders (H360-460B).......................................................................359
Cylinders (Two-Speed).......................................................................359
REPAIRS.............................................................................................360
REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..........................................360
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....360
Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.....................364
Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...............362
DISASSEMBLY.....................................................................................362
ASSEMBLY........................................................................................364
INSTALLATION OF THE LIFT CYLINDER IN THE MAST...................................................364
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....364
Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead............364
CHEVRON PACKING.................................................................................365
LIFT CYLINDERS FOR VISTA MASTS......................................................................368
DESCRIPTION.....................................................................................368
Lowering Control Valve......................................................................370
REMOVAL.........................................................................................371
DISASSEMBLY.....................................................................................371
ASSEMBLY........................................................................................371
INSTALLATION....................................................................................372
Main Lift Cylinders.........................................................................372
Free-Lift Cylinders.........................................................................372
CHECKS AND ADJUSTMENTS..............................................................................373
CHECK FOR LEAKS IN LIFT SYSTEM..................................................................373
TROUBLESHOOTING.....................................................................................374
SPECIFICATIONS......................................................................................375
4000521.................................................................................................376
INTRODUCTION........................................................................................377
GENERAL.........................................................................................377
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................377
REPAIRS.............................................................................................378
FORKS...........................................................................................378
Removal.....................................................................................378
Installation................................................................................379
CARRIAGES.......................................................................................379
Removal.....................................................................................379
Repairs.....................................................................................380
Installation................................................................................380
MASTS...........................................................................................382
Removal.....................................................................................382
Disassembly.................................................................................383
Cleaning and Inspection.....................................................................388
Assembly....................................................................................391
Installation................................................................................393
LIFT CYLINDERS..................................................................................393
Removal.....................................................................................393
Disassembly.................................................................................394
Assembly....................................................................................394
Installation................................................................................394
HEADER HOSE ARRANGEMENTS........................................................................397
Installation................................................................................397
CHECKS AND ADJUSTMENTS..............................................................................406
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................406
Check The Lift Cylinders For Leaks..........................................................406
Check The Tilt Cylinders For Leaks..........................................................406
ADJUST THE TILT CYLINDERS.......................................................................406
ADJUST THE LIFT CHAINS..........................................................................407
ADJUST THE MAST.................................................................................408
ADJUST THE CARRIAGE.............................................................................409
TROUBLESHOOTING.....................................................................................410
4000522.................................................................................................413
INTRODUCTION........................................................................................414
GENERAL.........................................................................................414
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................414
REPAIRS.............................................................................................415
FORKS...........................................................................................415
Removal.....................................................................................415
Installation................................................................................416
CARRIAGES.......................................................................................416
Removal.....................................................................................416
Repairs.....................................................................................417
Installation................................................................................417
MASTS...........................................................................................419
Removal.....................................................................................419
Disassembly.................................................................................420
Cleaning and Inspection.....................................................................425
Assembly....................................................................................428
Installation................................................................................430
LIFT CYLINDERS..................................................................................430
Removal.....................................................................................430
Disassembly.................................................................................431
Assembly....................................................................................431
Installation................................................................................431
HEADER HOSE ARRANGEMENTS........................................................................434
Installation................................................................................434
CHECKS AND ADJUSTMENTS..............................................................................443
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................443
Check The Lift Cylinders For Leaks..........................................................443
Check The Tilt Cylinders For Leaks..........................................................443
ADJUST THE TILT CYLINDERS.......................................................................443
ADJUST THE LIFT CHAINS..........................................................................444
ADJUST THE MAST.................................................................................445
ADJUST THE CARRIAGE.............................................................................446
TROUBLESHOOTING.....................................................................................447
8000231.................................................................................................450
INTRODUCTION........................................................................................450
NOMENCLATURE, THREADS...........................................................................450
STRENGTH IDENTIFICATION.........................................................................451
TABLE 1. BOLTS AND SCREWS...........................................................................451
TABLE 2. STUDS AND NUTS.............................................................................452
TABLE 3. TORQUE NUTS................................................................................453
TABLE 4. TORQUE NUTS WITH NYLON INSERT..............................................................454
TABLE 5. TORQUE VALUES FOR INCH FASTENERS...........................................................455
TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.........................................................456
8000531.................................................................................................459
INTRODUCTION........................................................................................459
GENERAL.........................................................................................459
Serial Number...............................................................................459
HOW TO MOVE A DISABLED LIFT TRUCK...............................................................459
How To Tow The Lift Truck...................................................................459
HOW TO PUT A LIFT TRUCK ON BLOCKS...............................................................460
How To Raise The Drive Tyres................................................................460
How To Raise The Steering Tyres.............................................................460
TABLE 1. MAINTENANCE SCHEDULE...................................................................461
MAINTENANCE PROCEDURES..............................................................................464
EVERY 8 HOURS OR DAILY..............................................................................464
HOW TO MAKE CHECKS WITH THE ENGINE STOPPED......................................................464
Tyres And Wheels............................................................................464
Forks.......................................................................................465
Forks, Adjustment...........................................................................465
Forks, Removal..............................................................................465
Forks, Installation.........................................................................465
Inspection Of Forks, Mast, And Lift Chains..................................................466
Safety Labels...............................................................................467
Operator Restraint System...................................................................467
Steering Column Latch.......................................................................468
Check For Fuel, Oil, Or Coolant Leaks.......................................................469
Drive Belt..................................................................................469
Engine Oil..................................................................................469
Hydraulic System............................................................................469
HOW TO MAKE CHECKS WITH THE ENGINE RUNNING......................................................470
Battery.....................................................................................470
Gauges, Indicator Lights, Horn, Fuses And Relays............................................470
Transmission Oil Level......................................................................471
Steering System.............................................................................471
Service Brakes..............................................................................471
Parking Brake...............................................................................472
Cooling System..............................................................................472
Control Levers And Pedals...................................................................473
Lift System Ooperation......................................................................473
EVERY 250 HOURS OR TWO MONTHS.......................................................................473
PARKING BRAKE LINKAGE...........................................................................473
ENGINE FILTER AND OIL...........................................................................473
Oil Filter And Oil..........................................................................473
Air Filter..................................................................................473
Gasoline And LPG Fuel Filter................................................................474
Fuel Filter, Diesel Engine..................................................................474
How To Drain The Water From The Fuel Filter.................................................474
TRANSMISSION OIL LEVEL..........................................................................474
BATTERY.........................................................................................475
HYDRAULIC TANK BREATHER.........................................................................475
WHEEL NUTS......................................................................................475
ENGINE SPEED....................................................................................475
LPG Carburettor.............................................................................475
Gasoline Carburettor........................................................................476
Diesel......................................................................................476
LIFT CHAINS.....................................................................................476
Lubrication.................................................................................476
Check For Wear..............................................................................476
MAST............................................................................................477
STEERING AXLE...................................................................................477
PEDALS, LEVERS, CABLES AND OTHER LINKAGES.......................................................477
SPARK PLUGS (Mazda M4-1.5G Or M4-2.0G Engine)...................................................477
DIFFERENTIAL....................................................................................478
DRIVE BELTS.....................................................................................478
Mazda M4-1.5G Gasoline/LPG Engine...........................................................478
Mazda M4-2.0G Gasoline/LPG Engine...........................................................478
Mazda M4-2.5D Diesel Engine.................................................................479
INCHING BRAKE...................................................................................479
PCV VALVE.......................................................................................479
FORKS...........................................................................................479
BRAKE FLUID.....................................................................................479
EVERY 1000 HOURS OR SIX MONTHS......................................................................480
AIR FILTER......................................................................................480
DIESEL FUEL SYSTEM..............................................................................480
Fuel Filter Replacement.....................................................................480
Remove Air From The Fuel System.............................................................480
GASOLINE FUEL FILTER............................................................................480
LPG FUEL FILTER.................................................................................480
SPARK PLUGS.....................................................................................481
IGNITION SYSTEM.................................................................................481
Mazda M4-1.5G Or M4-2.0G Engine.............................................................481
INJECTION PUMP TIMING, MAZDA M4-2.5D DIESEL ENGINE..............................................482
VALVE CLEARANCE ADJUSTMENT......................................................................482
EVERY 2000 HOURS OR YEARLY......................................................................483
THROTTLE CABLE..................................................................................483
DIFFERENTIAL....................................................................................483
HYDRAULIC SYSTEM................................................................................483
Replace The Hydraulic Oil And Filter........................................................483
TIMING BELT, MAZDA M4-2.0G ENGINE...............................................................483
PCV VALVE.......................................................................................484
COOLING SYSTEM..................................................................................484
TRANSMISSION....................................................................................484
Replace The Transmission Oil And Filter.....................................................484
WHEEL BEARINGS..................................................................................484
Steer Wheels................................................................................484
Drive Wheels................................................................................484
GENERAL PROCEDURES..................................................................................485
CHECK THE HOOD LATCH............................................................................485
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................486
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................487
Check The Lift Cylinders For Leaks..........................................................487
Check The Tilt Cylinders For Leaks..........................................................487
ADJUST THE TILT CYLINDERS.......................................................................487
LIFT CHAIN ADJUSTMENTS..........................................................................488
SERVICE BRAKES..................................................................................489
DIESEL ENGINE FUEL INJECTORS....................................................................490
WELDING REPAIRS.................................................................................490
CHANGES TO THE OVERHEAD GUARD...................................................................490
WHEELS AND TYRES................................................................................490
General.....................................................................................490
HOW TO CHANGE A SOLID RUBBER TYRE ("S" SERIES)..................................................491
Remove And Install The Tyre On The Wheel....................................................491
HOW TO REPAIR A PNEUMATIC TYRE..................................................................491
Remove The Wheels From The Lift Truck.......................................................492
Remove The Tyre From The Wheel..............................................................492
Install The Wheel In The Tyre...............................................................494
Pneumatic Tyres, Add Air To The Tyres.......................................................495
Install The Wheels..........................................................................495
SOLID RUBBER TYRES ON PNEUMATIC WHEELS..........................................................496
Remove The Tyre From The Wheel..............................................................496
Install The Tyre On The Wheel...............................................................496
OPERATING PROCEDURES FOR A NEW OR REBUILT ENGINE................................................498
8000544.................................................................................................500
FIGURE 1. WIRING SCHEMATIC FOR THE MAZDA M4-2.0 GASOLINE OR LPG ENGINE.............................501
FIGURE 2. WIRING SCHEMATIC FOR THE MAZDA M4-2.5D DIESEL ENGINE (Pneumatic Trucks Only)..............503
FIGURE 3. LIGHTS WIRING SCHEMATIC, US...............................................................505
FIGURE 4. LIGHTS WIRING SCHEMATIC, EUROPE (Pneumatic Trucks Only)...................................507
FIGURE 5. INSTRUMENT CLUSTER WIRING SCHEMATIC.......................................................508
FIGURE 6. HYDRAULIC SYSTEM SCHEMATIC................................................................509
FIGURE 7. HYDRAULIC SYSTEM ARRANGEMENT..............................................................510
FIGURE 8. ELECTRICAL SCHEMATIC FOR THE HAND LEVER DIRECTION CONTROL.................................510
FIGURE 9. ELECTRICAL SCHEMATIC FOR MONOTROL.........................................................511
FIGURE 10. HYDRAULIC SCHEMATIC FOR THE TRANSMISSION (NEUTRAL).......................................511
8000546.................................................................................................513
HYSTER D001 (H1.50-1.75XM, H2.00XMS EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V
