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Hyster D002 (S30-50E, S60ES) Service Manual – PDF DOWNLOAD
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Description
Hyster D002 (S30-50E, S60ES) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster D002 (S30-50E, S60ES) Service Manual – PDF DOWNLOAD
Language : English
Pages : 523
Downloadable : Yes
File Type : PDF
Size: 13.5 MB
TABLE OF CONTENTS:
Hyster D002 (S30-50E, S60ES) Service Manual – PDF DOWNLOAD
Alternator................................................................................................... 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 Brake System................................................................................................. 16 INTRODUCTION............................................................................................. 16 GENERAL.............................................................................................. 16 DESCRIPTION AND OPERATION............................................................................ 16 REPAIRS.................................................................................................. 20 CLEANING PROCEDURES.................................................................................. 20 REMOVAL AND DISASSEMBLY.............................................................................. 20 INSPECTION........................................................................................... 21 ASSEMBLY............................................................................................. 22 CHECKS AND ADJUSTMENTS................................................................................... 24 ADJUSTING THE SERVICE BRAKES......................................................................... 24 ADJUSTING THE PARKING BRAKE.......................................................................... 24 REMOVING THE AIR FROM THE BRAKE SYSTEM............................................................... 24 ADJUSTING THE SERVICE BRAKE PEDAL.................................................................... 25 TROUBLESHOOTING.......................................................................................... 26 Capacities & Specification................................................................................... 28 Cooling System............................................................................................... 31 INTRODUCTION............................................................................................. 31 GENERAL.............................................................................................. 31 DESCRIPTION.......................................................................................... 31 REPAIRS.................................................................................................. 34 FAN ASSEMBLY......................................................................................... 34 Removal (S30–120E)............................................................................... 34 Removal (H60–110E)............................................................................... 34 Disassembly (S30–120E)........................................................................... 34 Disassembly (H60–110E)........................................................................... 35 Assembly (Both Series)........................................................................... 35 Fan Belt Adjustment.............................................................................. 38 Installation..................................................................................... 38 RADIATOR............................................................................................. 39 Removal.......................................................................................... 39 Installation..................................................................................... 39 Cleaning and Inspection.......................................................................... 40 TROUBLESHOOTING.......................................................................................... 41 Diagrams..................................................................................................... 42 Drive Axle................................................................................................... 48 INTRODUCTION............................................................................................. 48 General.............................................................................................. 48 Description.......................................................................................... 48 REPAIRS.................................................................................................. 49 Removal.............................................................................................. 49 Installation......................................................................................... 50 Axle Housing For S30-100E And S40-50F Lift Trucks.................................................... 51 Wheels And Tires..................................................................................... 53 TROUBLESHOOTING.......................................................................................... 55 SPECIFICATIONS........................................................................................... 56 Electrical System Troubleshooting............................................................................ 58 HIGH ENERGY IGNITION (HEI)............................................................................... 58 DESCRIPTION.......................................................................................... 58 REPAIRS.................................................................................................. 60 DISTRIBUTOR.......................................................................................... 60 Removal.......................................................................................... 60 Disassembly...................................................................................... 60 Assembly......................................................................................... 65 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED......................... 66 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED.......................... 67 IGNITION COIL........................................................................................ 67 Removal, Some 4 And 6 Cylinder Models............................................................ 67 Installation, Some 4 And 6 Cylinder Models....................................................... 68 Removal, V8, Some 4 And 6 Cylinder Models........................................................ 68 Installation, V8, Some 4 And 6 Cylinder Models................................................... 69 ELECTRONIC MODULE.................................................................................... 70 Removal.......................................................................................... 70 Installation..................................................................................... 70 SENSING COIL......................................................................................... 71 Removal.......................................................................................... 71 Installation..................................................................................... 71 SPARK PLUGS.......................................................................................... 71 Removal.......................................................................................... 71 Installation..................................................................................... 72 CHECKS AND ADJUSTMENTS............................................................................... 72 Visual Checks.................................................................................... 72 Check The High Voltage Wires..................................................................... 72 Checking The Ignition Coil....................................................................... 72 Coil In Distributor Cap Design................................................................... 72 Separate Coil Design............................................................................. 73 Checking The Sensing Coil........................................................................ 73 Check The Electronic Module...................................................................... 74 Ignition Timing Adjustment....................................................................... 74 Ignition System, GM V8-366 (6-litre)............................................................. 75 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)................................. 75 SPECIFICATIONS........................................................................................... 75 TROUBLESHOOTING.......................................................................................... 76 Electrical Warning Devices................................................................................... 77 ELECTRICAL WARNING DEVICES............................................................................... 77 GENERAL.............................................................................................. 77 DESCRIPTION.......................................................................................... 77 Operator Controlled Horns........................................................................ 77 System Warning Lights, Buzzers and Bells......................................................... 77 Reverse Warning Horns............................................................................ 78 Warning Lights................................................................................... 78 REPLACEMENT.......................................................................................... 79 General.......................................................................................... 79 Replacing Horns or Bells......................................................................... 79 Replacing Horn Relay or Buzzer................................................................... 79 Replacing Warning Lights......................................................................... 79 Light Assemblies................................................................................. 80 Replacing Flashing Units......................................................................... 80 Flow Control Valve........................................................................................... 81 INTRODUCTION............................................................................................. 81 General.............................................................................................. 81 Description.......................................................................................... 81 Operation............................................................................................ 81 Flow Regulator Valve............................................................................. 82 Steering Relief Valve............................................................................ 83 Relief Valve for Cold Oil........................................................................ 84 REPAIRS.................................................................................................. 84 Removal.............................................................................................. 84 Disassembly.......................................................................................... 84 Cleaning and Inspection.............................................................................. 84 Assembly and Installation............................................................................ 84 CHECKS AND ADJUSTMENTS................................................................................... 85 Removing air from the Hydraulic System............................................................... 85 Adjusting the Setting of the Relief Valve............................................................ 85 Frame........................................................................................................ 87 INTRODUCTION............................................................................................. 87 General.............................................................................................. 87 Description.......................................................................................... 87 DISASSEMBLY AND ASSEMBLY................................................................................. 88 Counterweight........................................................................................ 88 Hood and Seat........................................................................................ 90 Operator Restraint System............................................................................ 91 Exhaust System....................................................................................... 92 Overhead Guard....................................................................................... 92 Engine (Removal and Installation).................................................................... 95 REPAIRS.................................................................................................. 97 Fuel and Hydraulic Tanks............................................................................. 97 Decal Replacement.................................................................................... 98 GM Engine....................................................................................................100 INTRODUCTION.............................................................................................100 GENERAL..............................................................................................100 DESCRIPTION..........................................................................................101 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................101 CYLINDER HEAD AND MECHANISM..........................................................................101 Cylinder Head, Removal...........................................................................101 Cylinder Head, Disassembly.......................................................................102 Cleaning And Inspection..........................................................................103 Valve And Valve Seats............................................................................104 Studs For The Rocker Arms........................................................................104 Hydraulic Valve Lifters, Replacement.............................................................104 Hydraulic Valve Lifters, Cleaning And Inspection.................................................105 Cylinder Head, Assembly..........................................................................105 Cylinder Head, Installation......................................................................105 Rocker Arm Cover, Installation...................................................................106 TIMING GEAR COVER....................................................................................107 Removal..........................................................................................107 Installation.....................................................................................107 CAMSHAFT.............................................................................................108 Removal..........................................................................................108 Inspection.......................................................................................109 Camshaft Bearings, Removal.......................................................................109 Camshaft Bearings, Installation..................................................................109 DISTRIBUTOR..........................................................................................110 Removal..........................................................................................110 Installation.....................................................................................110 LUBRICATION SYSTEM...................................................................................111 Oil Sump, Removal................................................................................111 Oil Sump, Installation...........................................................................111 Oil Pump, Removal................................................................................111 Oil Pump, Disassembly and Repair.................................................................111 Oil Pump, Assembly...............................................................................112 Oil Pump, Installation...........................................................................112 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................112 Connecting Rod Bearings, Replacement.............................................................112 Piston And Connecting Rod Assemblies, Removal....................................................113 Disassembly......................................................................................114 Piston, Cleaning And Inspection..................................................................114 Cylinder Bores, Inspection And Repair............................................................114 Piston Rings.....................................................................................115 Assembly.........................................................................................116 Piston And Connecting Rod Assemblies, Installation...............................................116 CRANKSHAFT...........................................................................................117 Main Bearings, Replacement.......................................................................117 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................118 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........118 Crankshaft, Removal..............................................................................119 Inspection and Repair............................................................................120 How To Check The Clearance Between The Main Bearings And Their Journals..........................120 Installation.....................................................................................121 FLYWHEEL AND FLYWHEEL HOUSING........................................................................122 Flywheel, Removal................................................................................122 Ring Gear, Replacement...........................................................................123 Flywheel, Installation...........................................................................123 COOLING SYSTEM.......................................................................................123 Coolant Pump.....................................................................................123 Fan Drive........................................................................................124 Viscous Fan Drive................................................................................124 ENGINE SPECIFICATIONS....................................................................................125 ENGINE DATA..........................................................................................125 CYLINDER HEAD........................................................................................125 HYDRAULIC VALVE LIFTER...............................................................................126 CAMSHAFT.............................................................................................126 PISTONS..............................................................................................126 CYLINDER BORE........................................................................................127 CRANKSHAFT...........................................................................................127 CONNECTING RODS......................................................................................127 COOLING SYSTEM.......................................................................................128 LUBRICATION SYSTEM...................................................................................128 TORQUE SPECIFICATIONS....................................................................................128 High Energy Ignition System..................................................................................131 HIGH ENERGY IGNITION (HEI)...............................................................................131 DESCRIPTION..........................................................................................131 REPAIRS..................................................................................................133 DISTRIBUTOR..........................................................................................133 Removal..........................................................................................133 Disassembly......................................................................................133 Assembly.........................................................................................138 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................139 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................140 IGNITION COIL........................................................................................140 Removal, Some 4 And 6 Cylinder Models............................................................140 Installation, Some 4 And 6 Cylinder Models.......................................................141 Removal, V8, Some 4 And 6 Cylinder Models........................................................141 Installation, V8, Some 4 And 6 Cylinder Models...................................................142 ELECTRONIC MODULE....................................................................................143 Removal..........................................................................................143 Installation.....................................................................................143 SENSING COIL.........................................................................................144 Removal..........................................................................................144 Installation.....................................................................................144 SPARK PLUGS..........................................................................................144 Removal..........................................................................................144 Installation.....................................................................................145 CHECKS AND ADJUSTMENTS...............................................................................145 Visual Checks....................................................................................145 Check The High Voltage Wires.....................................................................145 Checking The Ignition Coil.......................................................................145 Coil In Distributor Cap Design...................................................................145 Separate Coil Design.............................................................................146 Checking The Sensing Coil........................................................................146 Check The Electronic Module......................................................................147 Ignition Timing Adjustment.......................................................................147 Ignition System, GM V8-366 (6-litre).............................................................148 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................148 SPECIFICATIONS...........................................................................................148 TROUBLESHOOTING..........................................................................................149 Hydraulic Gear Pumps.........................................................................................150 INTRODUCTION.............................................................................................150 DESCRIPTION..........................................................................................150 OPERATION............................................................................................150 Flow Control Valve...............................................................................152 Relief Valve.....................................................................................152 REPAIRS..................................................................................................153 REMOVAL..............................................................................................153 DISASSEMBLY..........................................................................................153 CLEANING.............................................................................................155 INSPECTION...........................................................................................155 ASSEMBLY.............................................................................................156 INSTALLATION.........................................................................................157 CHECKS AND ADUSTMENTS....................................................................................158 CHECK THE OUTPUT OF THE PUMP.........................................................................158 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................158 TROUBLESHOOTING..........................................................................................160 Hydraulic Pump Drive Assembly................................................................................163 INTRODUCTION.............................................................................................163 GENERAL..............................................................................................163 DESCRIPTION..........................................................................................163 REPAIRS..................................................................................................163 REMOVAL AND DISASSEMBLY..............................................................................163 CLEANING.............................................................................................165 INSPECTION...........................................................................................165 ASSEMBLY AND INSTALLATION............................................................................165 TROUBLESHOOTING..........................................................................................167 GENERAL..............................................................................................167 Instrument Panel indicators & Senders........................................................................168 INTRODUCTION.............................................................................................168 GENERAL..............................................................................................168 DESCRIPTION..............................................................................................168 GENERAL..............................................................................................168 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................171 LED DISPLAY PANEL....................................................................................171 Battery Discharge Indicators.....................................................................171 Brush Wear Indicators............................................................................172 Motor Temperature Indicators.....................................................................173 "LX" SERIES DISPLAY PANEL............................................................................174 Hourmeter Functions..............................................................................175 Battery Indicator Function.......................................................................175 Status Code Function.............................................................................175 "ZX" SERIES DISPLAY PANELS...........................................................................175 Display Panel....................................................................................176 Basic Display Panels.............................................................................176 Performance Display..............................................................................178 Brush Wear Indicators............................................................................181 CHECKS AND ADJUSTMENTS...................................................................................181 GENERAL..............................................................................................181 REPLACEMENT..............................................................................................182 GENERAL..............................................................................................182 METER REPLACEMENT....................................................................................182 SENDER REPLACEMENT...................................................................................183 Fuel Level Sender................................................................................183 Pressure And Temperature Sender..................................................................183 I.T.W. DISPLAY PANEL.................................................................................184 Removal..........................................................................................184 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................185 Removal..........................................................................................185 Replacing Display Panel Assembly.................................................................185 Indicator LEDs...................................................................................185 Battery Indicators...............................................................................185 Digital Display (Performance Disply Panel Only)..................................................185 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....185 Replacing Parts Of The Basic Display Panel.......................................................186 Replacing Parts Of The Performance Display Panel.................................................188 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................188 Removal And Replacement..........................................................................188 SPECIFICATIONS...........................................................................................189 TROUBLESHOOTING..........................................................................................190 Lift Cylinders...............................................................................................191 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................191 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................191 LIFT CYLINDERS...........................................................................................194 GENERAL..............................................................................................194 DESCRIPTION..........................................................................................194 Lowering Control Valve...........................................................................194 Cylinders (General)..............................................................................197 Cylinders (H520-620B,H700-800A)..................................................................199 Cylinders (H360-460B)............................................................................200 Cylinders (Two-Speed)............................................................................200 REPAIRS..................................................................................................201 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................201 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........201 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................205 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................203 DISASSEMBLY..........................................................................................203 ASSEMBLY.............................................................................................205 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................205 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........205 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................205 CHEVRON PACKING......................................................................................206 LIFT CYLINDERS FOR VISTA MASTS...........................................................................209 DESCRIPTION..........................................................................................209 Lowering Control Valve...........................................................................211 REMOVAL..............................................................................................212 DISASSEMBLY..........................................................................................212 ASSEMBLY.............................................................................................212 INSTALLATION.........................................................................................213 Main Lift Cylinders..............................................................................213 Free-Lift Cylinders..............................................................................213 CHECKS AND ADJUSTMENTS...................................................................................214 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................214 TROUBLESHOOTING..........................................................................................215 SPECIFICATIONS...........................................................................................216 LPG Fuel System..............................................................................................217 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................217 GENERAL..............................................................................................217 DESCRIPTION..........................................................................................217 Fuel Tank........................................................................................218 Fuel Filter And Fuel Valve Unit..................................................................219 Vaporizer........................................................................................219 The IMPCO CA 100 Carbureto.......................................................................221 IMPCO CA 50 Carburetor...........................................................................223 The Governor (GM Engines Only)...................................................................224 Governor With Electronic Controller..............................................................225 REPAIRS..................................................................................................226 LPG TANK.............................................................................................226 Removal..........................................................................................226 Installation.....................................................................................227 REPLACE THE HOSES....................................................................................227 HYDROSTATIC RELIEF VALVE.............................................................................227 Removal and Installation.........................................................................227 FILTER UNIT..........................................................................................228 Replacement Of the Fuel Filter Element...........................................................228 Replacement of the Diaphragm and Fuel Valve......................................................229 VAPORIZER............................................................................................229 Removal..........................................................................................229 Disassembly......................................................................................229 Cleaning.........................................................................................229 Inspection.......................................................................................229 Assembly.........................................................................................231 Installation.....................................................................................231 CARBURETOR (IMPCO CA 100)............................................................................233 Removal..........................................................................................233 Disassembly......................................................................................233 Cleaning.........................................................................................233 Assembly.........................................................................................233 Installation.....................................................................................236 CARBURETER (IMPCO CA 50).............................................................................235 Removal..........................................................................................235 Disassembly......................................................................................235 Cleaning.........................................................................................236 Inspection.......................................................................................236 Assembly (See FIGURE 26.)........................................................................236 Installation.....................................................................................236 CHECKS AND ADJUSTMENTS...................................................................................237 CHECK THE FILTER UNIT................................................................................237 CHECK THE VAPORIZER..................................................................................237 Pressure Reducer Valve...........................................................................237 Vapor Valve......................................................................................237 ADJUST THE CARBURETOR................................................................................237 Idle Mixture.....................................................................................237 Idle Speed.......................................................................................237 Power Mixture....................................................................................237 ADJUST THE GOVERNOR (GM Engines Only)................................................................238 Checks...........................................................................................238 Main Adjusting Screw.............................................................................238 Secondary Adjusting Screw........................................................................238 AISAN Governor...................................................................................239 Adjustment, AISAN Governor.......................................................................239 TROUBLESHOOTING..........................................................................................240 Main Control Valve...........................................................................................244 INTRODUCTION.............................................................................................244 GENERAL..............................................................................................244 DESCRIPTION..........................................................................................244 OPERATION............................................................................................246 Lift Spool.......................................................................................246 Tilt Spool.......................................................................................246 Relief Valve, Single–Stage.......................................................................249 Relief Valve, Two–Stage..........................................................................250 REPAIRS..................................................................................................250 REMOVAL AND DISASSEMBLY..............................................................................250 CLEANING AND INSPECTION..............................................................................251 ASSEMBLY.............................................................................................251 INSTALLATION.........................................................................................251 CHECKS AND ADJUSTMENTS...................................................................................251 ADJUST THE SINGLE–STAGE RELIEF VALVE.................................................................251 ADJUST THE TWO–STAGE RELIEF VALVE....................................................................252 ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY................................253 TROUBLESHOOTING..........................................................................................253 Mast Description.............................................................................................255 INTRODUCTION.............................................................................................255 GENERAL..............................................................................................255 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................257 FULL FREE-LIFT MASTS.................................................................................257 THREE-STAGE MASTS....................................................................................259 FOUR-STAGE MASTS.....................................................................................260 SEQUENCE VALVE.......................................................................................260 Mast Repair..................................................................................................262 INTRODUCTION.............................................................................................262 GENERAL..............................................................................................262 REPAIRS..................................................................................................262 FORKS................................................................................................262 CARRIAGE.............................................................................................262 Removal..........................................................................................262 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................263 Installation.....................................................................................264 MASTS................................................................................................266 Removal..........................................................................................266 Disassembly......................................................................................268 Cleaning and Inspection..........................................................................272 Assembly.........................................................................................273 INSTALLATION.........................................................................................274 CHECKS AND ADJUSTMENTS...................................................................................274 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................274 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................275 LIFT CHAIN ADJUSTMENTS...............................................................................275 MAST ADJUSTMENTS.....................................................................................276 Guide Shoe Adjustment............................................................................277 CARRIAGE ADJUSTMENT..................................................................................279 TROUBLESHOOTING..........................................................................................281 Master Cylinder..............................................................................................282 INTRODUCTION.............................................................................................282 GENERAL..............................................................................................282 DESCRIPTION..........................................................................................282 REPAIRS..................................................................................................282 REMOVAL AND DISASSEMBLY..............................................................................282 CLEANING ............................................................................................283 ASSEMBLY.............................................................................................283 CHECKS AND ADJUSTMENTS...................................................................................283 CHECKS...............................................................................................283 Oil Clutch...................................................................................................284 INTRODUCTION.............................................................................................284 General..............................................................................................284 Description..........................................................................................284 REAPAIRS.................................................................................................286 Removal..............................................................................................286 Cleaning.............................................................................................286 Inspection...........................................................................................286 Installation.........................................................................................286 CHECKS AND ADJUSTMENTS...................................................................................288 Adjusting the Clutch Pedal Height....................................................................288 Adjusting the Clearance of the Release Mechanism.....................................................288 TROUBLESHOOTING..........................................................................................289 Periodic Maintenance.........................................................................................291 INTRODUCTION.............................................................................................291 General..............................................................................................291 Maintenance Schedule.................................................................................291 MAINTENANCE PROCEDURES...................................................................................294 EVERY 8 HOURS OR DAILY...................................................................................294 Checks With The Engine Running.......................................................................298 Checks With The Engine Stopped.......................................................................294 EVERY 350 HOURS OR TWO MONTHS............................................................................299 Engine Oil And Filter ...............................................................................299 Fuel Filter (Diesel).................................................................................299 Removing Air From The Diesel Fuel System.............................................................300 Brake Fluid..........................................................................................300 Hydraulic Tank Breather..............................................................................300 Cooling Fan..........................................................................................301 Other Lubrication Points.............................................................................301 Uprights.............................................................................................301 Forks................................................................................................302 EVERY 1000 HOURS OR SIX MONTHS...........................................................................303 Ignition System (Gas Engine).........................................................................303 PCV Valve (Gas Engine)...............................................................................303 EVERY 2000 HOURS OR YEARLY...............................................................................303 PCV Valve (Gas Engine)...............................................................................303 Differential.........................................................................................303 Adjusting The Oil Clutch Pedal.......................................................................304 Oil Filter For The Powershift Transmission Or The Oil Clutch.........................................304 Hydraulic System.....................................................................................304 Changing The Gasoline Fuel Filter....................................................................304 Changing The Fule Filter For LPG.....................................................................304 WHEELS AND TIRES.........................................................................................305 Changing Tires.......................................................................................305 Perkins Engine 4.154.........................................................................................306 INTRODUCTION.............................................................................................306 General..............................................................................................306 Description..........................................................................................306 ENGINE REPAIRS...........................................................................................306 REMOVAL AND INSTALLATION.................................................................................306 CYLINDER HEAD............................................................................................306 Removal..............................................................................................306 Installation.........................................................................................306 CYLINDER HEAD REPAIRS....................................................................................308 Valve Seats..............................................................................................308 Valve Springs............................................................................................308 Cylinder Head........................................................................................308 Valves...............................................................................................309 Valve Guides.........................................................................................309 ROCKER ARM ASSEMBLY......................................................................................309 Disassembly and Repair...............................................................................309 Assembly and Installation............................................................................310 COMBUSTION CHAMBER PLUGS.................................................................................310 TIMING GEAR CASE AND TIMING GEARS........................................................................310 Removal..............................................................................................310 Installation.........................................................................................311 PISTONS AND CONNECTING RODS..............................................................................313 Removal..............................................................................................313 Disassembly..........................................................................................313 Inspection...........................................................................................314 Assembly.............................................................................................314 Installation.........................................................................................315 CRANKCASE, MAIN BEARINGS AND CYLINDER LINERS.............................................................315 Removal of the Crankshaft............................................................................315 Inspection...........................................................................................316 Installation.........................................................................................317 Cylinder Liners......................................................................................318 Removal..........................................................................................318 Installation.....................................................................................318 CAMSHAFT AND CAM FOLLOWERS...............................................................................319 Removal..............................................................................................319 Inspection...........................................................................................319 Assembly and Installation............................................................................319 FUEL SYSTEM..............................................................................................320 Fuel Pump............................................................................................320 Removal..........................................................................................320 Installation.....................................................................................321 Fuel Injection Pump..................................................................................321 Removal..........................................................................................321 Repairs..........................................................................................321 Installation.....................................................................................322 Fuel Injectors.......................................................................................322 Removal..........................................................................................322 Repairs..........................................................................................322 Installation.....................................................................................322 Cold Start aid.......................................................................................322 Description......................................................................................322 Removal..........................................................................................322 Installation.....................................................................................323 COOLING SYSTEM...........................................................................................323 Thermostat...........................................................................................323 Water Pump...........................................................................................323 Removal..........................................................................................323 Installation.....................................................................................324 OIL PUMP.................................................................................................325 Removal..............................................................................................325 Installation.........................................................................................326 FLYWHEEL AND FLYWHEEL HOUSING............................................................................326 Removal..............................................................................................326 Installation.........................................................................................326 CHECKS AND ADJUSTMENTS...................................................................................327 Checking the Fuel Injector...........................................................................327 Removing the Air from the Fuel System................................................................327 Timing of the Fuel Injection Pump....................................................................328 Checking the Timing for Old Style Pumps..........................................................328 Making New Timing Mark on a New Timing Gear Case.................................................330 Checking the Timing Mark of a New Fuel Injection Pump............................................331 Valve Clearance Adjustment...........................................................................331 Adjusting the Throttle Linkage.......................................................................332 TROUBLESHOOTING..........................................................................................333 SPECIFICATIONS...........................................................................................334 Rochester Carburetor.........................................................................................337 INTRODUCTION.............................................................................................337 GENERAL..............................................................................................337 DESCRIPTION..........................................................................................337 OPERATION............................................................................................338 The Float System.................................................................................338 The Idle System..................................................................................338 The Main Metering System (GM 6-250)..............................................................339 The Power System (GM 6-250)......................................................................340 The Accelerator Pump System......................................................................340 Choke System.....................................................................................340 REPAIRS..................................................................................................341 REMOVAL..............................................................................................341 DISASSEMBLY..........................................................................................341 Cleaning.............................................................................................341 ASSEMBLY.............................................................................................341 INSTALLATION.........................................................................................341 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)......................................................346 GOVERNOR (PNEUMATIC) (Early Units)...................................................................347 CHECKS AND ADJUSTMENTS...................................................................................348 GENERAL..............................................................................................348 ADJUST THE CHOKE CONTROL.............................................................................348 ADJUST THE IDLE SPEED................................................................................348 ADJSUT THE IDLE MIXTURE..............................................................................349 ADJUST THE FAST IDLE.................................................................................349 ADJUST THE THROTTLE LINKAGE,(Later Models)...........................................................350 ADJUST THE THROTTLE LINKAGE,(Early Models)...........................................................351 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)........................................351 Check the Governor...............................................................................351 GOVERNOR (AISAN Type) (Early GM Engines Only)........................................................352 Checks...........................................................................................353 Adjustments......................................................................................353 GOVERNOR (HOOF Type) (Early GM Engines Only).........................................................353 Adjust the Governor..............................................................................353 TROUBLESHOOTING..........................................................................................355 SAE & Metric Fasteners.......................................................................................356 INTRODUCTION.............................................................................................356 NOMENCLATURE, THREADS................................................................................356 STRENGTH IDENTIFICATION..............................................................................357 TABLE 1. BOLTS AND SCREWS................................................................................357 TABLE 2. STUDS AND NUTS..................................................................................358 TABLE 3. TORQUE NUTS.....................................................................................359 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................360 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................361 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................362 Single Speed PS Transmission Description & Operation.........................................................365 INTRODUCTION.............................................................................................365 GENERAL..............................................................................................365 DESCRIPTION..............................................................................................365 OPERATION................................................................................................367 THE TORQUE CONVERTER.................................................................................367 THE PLANETARY GEAR SET...............................................................................369 CLUTCHES.............................................................................................371 HYDRAULIC SYSTEM.....................................................................................371 H60-110E.........................................................................................371 S40-50F, S30-120E................................................................................372 CONTROL VALVE........................................................................................373 Monotrol Regulator...............................................................................373 Clutch Regulator.................................................................................373 Torque Converter Regulator.......................................................................374 Direction Spool..................................................................................375 Modulation Spool, All Models Except S100-120E....................................................375 Modulation Spool and Accumulator Valve, S100-120E................................................375 The Valve For The Parking Brake Solenoid.........................................................376 The Inching Valve................................................................................376 THE ELECTRICAL CIRCUIT...............................................................................377 Electrical Circuit For the Direction.............................................................377 OIL FLOW DIAGRAMS....................................................................................378 PARK or NEUTRAL..................................................................................378 "1" Circuit Monotrol.............................................................................378 "2" Circuit - Clutch Apply.......................................................................378 "3" Circuit - Torque Converter...................................................................378 FORWARD..............................................................................................378 "1" Circuit - Monotrol...........................................................................378 "2" Circuit......................................................................................379 FORWARD - INCHING....................................................................................379 REVERSE..............................................................................................379 TROUBLESHOOTING..........................................................................................388 Single Speed PS Transmission Repair..........................................................................389 INTRODUCTION.............................................................................................389 General..............................................................................................389 REPAIRS..................................................................................................390 Removal..............................................................................................390 Disassembly..........................................................................................390 Inspection...........................................................................................394 Transmission.....................................................................................394 Torque Converter.................................................................................394 Repairing the Control Valve..........................................................................394 DIFFERENTIAL.............................................................................................397 Removal..............................................................................................397 Disassembly..........................................................................................399 Cleaning and Inspection..............................................................................399 Assembly.............................................................................................399 Adjusting the Differential...........................................................................400 Installation.........................................................................................402 Assembly of Transmission.............................................................................402 Installation of the Transmission.....................................................................408 Monotrol Pedal.......................................................................................409 Removal and Disassembly..............................................................................409 Assembly and Installation............................................................................409 CHECKS AND ADJUSTMENTS...................................................................................409 Checking the Monotrol Pedal for Leakage..............................................................409 Monotrol Linkage.....................................................................................409 Stall Test...........................................................................................410 Checking the Oil Pressures...........................................................................411 Monotrol Pressure................................................................................411 Clutch Pressure..................................................................................413 Inching Pressure.................................................................................413 Torque Converter Pressure........................................................................414 Modulator Spool/Clutch Engage Pressure...........................................................414 Checking the Powershift Electrical Circuit...........................................................414 Checking the Circuit for the Direction Control Lever.................................................415 TROUBLESHOOTING..........................................................................................416 Starter......................................................................................................423 INTRODUCTION.............................................................................................423 GENERAL..............................................................................................423 DESCRIPTION AND OPERATION............................................................................423 REPAIRS..................................................................................................425 REMOVAL..............................................................................................425 DISSASEMBLY..........................................................................................425 CLEANING.............................................................................................426 ASSEMBLY.............................................................................................426 INSTALLATION.........................................................................................426 CHECKS AND ADJUSTMENTS...................................................................................427 GENERAL..............................................................................................427 TROUBLESHOOTING..........................................................................................429 Steer Axle...................................................................................................431 INTRODUCTION.............................................................................................431 GENERAL..............................................................................................431 DESCRIPTION..........................................................................................431 REPAIRS..................................................................................................432 STEERING AXLES WITH STUB SHAFT MOUNTS................................................................432 Removal..........................................................................................433 Installation.....................................................................................433 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS...............................................................434 Removal..........................................................................................434 Installation.....................................................................................435 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)............................436 Removal..........................................................................................436 Installation.....................................................................................437 WHEELS AND HUBS......................................................................................437 Removal and Disassembly..........................................................................437 Cleaning.........................................................................................437 Assembly And Installation........................................................................437 SPINDLES, BEARING AND TIE RODS.......................................................................437 Removal And Disassembly..........................................................................437 Cleaning.........................................................................................437 Assembly And Installation........................................................................437 STEERING CYLINDER....................................................................................439 Removal And Disassembly..........................................................................439 Cleaning.........................................................................................440 Assembly And Installation........................................................................440 CHECKS AND ADJUSTMENTS...................................................................................442 STEERING CYLINDER....................................................................................442 CENTER PIVOT OR RUBBER MOUNTS........................................................................442 SPINDLE AND HUB......................................................................................442 TROUBLESHOOTING..........................................................................................443 Steer Control unit...........................................................................................444 INTRODUCTION.............................................................................................444 GENERAL..............................................................................................444 DESCRIPTION..........................................................................................444 OPERATION............................................................................................444 REPAIRS..................................................................................................444 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................444 TYPE "A" STEERING COLUMN ASSEMBLY....................................................................446 Removal And Disassembly..........................................................................446 Assembly And Installation........................................................................446 TYPE "A" STEERING COLUMN.............................................................................447 TYPE "A" STEERING COLUMN.............................................................................448 TYPE "B" STEERING COLUMN.............................................................................449 Removal And Disassembly..........................................................................449 Assembly And Installation........................................................................449 TYPE "B" STEERING COLUMN.............................................................................450 Disassembly of Steering Control Unit.............................................................451 Cleaning of Steering Control Unit................................................................451 Assembly of Steering Control Unit................................................................453 CHECKS AND ADJUSTMENTS...................................................................................456 REMOVE AIR FROM THE SYSTEM...........................................................................456 TROUBLESHOOTING..........................................................................................457 Tilt Cylinder................................................................................................458 INTRODUCTION.............................................................................................458 GENERAL..............................................................................................458 DESCRIPTION..........................................................................................458 REPAIRS..................................................................................................458 REMOVAL..............................................................................................458 DISASSEMBLY..........................................................................................458 CLEANING.............................................................................................458 ASSEMBLY.............................................................................................458 Tilt Cylinders with O-Rings or Single Lip Seals..................................................458 Tilt Cylinders for the XM and XMS Models.........................................................459 Tilt Cylinders for H700 800A and Early Model H700 920B...........................................461 INSTALLATION.........................................................................................461 Tilt Cylinders Using Chevron Packing.............................................................462 CHECKS AND ADJUSTMENTS...................................................................................464 CHECK THE TILT CYLINDERS FOR LEAKS...................................................................464 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..............................................464 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.................................................465 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS................................................466 TROUBLESHOOTING..........................................................................................468 Two Speed Manual Transmission................................................................................469 INTRODUCTION.............................................................................................469 General..............................................................................................469 Description..........................................................................................469 Operation............................................................................................470 REPAIRS..................................................................................................471 Removal..............................................................................................471 Installation.........................................................................................471 Disassembly..........................................................................................472 Cleaning.............................................................................................473 Inspection...........................................................................................473 Assembly.............................................................................................473 DIFFERENTIAL.............................................................................................478 Removal..............................................................................................478 Disassembly..........................................................................................479 Cleaning and Inspection..............................................................................479 Assembly.............................................................................................479 Adjusting the Differential...........................................................................480 Installation.........................................................................................482 TROUBLESHOOTING..........................................................................................482 Vista Upright Description & Repair...........................................................................486 INTRODUCTION.............................................................................................486 GENERAL..............................................................................................486 VISTA TWO-STAGE MASTS....................................................................................488 DESCRIPTION..........................................................................................488 OPERATION............................................................................................491 VISTA THREE-STAGE MASTS..................................................................................491 DESCRIPTION..........................................................................................491 OPERATION............................................................................................493 SEQUENCE VALVE.......................................................................................495 Vista Uprights Repair........................................................................................498 INTRODUCTION.............................................................................................498 GENERAL..............................................................................................498 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................498 REPAIRS..................................................................................................499 FORKS................................................................................................499 Removal..........................................................................................499 CARRIAGE.............................................................................................499 Removal (Two-Stage and Later Production Three-Stage Carriages)...................................499 Removal (Carriages with Removable Stop Block)....................................................500 Installation (Two-Stage and Later Production Three-Stage Carriages)..............................501 Installation (Carriages With Removable Stop Block)...............................................501 TWO-STAGE MASTS..........................................................................................503 REMOVAL..............................................................................................503 DISASSEMBLY..........................................................................................504 CLEANING AND INSPECTION..............................................................................505 ASSEMBLY.............................................................................................506 INSTALLATION.........................................................................................507 THREE-STAGE MASTS........................................................................................507 REMOVAL..............................................................................................507 DISASSEMBLY..........................................................................................507 CLEANING AND INSPECTION..............................................................................509 ASSEMBLY.............................................................................................509 INSTALLATION.........................................................................................510 LIFT AND TILT CYLINDERS..............................................................................511 SIDE SHIFT CARRIAGE..................................................................................511 Removal..........................................................................................511 Repairs..........................................................................................511 Installation.....................................................................................511 SEQUENCE VALVE.......................................................................................512 Removal and Disassembly..........................................................................515 Cleaning.........................................................................................515 Assembly and Installation........................................................................515 CHECKS AND ADJUSTMENTS...................................................................................516 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................516 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................516 LIFTING CHAIN ADJUSTMENTS............................................................................517 MAST ADJUSTMENTS.....................................................................................518 CARRIAGE ADJUSTMENT..................................................................................519 HEADER HOSE ROLLER ADJUSTMENT, 2-STAGE...............................................................520 TROUBLESHOOTING..........................................................................................521 TORQUE SPECIFICATIONS....................................................................................522 VISTA MASTS..............................................................................................523
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