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Hyster D003 (H30-60H Ser#E3) Service Manual – PDF DOWNLOAD
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Description
Hyster D003 (H30-60H Ser#E3) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster D003 (H30-60H Ser#E3) Service Manual – PDF DOWNLOAD
Language : English
Pages : 484
Downloadable : Yes
File Type : PDF
Size: 15.8 MB
TABLE OF CONTENTS:
Hyster D003 (H30-60H Ser#E3) 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............................................................................ 17 REPAIRS.................................................................................................. 17 REMOVAL AND DISASSEMBLY.............................................................................. 17 CLEANING............................................................................................. 18 INSPECTION........................................................................................... 19 ASSEMBLY............................................................................................. 19 CHECKS AND ADJUSTMENTS................................................................................... 21 BRAKE SHOES.......................................................................................... 21 Parking Brake.................................................................................... 21 Seat Actuated Park Brake, J40–60AS............................................................... 21 Removing The Air From The Brake System........................................................... 22 TROUBLESHOOTING.......................................................................................... 23 Capacities & Specification................................................................................... 26 Cooling System............................................................................................... 29 COOLING SYSTEM........................................................................................... 29 INTRODUCTION......................................................................................... 29 DESCRIPTION.......................................................................................... 29 RADIATOR............................................................................................. 29 RADIATOR CAP......................................................................................... 29 THERMOSTAT........................................................................................... 29 WATER PUMP........................................................................................... 30 FAN AND FAN SHROUD................................................................................... 30 REPAIRS.................................................................................................. 30 COOLING SYSTEM CHECKS................................................................................ 30 Exhaust Leaks.................................................................................... 30 RADIATOR............................................................................................. 30 Checks........................................................................................... 30 Cleaning The Radiator............................................................................ 30 Drain The Cooling System......................................................................... 32 Fill The Cooling System.......................................................................... 32 WATER PUMP........................................................................................... 32 Checks........................................................................................... 32 THERMOSTAT........................................................................................... 33 Checks........................................................................................... 33 FAN AND FAN SHROUD................................................................................... 33 TROUBLESHOOTING.......................................................................................... 34 Diagrams..................................................................................................... 35 Drive Axle................................................................................................... 41 INTRODUCTION............................................................................................. 41 GENERAL.............................................................................................. 41 DESCRIPTION.......................................................................................... 41 REPAIRS.................................................................................................. 41 DISASSEMBLY.......................................................................................... 42 CLEANING............................................................................................. 44 ASSEMBLY............................................................................................. 44 TROUBLESHOOTING.......................................................................................... 46 Electrical System Troubleshooting............................................................................ 47 ELECTRICAL SYSTEM COMPLETELY DEAD........................................................................ 47 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN .................................................... 48 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER.............................................. 50 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK............................................. 51 STARTER CRANKS SLOWLY.................................................................................... 53 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START................................................ 54 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND.............................................................. 56 CHARGING SYSTEM DOES NOT FUNCTION........................................................................ 57 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW..................................................... 60 BATTERY IS BEING OVERCHARGED............................................................................. 63 ONE OR MORE DASH GAUGES DO NOT WORK...................................................................... 64 HORN DOES NOT BLOW....................................................................................... 68 POWERSHIFT TRANSMISSION WILL NOT ENGAGE.................................................................. 69 ELECTRICAL SCHEMATIC S20-30A, H20-30E.................................................................... 70 ELECTRICAL S30-50C....................................................................................... 71 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG.............................................................. 72 ELECTRICAL SCHEMATIC H30-60H DIESEL...................................................................... 74 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG.............................................................. 76 ELECTRICAL SCHEMATIC H60-90C DIESEL...................................................................... 77 ELECTRICAL SCHEMATIC S30-60ES............................................................................ 78 ELECTRICAL SCHEMATIC S60-120E............................................................................ 79 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG............................................................ 80 ELECTRICAL SCHEMATIC S125-150A DIESEL.................................................................... 81 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG............................................................ 82 ELECTRICAL SCHEMATIC H110-150F DIESEL.................................................................... 83 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG.................................................. 84 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL......................................................... 85 ELECTRICAL SCHEMATIC H300A............................................................................... 86 ELECTRICAL SCHEMATIC H300-350B........................................................................... 87 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL............................................................ 88 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL............................................................ 89 ELECTRICAL SCHEMATIC H700-800A........................................................................... 90 ELECTRICAL SCHEMATIC P40-50A GASOLINE.................................................................... 92 ELECTRICAL SCHEMATIC P40-50A DIESEL...................................................................... 93 ELECTRICAL SCHEMATIC P60-80A GASOLINE.................................................................... 94 ELECTRICAL SCHEMATIC P60-80A DIESEL...................................................................... 95 ELECTRICAL SCHEMATIC KE GAS GASOLINE..................................................................... 96 ELECTRICAL SCHEMATIC KE DIESEL........................................................................... 97 ELECTRICAL SCHEMATIC M200-400H GASOLINE.................................................................. 98 ELECTRICAL SCHEMATIC M200-400H DIESEL....................................................................100 ELECTRICAL SCHEMATIC M600A...............................................................................102 Electrical Warning Devices...................................................................................104 ELECTRICAL WARNING DEVICES...............................................................................104 GENERAL..............................................................................................104 DESCRIPTION..........................................................................................104 Operator Controlled Horns........................................................................104 System Warning Lights, Buzzers and Bells.........................................................104 Reverse Warning Horns............................................................................105 Warning Lights...................................................................................105 REPLACEMENT..........................................................................................106 General..........................................................................................106 Replacing Horns or Bells.........................................................................106 Replacing Horn Relay or Buzzer...................................................................106 Replacing Warning Lights.........................................................................106 Light Assemblies.................................................................................107 Replacing Flashing Units.........................................................................107 Frame........................................................................................................108 INTRODUCTION.............................................................................................108 GENERAL..............................................................................................108 DESCRIPTION..........................................................................................108 Main Frame.......................................................................................108 Fuel Tank........................................................................................108 Hydraulic Tank...................................................................................108 REMOVAL AND DISASSEMBLY..................................................................................109 COUNTERWEIGHT REMOVAL................................................................................109 FUEL TANK REMOVAL....................................................................................109 HYDRAULIC TANK REMOVAL...............................................................................110 HOOD AND SEAT REMOVAL................................................................................110 OVERHEAD GUARD REMOVAL...............................................................................110 ENGINE AND TRANSMISSION REMOVAL......................................................................110 REPAIRS..................................................................................................111 FUEL OR HYDRAULIC TANK...............................................................................111 Small Leaks......................................................................................111 Large Leaks......................................................................................112 PAINTING INSTRUCTIONS................................................................................113 LABEL REPLACEMENT....................................................................................114 ASSEMBLY AND INSTALLATION................................................................................114 GENERAL..............................................................................................114 COUNTERWEIGHT INSTALLATION...........................................................................114 FUEL TANK INSTALLATION...............................................................................114 HYDRAULIC TANK INSTALLATION..........................................................................114 ENGINE AND TRANSMISSION INSTALLATION.................................................................115 GM Engine....................................................................................................116 INTRODUCTION.............................................................................................116 GENERAL..............................................................................................116 DESCRIPTION..........................................................................................117 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................117 CYLINDER HEAD AND MECHANISM..........................................................................117 Cylinder Head, Removal...........................................................................117 Cylinder Head, Disassembly.......................................................................118 Cleaning And Inspection..........................................................................119 Valve And Valve Seats............................................................................120 Studs For The Rocker Arms........................................................................120 Hydraulic Valve Lifters, Replacement.............................................................120 Hydraulic Valve Lifters, Cleaning And Inspection.................................................121 Cylinder Head, Assembly..........................................................................121 Cylinder Head, Installation......................................................................121 Rocker Arm Cover, Installation...................................................................122 TIMING GEAR COVER....................................................................................123 Removal..........................................................................................123 Installation.....................................................................................123 CAMSHAFT.............................................................................................124 Removal..........................................................................................124 Inspection.......................................................................................125 Camshaft Bearings, Removal.......................................................................125 Camshaft Bearings, Installation..................................................................125 DISTRIBUTOR..........................................................................................126 Removal..........................................................................................126 Installation.....................................................................................126 LUBRICATION SYSTEM...................................................................................127 Oil Sump, Removal................................................................................127 Oil Sump, Installation...........................................................................127 Oil Pump, Removal................................................................................127 Oil Pump, Disassembly and Repair.................................................................127 Oil Pump, Assembly...............................................................................128 Oil Pump, Installation...........................................................................128 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................128 Connecting Rod Bearings, Replacement.............................................................128 Piston And Connecting Rod Assemblies, Removal....................................................129 Disassembly......................................................................................130 Piston, Cleaning And Inspection..................................................................130 Cylinder Bores, Inspection And Repair............................................................130 Piston Rings.....................................................................................131 Assembly.........................................................................................132 Piston And Connecting Rod Assemblies, Installation...............................................132 CRANKSHAFT...........................................................................................133 Main Bearings, Replacement.......................................................................133 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................134 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........134 Crankshaft, Removal..............................................................................135 Inspection and Repair............................................................................136 How To Check The Clearance Between The Main Bearings And Their Journals..........................136 Installation.....................................................................................137 FLYWHEEL AND FLYWHEEL HOUSING........................................................................138 Flywheel, Removal................................................................................138 Ring Gear, Replacement...........................................................................139 Flywheel, Installation...........................................................................139 COOLING SYSTEM.......................................................................................139 Coolant Pump.....................................................................................139 Fan Drive........................................................................................140 Viscous Fan Drive................................................................................140 ENGINE SPECIFICATIONS....................................................................................141 ENGINE DATA..........................................................................................141 CYLINDER HEAD........................................................................................141 HYDRAULIC VALVE LIFTER...............................................................................142 CAMSHAFT.............................................................................................142 PISTONS..............................................................................................142 CYLINDER BORE........................................................................................143 CRANKSHAFT...........................................................................................143 CONNECTING RODS......................................................................................143 COOLING SYSTEM.......................................................................................144 LUBRICATION SYSTEM...................................................................................144 TORQUE SPECIFICATIONS....................................................................................144 High Energy Ignition System..................................................................................147 HIGH ENERGY IGNITION (HEI)...............................................................................147 DESCRIPTION..........................................................................................147 REPAIRS..................................................................................................149 DISTRIBUTOR..........................................................................................149 Removal..........................................................................................149 Disassembly......................................................................................149 Assembly.........................................................................................154 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................155 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................156 IGNITION COIL........................................................................................156 Removal, Some 4 And 6 Cylinder Models............................................................156 Installation, Some 4 And 6 Cylinder Models.......................................................157 Removal, V8, Some 4 And 6 Cylinder Models........................................................157 Installation, V8, Some 4 And 6 Cylinder Models...................................................158 ELECTRONIC MODULE....................................................................................159 Removal..........................................................................................159 Installation.....................................................................................159 SENSING COIL.........................................................................................160 Removal..........................................................................................160 Installation.....................................................................................160 SPARK PLUGS..........................................................................................160 Removal..........................................................................................160 Installation.....................................................................................161 CHECKS AND ADJUSTMENTS...............................................................................161 Visual Checks....................................................................................161 Check The High Voltage Wires.....................................................................161 Checking The Ignition Coil.......................................................................161 Coil In Distributor Cap Design...................................................................161 Separate Coil Design.............................................................................162 Checking The Sensing Coil........................................................................162 Check The Electronic Module......................................................................163 Ignition Timing Adjustment.......................................................................163 Ignition System, GM V8-366 (6-litre).............................................................164 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................164 SPECIFICATIONS...........................................................................................164 TROUBLESHOOTING..........................................................................................165 Hydraulic Gear Pumps.........................................................................................166 INTRODUCTION.............................................................................................166 DESCRIPTION..........................................................................................166 OPERATION............................................................................................166 Flow Control Valve...............................................................................168 Relief Valve.....................................................................................168 REPAIRS..................................................................................................169 REMOVAL..............................................................................................169 DISASSEMBLY..........................................................................................169 CLEANING.............................................................................................171 INSPECTION...........................................................................................171 ASSEMBLY.............................................................................................172 INSTALLATION.........................................................................................173 CHECKS AND ADUSTMENTS....................................................................................174 CHECK THE OUTPUT OF THE PUMP.........................................................................174 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................174 TROUBLESHOOTING..........................................................................................176 Hydraulic Pump Drive Assembly................................................................................179 INTRODUCTION.............................................................................................179 GENERAL..............................................................................................179 DESCRIPTION..........................................................................................179 REPAIRS..................................................................................................179 REMOVAL AND DISASSEMBLY..............................................................................179 CLEANING.............................................................................................181 INSPECTION...........................................................................................181 ASSEMBLY AND INSTALLATION............................................................................181 TROUBLESHOOTING..........................................................................................183 GENERAL..............................................................................................183 Hydraulic System.............................................................................................184 INTRODUCTION.............................................................................................184 General..............................................................................................184 Description..........................................................................................184 Hydraulic Control Valve..............................................................................190 REPAIRS..................................................................................................194 Disassembly..........................................................................................194 Cleaning.............................................................................................194 Inspection...........................................................................................194 Assembly.............................................................................................195 CHECKS AND ADJUSTMENT....................................................................................196 Relief Valve.........................................................................................196 TROUBLESHOOTING..........................................................................................198 INCH (SAE) & Metric Fasteners................................................................................200 INTRODUCTION.............................................................................................200 NOMENCLATURE, THREADS................................................................................200 STRENGTH IDENTIFICATION..............................................................................201 TABLE 1. BOLTS AND SCREWS................................................................................201 TABLE 2. STUDS AND NUTS..................................................................................202 TABLE 3. TORQUE NUTS.....................................................................................203 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................204 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................205 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................206 Instrument Panel Indicators & Senders........................................................................209 INTRODUCTION.............................................................................................209 GENERAL..............................................................................................209 DESCRIPTION..............................................................................................209 GENERAL..............................................................................................209 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................212 LED DISPLAY PANEL....................................................................................212 Battery Discharge Indicators.....................................................................212 Brush Wear Indicators............................................................................213 Motor Temperature Indicators.....................................................................214 "LX" SERIES DISPLAY PANEL............................................................................215 Hourmeter Functions..............................................................................216 Battery Indicator Function.......................................................................216 Status Code Function.............................................................................216 "ZX" SERIES DISPLAY PANELS...........................................................................216 Display Panel....................................................................................217 Basic Display Panels.............................................................................217 Performance Display..............................................................................219 Brush Wear Indicators............................................................................222 CHECKS AND ADJUSTMENTS...................................................................................222 GENERAL..............................................................................................222 REPLACEMENT..............................................................................................223 GENERAL..............................................................................................223 METER REPLACEMENT....................................................................................223 SENDER REPLACEMENT...................................................................................224 Fuel Level Sender................................................................................224 Pressure And Temperature Sender..................................................................224 I.T.W. DISPLAY PANEL.................................................................................225 Removal..........................................................................................225 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................226 Removal..........................................................................................226 Replacing Display Panel Assembly.................................................................226 Indicator LEDs...................................................................................226 Battery Indicators...............................................................................226 Digital Display (Performance Disply Panel Only)..................................................226 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....226 Replacing Parts Of The Basic Display Panel.......................................................227 Replacing Parts Of The Performance Display Panel.................................................229 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................229 Removal And Replacement..........................................................................229 SPECIFICATIONS...........................................................................................230 TROUBLESHOOTING..........................................................................................231 Lift Cylinder................................................................................................232 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................232 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................232 LIFT CYLINDERS...........................................................................................235 GENERAL..............................................................................................235 DESCRIPTION..........................................................................................235 Lowering Control Valve...........................................................................235 Cylinders (General)..............................................................................238 Cylinders (H520-620B,H700-800A)..................................................................240 Cylinders (H360-460B)............................................................................241 Cylinders (Two-Speed)............................................................................241 REPAIRS..................................................................................................242 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................242 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........242 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................246 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................244 DISASSEMBLY..........................................................................................244 ASSEMBLY.............................................................................................246 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................246 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........246 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................246 CHEVRON PACKING......................................................................................247 LIFT CYLINDERS FOR VISTA MASTS...........................................................................250 DESCRIPTION..........................................................................................250 Lowering Control Valve...........................................................................252 REMOVAL..............................................................................................253 DISASSEMBLY..........................................................................................253 ASSEMBLY.............................................................................................253 INSTALLATION.........................................................................................254 Main Lift Cylinders..............................................................................254 Free-Lift Cylinders..............................................................................254 CHECKS AND ADJUSTMENTS...................................................................................255 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................255 TROUBLESHOOTING..........................................................................................256 SPECIFICATIONS...........................................................................................257 LPG Fuel System..............................................................................................258 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................258 GENERAL..............................................................................................258 DESCRIPTION..........................................................................................258 Fuel Tank........................................................................................259 Fuel Filter And Fuel Valve Unit..................................................................260 Vaporizer........................................................................................260 The IMPCO CA 100 Carbureto.......................................................................262 IMPCO CA 50 Carburetor...........................................................................264 The Governor (GM Engines Only)...................................................................265 Governor With Electronic Controller..............................................................266 REPAIRS..................................................................................................267 LPG TANK.............................................................................................267 Removal..........................................................................................267 Installation.....................................................................................268 REPLACE THE HOSES....................................................................................268 HYDROSTATIC RELIEF VALVE.............................................................................268 Removal and Installation.........................................................................268 FILTER UNIT..........................................................................................269 Replacement Of the Fuel Filter Element...........................................................269 Replacement of the Diaphragm and Fuel Valve......................................................270 VAPORIZER............................................................................................270 Removal..........................................................................................270 Disassembly......................................................................................270 Cleaning.........................................................................................270 Inspection.......................................................................................270 Assembly.........................................................................................272 Installation.....................................................................................272 CARBURETOR (IMPCO CA 100)............................................................................274 Removal..........................................................................................274 Disassembly......................................................................................274 Cleaning.........................................................................................274 Assembly.........................................................................................274 Installation.....................................................................................277 CARBURETER (IMPCO CA 50).............................................................................276 Removal..........................................................................................276 Disassembly......................................................................................276 Cleaning.........................................................................................277 Inspection.......................................................................................277 Assembly (See FIGURE 26.)........................................................................277 Installation.....................................................................................277 CHECKS AND ADJUSTMENTS...................................................................................278 CHECK THE FILTER UNIT................................................................................278 CHECK THE VAPORIZER..................................................................................278 Pressure Reducer Valve...........................................................................278 Vapor Valve......................................................................................278 ADJUST THE CARBURETOR................................................................................278 Idle Mixture.....................................................................................278 Idle Speed.......................................................................................278 Power Mixture....................................................................................278 ADJUST THE GOVERNOR (GM Engines Only)................................................................279 Checks...........................................................................................279 Main Adjusting Screw.............................................................................279 Secondary Adjusting Screw........................................................................279 AISAN Governor...................................................................................280 Adjustment, AISAN Governor.......................................................................280 TROUBLESHOOTING..........................................................................................281 Mast Description.............................................................................................285 INTRODUCTION.............................................................................................285 GENERAL..............................................................................................285 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................287 FULL FREE-LIFT MASTS.................................................................................287 THREE-STAGE MASTS....................................................................................289 FOUR-STAGE MASTS.....................................................................................290 SEQUENCE VALVE.......................................................................................290 Mast Repair..................................................................................................292 INTRODUCTION.............................................................................................292 GENERAL..............................................................................................292 REPAIRS..................................................................................................292 FORKS................................................................................................292 CARRIAGE.............................................................................................292 Removal..........................................................................................292 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................293 Installation.....................................................................................294 MASTS................................................................................................296 Removal..........................................................................................296 Disassembly......................................................................................298 Cleaning and Inspection..........................................................................302 Assembly.........................................................................................303 INSTALLATION.........................................................................................304 CHECKS AND ADJUSTMENTS...................................................................................304 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................304 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................305 LIFT CHAIN ADJUSTMENTS...............................................................................305 MAST ADJUSTMENTS.....................................................................................306 Guide Shoe Adjustment............................................................................307 CARRIAGE ADJUSTMENT..................................................................................309 TROUBLESHOOTING..........................................................................................311 Master Cylinder..............................................................................................312 INTRODUCTION.............................................................................................312 GENERAL..............................................................................................312 DESCRIPTION..........................................................................................312 REPAIRS..................................................................................................312 REMOVAL AND DISASSEMBLY..............................................................................312 CLEANING ............................................................................................313 ASSEMBLY.............................................................................................313 CHECKS AND ADJUSTMENTS...................................................................................313 CHECKS...............................................................................................313 Oil Clutch Transmission......................................................................................314 INTRODUCTION.............................................................................................314 GENERAL..............................................................................................314 DESCRIPTION..........................................................................................314 REPAIRS..................................................................................................317 REMOVAL..............................................................................................317 DISASSEMBLY..........................................................................................317 CLEANING.............................................................................................324 INSPECTION...........................................................................................324 ASSEMBLY.............................................................................................324 INSTALLATION.........................................................................................332 TROUBLESHOOTING..........................................................................................332 SPECIFICATIONS...........................................................................................333 Oil Clutch...................................................................................................334 INTRODUCTION.............................................................................................334 GENERAL..............................................................................................334 DESCRIPTION AND OPERATION ...........................................................................334 REPAIRS..................................................................................................335 REMOVAL..............................................................................................335 INSPECTION...........................................................................................335 INSTALLATION.........................................................................................336 ADJUSTMENTS..............................................................................................338 ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL.............................................................338 ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS....................338 TROUBLESHOOTING..........................................................................................339 Periodic Maintenance.........................................................................................341 INTRODUCTION.............................................................................................341 General..............................................................................................341 MAINTENANCE SCHEDULE.....................................................................................341 MAINTENANCE PROCEDURES...................................................................................343 Every 8 Hours or Daily...............................................................................343 Engine Oil.......................................................................................343 Air Cleaner......................................................................................343 Cooling System...................................................................................344 Fuel Filter......................................................................................344 Hydraulic Oil....................................................................................344 Battery..........................................................................................344 Tires............................................................................................345 Forks............................................................................................345 Lift Chains......................................................................................346 Drive Belts......................................................................................347 Brake Fluid......................................................................................347 Every 150 Hours or Monthly...........................................................................347 Uprights.........................................................................................347 Steering Axle....................................................................................349 Every 200 Hours......................................................................................349 Engine Oil (Perkins).............................................................................349 Every 350 Hours or Two Months........................................................................350 Engine Oil (GM) .................................................................................350 Fuel Filters.....................................................................................350 Every 1000 Hours or Six Months.......................................................................351 Fuel Filters.....................................................................................351 Ignition System..................................................................................351 Brakes...........................................................................................351 Every 2000 Hours or Yearly...........................................................................352 Differential/Transmission........................................................................352 Clutch Pedal.....................................................................................352 Hydraulic System.................................................................................352 PCV Valve........................................................................................354 Perkins Engine 4.154.........................................................................................355 INTRODUCTION.............................................................................................355 General..............................................................................................355 Description..........................................................................................355 ENGINE...................................................................................................355 Removal..............................................................................................355 Installation.........................................................................................356 CYLINDER HEAD AND VALVE MECHANISM........................................................................356 Cylinder Head........................................................................................356 Removal..........................................................................................356 Repairs..........................................................................................357 Installation.....................................................................................357 Valve Guides.....................................................................................359 Valve Mechanism......................................................................................359 Valves...........................................................................................359 Valve Springs....................................................................................359 Rocker Arm Assembly..............................................................................359 LUBRICATION..............................................................................................360 Oil Pump.............................................................................................360 Removal and Disassembly..........................................................................360 Repairs..........................................................................................360 Assembly and Installation........................................................................360 Relief Valve.....................................................................................361 TIMING GEAR CASE AND CAMSHAFT............................................................................361 Timing Gear Cover....................................................................................361 Removal..........................................................................................361 Installation.....................................................................................361 Idle Gears...........................................................................................361 Removal..........................................................................................361 Installation.....................................................................................362 Camshaft Gear and Camshaft...........................................................................362 Removal..........................................................................................362 Installation.....................................................................................363 Fuel Pump Gear.......................................................................................363 Removal..........................................................................................363 Installation.....................................................................................364 Timing Gear Case.....................................................................................364 Removal..........................................................................................364 Installation.....................................................................................364 CRANKSHAFT AND MAIN BEARINGS.............................................................................365 Removal..............................................................................................365 Installation.........................................................................................365 PISTONS AND PISTON RODS..................................................................................366 Removal..............................................................................................366 Disassembly..........................................................................................366 Repairs..............................................................................................367 Assembly.............................................................................................367 Installation.........................................................................................368 CYLINDER LINERS..........................................................................................369 Removal .............................................................................................369 Installation.........................................................................................369 FLYWHEEL AND FLYWHEEL HOUSING............................................................................369 Removal..............................................................................................369 Installation.........................................................................................369 FUEL PUMP................................................................................................369 Removal..............................................................................................369 Installation.........................................................................................370 FUEL INJECTION PUMP......................................................................................370 Removal..............................................................................................370 Installation.........................................................................................370 FUEL INJECTORS...........................................................................................371 Checks...............................................................................................371 Installation.........................................................................................371 COOLING SYSTEM...........................................................................................372 Thermostat...........................................................................................372 Removal..........................................................................................372 Installation.....................................................................................372 Water Pump...........................................................................................372 Removal..........................................................................................372 Assembly.........................................................................................373 CHECKS AND ADJUSTMENTS...................................................................................373 Removing Air From The Fuel System....................................................................373 Timing...............................................................................................374 Fuel Injection Pump..............................................................................374 Valve Clearance Adjustment...........................................................................377 Adjusting The Throttle Linkage.......................................................................377 TROUBLESHOOTING..........................................................................................379 SPECIFICATIONS...........................................................................................380 Rochester Carburetor.........................................................................................384 INTRODUCTION.............................................................................................384 GENERAL..............................................................................................384 DESCRIPTION..........................................................................................384 OPERATION............................................................................................385 The Float System.................................................................................385 The Idle System..................................................................................385 The Main Metering System (GM 6-250)..............................................................386 The Power System (GM 6-250)......................................................................387 The Accelerator Pump System......................................................................387 Choke System.....................................................................................387 REPAIRS..................................................................................................388 REMOVAL..............................................................................................388 DISASSEMBLY..........................................................................................388 Cleaning.............................................................................................388 ASSEMBLY.............................................................................................388 INSTALLATION.........................................................................................388 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)......................................................393 GOVERNOR (PNEUMATIC) (Early Units)...................................................................394 CHECKS AND ADJUSTMENTS...................................................................................395 GENERAL..............................................................................................395 ADJUST THE CHOKE CONTROL.............................................................................395 ADJUST THE IDLE SPEED................................................................................395 ADJSUT THE IDLE MIXTURE..............................................................................396 ADJUST THE FAST IDLE.................................................................................396 ADJUST THE THROTTLE LINKAGE,(Later Models)...........................................................397 ADJUST THE THROTTLE LINKAGE,(Early Models)...........................................................398 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)........................................398 Check the Governor...............................................................................398 GOVERNOR (AISAN Type) (Early GM Engines Only)........................................................399 Checks...........................................................................................400 Adjustments......................................................................................400 GOVERNOR (HOOF Type) (Early GM Engines Only).........................................................400 Adjust the Governor..............................................................................400 TROUBLESHOOTING..........................................................................................402 Single Speed PS Transmission Repair..........................................................................403 INTRODUCTION.............................................................................................403 General..............................................................................................403 REPAIRS..................................................................................................404 REMOVAL..................................................................................................404 DISASSEMBLY..............................................................................................404 CLEANING.................................................................................................412 INSPECTION...............................................................................................413 ASSEMBLY.................................................................................................413 Assembling the Control Valve.........................................................................413 Assembling the Differential..........................................................................416 Assembling the Transmission..........................................................................424 Installation.........................................................................................428 MONOTROL Pedal.......................................................................................428 CHECKS AND ADJUSTMENTS...................................................................................429 Checking the MONOTROL Pedal for Leakage..............................................................429 MONOTROL Pedal.......................................................................................429 Stall Test...........................................................................................429 Checking the Oil Pressures...........................................................................430 MONOTROL Pressure................................................................................431 Clutch Apply Pressure............................................................................433 Inching Spool Operation..........................................................................434 Torque Converter and Oil Cooler Pressure.........................................................434 CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT...............................................................434 CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER.....................................................435 ADJUSTING THE OIL SUMP TUBE..............................................................................436 TROUBLESHOOTING..........................................................................................436 Pressure Tests.......................................................................................439 Troubleshooting the Differential.....................................................................440 Starter......................................................................................................442 INTRODUCTION.............................................................................................442 GENERAL..............................................................................................442 DESCRIPTION AND OPERATION............................................................................442 REPAIRS..................................................................................................444 REMOVAL..............................................................................................444 DISSASEMBLY..........................................................................................444 CLEANING.............................................................................................445 ASSEMBLY.............................................................................................445 INSTALLATION.........................................................................................445 CHECKS AND ADJUSTMENTS...................................................................................446 GENERAL..............................................................................................446 TROUBLESHOOTING..........................................................................................448 Steering Axle................................................................................................450 INTRODUCTION.............................................................................................450 General..............................................................................................450 Description..........................................................................................450 REPAIRS..................................................................................................452 Steering Cylinder....................................................................................452 Steering Axle........................................................................................453 Wheel Hubs...........................................................................................455 Spindles and Kingpins................................................................................456 The Center Arm Assembly..............................................................................457 CHECKS AND ADJUSTMENT....................................................................................458 Removing Air from the Steering System ...............................................................458 Hydraulic Pressure...................................................................................458 Mechanical Adjustment................................................................................459 Steering Control Unit........................................................................................460 INTRODUCTION.............................................................................................460 GENERAL..............................................................................................460 DESCRIPTION..........................................................................................460 OPERATION............................................................................................460 REPAIRS..................................................................................................460 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................460 TYPE "A" STEERING COLUMN ASSEMBLY....................................................................462 Removal And Disassembly..........................................................................462 Assembly And Installation........................................................................462 TYPE "A" STEERING COLUMN.............................................................................463 TYPE "A" STEERING COLUMN.............................................................................464 TYPE "B" STEERING COLUMN.............................................................................465 Removal And Disassembly..........................................................................465 Assembly And Installation........................................................................465 TYPE "B" STEERING COLUMN.............................................................................466 Disassembly of Steering Control Unit.............................................................467 Cleaning of Steering Control Unit................................................................467 Assembly of Steering Control Unit................................................................469 CHECKS AND ADJUSTMENTS...................................................................................472 REMOVE AIR FROM THE SYSTEM...........................................................................472 TROUBLESHOOTING..........................................................................................473 Tilt Cylinders...............................................................................................474 INTRODUCTION.............................................................................................474 GENERAL..............................................................................................474 DESCRIPTION..........................................................................................474 REPAIRS..................................................................................................474 REMOVAL..............................................................................................474 DISASSEMBLY..........................................................................................474 CLEANING.............................................................................................474 ASSEMBLY.............................................................................................474 Tilt Cylinders with O-Rings or Single Lip Seals..................................................474 Tilt Cylinders for the XM and XMS Models.........................................................475 Tilt Cylinders for H700 800A and Early Model H700 920B...........................................477 INSTALLATION.........................................................................................477 Tilt Cylinders Using Chevron Packing.............................................................478 CHECKS AND ADJUSTMENTS...................................................................................480 CHECK THE TILT CYLINDERS FOR LEAKS...................................................................480 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..............................................480 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.................................................481 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS................................................482 TROUBLESHOOTING..........................................................................................484
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