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Hyster D005 (H60-110E [Americas]) Service Manual – PDF DOWNLOAD
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Description
Hyster D005 (H60-110E [Americas]) Service Manual – PDF DOWNLOAD
FILE DETAILS
Hyster D005 (H60-110E [Americas]) Service Manual – PDF DOWNLOAD
Language : English
Pages : 639
Downloadable : Yes
File Type : PDF
Size: 25.3 MB
TABLE OF CONTENTS:
Hyster D005 (H60-110E [Americas]) Service Manual – PDF DOWNLOAD
6003......................................................................................................... 1 INTRODUCTION............................................................................................. 1 GENERAL.............................................................................................. 1 DESCRIPTION.......................................................................................... 2 REMOVAL AND INSTALLATION OF THE ENGINE............................................................... 2 CYLINDER HEAD AND MECHANISM.......................................................................... 2 Cylinder Head, Removal........................................................................... 2 Cylinder Head, Disassembly....................................................................... 3 Cleaning And Inspection.......................................................................... 4 Valve And Valve Seats............................................................................ 5 Studs For The Rocker Arms........................................................................ 5 Hydraulic Valve Lifters, Replacement............................................................. 5 Hydraulic Valve Lifters, Cleaning And Inspection................................................. 6 Cylinder Head, Assembly.......................................................................... 6 Cylinder Head, Installation...................................................................... 6 Rocker Arm Cover, Installation................................................................... 7 TIMING GEAR COVER.................................................................................... 8 Removal.......................................................................................... 8 Installation..................................................................................... 8 CAMSHAFT............................................................................................. 9 Removal.......................................................................................... 9 Inspection....................................................................................... 10 Camshaft Bearings, Removal....................................................................... 10 Camshaft Bearings, Installation.................................................................. 10 DISTRIBUTOR.......................................................................................... 11 Removal.......................................................................................... 11 Installation..................................................................................... 11 LUBRICATION SYSTEM................................................................................... 12 Oil Sump, Removal................................................................................ 12 Oil Sump, Installation........................................................................... 12 Oil Pump, Removal................................................................................ 12 Oil Pump, Disassembly and Repair................................................................. 12 Oil Pump, Assembly............................................................................... 13 Oil Pump, Installation........................................................................... 13 PISTON AND CONNECTING ROD ASSEMBLIES................................................................. 13 Connecting Rod Bearings, Replacement............................................................. 13 Piston And Connecting Rod Assemblies, Removal.................................................... 14 Disassembly...................................................................................... 15 Piston, Cleaning And Inspection.................................................................. 15 Cylinder Bores, Inspection And Repair............................................................ 15 Piston Rings..................................................................................... 16 Assembly......................................................................................... 17 Piston And Connecting Rod Assemblies, Installation............................................... 17 CRANKSHAFT........................................................................................... 18 Main Bearings, Replacement....................................................................... 18 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only)......................... 19 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal)......... 19 Crankshaft, Removal.............................................................................. 20 Inspection and Repair............................................................................ 21 How To Check The Clearance Between The Main Bearings And Their Journals.......................... 21 Installation..................................................................................... 22 FLYWHEEL AND FLYWHEEL HOUSING........................................................................ 23 Flywheel, Removal................................................................................ 23 Ring Gear, Replacement........................................................................... 24 Flywheel, Installation........................................................................... 24 COOLING SYSTEM....................................................................................... 24 Coolant Pump..................................................................................... 24 Fan Drive........................................................................................ 25 Viscous Fan Drive................................................................................ 25 ENGINE SPECIFICATIONS.................................................................................... 26 ENGINE DATA.......................................................................................... 26 CYLINDER HEAD........................................................................................ 26 HYDRAULIC VALVE LIFTER............................................................................... 27 CAMSHAFT............................................................................................. 27 PISTONS.............................................................................................. 27 CYLINDER BORE........................................................................................ 28 CRANKSHAFT........................................................................................... 28 CONNECTING RODS...................................................................................... 28 COOLING SYSTEM....................................................................................... 29 LUBRICATION SYSTEM................................................................................... 29 TORQUE SPECIFICATIONS.................................................................................... 29 22002........................................................................................................ 32 General.................................................................................................. 34 Description.............................................................................................. 34 Alternator Repair........................................................................................ 36 Alternator Type A.................................................................................... 36 Remove and Disassemble........................................................................... 36 Clean............................................................................................ 37 Assemble......................................................................................... 37 Install.......................................................................................... 38 Alternator Type B.................................................................................... 41 Remove and Disassemble........................................................................... 41 Clean............................................................................................ 41 Assemble......................................................................................... 42 Install.......................................................................................... 43 General Check and Adjustment............................................................................. 44 Low Output Check (Type A or Type B)...................................................................... 44 High Output Check (Type A or Type B)..................................................................... 46 Brushes Circuit Check.................................................................................... 47 Delco Alternators.................................................................................... 47 Motorola Alternators................................................................................. 48 Diodes Check............................................................................................. 49 Diodes Bridge Check...................................................................................... 49 Delco and Leece-Neville Alternators.................................................................. 49 Motorola Alternators................................................................................. 49 Rotor Field Winding Check................................................................................ 50 Stator Windings Check.................................................................................... 51 Voltage Regulator Check.................................................................................. 51 Troubleshooting.......................................................................................... 52 90011........................................................................................................ 54 INTRODUCTION............................................................................................. 54 GENERAL.............................................................................................. 54 DESCRIPTION.......................................................................................... 54 OPERATION............................................................................................ 55 The Float System................................................................................. 55 The Idle System.................................................................................. 55 The Main Metering System (GM 6-250).............................................................. 56 The Power System (GM 6-250)...................................................................... 57 The Accelerator Pump System...................................................................... 57 Choke System..................................................................................... 57 REPAIRS.................................................................................................. 58 REMOVAL.............................................................................................. 58 DISASSEMBLY.......................................................................................... 58 Cleaning............................................................................................. 58 ASSEMBLY............................................................................................. 58 INSTALLATION......................................................................................... 58 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)...................................................... 63 GOVERNOR (PNEUMATIC) (Early Units)................................................................... 64 CHECKS AND ADJUSTMENTS................................................................................... 65 GENERAL.............................................................................................. 65 ADJUST THE CHOKE CONTROL............................................................................. 65 ADJUST THE IDLE SPEED................................................................................ 65 ADJSUT THE IDLE MIXTURE.............................................................................. 66 ADJUST THE FAST IDLE................................................................................. 66 ADJUST THE THROTTLE LINKAGE,(Later Models)........................................................... 67 ADJUST THE THROTTLE LINKAGE,(Early Models)........................................................... 68 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)........................................ 68 Check the Governor............................................................................... 68 GOVERNOR (AISAN Type) (Early GM Engines Only)........................................................ 69 Checks........................................................................................... 70 Adjustments...................................................................................... 70 GOVERNOR (HOOF Type) (Early GM Engines Only)......................................................... 70 Adjust the Governor.............................................................................. 70 TROUBLESHOOTING.......................................................................................... 72 90015........................................................................................................ 73 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................ 73 GENERAL.............................................................................................. 73 DESCRIPTION.......................................................................................... 73 Fuel Tank........................................................................................ 74 Fuel Filter And Fuel Valve Unit.................................................................. 75 Vaporizer........................................................................................ 75 The IMPCO CA 100 Carbureto....................................................................... 77 IMPCO CA 50 Carburetor........................................................................... 79 The Governor (GM Engines Only)................................................................... 80 Governor With Electronic Controller.............................................................. 81 REPAIRS.................................................................................................. 82 LPG TANK............................................................................................. 82 Removal.......................................................................................... 82 Installation..................................................................................... 83 REPLACE THE HOSES.................................................................................... 83 HYDROSTATIC RELIEF VALVE............................................................................. 83 Removal and Installation......................................................................... 83 FILTER UNIT.......................................................................................... 84 Replacement Of the Fuel Filter Element........................................................... 84 Replacement of the Diaphragm and Fuel Valve...................................................... 85 VAPORIZER............................................................................................ 85 Removal.......................................................................................... 85 Disassembly...................................................................................... 85 Cleaning......................................................................................... 85 Inspection....................................................................................... 85 Assembly......................................................................................... 87 Installation..................................................................................... 87 CARBURETOR (IMPCO CA 100)............................................................................ 89 Removal.......................................................................................... 89 Disassembly...................................................................................... 89 Cleaning......................................................................................... 89 Assembly......................................................................................... 89 Installation..................................................................................... 92 CARBURETER (IMPCO CA 50)............................................................................. 91 Removal.......................................................................................... 91 Disassembly...................................................................................... 91 Cleaning......................................................................................... 92 Inspection....................................................................................... 92 Assembly (See FIGURE 26.)........................................................................ 92 Installation..................................................................................... 92 CHECKS AND ADJUSTMENTS................................................................................... 93 CHECK THE FILTER UNIT................................................................................ 93 CHECK THE VAPORIZER.................................................................................. 93 Pressure Reducer Valve........................................................................... 93 Vapor Valve...................................................................................... 93 ADJUST THE CARBURETOR................................................................................ 93 Idle Mixture..................................................................................... 93 Idle Speed....................................................................................... 93 Power Mixture.................................................................................... 93 ADJUST THE GOVERNOR (GM Engines Only)................................................................ 94 Checks........................................................................................... 94 Main Adjusting Screw............................................................................. 94 Secondary Adjusting Screw........................................................................ 94 AISAN Governor................................................................................... 95 Adjustment, AISAN Governor....................................................................... 95 TROUBLESHOOTING.......................................................................................... 96 100101.......................................................................................................100 INTRODUCTION.............................................................................................100 GENERAL..............................................................................................100 DESCRIPTION..........................................................................................100 DISASSEMBLY AND ASSEMBLY.................................................................................101 COUNTERWEIGHT........................................................................................102 Removal..........................................................................................102 Installation.....................................................................................102 OVERHEAD GUARD.......................................................................................102 Removal..........................................................................................102 Installation.....................................................................................102 HOOD AND SEAT REMOVAL................................................................................102 ENGINE...............................................................................................102 Removal..........................................................................................102 INSTALLATION.....................................................................................103 FUEL TANK............................................................................................103 REPAIRS..................................................................................................103 FUEL AND HYDRAULIC TANKS.............................................................................103 Small Leaks......................................................................................103 Large Leaks......................................................................................104 OTHER REPAIRS............................................................................................105 TILT CYLINDER MOUNTS.................................................................................105 STEERING AXLE MOUNT..................................................................................105 LABEL REPLACEMENT....................................................................................105 130082.......................................................................................................107 INTRODUCTION.............................................................................................107 GENERAL..............................................................................................107 DESCRIPTION..........................................................................................107 REPAIRS..................................................................................................107 REMOVAL..............................................................................................107 DISASSEMBLY..........................................................................................109 CLEANING.............................................................................................109 INSPECTION...........................................................................................110 ASSEMBLY.............................................................................................110 The Pinion Assembly..............................................................................110 The Differential.................................................................................112 INSTALLATION.........................................................................................113 TROUBLESHOOTING..........................................................................................116 130088.......................................................................................................117 INTRODUCTION.............................................................................................117 GENERAL..............................................................................................117 DESCRIPTION..........................................................................................117 OPERATION............................................................................................117 REPAIRS..................................................................................................118 REMOVAL..............................................................................................118 Removing the Transmission (Both Methods).........................................................120 Removing The Transmission Without Removing The Drive Axle........................................120 Removing The Transmission With The Drive Axle....................................................120 DISASSEMBLY..........................................................................................121 Removing the Selector Rails and Forks............................................................121 Removing the Hypoid Ring Gear and Differential...................................................121 Removing the Gear Assemblies.....................................................................123 CLEANING.............................................................................................125 INSPECTION...........................................................................................126 ASSEMBLY.............................................................................................127 Assembling The Hypoid Pinion and Ring Gear and Differential......................................127 Assembling the Range Countershaft................................................................128 Assembling The Forward Countershaft..............................................................129 Assembling The Forward and Reverse Main Shaft....................................................130 Assembling The Input Gear and Range Main Shaft ..................................................130 Installing the Differential Assembly.............................................................133 Installing the Selector Rails and Forks..........................................................136 INSTALLATION.........................................................................................137 CHECKS AND ADJUSTMENTS...................................................................................138 LINKAGE ADJUSTMENTS..................................................................................138 TROUBLESHOOTING - DIFFERENTIAL...........................................................................140 TROUBLESHOOTING - TRANSMISSION...........................................................................141 SPECIFICATIONS...........................................................................................142 140049.......................................................................................................143 INTRODUCTION.............................................................................................143 GENERAL..............................................................................................143 DESCRIPTION..........................................................................................143 REPAIRS..................................................................................................143 DISASSEMBLY..........................................................................................144 CLEANING.............................................................................................146 ASSEMBLY.............................................................................................146 TROUBLESHOOTING..........................................................................................148 160054.......................................................................................................149 INTRODUCTION.............................................................................................149 GENERAL..............................................................................................149 DESCRIPTION..........................................................................................149 OPERATION............................................................................................149 REPAIRS..................................................................................................149 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................149 TYPE "A" STEERING COLUMN ASSEMBLY....................................................................151 Removal And Disassembly..........................................................................151 Assembly And Installation........................................................................151 TYPE "A" STEERING COLUMN.............................................................................152 TYPE "A" STEERING COLUMN.............................................................................153 TYPE "B" STEERING COLUMN.............................................................................154 Removal And Disassembly..........................................................................154 Assembly And Installation........................................................................154 TYPE "B" STEERING COLUMN.............................................................................155 Disassembly of Steering Control Unit.............................................................156 Cleaning of Steering Control Unit................................................................156 Assembly of Steering Control Unit................................................................158 CHECKS AND ADJUSTMENTS...................................................................................161 REMOVE AIR FROM THE SYSTEM...........................................................................161 TROUBLESHOOTING..........................................................................................162 160060.......................................................................................................163 INTRODUCTION.............................................................................................163 GENERAL..............................................................................................163 DESCRIPTION..........................................................................................163 REPAIRS..................................................................................................164 STEERING AXLES WITH STUB SHAFT MOUNTS................................................................164 Removal..........................................................................................165 Installation.....................................................................................165 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS...............................................................166 Removal..........................................................................................166 Installation.....................................................................................167 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)............................168 Removal..........................................................................................168 Installation.....................................................................................169 WHEELS AND HUBS......................................................................................169 Removal and Disassembly..........................................................................169 Cleaning.........................................................................................169 Assembly And Installation........................................................................169 SPINDLES, BEARING AND TIE RODS.......................................................................169 Removal And Disassembly..........................................................................169 Cleaning.........................................................................................169 Assembly And Installation........................................................................169 STEERING CYLINDER....................................................................................171 Removal And Disassembly..........................................................................171 Cleaning.........................................................................................172 Assembly And Installation........................................................................172 CHECKS AND ADJUSTMENTS...................................................................................174 STEERING CYLINDER....................................................................................174 CENTER PIVOT OR RUBBER MOUNTS........................................................................174 SPINDLE AND HUB......................................................................................174 TROUBLESHOOTING..........................................................................................175 180080.......................................................................................................176 INTRODUCTION.............................................................................................176 GENERAL..............................................................................................176 DESCRIPTION AND OPERATION............................................................................177 REPAIRS..................................................................................................177 REMOVAL AND DISASSEMBLY..............................................................................177 CLEANING.............................................................................................178 INSPECTION...........................................................................................179 ASSEMBLY.............................................................................................179 CHECKS AND ADJUSTMENTS...................................................................................181 BRAKE SHOES..........................................................................................181 Parking Brake....................................................................................181 Seat Actuated Park Brake, J40–60AS...............................................................181 Removing The Air From The Brake System...........................................................182 TROUBLESHOOTING..........................................................................................183 190064.......................................................................................................186 INTRODUCTION.............................................................................................186 GENERAL..............................................................................................186 DESCRIPTION..........................................................................................186 REPAIRS..................................................................................................186 REMOVAL AND DISASSEMBLY..............................................................................186 CLEANING.............................................................................................188 INSPECTION...........................................................................................188 ASSEMBLY AND INSTALLATION............................................................................188 TROUBLESHOOTING..........................................................................................190 GENERAL..............................................................................................190 190097.......................................................................................................191 INTRODUCTION.............................................................................................191 DESCRIPTION..........................................................................................191 OPERATION............................................................................................191 Flow Control Valve...............................................................................193 Relief Valve.....................................................................................193 REPAIRS..................................................................................................194 REMOVAL..............................................................................................194 DISASSEMBLY..........................................................................................194 CLEANING.............................................................................................196 INSPECTION...........................................................................................196 ASSEMBLY.............................................................................................197 INSTALLATION.........................................................................................198 CHECKS AND ADUSTMENTS....................................................................................199 CHECK THE OUTPUT OF THE PUMP.........................................................................199 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................199 TROUBLESHOOTING..........................................................................................201 200090.......................................................................................................204 INTRODUCTION.............................................................................................204 GENERAL..............................................................................................204 DESCRIPTION..........................................................................................204 OPERATION............................................................................................206 Lift Spool.......................................................................................206 Tilt Spool.......................................................................................206 Relief Valve, Single–Stage.......................................................................209 Relief Valve, Two–Stage..........................................................................210 REPAIRS..................................................................................................210 REMOVAL AND DISASSEMBLY..............................................................................210 CLEANING AND INSPECTION..............................................................................211 ASSEMBLY.............................................................................................211 INSTALLATION.........................................................................................211 CHECKS AND ADJUSTMENTS...................................................................................211 ADJUST THE SINGLE–STAGE RELIEF VALVE.................................................................211 ADJUST THE TWO–STAGE RELIEF VALVE....................................................................212 ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY................................213 TROUBLESHOOTING..........................................................................................213 600105.......................................................................................................215 INTRODUCTION.............................................................................................215 GENERAL..............................................................................................215 DESCRIPTION..........................................................................................215 ENGINE SERIAL NUMBER CODES...........................................................................216 REMOVAL AND INSTALLATION.............................................................................216 ENGINE...................................................................................................216 CYLINDER HEAD........................................................................................216 Removal..........................................................................................216 Installation.....................................................................................217 Cylinder Head Repairs............................................................................218 OIL PUMP.............................................................................................220 Removal..........................................................................................220 Disassembly......................................................................................220 Inspection.......................................................................................220 Assembly.........................................................................................221 Installation.....................................................................................221 RELIEF VALVE.........................................................................................222 TIMING GEAR CASE AND TIMING GEARS....................................................................222 Removal..........................................................................................222 Installation.....................................................................................223 PISTONS AND CONNECTING RODS..........................................................................224 Removal..........................................................................................224 Disassembly......................................................................................224 Inspection.......................................................................................225 Assembly.........................................................................................226 Installation.....................................................................................226 CRANKSHAFT AND MAIN BEARINGS.........................................................................227 Removal..........................................................................................227 Inspection.......................................................................................227 Assembly.........................................................................................228 CAMSHAFT AND CAM FOLLOWERS...........................................................................229 Removal..........................................................................................229 Inspection.......................................................................................230 Assembly.........................................................................................230 FLYWHEEL AND FLYWHEEL HOUSING........................................................................231 Removal..........................................................................................231 Repairs..........................................................................................231 Installation.....................................................................................231 STEERING PUMP DRIVE..................................................................................231 Removal..........................................................................................231 Installation.....................................................................................232 PCV VALVE............................................................................................232 FUEL SYSTEM..............................................................................................232 FUEL PUMP............................................................................................232 Removal..........................................................................................232 Disassembly......................................................................................232 Assembly.........................................................................................232 Installation.....................................................................................233 FUEL INJECTION PUMP..................................................................................233 Removal..........................................................................................233 Repairs..........................................................................................233 Installation.....................................................................................233 FUEL INJECTORS.......................................................................................233 Removal..........................................................................................233 Repairs..........................................................................................234 Installation.....................................................................................234 COLD START AID.......................................................................................234 Description......................................................................................234 Removal..........................................................................................234 Installation.....................................................................................234 COOLING SYSTEM...........................................................................................235 THERMOSTAT...........................................................................................235 Removal..........................................................................................235 Inspection.......................................................................................235 Installation.....................................................................................235 WATER PUMP...........................................................................................235 Removal..........................................................................................235 Disassembly......................................................................................235 Assembly.........................................................................................235 Installation.....................................................................................235 CHECKS AND ADJUSTMENTS...................................................................................235 CHECKING THE INJECTORS...............................................................................235 Repairs..........................................................................................236 Installation.....................................................................................236 REMOVING AIR FROM THE FUEL SYSTEM....................................................................236 CHECKING THE TIMING MARKS............................................................................237 Method A.........................................................................................237 Method B.........................................................................................238 CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL...........................239 VALVE CLEARANCE ADJUSTMENT...........................................................................240 ADJUSTING THE THROTTLE LINKAGE.......................................................................240 TROUBLESHOOTING..........................................................................................242 SPECIFICATIONS...........................................................................................243 TORQUE SPECIFICATIONS....................................................................................246 700108.......................................................................................................247 INTRODUCTION.............................................................................................247 GENERAL..............................................................................................247 DESCRIPTION..........................................................................................247 REPAIRS..................................................................................................250 FAN ASSEMBLY.........................................................................................250 Removal (S30–120E)...............................................................................250 Removal (H60–110E)...............................................................................250 Disassembly (S30–120E)...........................................................................250 Disassembly (H60–110E)...........................................................................251 Assembly (Both Series)...........................................................................251 Fan Belt Adjustment..............................................................................254 Installation.....................................................................................254 RADIATOR.............................................................................................255 Removal..........................................................................................255 Installation.....................................................................................255 Cleaning and Inspection..........................................................................256 TROUBLESHOOTING..........................................................................................257 700626.......................................................................................................258 General..................................................................................................260 Description..............................................................................................261 Radiator.............................................................................................261 Radiator Cap.........................................................................................261 Thermostat...........................................................................................261 Water Pump...........................................................................................262 Fan and Fan Shroud...................................................................................262 Cooling System Checks....................................................................................262 Radiator.............................................................................................262 Thermostat...........................................................................................262 Water Pump...........................................................................................263 Exhaust Leaks........................................................................................263 Fan and Fan Shroud...................................................................................263 Radiator Cleaning........................................................................................263 Drain................................................................................................263 Clean................................................................................................263 Fill.................................................................................................264 Troubleshooting..........................................................................................265 1200110......................................................................................................267 INTRODUCTION.............................................................................................267 GENERAL..............................................................................................267 DESCRIPTION..........................................................................................267 REPAIRS..................................................................................................268 REMOVAL..............................................................................................268 CLEANING.............................................................................................268 INSPECTION...........................................................................................269 ASSEMBLY.............................................................................................269 CHECKS AND ADJUSTMENT....................................................................................271 ADJUSTING THE CLUTCH PEDAL HEIGHT....................................................................271 ADJUSTING THE CLEARANCE OF THE RELEASE MECHANISM.....................................................271 ADJUSTING THE BY-PASS VALVE FOR COLD AIR.............................................................271 TROUBLESHOOTING..........................................................................................272 1300111......................................................................................................274 INTRODUCTION.............................................................................................274 GENERAL..............................................................................................274 REPAIRS..................................................................................................274 REMOVAL..............................................................................................274 DISASSEMBLY..........................................................................................275 CLEANING.............................................................................................278 INSPECTION...........................................................................................278 REPAIRING THE CONTROL VALVE..........................................................................279 ASSEMBLY.............................................................................................282 INSTALLATION.........................................................................................286 Removal and Disassembly..........................................................................288 MONOTROL PEDAL.......................................................................................288 Assembly and Installation........................................................................289 CHECKS AND ADJUSTMENTS...................................................................................289 CHECKING THE MONOTROL PEDAL FOR LEAKAGE..............................................................289 STALL TEST...........................................................................................289 MONOTROL LINKAGE.....................................................................................289 CHECKING THE OIL PRESSURES...........................................................................290 Clutch Pressure (Check Port "2").................................................................293 Inching Pressure (Check Port "2")................................................................293 Torque Converter Pressure (Check Port "3").......................................................294 Modulator Spool/Clutch Engage Pressure (Check Port "4")..........................................294 Bypass Valve for Cold Oil........................................................................294 CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT...........................................................295 CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER.................................................295 TROUBLESHOOTING..........................................................................................297 PRESSURE TESTS...........................................................................................300 SPECIFICATIONS...........................................................................................302 1300113......................................................................................................303 .........................................................................................................303 .........................................................................................................304 .........................................................................................................305 .........................................................................................................306 .........................................................................................................307 .........................................................................................................308 .........................................................................................................309 .........................................................................................................310 .........................................................................................................311 .........................................................................................................312 .........................................................................................................313 .........................................................................................................314 .........................................................................................................315 .........................................................................................................316 .........................................................................................................317 .........................................................................................................318 .........................................................................................................319 .........................................................................................................320 .........................................................................................................321 .........................................................................................................322 .........................................................................................................323 .........................................................................................................324 .........................................................................................................325 .........................................................................................................326 .........................................................................................................327 .........................................................................................................328 .........................................................................................................329 .........................................................................................................330 1800119......................................................................................................331 INTRODUCTION.............................................................................................331 GENERAL..............................................................................................331 DESCRIPTION AND OPERATION............................................................................331 REPAIRS..................................................................................................332 REMOVAL AND DISASSEMBLY..............................................................................332 INSPECTION...........................................................................................332 ASSEMBLY.............................................................................................332 1900118......................................................................................................333 INTRODUCTION.............................................................................................333 GENERAL..............................................................................................333 DESCRIPTION..........................................................................................333 OPERATION............................................................................................333 REPAIRS..................................................................................................335 REMOVAL..............................................................................................335 DISASSEMBLY..........................................................................................335 INSPECTION...........................................................................................335 ASSEMBLY.............................................................................................335 INSTALLATION.........................................................................................335 CHECKS AND ADJUSTMENTS...................................................................................336 ADJUSTING THE RELIEF VALVE...........................................................................336 1900217......................................................................................................337 INTRODUCTION.............................................................................................337 GENERAL..............................................................................................337 DESCRIPTION..........................................................................................337 OPERATION............................................................................................337 Steering System..................................................................................337 Lift System......................................................................................337 REPAIR...................................................................................................343 HYDRAULIC TANK.......................................................................................343 MAIN HYDRAULIC PUMP..................................................................................343 FLOW REGULATOR VALVE.................................................................................343 STEERING CONTROL UNIT................................................................................343 STEERING CYLINDER....................................................................................343 CONTROL VALVES ......................................................................................343 LIFT AND TILT CYLINDERS..............................................................................343 CHECKS AND ADJUSTMENTS...................................................................................343 ADJUSTING THE STEERING RELIEF VALVE PRESSURE.........................................................343 ADJUSTING THE LIFT AND TILT RELIEF VALVE PRESSURE....................................................344 ADJUSTING THE TWO-STAGE RELIEF VALVE.................................................................344 ADJUSTING THE AUXILIARY RELIEF VALVE.................................................................345 TROUBLESHOOTING..........................................................................................346 2100103......................................................................................................347 General..................................................................................................349 Description..............................................................................................349 Tilt Cylinder............................................................................................349 Remove...............................................................................................349 Disassemble..........................................................................................349 Clean................................................................................................349 Assemble.............................................................................................349 Tilt Cylinders with O-Ring or Single-Lip Seals...................................................349 Tilt Cylinders for XM and XMS Models.............................................................351 Tilt Cylinders for H700-800A and Early Model H700-920B...........................................352 Install..............................................................................................353 Tilt Cylinders Using Chevron Packing.............................................................354 Install......................................................................................355 Tilt Cylinder Leak Check.................................................................................357 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment......................................................358 Torque Specifications....................................................................................358 Piston Rod Nut.......................................................................................358 Retainer.............................................................................................360 Troubleshooting..........................................................................................361 2200106......................................................................................................364 General..................................................................................................366 Description and Operation................................................................................366 Starter Repair...........................................................................................368 Remove...............................................................................................368 Disassemble..........................................................................................368 Clean................................................................................................369 Assemble.............................................................................................369 Install..............................................................................................370 General Checks and Adjustments...........................................................................370 Troubleshooting..........................................................................................373 2200143......................................................................................................377 INTRODUCTION.............................................................................................377 GENERAL..............................................................................................377 DESCRIPTION..............................................................................................377 GENERAL..............................................................................................377 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................380 LED DISPLAY PANEL....................................................................................380 Battery Discharge Indicators.....................................................................380 Brush Wear Indicators............................................................................381 Motor Temperature Indicators.....................................................................382 "LX" SERIES DISPLAY PANEL............................................................................383 Hourmeter Functions..............................................................................384 Battery Indicator Function.......................................................................384 Status Code Function.............................................................................384 "ZX" SERIES DISPLAY PANELS...........................................................................384 Display Panel....................................................................................385 Basic Display Panels.............................................................................385 Performance Display..............................................................................387 Brush Wear Indicators............................................................................390 CHECKS AND ADJUSTMENTS...................................................................................390 GENERAL..............................................................................................390 REPLACEMENT..............................................................................................391 GENERAL..............................................................................................391 METER REPLACEMENT....................................................................................391 SENDER REPLACEMENT...................................................................................392 Fuel Level Sender................................................................................392 Pressure And Temperature Sender..................................................................392 I.T.W. DISPLAY PANEL.................................................................................393 Removal..........................................................................................393 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................394 Removal..........................................................................................394 Replacing Display Panel Assembly.................................................................394 Indicator LEDs...................................................................................394 Battery Indicators...............................................................................394 Digital Display (Performance Disply Panel Only)..................................................394 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....394 Replacing Parts Of The Basic Display Panel.......................................................395 Replacing Parts Of The Performance Display Panel.................................................397 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................397 Removal And Replacement..........................................................................397 SPECIFICATIONS...........................................................................................398 TROUBLESHOOTING..........................................................................................399 2200144......................................................................................................400 ELECTRICAL WARNING DEVICES...............................................................................400 GENERAL..............................................................................................400 DESCRIPTION..........................................................................................400 Operator Controlled Horns........................................................................400 System Warning Lights, Buzzers and Bells.........................................................400 Reverse Warning Horns............................................................................401 Warning Lights...................................................................................401 REPLACEMENT..........................................................................................402 General..........................................................................................402 Replacing Horns or Bells.........................................................................402 Replacing Horn Relay or Buzzer...................................................................402 Replacing Warning Lights.........................................................................402 Light Assemblies.................................................................................403 Replacing Flashing Units.........................................................................403 2200153......................................................................................................404 ELECTRICAL SYSTEM COMPLETELY DEAD........................................................................404 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN ....................................................405 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER..............................................407 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK.............................................408 STARTER CRANKS SLOWLY....................................................................................410 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START................................................411 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND..............................................................413 CHARGING SYSTEM DOES NOT FUNCTION........................................................................414 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW.....................................................417 BATTERY IS BEING OVERCHARGED.............................................................................420 ONE OR MORE DASH GAUGES DO NOT WORK......................................................................421 HORN DOES NOT BLOW.......................................................................................425 POWERSHIFT TRANSMISSION WILL NOT ENGAGE..................................................................426 ELECTRICAL SCHEMATIC S20-30A, H20-30E....................................................................427 ELECTRICAL S30-50C.......................................................................................428 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG..............................................................429 ELECTRICAL SCHEMATIC H30-60H DIESEL......................................................................431 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG..............................................................433 ELECTRICAL SCHEMATIC H60-90C DIESEL......................................................................434 ELECTRICAL SCHEMATIC S30-60ES............................................................................435 ELECTRICAL SCHEMATIC S60-120E............................................................................436 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG............................................................437 ELECTRICAL SCHEMATIC S125-150A DIESEL....................................................................438 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG............................................................439 ELECTRICAL SCHEMATIC H110-150F DIESEL....................................................................440 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG..................................................441 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL.........................................................442 ELECTRICAL SCHEMATIC H300A...............................................................................443 ELECTRICAL SCHEMATIC H300-350B...........................................................................444 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL............................................................445 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL............................................................446 ELECTRICAL SCHEMATIC H700-800A...........................................................................447 ELECTRICAL SCHEMATIC P40-50A GASOLINE....................................................................449 ELECTRICAL SCHEMATIC P40-50A DIESEL......................................................................450 ELECTRICAL SCHEMATIC P60-80A GASOLINE....................................................................451 ELECTRICAL SCHEMATIC P60-80A DIESEL......................................................................452 ELECTRICAL SCHEMATIC KE GAS GASOLINE.....................................................................453 ELECTRICAL SCHEMATIC KE DIESEL...........................................................................454 ELECTRICAL SCHEMATIC M200-400H GASOLINE..................................................................455 ELECTRICAL SCHEMATIC M200-400H DIESEL....................................................................457 ELECTRICAL SCHEMATIC M600A...............................................................................459 4000115......................................................................................................461 INTRODUCTION.............................................................................................461 GENERAL..............................................................................................461 REPAIRS..................................................................................................461 FORKS................................................................................................461 CARRIAGE.............................................................................................461 Removal..........................................................................................461 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................462 Installation.....................................................................................463 MASTS................................................................................................465 Removal..........................................................................................465 Disassembly......................................................................................467 Cleaning and Inspection..........................................................................471 Assembly.........................................................................................472 INSTALLATION.........................................................................................473 CHECKS AND ADJUSTMENTS...................................................................................473 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................473 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................474 LIFT CHAIN ADJUSTMENTS...............................................................................474 MAST ADJUSTMENTS.....................................................................................475 Guide Shoe Adjustment............................................................................476 CARRIAGE ADJUSTMENT..................................................................................478 TROUBLESHOOTING..........................................................................................480 4000135......................................................................................................481 Safety Procedures When Working Near Mast.................................................................483 General..................................................................................................488 Description..............................................................................................488 Lowering Control Valve...............................................................................488 Cylinders (General)..................................................................................491 Cylinders (H520-620B, H700-800A).....................................................................491 Retainer, Install................................................................................491 Cylinders (H360-460B)................................................................................493 Cylinders (Two-Speed)................................................................................496 Lift Cylinder Repair.....................................................................................497 Lift Cylinder Removal Without Removing Mast..........................................................497 Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast....................497 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead.......................498 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder.........................499 Disasemble...........................................................................................499 Assemble.............................................................................................499 Lift Cylinder Installation in Mast...................................................................501 Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast.....................501 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead.......................501 Chevron-Style Packing................................................................................501 Chevron-Style Packing Installation on Piston.....................................................502 Chevron-Style Packing Installation in Packing Gland..............................................504 Lift Cylinders for Vista Masts...........................................................................505 Description..........................................................................................505 Lowering Control Valve...........................................................................505 Remove...............................................................................................507 Disassemble..........................................................................................508 Assemble.............................................................................................509 Install..............................................................................................510 Main Lift Cylinders..............................................................................510 Free-Lift Cylinder...............................................................................510 Lift System Leak Check...................................................................................510 Specifications...........................................................................................511 Troubleshooting..........................................................................................512 4000167......................................................................................................515 INTRODUCTION.............................................................................................515 GENERAL..............................................................................................515 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................517 FULL FREE-LIFT MASTS.................................................................................517 THREE-STAGE MASTS....................................................................................519 FOUR-STAGE MASTS.....................................................................................520 SEQUENCE VALVE.......................................................................................520 4000197......................................................................................................522 INTRODUCTION.............................................................................................522 GENERAL..............................................................................................522 VISTA TWO-STAGE MASTS....................................................................................524 DESCRIPTION..........................................................................................524 OPERATION............................................................................................527 VISTA THREE-STAGE MASTS..................................................................................527 DESCRIPTION..........................................................................................527 OPERATION............................................................................................529 SEQUENCE VALVE.......................................................................................531 4000198......................................................................................................534 .........................................................................................................534 .........................................................................................................535 .........................................................................................................536 .........................................................................................................537 .........................................................................................................538 .........................................................................................................539 .........................................................................................................540 .........................................................................................................541 .........................................................................................................542 .........................................................................................................543 .........................................................................................................544 .........................................................................................................545 .........................................................................................................546 .........................................................................................................547 .........................................................................................................548 .........................................................................................................549 .........................................................................................................550 .........................................................................................................551 .........................................................................................................552 .........................................................................................................553 .........................................................................................................554 .........................................................................................................555 .........................................................................................................556 .........................................................................................................557 .........................................................................................................558 .........................................................................................................559 .........................................................................................................560 .........................................................................................................561 .........................................................................................................562 .........................................................................................................563 .........................................................................................................564 .........................................................................................................565 8000114......................................................................................................566 INTRODUCTION.............................................................................................566 GENERAL..............................................................................................566 MAINTENANCE SCHEDULE.................................................................................566 MAINTENANCE SCHEDULE.....................................................................................567 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY............................................................569 CHECK WITH THE ENGINE STOPPED........................................................................569 Hydraulic Tank...................................................................................569 Air Cleaner......................................................................................569 Engine Oil.......................................................................................569 Fuel Filter (Diesel).............................................................................570 Battery..........................................................................................570 Cooling System...................................................................................570 Drive Belts......................................................................................571 Tires And Wheels.................................................................................571 Forks............................................................................................572 Lift Chains......................................................................................572 CHECKS WITH THE ENGINE RUNNING.......................................................................573 Start the engine.................................................................................573 Transmission.....................................................................................573 Mast Operation...................................................................................574 Brakes...........................................................................................574 EVERY 350 HOURS OR TWO MONTHS............................................................................574 ENGINE OIL AND FILTER (PERKINS ENGINE)...............................................................574 ENGINE OIL AND FILTER (GASOLINE ENGINE)..............................................................575 PRIMARY FUEL FILTER (PERKINS ENGINE).................................................................575 BRAKE FLUID..........................................................................................575 HYDRAULIC TANK BREATHER..............................................................................576 COOLING FAN..........................................................................................576 STEERING AXLE........................................................................................576 UNIVERSAL JOINT......................................................................................576 OTHER LUBRICATION POINTS.............................................................................576 MASTS................................................................................................577 FORKS................................................................................................578 EVERY 1000 HOURS OR SIX MONTHS...........................................................................579 FINAL FUEL FILTER (DIESEL)...........................................................................579 REMOVING AIR FROM THE DIESEL FUEL SYSTEM.............................................................579 IGNITION SYSTEM (GAS ENGINE).........................................................................579 PCV VALVE (GAS ENGINE)...............................................................................579 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM..........................................................580 Check The Lift Cylinders For Leaks...............................................................580 Check The Tilt Cylinder For Leaks................................................................580 EVERY 2000 HOURS OR YEARLY...............................................................................580 PCV VALVE (GAS ENGINE)...............................................................................580 PCV VALVE (DIESEL ENGINE)............................................................................581 DIFFERENTIAL.........................................................................................581 ADJUSTING THE OIL CLUTCH PEDAL.......................................................................581 OIL FILTER FOR THE POWERSHIFT TRANSMISSION OR THE OIL CLUTCH.........................................582 HYDRAULIC SYSTEM.....................................................................................582 Changing The Hydraulic Oil Filter................................................................582 Changing The Hydraulic Oil.......................................................................582 CHANGE THE GASOLINE FUEL FILTER......................................................................583 CHANGE THE FUEL FILTER FOR LPG.......................................................................583 WHEELS AND TIRES.........................................................................................583 DRIVE TIRES..........................................................................................583 STEERING TIRES.......................................................................................586 Disassembly......................................................................................586 Assembly.........................................................................................586 8000116......................................................................................................587 GENERAL..................................................................................................587 TRAVEL SPEEDS............................................................................................587 HYDRAULIC SYSTEM.........................................................................................587 TIRE PRESSURE............................................................................................588 CAPACITIES...............................................................................................588 ELECTRICAL...............................................................................................588 LIFT SPEEDS..............................................................................................588 LOWERING SPEEDS..........................................................................................589 ENGINE, GENERAL INFORMATION..............................................................................590 ENGINE, SERVICE, PERKINS 2.482...........................................................................590 ENGINE, SERVICE, GM 6-250................................................................................592 8000117......................................................................................................593 ELECTRICAL WIRING DIAGRAM (GAS AND LPG)..................................................................594 ELECTRICAL WIRING DIAGRAM (DIESEL).......................................................................596 HYDRAULIC SCHEMATIC-EARLY UNITS..........................................................................598 HYDRAULIC SCHEMATIC-LATER UNITS..........................................................................600 8000231......................................................................................................601 General..................................................................................................603 Nomenclature, Threads................................................................................603 Strength Identification..............................................................................604 Fastener Torque Tables...............................................................................608 Conversion Table.....................................................................................610 Unlock-2200107...............................................................................................612
HYSTER D005 (H60-110E [AMERICAS]) SERVICE MANUAL – PDF DOWNLOAD:
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