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Hyster D005 (H60-110E [Europe]) Service Manual – PDF DOWNLOAD
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Description
Hyster D005 (H60-110E [Europe]) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster D005 (H60-110E [Europe]) Service Manual – PDF DOWNLOAD
Language : English
Pages : 583
Downloadable : Yes
File Type : PDF
Size: 15.7 MB
TABLE OF CONTENTS:
Hyster D005 (H60-110E [Europe]) 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 INTRODUCTION........................................................................................ 32 GENERAL......................................................................................... 32 DESCRIPTION..................................................................................... 32 REPAIRS............................................................................................. 34 GENERAL......................................................................................... 34 REMOVAL AND DISASSEMBLY (Type A)................................................................ 34 CLEANING........................................................................................ 34 ASSEMBLY (Type A)............................................................................... 35 REMOVAL AND DISAASSEMBLY (Type B)............................................................... 37 CLEANING........................................................................................ 39 ASSEMBLY (Type B)............................................................................... 39 INSTALLATION (Type A and Type B)................................................................ 40 CHECKS AND ADJUSTMENTS.............................................................................. 40 GENERAL......................................................................................... 40 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B).......................................... 41 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)......................................... 42 CHECK THE CIRCUIT FOR THE BRUSHES............................................................... 44 Delco Alternators........................................................................... 44 Motorola Alternators........................................................................ 44 CHECK THE DIODES................................................................................ 44 CHECK THE DIODE BRIDGE.......................................................................... 44 Delco and Leece–Neville Alternators......................................................... 44 Motorola Alternators........................................................................ 44 CHECK THE FIELD WINDING FOR THE ROTOR........................................................... 45 CHECK THE WINDINGS IN THE STATOR................................................................ 45 CHECK THE VOLTAGE REGULATOR..................................................................... 46 TROUBLESHOOTING..................................................................................... 46 90011................................................................................................... 47 INTRODUCTION........................................................................................ 47 GENERAL......................................................................................... 47 DESCRIPTION..................................................................................... 47 OPERATION....................................................................................... 48 The Float System............................................................................ 48 The Idle System............................................................................. 48 The Main Metering System (GM 6-250)......................................................... 49 The Power System (GM 6-250)................................................................. 50 The Accelerator Pump System................................................................. 50 Choke System................................................................................ 50 REPAIRS............................................................................................. 51 REMOVAL......................................................................................... 51 DISASSEMBLY..................................................................................... 51 Cleaning........................................................................................ 51 ASSEMBLY........................................................................................ 51 INSTALLATION.................................................................................... 51 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)................................................. 56 GOVERNOR (PNEUMATIC) (Early Units).............................................................. 57 CHECKS AND ADJUSTMENTS.............................................................................. 58 GENERAL......................................................................................... 58 ADJUST THE CHOKE CONTROL........................................................................ 58 ADJUST THE IDLE SPEED........................................................................... 58 ADJSUT THE IDLE MIXTURE......................................................................... 59 ADJUST THE FAST IDLE............................................................................ 59 ADJUST THE THROTTLE LINKAGE,(Later Models)...................................................... 60 ADJUST THE THROTTLE LINKAGE,(Early Models)...................................................... 61 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)................................... 61 Check the Governor.......................................................................... 61 GOVERNOR (AISAN Type) (Early GM Engines Only)................................................... 62 Checks...................................................................................... 63 Adjustments................................................................................. 63 GOVERNOR (HOOF Type) (Early GM Engines Only).................................................... 63 Adjust the Governor......................................................................... 63 TROUBLESHOOTING..................................................................................... 65 90015................................................................................................... 66 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)........................................................... 66 GENERAL......................................................................................... 66 DESCRIPTION..................................................................................... 66 Fuel Tank................................................................................... 67 Fuel Filter And Fuel Valve Unit............................................................. 68 Vaporizer................................................................................... 68 The IMPCO CA 100 Carbureto.................................................................. 70 IMPCO CA 50 Carburetor...................................................................... 72 The Governor (GM Engines Only).............................................................. 73 Governor With Electronic Controller......................................................... 74 REPAIRS............................................................................................. 75 LPG TANK........................................................................................ 75 Removal..................................................................................... 75 Installation................................................................................ 76 REPLACE THE HOSES............................................................................... 76 HYDROSTATIC RELIEF VALVE........................................................................ 76 Removal and Installation.................................................................... 76 FILTER UNIT..................................................................................... 77 Replacement Of the Fuel Filter Element...................................................... 77 Replacement of the Diaphragm and Fuel Valve................................................. 78 VAPORIZER....................................................................................... 78 Removal..................................................................................... 78 Disassembly................................................................................. 78 Cleaning.................................................................................... 78 Inspection.................................................................................. 78 Assembly.................................................................................... 80 Installation................................................................................ 80 CARBURETOR (IMPCO CA 100)....................................................................... 82 Removal..................................................................................... 82 Disassembly................................................................................. 82 Cleaning.................................................................................... 82 Assembly.................................................................................... 82 Installation................................................................................ 85 CARBURETER (IMPCO CA 50)........................................................................ 84 Removal..................................................................................... 84 Disassembly................................................................................. 84 Cleaning.................................................................................... 85 Inspection.................................................................................. 85 Assembly (See FIGURE 26.)................................................................... 85 Installation................................................................................ 85 CHECKS AND ADJUSTMENTS.............................................................................. 86 CHECK THE FILTER UNIT........................................................................... 86 CHECK THE VAPORIZER............................................................................. 86 Pressure Reducer Valve...................................................................... 86 Vapor Valve................................................................................. 86 ADJUST THE CARBURETOR........................................................................... 86 Idle Mixture................................................................................ 86 Idle Speed.................................................................................. 86 Power Mixture............................................................................... 86 ADJUST THE GOVERNOR (GM Engines Only)........................................................... 87 Checks...................................................................................... 87 Main Adjusting Screw........................................................................ 87 Secondary Adjusting Screw................................................................... 87 AISAN Governor.............................................................................. 88 Adjustment, AISAN Governor.................................................................. 88 TROUBLESHOOTING..................................................................................... 89 100101.................................................................................................. 93 INTRODUCTION........................................................................................ 93 GENERAL......................................................................................... 93 DESCRIPTION..................................................................................... 93 DISASSEMBLY AND ASSEMBLY............................................................................ 94 COUNTERWEIGHT................................................................................... 95 Removal..................................................................................... 95 Installation................................................................................ 95 OVERHEAD GUARD.................................................................................. 95 Removal..................................................................................... 95 Installation................................................................................ 95 HOOD AND SEAT REMOVAL........................................................................... 95 ENGINE.......................................................................................... 95 Removal..................................................................................... 95 INSTALLATION................................................................................ 96 FUEL TANK....................................................................................... 96 REPAIRS............................................................................................. 96 FUEL AND HYDRAULIC TANKS........................................................................ 96 Small Leaks................................................................................. 96 Large Leaks................................................................................. 97 OTHER REPAIRS....................................................................................... 98 TILT CYLINDER MOUNTS............................................................................ 98 STEERING AXLE MOUNT............................................................................. 98 LABEL REPLACEMENT............................................................................... 98 130082..................................................................................................100 INTRODUCTION........................................................................................100 GENERAL.........................................................................................100 DESCRIPTION.....................................................................................100 REPAIRS.............................................................................................100 REMOVAL.........................................................................................100 DISASSEMBLY.....................................................................................102 CLEANING........................................................................................102 INSPECTION......................................................................................103 ASSEMBLY........................................................................................103 The Pinion Assembly.........................................................................103 The Differential............................................................................105 INSTALLATION....................................................................................106 TROUBLESHOOTING.....................................................................................109 130088..................................................................................................110 INTRODUCTION........................................................................................110 GENERAL.........................................................................................110 DESCRIPTION.....................................................................................110 OPERATION.......................................................................................110 REPAIRS.............................................................................................111 REMOVAL.........................................................................................111 Removing the Transmission (Both Methods)....................................................113 Removing The Transmission Without Removing The Drive Axle...................................113 Removing The Transmission With The Drive Axle...............................................113 DISASSEMBLY.....................................................................................114 Removing the Selector Rails and Forks.......................................................114 Removing the Hypoid Ring Gear and Differential..............................................114 Removing the Gear Assemblies................................................................116 CLEANING........................................................................................118 INSPECTION......................................................................................119 ASSEMBLY........................................................................................120 Assembling The Hypoid Pinion and Ring Gear and Differential.................................120 Assembling the Range Countershaft...........................................................121 Assembling The Forward Countershaft.........................................................122 Assembling The Forward and Reverse Main Shaft...............................................123 Assembling The Input Gear and Range Main Shaft .............................................123 Installing the Differential Assembly........................................................126 Installing the Selector Rails and Forks.....................................................129 INSTALLATION....................................................................................130 CHECKS AND ADJUSTMENTS..............................................................................131 LINKAGE ADJUSTMENTS.............................................................................131 TROUBLESHOOTING - DIFFERENTIAL......................................................................133 TROUBLESHOOTING - TRANSMISSION......................................................................134 SPECIFICATIONS......................................................................................135 140049..................................................................................................136 INTRODUCTION........................................................................................136 GENERAL.........................................................................................136 DESCRIPTION.....................................................................................136 REPAIRS.............................................................................................136 DISASSEMBLY.....................................................................................137 CLEANING........................................................................................139 ASSEMBLY........................................................................................139 TROUBLESHOOTING.....................................................................................141 160054..................................................................................................142 INTRODUCTION........................................................................................142 GENERAL.........................................................................................142 DESCRIPTION.....................................................................................142 OPERATION.......................................................................................142 REPAIRS.............................................................................................142 STEERING WHEEL AND COLUMN ASSEMBLY..............................................................142 TYPE "A" STEERING COLUMN ASSEMBLY...............................................................144 Removal And Disassembly.....................................................................144 Assembly And Installation...................................................................144 TYPE "A" STEERING COLUMN........................................................................145 TYPE "A" STEERING COLUMN........................................................................146 TYPE "B" STEERING COLUMN........................................................................147 Removal And Disassembly.....................................................................147 Assembly And Installation...................................................................147 TYPE "B" STEERING COLUMN........................................................................148 Disassembly of Steering Control Unit........................................................149 Cleaning of Steering Control Unit...........................................................149 Assembly of Steering Control Unit...........................................................151 CHECKS AND ADJUSTMENTS..............................................................................154 REMOVE AIR FROM THE SYSTEM......................................................................154 TROUBLESHOOTING.....................................................................................155 160060..................................................................................................156 INTRODUCTION........................................................................................156 GENERAL.........................................................................................156 DESCRIPTION.....................................................................................156 REPAIRS.............................................................................................157 STEERING AXLES WITH STUB SHAFT MOUNTS...........................................................157 Removal.....................................................................................158 Installation................................................................................158 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS..........................................................159 Removal.....................................................................................159 Installation................................................................................160 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981).......................161 Removal.....................................................................................161 Installation................................................................................162 WHEELS AND HUBS.................................................................................162 Removal and Disassembly.....................................................................162 Cleaning....................................................................................162 Assembly And Installation...................................................................162 SPINDLES, BEARING AND TIE RODS..................................................................162 Removal And Disassembly.....................................................................162 Cleaning....................................................................................162 Assembly And Installation...................................................................162 STEERING CYLINDER...............................................................................164 Removal And Disassembly.....................................................................164 Cleaning....................................................................................165 Assembly And Installation...................................................................165 CHECKS AND ADJUSTMENTS..............................................................................167 STEERING CYLINDER...............................................................................167 CENTER PIVOT OR RUBBER MOUNTS...................................................................167 SPINDLE AND HUB.................................................................................167 TROUBLESHOOTING.....................................................................................168 180080..................................................................................................169 INTRODUCTION........................................................................................169 GENERAL.........................................................................................169 DESCRIPTION AND OPERATION.......................................................................170 REPAIRS.............................................................................................170 REMOVAL AND DISASSEMBLY.........................................................................170 CLEANING........................................................................................171 INSPECTION......................................................................................172 ASSEMBLY........................................................................................172 CHECKS AND ADJUSTMENTS..............................................................................174 BRAKE SHOES.....................................................................................174 Parking Brake...............................................................................174 Seat Actuated Park Brake, J40–60AS..........................................................174 Removing The Air From The Brake System......................................................175 TROUBLESHOOTING.....................................................................................176 190064..................................................................................................179 INTRODUCTION........................................................................................179 GENERAL.........................................................................................179 DESCRIPTION.....................................................................................179 REPAIRS.............................................................................................179 REMOVAL AND DISASSEMBLY.........................................................................179 CLEANING........................................................................................181 INSPECTION......................................................................................181 ASSEMBLY AND INSTALLATION.......................................................................181 TROUBLESHOOTING.....................................................................................183 GENERAL.........................................................................................183 190097..................................................................................................184 INTRODUCTION........................................................................................184 DESCRIPTION.....................................................................................184 OPERATION.......................................................................................184 Flow Control Valve..........................................................................186 Relief Valve................................................................................186 REPAIRS.............................................................................................187 REMOVAL.........................................................................................187 DISASSEMBLY.....................................................................................187 CLEANING........................................................................................189 INSPECTION......................................................................................189 ASSEMBLY........................................................................................190 INSTALLATION....................................................................................191 CHECKS AND ADUSTMENTS...............................................................................192 CHECK THE OUTPUT OF THE PUMP....................................................................192 CHECK FOR AIR IN THE HYDRAULIC SYSTEM...........................................................192 TROUBLESHOOTING.....................................................................................194 200090..................................................................................................197 INTRODUCTION........................................................................................197 GENERAL.........................................................................................197 DESCRIPTION.....................................................................................197 OPERATION.......................................................................................199 Lift Spool..................................................................................199 Tilt Spool..................................................................................199 Relief Valve, Single–Stage..................................................................202 Relief Valve, Two–Stage.....................................................................203 REPAIRS.............................................................................................203 REMOVAL AND DISASSEMBLY.........................................................................203 CLEANING AND INSPECTION.........................................................................204 ASSEMBLY........................................................................................204 INSTALLATION....................................................................................204 CHECKS AND ADJUSTMENTS..............................................................................204 ADJUST THE SINGLE–STAGE RELIEF VALVE............................................................204 ADJUST THE TWO–STAGE RELIEF VALVE...............................................................205 ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY...........................206 TROUBLESHOOTING.....................................................................................206 600105..................................................................................................208 INTRODUCTION........................................................................................208 GENERAL.........................................................................................208 DESCRIPTION.....................................................................................208 ENGINE SERIAL NUMBER CODES......................................................................209 REMOVAL AND INSTALLATION........................................................................209 ENGINE..............................................................................................209 CYLINDER HEAD...................................................................................209 Removal.....................................................................................209 Installation................................................................................210 Cylinder Head Repairs.......................................................................211 OIL PUMP........................................................................................213 Removal.....................................................................................213 Disassembly.................................................................................213 Inspection..................................................................................213 Assembly....................................................................................214 Installation................................................................................214 RELIEF VALVE....................................................................................215 TIMING GEAR CASE AND TIMING GEARS...............................................................215 Removal.....................................................................................215 Installation................................................................................216 PISTONS AND CONNECTING RODS.....................................................................217 Removal.....................................................................................217 Disassembly.................................................................................217 Inspection..................................................................................218 Assembly....................................................................................219 Installation................................................................................219 CRANKSHAFT AND MAIN BEARINGS....................................................................220 Removal.....................................................................................220 Inspection..................................................................................220 Assembly....................................................................................221 CAMSHAFT AND CAM FOLLOWERS......................................................................222 Removal.....................................................................................222 Inspection..................................................................................223 Assembly....................................................................................223 FLYWHEEL AND FLYWHEEL HOUSING...................................................................224 Removal.....................................................................................224 Repairs.....................................................................................224 Installation................................................................................224 STEERING PUMP DRIVE.............................................................................224 Removal.....................................................................................224 Installation................................................................................225 PCV VALVE.......................................................................................225 FUEL SYSTEM.........................................................................................225 FUEL PUMP.......................................................................................225 Removal.....................................................................................225 Disassembly.................................................................................225 Assembly....................................................................................225 Installation................................................................................226 FUEL INJECTION PUMP.............................................................................226 Removal.....................................................................................226 Repairs.....................................................................................226 Installation................................................................................226 FUEL INJECTORS..................................................................................226 Removal.....................................................................................226 Repairs.....................................................................................227 Installation................................................................................227 COLD START AID..................................................................................227 Description.................................................................................227 Removal.....................................................................................227 Installation................................................................................227 COOLING SYSTEM......................................................................................228 THERMOSTAT......................................................................................228 Removal.....................................................................................228 Inspection..................................................................................228 Installation................................................................................228 WATER PUMP......................................................................................228 Removal.....................................................................................228 Disassembly.................................................................................228 Assembly....................................................................................228 Installation................................................................................228 CHECKS AND ADJUSTMENTS..............................................................................228 CHECKING THE INJECTORS..........................................................................228 Repairs.....................................................................................229 Installation................................................................................229 REMOVING AIR FROM THE FUEL SYSTEM...............................................................229 CHECKING THE TIMING MARKS.......................................................................230 Method A....................................................................................230 Method B....................................................................................231 CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL......................232 VALVE CLEARANCE ADJUSTMENT......................................................................233 ADJUSTING THE THROTTLE LINKAGE..................................................................233 TROUBLESHOOTING.....................................................................................235 SPECIFICATIONS......................................................................................236 TORQUE SPECIFICATIONS...............................................................................239 700108..................................................................................................240 INTRODUCTION........................................................................................240 GENERAL.........................................................................................240 DESCRIPTION.....................................................................................240 REPAIRS.............................................................................................243 FAN ASSEMBLY....................................................................................243 Removal (S30–120E)..........................................................................243 Removal (H60–110E)..........................................................................243 Disassembly (S30–120E)......................................................................243 Disassembly (H60–110E)......................................................................244 Assembly (Both Series)......................................................................244 Fan Belt Adjustment.........................................................................247 Installation................................................................................247 RADIATOR........................................................................................248 Removal.....................................................................................248 Installation................................................................................248 Cleaning and Inspection.....................................................................249 TROUBLESHOOTING.....................................................................................250 700626..................................................................................................251 COOLING SYSTEM......................................................................................251 INTRODUCTION....................................................................................251 DESCRIPTION.....................................................................................251 RADIATOR........................................................................................251 RADIATOR CAP....................................................................................251 THERMOSTAT......................................................................................251 WATER PUMP......................................................................................252 FAN AND FAN SHROUD .............................................................................252 REPAIRS.............................................................................................252 COOLING SYSTEM CHECKS...........................................................................252 Exhaust Leaks...............................................................................252 RADIATOR........................................................................................252 Checks......................................................................................252 Cleaning The Radiator.......................................................................252 Drain The Cooling System....................................................................254 Fill The Cooling System.....................................................................254 WATER PUMP......................................................................................254 Checks......................................................................................254 THERMOSTAT......................................................................................255 Checks......................................................................................255 FAN AND FAN SHROUD .............................................................................255 TROUBLESHOOTING.....................................................................................256 1200110.................................................................................................257 INTRODUCTION........................................................................................257 GENERAL.........................................................................................257 DESCRIPTION.....................................................................................257 REPAIRS.............................................................................................258 REMOVAL.........................................................................................258 CLEANING........................................................................................258 INSPECTION......................................................................................259 ASSEMBLY........................................................................................259 CHECKS AND ADJUSTMENT...............................................................................261 ADJUSTING THE CLUTCH PEDAL HEIGHT...............................................................261 ADJUSTING THE CLEARANCE OF THE RELEASE MECHANISM................................................261 ADJUSTING THE BY-PASS VALVE FOR COLD AIR........................................................261 TROUBLESHOOTING.....................................................................................262 1300111.................................................................................................264 INTRODUCTION........................................................................................264 GENERAL.........................................................................................264 REPAIRS.............................................................................................264 REMOVAL.........................................................................................264 DISASSEMBLY.....................................................................................265 CLEANING........................................................................................268 INSPECTION......................................................................................268 REPAIRING THE CONTROL VALVE.....................................................................269 ASSEMBLY........................................................................................272 INSTALLATION....................................................................................276 Removal and Disassembly.....................................................................278 MONOTROL PEDAL..................................................................................278 Assembly and Installation...................................................................279 CHECKS AND ADJUSTMENTS..............................................................................279 CHECKING THE MONOTROL PEDAL FOR LEAKAGE.........................................................279 STALL TEST......................................................................................279 MONOTROL LINKAGE................................................................................279 CHECKING THE OIL PRESSURES......................................................................280 Clutch Pressure (Check Port "2")............................................................283 Inching Pressure (Check Port "2")...........................................................283 Torque Converter Pressure (Check Port "3")..................................................284 Modulator Spool/Clutch Engage Pressure (Check Port "4").....................................284 Bypass Valve for Cold Oil...................................................................284 CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT......................................................285 CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER............................................285 TROUBLESHOOTING.....................................................................................287 PRESSURE TESTS......................................................................................290 SPECIFICATIONS......................................................................................292 1300113.................................................................................................293 INTRODUCTION........................................................................................293 GENERAL.........................................................................................293 DESCRIPTION.........................................................................................293 OPERATION...........................................................................................295 THE TORQUE CONVERTER............................................................................295 THE PLANETARY GEAR SET..........................................................................297 CLUTCHES........................................................................................299 HYDRAULIC SYSTEM................................................................................299 H60-110E....................................................................................299 S40-50F, S30-120E...........................................................................300 CONTROL VALVE...................................................................................301 Monotrol Regulator..........................................................................301 Clutch Regulator............................................................................301 Torque Converter Regulator..................................................................302 Direction Spool.............................................................................303 Modulation Spool, All Models Except S100-120E...............................................303 Modulation Spool and Accumulator Valve, S100-120E...........................................303 The Valve For The Parking Brake Solenoid....................................................304 The Inching Valve...........................................................................304 THE ELECTRICAL CIRCUIT..........................................................................305 Electrical Circuit For the Direction........................................................305 OIL FLOW DIAGRAMS...............................................................................306 PARK or NEUTRAL.............................................................................306 "1" Circuit Monotrol........................................................................306 "2" Circuit - Clutch Apply..................................................................306 "3" Circuit - Torque Converter..............................................................306 FORWARD.........................................................................................306 "1" Circuit - Monotrol......................................................................306 "2" Circuit.................................................................................307 FORWARD - INCHING...............................................................................307 REVERSE.........................................................................................307 TROUBLESHOOTING.....................................................................................316 1800119.................................................................................................317 INTRODUCTION........................................................................................317 GENERAL.........................................................................................317 DESCRIPTION AND OPERATION.......................................................................317 REPAIRS.............................................................................................318 REMOVAL AND DISASSEMBLY.........................................................................318 INSPECTION......................................................................................318 ASSEMBLY........................................................................................318 1900118.................................................................................................319 INTRODUCTION........................................................................................319 GENERAL.........................................................................................319 DESCRIPTION.....................................................................................319 OPERATION.......................................................................................319 REPAIRS.............................................................................................321 REMOVAL.........................................................................................321 DISASSEMBLY.....................................................................................321 INSPECTION......................................................................................321 ASSEMBLY........................................................................................321 INSTALLATION....................................................................................321 CHECKS AND ADJUSTMENTS..............................................................................322 ADJUSTING THE RELIEF VALVE......................................................................322 1900217.................................................................................................323 INTRODUCTION........................................................................................323 GENERAL.........................................................................................323 DESCRIPTION.....................................................................................323 OPERATION.......................................................................................323 Steering System.............................................................................323 Lift System.................................................................................323 REPAIR..............................................................................................329 HYDRAULIC TANK..................................................................................329 MAIN HYDRAULIC PUMP.............................................................................329 FLOW REGULATOR VALVE............................................................................329 STEERING CONTROL UNIT...........................................................................329 STEERING CYLINDER...............................................................................329 CONTROL VALVES .................................................................................329 LIFT AND TILT CYLINDERS.........................................................................329 CHECKS AND ADJUSTMENTS..............................................................................329 ADJUSTING THE STEERING RELIEF VALVE PRESSURE....................................................329 ADJUSTING THE LIFT AND TILT RELIEF VALVE PRESSURE...............................................330 ADJUSTING THE TWO-STAGE RELIEF VALVE............................................................330 ADJUSTING THE AUXILIARY RELIEF VALVE............................................................331 TROUBLESHOOTING.....................................................................................332 2100103.................................................................................................333 INTRODUCTION........................................................................................336 GENERAL.........................................................................................336 DESCRIPTION.....................................................................................336 REPAIRS.............................................................................................336 REMOVAL.........................................................................................336 DISASSEMBLY.....................................................................................336 CLEANING........................................................................................336 ASSEMBLY........................................................................................336 Tilt Cylinders for the XM and XMS Models....................................................336 Tilt Cylinders with O-Ring or Single Lip Seals..............................................338 Tilt Cylinders for H700-800A and Early Model H700-920B......................................338 INSTALLATION....................................................................................338 Tilt Cylinders with Chevron Packing.........................................................338 CHECKS AND ADJUSTMENTS..............................................................................342 CHECK THE TILT CYLINDERS FOR LEAKS..............................................................342 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.........................................342 TROUBLESHOOTING.....................................................................................345 2200106.................................................................................................348 INTRODUCTION........................................................................................348 GENERAL.........................................................................................348 DESCRIPTION AND OPERATION.......................................................................348 REPAIRS.............................................................................................350 REMOVAL.........................................................................................350 DISSASEMBLY.....................................................................................350 CLEANING........................................................................................351 ASSEMBLY........................................................................................351 INSTALLATION....................................................................................351 CHECKS AND ADJUSTMENTS..............................................................................352 GENERAL.........................................................................................352 TROUBLESHOOTING.....................................................................................354 2200107.................................................................................................356 HIGH ENERGY IGNITION (HEI)..........................................................................356 DESCRIPTION.....................................................................................356 REPAIRS.............................................................................................358 DISTRIBUTOR.....................................................................................358 Removal.....................................................................................358 Disassembly.................................................................................358 Assembly....................................................................................363 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED....................364 INSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED....................365 IGNITION COIL...................................................................................365 Removal, Some 4 and 6 Cylinder Models.......................................................365 Installation, Some 4 and 6 Cylinder Models..................................................366 Removal, V8, Some 4 and 6 Cylinder Models...................................................366 Installation, V8, Some 4 and 6 Cylinder Models..............................................367 ELECTRONIC MODULE...............................................................................368 Removal.....................................................................................368 Installation................................................................................368 SENSING COIL....................................................................................369 Removal.....................................................................................369 Installation................................................................................369 SPARK PLUGS.....................................................................................369 Removal.....................................................................................369 Installation................................................................................370 CHECKS AND ADJUSTMENTS..........................................................................370 Visual Checks...............................................................................370 Check The High Voltage Wires................................................................370 Checking The Ignition Coil..................................................................370 Coil In Distributor Cap Design..............................................................370 Separate Coil Design........................................................................371 Checking The Sensing Coil...................................................................371 Check The Electronic Module.................................................................372 Ignition Timing Adjustment..................................................................372 Ignition System, GM V8-366 (6-litre)........................................................373 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)............................373 SPECIFICATIONS......................................................................................373 TROUBLESHOOTING.....................................................................................374 2200143.................................................................................................375 INTRODUCTION........................................................................................375 GENERAL.........................................................................................375 DESCRIPTION.........................................................................................375 GENERAL.........................................................................................375 STEERING COLUMN GAUGES, METERS AND INDICATORS...................................................378 LED DISPLAY PANEL...............................................................................378 Battery Discharge Indicators ...............................................................378 Brush Wear Indicators.......................................................................379 Motor Temperature Indicators................................................................380 "LX" SERIES INSTRUMENT PANEL DISPLAY............................................................381 Hourmeter Functions.........................................................................382 Battery Indicator Function..................................................................382 Status Code Function........................................................................382 CHECKS AND ADJUSTMENTS..............................................................................382 GENERAL.........................................................................................382 REPLACEMENT.........................................................................................383 GENERAL.........................................................................................383 METER REPLACEMENT...............................................................................383 SENDER REPLACEMENT..............................................................................384 Fuel Level Sender...........................................................................384 Pressure And Temperature Sender.............................................................385 I.T.W. DISPLAY PANEL............................................................................385 Removal.....................................................................................385 SPECIFICATIONS......................................................................................386 TROUBLESHOOTING.....................................................................................387 2200144.................................................................................................388 ELECTRICAL WARNING DEVICES..........................................................................388 GENERAL.........................................................................................388 DESCRIPTION.....................................................................................388 Operator Controlled Horns...................................................................388 System Warning Lights, Buzzers and Bells....................................................388 Reverse Warning Horns.......................................................................389 Warning Lights..............................................................................389 REPLACEMENT.....................................................................................390 General.....................................................................................390 Replacing Horns or Bells....................................................................390 Replacing Horn Relay or Buzzer..............................................................390 Replacing Warning Lights....................................................................390 Light Assemblies............................................................................391 Replacing Flashing Units....................................................................391 2200153.................................................................................................392 ELECTRICAL SYSTEM COMPLETELY DEAD...................................................................392 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN ...............................................393 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER.........................................395 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK........................................396 STARTER CRANKS SLOWLY...............................................................................398 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START...........................................399 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND.........................................................401 CHARGING SYSTEM DOES NOT FUNCTION...................................................................402 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW................................................405 BATTERY IS BEING OVERCHARGED........................................................................408 ONE OR MORE DASH GAUGES DO NOT WORK.................................................................409 HORN DOES NOT BLOW..................................................................................413 POWERSHIFT TRANSMISSION WILL NOT ENGAGE.............................................................414 ELECTRICAL SCHEMATIC S20-30A, H20-30E...............................................................415 ELECTRICAL S30-50C..................................................................................416 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG.........................................................417 ELECTRICAL SCHEMATIC H30-60H DIESEL.................................................................419 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG.........................................................421 ELECTRICAL SCHEMATIC H60-90C DIESEL.................................................................422 ELECTRICAL SCHEMATIC S30-60ES.......................................................................423 ELECTRICAL SCHEMATIC S60-120E.......................................................................424 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG.......................................................425 ELECTRICAL SCHEMATIC S125-150A DIESEL...............................................................426 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG.......................................................427 ELECTRICAL SCHEMATIC H110-150F DIESEL...............................................................428 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG.............................................429 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL....................................................430 ELECTRICAL SCHEMATIC H300A..........................................................................431 ELECTRICAL SCHEMATIC H300-350B......................................................................432 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL.......................................................433 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL.......................................................434 ELECTRICAL SCHEMATIC H700-800A......................................................................435 ELECTRICAL SCHEMATIC P40-50A GASOLINE...............................................................437 ELECTRICAL SCHEMATIC P40-50A DIESEL.................................................................438 ELECTRICAL SCHEMATIC P60-80A GASOLINE...............................................................439 ELECTRICAL SCHEMATIC P60-80A DIESEL.................................................................440 ELECTRICAL SCHEMATIC KE GAS GASOLINE................................................................441 ELECTRICAL SCHEMATIC KE DIESEL......................................................................442 ELECTRICAL SCHEMATIC M200-400H GASOLINE.............................................................443 ELECTRICAL SCHEMATIC M200-400H DIESEL...............................................................445 ELECTRICAL SCHEMATIC M600A..........................................................................447 4000115.................................................................................................449 INTRODUCTION........................................................................................449 GENERAL.........................................................................................449 REPAIRS.............................................................................................449 FORKS...........................................................................................449 CARRIAGE........................................................................................449 Removal.....................................................................................449 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................450 Installation................................................................................451 MASTS...........................................................................................453 Removal.....................................................................................453 Disassembly.................................................................................455 Cleaning and Inspection.....................................................................459 Assembly....................................................................................460 INSTALLATION....................................................................................461 CHECKS AND ADJUSTMENTS..............................................................................461 CHECKING FOR LEAKS IN THE LIFT SYSTEM...........................................................461 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE..................................462 LIFT CHAIN ADJUSTMENTS..........................................................................462 MAST ADJUSTMENTS................................................................................463 Guide Shoe Adjustment.......................................................................464 CARRIAGE ADJUSTMENT.............................................................................466 TROUBLESHOOTING.....................................................................................468 4000135.................................................................................................469 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................469 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................469 LIFT CYLINDERS......................................................................................472 GENERAL.........................................................................................472 DESCRIPTION.....................................................................................472 Lowering Control Valve......................................................................472 Cylinders (General).........................................................................475 Cylinders (H520-620B,H700-800A).............................................................477 Cylinders (H360-460B).......................................................................478 Cylinders (Two-Speed).......................................................................478 REPAIRS.............................................................................................479 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..........................................479 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....479 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.....................483 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...............481 DISASSEMBLY.....................................................................................481 ASSEMBLY........................................................................................483 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...................................................483 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....483 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead............483 CHEVRON PACKING.................................................................................484 LIFT CYLINDERS FOR VISTA MASTS......................................................................487 DESCRIPTION.....................................................................................487 Lowering Control Valve......................................................................489 REMOVAL.........................................................................................490 DISASSEMBLY.....................................................................................490 ASSEMBLY........................................................................................490 INSTALLATION....................................................................................491 Main Lift Cylinders.........................................................................491 Free-Lift Cylinders.........................................................................491 CHECKS AND ADJUSTMENTS..............................................................................492 CHECK FOR LEAKS IN LIFT SYSTEM..................................................................492 TROUBLESHOOTING.....................................................................................493 SPECIFICATIONS......................................................................................494 4000167.................................................................................................495 INTRODUCTION........................................................................................495 GENERAL.........................................................................................495 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)...............................497 FULL FREE-LIFT MASTS............................................................................497 THREE-STAGE MASTS...............................................................................499 FOUR-STAGE MASTS................................................................................500 SEQUENCE VALVE..................................................................................500 4000197.................................................................................................502 INTRODUCTION........................................................................................502 GENERAL.........................................................................................502 VISTA TWO-STAGE MASTS...............................................................................504 DESCRIPTION.....................................................................................504 OPERATION.......................................................................................507 VISTA THREE-STAGE MASTS.............................................................................507 DESCRIPTION.....................................................................................507 OPERATION.......................................................................................509 SEQUENCE VALVE..................................................................................511 4000198.................................................................................................514 INTRODUCTION........................................................................................514 GENERAL.........................................................................................514 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................514 REPAIRS.............................................................................................515 FORKS...........................................................................................515 Removal.....................................................................................515 CARRIAGE........................................................................................515 Removal (Two-Stage and Later Production Three-Stage Carriages)..............................515 Removal (Carriages with Removable Stop Block)...............................................516 Installation (Two-Stage and Later Production Three-Stage Carriages).........................517 Installation (Carriages With Removable Stop Block)..........................................517 TWO-STAGE MASTS.....................................................................................519 REMOVAL.........................................................................................519 DISASSEMBLY.....................................................................................520 CLEANING AND INSPECTION.........................................................................521 ASSEMBLY........................................................................................522 INSTALLATION....................................................................................523 THREE-STAGE MASTS...................................................................................523 REMOVAL.........................................................................................523 DISASSEMBLY.....................................................................................523 CLEANING AND INSPECTION.........................................................................525 ASSEMBLY........................................................................................525 INSTALLATION....................................................................................526 LIFT AND TILT CYLINDERS.........................................................................527 SIDE SHIFT CARRIAGE.............................................................................527 Removal.....................................................................................527 Repairs.....................................................................................527 Installation................................................................................527 SEQUENCE VALVE..................................................................................528 Removal and Disassembly.....................................................................531 Cleaning....................................................................................531 Assembly and Installation...................................................................531 CHECKS AND ADJUSTMENTS..............................................................................532 CHECKING FOR LEAKS IN THE LIFT SYSTEM...........................................................532 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE..................................532 LIFTING CHAIN ADJUSTMENTS.......................................................................533 MAST ADJUSTMENTS................................................................................534 CARRIAGE ADJUSTMENT.............................................................................535 HEADER HOSE ROLLER ADJUSTMENT, 2-STAGE..........................................................536 TROUBLESHOOTING.....................................................................................537 TORQUE SPECIFICATIONS...............................................................................538 VISTA MASTS.........................................................................................539 8000114.................................................................................................540 INTRODUCTION........................................................................................540 GENERAL.........................................................................................540 MAINTENANCE SCHEDULE............................................................................540 MAINTENANCE SCHEDULE................................................................................541 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.......................................................543 CHECK WITH THE ENGINE STOPPED...................................................................543 Hydraulic Tank..............................................................................543 Air Cleaner.................................................................................543 Engine Oil..................................................................................543 Fuel Filter (Diesel)........................................................................544 Battery.....................................................................................544 Cooling System..............................................................................544 Drive Belts.................................................................................545 Tires And Wheels............................................................................545 Forks.......................................................................................546 Lift Chains.................................................................................546 CHECKS WITH THE ENGINE RUNNING..................................................................547 Start the engine............................................................................547 Transmission................................................................................547 Mast Operation..............................................................................548 Brakes......................................................................................548 EVERY 350 HOURS OR TWO MONTHS.......................................................................548 ENGINE OIL AND FILTER (PERKINS ENGINE)..........................................................548 ENGINE OIL AND FILTER (GASOLINE ENGINE).........................................................549 PRIMARY FUEL FILTER (PERKINS ENGINE)............................................................549 BRAKE FLUID.....................................................................................549 HYDRAULIC TANK BREATHER.........................................................................550 COOLING FAN.....................................................................................550 STEERING AXLE...................................................................................550 UNIVERSAL JOINT.................................................................................550 OTHER LUBRICATION POINTS........................................................................550 MASTS...........................................................................................551 FORKS...........................................................................................552 EVERY 1000 HOURS OR SIX MONTHS......................................................................553 FINAL FUEL FILTER (DIESEL)......................................................................553 REMOVING AIR FROM THE DIESEL FUEL SYSTEM........................................................553 IGNITION SYSTEM (GAS ENGINE)....................................................................553 PCV VALVE (GAS ENGINE)..........................................................................553 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................554 Check The Lift Cylinders For Leaks..........................................................554 Check The Tilt Cylinder For Leaks...........................................................554 EVERY 2000 HOURS OR YEARLY..........................................................................554 PCV VALVE (GAS ENGINE)..........................................................................554 PCV VALVE (DIESEL ENGINE).......................................................................555 DIFFERENTIAL....................................................................................555 ADJUSTING THE OIL CLUTCH PEDAL..................................................................555 OIL FILTER FOR THE POWERSHIFT TRANSMISSION OR THE OIL CLUTCH....................................556 HYDRAULIC SYSTEM................................................................................556 Changing The Hydraulic Oil Filter...........................................................556 Changing The Hydraulic Oil..................................................................556 CHANGE THE GASOLINE FUEL FILTER.................................................................557 CHANGE THE FUEL FILTER FOR LPG..................................................................557 WHEELS AND TIRES....................................................................................557 DRIVE TIRES.....................................................................................557 STEERING TIRES..................................................................................560 Disassembly.................................................................................560 Assembly....................................................................................560 8000116.................................................................................................561 GENERAL.............................................................................................561 TRAVEL SPEEDS.......................................................................................561 HYDRAULIC SYSTEM....................................................................................561 TIRE PRESSURE.......................................................................................562 CAPACITIES..........................................................................................562 ELECTRICAL..........................................................................................562 LIFT SPEEDS.........................................................................................562 LOWERING SPEEDS.....................................................................................563 ENGINE, GENERAL INFORMATION.........................................................................564 ENGINE, SERVICE, PERKINS 2.482......................................................................564 ENGINE, SERVICE, GM 6-250...........................................................................566 8000117.................................................................................................567 ELECTRICAL WIRING DIAGRAM (GAS AND LPG).............................................................568 ELECTRICAL WIRING DIAGRAM (DIESEL)..................................................................570 HYDRAULIC SCHEMATIC-EARLY UNITS.....................................................................572 HYDRAULIC SCHEMATIC-LATER UNITS.....................................................................574 8000231.................................................................................................575 INTRODUCTION........................................................................................575 NOMENCLATURE, THREADS...........................................................................575 STRENGTH IDENTIFICATION.........................................................................576 TABLE 1. BOLTS AND SCREWS...........................................................................576 TABLE 2. STUDS AND NUTS.............................................................................577 TABLE 3. TORQUE NUTS................................................................................578 TABLE 4. TORQUE NUTS WITH NYLON INSERT..............................................................579 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...........................................................580 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.........................................................581
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