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Hyster F003 (H2.00-3.00JS Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster F003 (H2.00-3.00JS Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS
Hyster F003 (H2.00-3.00JS Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 523
Downloadable : Yes
File Type : PDF
Size: 16.9 MB
TABLE OF CONTENTS:
Hyster F003 (H2.00-3.00JS 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 100179.................................................................................................. 93 INTRODUCTION........................................................................................ 93 General......................................................................................... 93 Description..................................................................................... 93 DISASSEMBLY AND ASSEMBLY............................................................................ 94 Overhead Guard.................................................................................. 94 Hood and Seat Removal........................................................................... 95 Counterweight................................................................................... 95 Engine and Transmission......................................................................... 95 REPAIRS............................................................................................. 97 Fuel and Hydraulic Tanks........................................................................ 97 Decal Replacement............................................................................... 98 120018..................................................................................................102 INTRODUCTION........................................................................................102 GENERAL.........................................................................................102 DESCRIPTION AND OPERATION ......................................................................102 REPAIRS.............................................................................................103 REMOVAL.........................................................................................103 INSPECTION......................................................................................103 INSTALLATION....................................................................................104 ADJUSTMENTS.........................................................................................106 ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL........................................................106 ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS...............106 TROUBLESHOOTING.....................................................................................107 130043..................................................................................................109 INTRODUCTION........................................................................................109 General.........................................................................................109 REPAIRS.............................................................................................110 REMOVAL.............................................................................................110 DISASSEMBLY.........................................................................................110 CLEANING............................................................................................118 INSPECTION..........................................................................................119 ASSEMBLY............................................................................................119 Assembling the Control Valve....................................................................119 Assembling the Differential.....................................................................122 Assembling the Transmission.....................................................................130 Installation....................................................................................134 MONOTROL Pedal..................................................................................134 CHECKS AND ADJUSTMENTS..............................................................................135 Checking the MONOTROL Pedal for Leakage.........................................................135 MONOTROL Pedal..................................................................................135 Stall Test......................................................................................135 Checking the Oil Pressures......................................................................136 MONOTROL Pressure...........................................................................137 Clutch Apply Pressure.......................................................................139 Inching Spool Operation.....................................................................140 Torque Converter and Oil Cooler Pressure....................................................140 CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT..........................................................140 CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER................................................141 ADJUSTING THE OIL SUMP TUBE.........................................................................142 TROUBLESHOOTING.....................................................................................142 Pressure Tests..................................................................................145 Troubleshooting the Differential................................................................146 130059..................................................................................................148 INTRODUCTION........................................................................................148 GENERAL.........................................................................................148 DESCRIPTION.....................................................................................148 REPAIRS.............................................................................................151 REMOVAL.........................................................................................151 DISASSEMBLY.....................................................................................151 CLEANING........................................................................................158 INSPECTION......................................................................................158 ASSEMBLY........................................................................................158 INSTALLATION....................................................................................166 TROUBLESHOOTING.....................................................................................166 SPECIFICATIONS......................................................................................167 140049..................................................................................................168 INTRODUCTION........................................................................................168 GENERAL.........................................................................................168 DESCRIPTION.....................................................................................168 REPAIRS.............................................................................................168 DISASSEMBLY.....................................................................................169 CLEANING........................................................................................171 ASSEMBLY........................................................................................171 TROUBLESHOOTING.....................................................................................173 160010..................................................................................................174 INTRODUCTION........................................................................................174 DESCRIPTION.....................................................................................174 GENERAL.........................................................................................174 REPAIRS.............................................................................................175 STEERING AXLE...................................................................................175 Removal.........................................................................................175 Installation....................................................................................176 STEERING CYLINDER...............................................................................176 Removal.........................................................................................176 Service.........................................................................................177 Installation....................................................................................177 HUBS............................................................................................177 Removal.........................................................................................177 Installation....................................................................................178 SPINDLES........................................................................................178 Removal.........................................................................................178 Installation....................................................................................179 CHECKS AND ADJUSTMENTS..............................................................................179 REMOVE THE AIR FROM THE STEERING SYSTEM.........................................................179 SET THE PRESSURE RELIEF VALVE...................................................................179 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL).........................................179 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION..............................................179 H2.00-3.00J (H40-60J) With Powershift Transmission..............................................179 TROUBLESHOOTING.....................................................................................181 160054..................................................................................................182 INTRODUCTION........................................................................................182 GENERAL.........................................................................................182 DESCRIPTION.....................................................................................182 OPERATION.......................................................................................182 REPAIRS.............................................................................................182 STEERING WHEEL AND COLUMN ASSEMBLY..............................................................182 TYPE "A" STEERING COLUMN ASSEMBLY...............................................................184 Removal And Disassembly.....................................................................184 Assembly And Installation...................................................................184 TYPE "A" STEERING COLUMN........................................................................185 TYPE "A" STEERING COLUMN........................................................................186 TYPE "B" STEERING COLUMN........................................................................187 Removal And Disassembly.....................................................................187 Assembly And Installation...................................................................187 TYPE "B" STEERING COLUMN........................................................................188 Disassembly of Steering Control Unit........................................................189 Cleaning of Steering Control Unit...........................................................189 Assembly of Steering Control Unit...........................................................191 CHECKS AND ADJUSTMENTS..............................................................................194 REMOVE AIR FROM THE SYSTEM......................................................................194 TROUBLESHOOTING.....................................................................................195 180013..................................................................................................196 INTRODUCTION........................................................................................196 GENERAL.........................................................................................196 DESCRIPTION.....................................................................................196 REPAIRS.............................................................................................196 REMOVAL AND DISASSEMBLY.........................................................................196 CLEANING .......................................................................................197 ASSEMBLY........................................................................................197 CHECKS AND ADJUSTMENTS..............................................................................197 CHECKS..........................................................................................197 180080..................................................................................................198 INTRODUCTION........................................................................................198 GENERAL.........................................................................................198 DESCRIPTION AND OPERATION.......................................................................199 REPAIRS.............................................................................................199 REMOVAL AND DISASSEMBLY.........................................................................199 CLEANING........................................................................................200 INSPECTION......................................................................................201 ASSEMBLY........................................................................................201 CHECKS AND ADJUSTMENTS..............................................................................203 BRAKE SHOES.....................................................................................203 Parking Brake...............................................................................203 Seat Actuated Park Brake, J40–60AS..........................................................203 Removing The Air From The Brake System......................................................204 TROUBLESHOOTING.....................................................................................205 190064..................................................................................................208 INTRODUCTION........................................................................................208 GENERAL.........................................................................................208 DESCRIPTION.....................................................................................208 REPAIRS.............................................................................................208 REMOVAL AND DISASSEMBLY.........................................................................208 CLEANING........................................................................................210 INSPECTION......................................................................................210 ASSEMBLY AND INSTALLATION.......................................................................210 TROUBLESHOOTING.....................................................................................212 GENERAL.........................................................................................212 190097..................................................................................................213 INTRODUCTION........................................................................................213 DESCRIPTION.....................................................................................213 OPERATION.......................................................................................213 Flow Control Valve..........................................................................215 Relief Valve................................................................................215 REPAIRS.............................................................................................216 REMOVAL.........................................................................................216 DISASSEMBLY.....................................................................................216 CLEANING........................................................................................218 INSPECTION......................................................................................218 ASSEMBLY........................................................................................219 INSTALLATION....................................................................................220 CHECKS AND ADUSTMENTS...............................................................................221 CHECK THE OUTPUT OF THE PUMP....................................................................221 CHECK FOR AIR IN THE HYDRAULIC SYSTEM...........................................................221 TROUBLESHOOTING.....................................................................................223 200065..................................................................................................226 INTRODUCTION........................................................................................226 General.........................................................................................226 Description.....................................................................................226 Hydraulic Control Valve.........................................................................232 REPAIRS.............................................................................................236 Disassembly.....................................................................................236 Cleaning........................................................................................236 Inspection......................................................................................236 Assembly........................................................................................237 CHECKS AND ADJUSTMENT...............................................................................238 Relief Valve....................................................................................238 TROUBLESHOOTING.....................................................................................240 600169..................................................................................................242 INTRODUCTION........................................................................................242 General.........................................................................................242 Description.....................................................................................242 ENGINE..............................................................................................242 Removal.........................................................................................242 Installation....................................................................................243 CYLINDER HEAD AND VALVE MECHANISM...................................................................243 Cylinder Head...................................................................................243 Removal.....................................................................................243 Repairs.....................................................................................244 Installation................................................................................244 Valve Guides................................................................................246 Valve Mechanism.................................................................................246 Valves......................................................................................246 Valve Springs...............................................................................246 Rocker Arm Assembly.........................................................................246 LUBRICATION.........................................................................................247 Oil Pump........................................................................................247 Removal and Disassembly.....................................................................247 Repairs.....................................................................................247 Assembly and Installation...................................................................247 Relief Valve................................................................................248 TIMING GEAR CASE AND CAMSHAFT.......................................................................248 Timing Gear Cover...............................................................................248 Removal.....................................................................................248 Installation................................................................................248 Idle Gears......................................................................................248 Removal.....................................................................................248 Installation................................................................................249 Camshaft Gear and Camshaft......................................................................249 Removal.....................................................................................249 Installation................................................................................250 Fuel Pump Gear..................................................................................250 Removal.....................................................................................250 Installation................................................................................251 Timing Gear Case................................................................................251 Removal.....................................................................................251 Installation................................................................................251 CRANKSHAFT AND MAIN BEARINGS........................................................................252 Removal.........................................................................................252 Installation....................................................................................252 PISTONS AND PISTON RODS.............................................................................253 Removal.........................................................................................253 Disassembly.....................................................................................253 Repairs.........................................................................................254 Assembly........................................................................................254 Installation....................................................................................255 CYLINDER LINERS.....................................................................................256 Removal ........................................................................................256 Installation....................................................................................256 FLYWHEEL AND FLYWHEEL HOUSING.......................................................................256 Removal.........................................................................................256 Installation....................................................................................256 FUEL PUMP...........................................................................................256 Removal.........................................................................................256 Installation....................................................................................257 FUEL INJECTION PUMP.................................................................................257 Removal.........................................................................................257 Installation....................................................................................257 FUEL INJECTORS......................................................................................258 Checks..........................................................................................258 Installation....................................................................................258 COOLING SYSTEM......................................................................................259 Thermostat......................................................................................259 Removal.....................................................................................259 Installation................................................................................259 Water Pump......................................................................................259 Removal.....................................................................................259 Assembly....................................................................................260 CHECKS AND ADJUSTMENTS..............................................................................260 Removing Air From The Fuel System...............................................................260 Timing..........................................................................................261 Fuel Injection Pump.........................................................................261 Valve Clearance Adjustment......................................................................264 Adjusting The Throttle Linkage..................................................................264 TROUBLESHOOTING.....................................................................................266 SPECIFICATIONS......................................................................................267 700626..................................................................................................271 COOLING SYSTEM......................................................................................271 INTRODUCTION....................................................................................271 DESCRIPTION.....................................................................................271 RADIATOR........................................................................................271 RADIATOR CAP....................................................................................271 THERMOSTAT......................................................................................271 WATER PUMP......................................................................................272 FAN AND FAN SHROUD .............................................................................272 REPAIRS.............................................................................................272 COOLING SYSTEM CHECKS...........................................................................272 Exhaust Leaks...............................................................................272 RADIATOR........................................................................................272 Checks......................................................................................272 Cleaning The Radiator.......................................................................272 Drain The Cooling System....................................................................274 Fill The Cooling System.....................................................................274 WATER PUMP......................................................................................274 Checks......................................................................................274 THERMOSTAT......................................................................................275 Checks......................................................................................275 FAN AND FAN SHROUD .............................................................................275 TROUBLESHOOTING.....................................................................................276 2100103.................................................................................................277 INTRODUCTION........................................................................................280 GENERAL.........................................................................................280 DESCRIPTION.....................................................................................280 REPAIRS.............................................................................................280 REMOVAL.........................................................................................280 DISASSEMBLY.....................................................................................280 CLEANING........................................................................................280 ASSEMBLY........................................................................................280 Tilt Cylinders for the XM and XMS Models....................................................280 Tilt Cylinders with O-Ring or Single Lip Seals..............................................282 Tilt Cylinders for H700-800A and Early Model H700-920B......................................282 INSTALLATION....................................................................................282 Tilt Cylinders with Chevron Packing.........................................................282 CHECKS AND ADJUSTMENTS..............................................................................286 CHECK THE TILT CYLINDERS FOR LEAKS..............................................................286 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.........................................286 TROUBLESHOOTING.....................................................................................289 2200106.................................................................................................292 INTRODUCTION........................................................................................292 GENERAL.........................................................................................292 DESCRIPTION AND OPERATION.......................................................................292 REPAIRS.............................................................................................294 REMOVAL.........................................................................................294 DISSASEMBLY.....................................................................................294 CLEANING........................................................................................295 ASSEMBLY........................................................................................295 INSTALLATION....................................................................................295 CHECKS AND ADJUSTMENTS..............................................................................296 GENERAL.........................................................................................296 TROUBLESHOOTING.....................................................................................298 2200107.................................................................................................300 HIGH ENERGY IGNITION (HEI)..........................................................................300 DESCRIPTION.....................................................................................300 REPAIRS.............................................................................................302 DISTRIBUTOR.....................................................................................302 Removal.....................................................................................302 Disassembly.................................................................................302 Assembly....................................................................................307 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED....................308 INSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED....................309 IGNITION COIL...................................................................................309 Removal, Some 4 and 6 Cylinder Models.......................................................309 Installation, Some 4 and 6 Cylinder Models..................................................310 Removal, V8, Some 4 and 6 Cylinder Models...................................................310 Installation, V8, Some 4 and 6 Cylinder Models..............................................311 ELECTRONIC MODULE...............................................................................312 Removal.....................................................................................312 Installation................................................................................312 SENSING COIL....................................................................................313 Removal.....................................................................................313 Installation................................................................................313 SPARK PLUGS.....................................................................................313 Removal.....................................................................................313 Installation................................................................................314 CHECKS AND ADJUSTMENTS..........................................................................314 Visual Checks...............................................................................314 Check The High Voltage Wires................................................................314 Checking The Ignition Coil..................................................................314 Coil In Distributor Cap Design..............................................................314 Separate Coil Design........................................................................315 Checking The Sensing Coil...................................................................315 Check The Electronic Module.................................................................316 Ignition Timing Adjustment..................................................................316 Ignition System, GM V8-366 (6-litre)........................................................317 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)............................317 SPECIFICATIONS......................................................................................317 TROUBLESHOOTING.....................................................................................318 2200143.................................................................................................319 INTRODUCTION........................................................................................319 GENERAL.........................................................................................319 DESCRIPTION.........................................................................................319 GENERAL.........................................................................................319 STEERING COLUMN GAUGES, METERS AND INDICATORS...................................................322 LED DISPLAY PANEL...............................................................................322 Battery Discharge Indicators ...............................................................322 Brush Wear Indicators.......................................................................323 Motor Temperature Indicators................................................................324 "LX" SERIES INSTRUMENT PANEL DISPLAY............................................................325 Hourmeter Functions.........................................................................326 Battery Indicator Function..................................................................326 Status Code Function........................................................................326 CHECKS AND ADJUSTMENTS..............................................................................326 GENERAL.........................................................................................326 REPLACEMENT.........................................................................................327 GENERAL.........................................................................................327 METER REPLACEMENT...............................................................................327 SENDER REPLACEMENT..............................................................................328 Fuel Level Sender...........................................................................328 Pressure And Temperature Sender.............................................................329 I.T.W. DISPLAY PANEL............................................................................329 Removal.....................................................................................329 SPECIFICATIONS......................................................................................330 TROUBLESHOOTING.....................................................................................331 2200144.................................................................................................332 ELECTRICAL WARNING DEVICES..........................................................................332 GENERAL.........................................................................................332 DESCRIPTION.....................................................................................332 Operator Controlled Horns...................................................................332 System Warning Lights, Buzzers and Bells....................................................332 Reverse Warning Horns.......................................................................333 Warning Lights..............................................................................333 REPLACEMENT.....................................................................................334 General.....................................................................................334 Replacing Horns or Bells....................................................................334 Replacing Horn Relay or Buzzer..............................................................334 Replacing Warning Lights....................................................................334 Light Assemblies............................................................................335 Replacing Flashing Units....................................................................335 2200153.................................................................................................336 ELECTRICAL SYSTEM COMPLETELY DEAD...................................................................336 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN ...............................................337 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER.........................................339 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK........................................340 STARTER CRANKS SLOWLY...............................................................................342 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START...........................................343 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND.........................................................345 CHARGING SYSTEM DOES NOT FUNCTION...................................................................346 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW................................................349 BATTERY IS BEING OVERCHARGED........................................................................352 ONE OR MORE DASH GAUGES DO NOT WORK.................................................................353 HORN DOES NOT BLOW..................................................................................357 POWERSHIFT TRANSMISSION WILL NOT ENGAGE.............................................................358 ELECTRICAL SCHEMATIC S20-30A, H20-30E...............................................................359 ELECTRICAL S30-50C..................................................................................360 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG.........................................................361 ELECTRICAL SCHEMATIC H30-60H DIESEL.................................................................363 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG.........................................................365 ELECTRICAL SCHEMATIC H60-90C DIESEL.................................................................366 ELECTRICAL SCHEMATIC S30-60ES.......................................................................367 ELECTRICAL SCHEMATIC S60-120E.......................................................................368 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG.......................................................369 ELECTRICAL SCHEMATIC S125-150A DIESEL...............................................................370 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG.......................................................371 ELECTRICAL SCHEMATIC H110-150F DIESEL...............................................................372 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG.............................................373 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL....................................................374 ELECTRICAL SCHEMATIC H300A..........................................................................375 ELECTRICAL SCHEMATIC H300-350B......................................................................376 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL.......................................................377 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL.......................................................378 ELECTRICAL SCHEMATIC H700-800A......................................................................379 ELECTRICAL SCHEMATIC P40-50A GASOLINE...............................................................381 ELECTRICAL SCHEMATIC P40-50A DIESEL.................................................................382 ELECTRICAL SCHEMATIC P60-80A GASOLINE...............................................................383 ELECTRICAL SCHEMATIC P60-80A DIESEL.................................................................384 ELECTRICAL SCHEMATIC KE GAS GASOLINE................................................................385 ELECTRICAL SCHEMATIC KE DIESEL......................................................................386 ELECTRICAL SCHEMATIC M200-400H GASOLINE.............................................................387 ELECTRICAL SCHEMATIC M200-400H DIESEL...............................................................389 ELECTRICAL SCHEMATIC M600A..........................................................................391 4000115.................................................................................................393 INTRODUCTION........................................................................................393 GENERAL.........................................................................................393 REPAIRS.............................................................................................393 FORKS...........................................................................................393 CARRIAGE........................................................................................393 Removal.....................................................................................393 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................394 Installation................................................................................395 MASTS...........................................................................................397 Removal.....................................................................................397 Disassembly.................................................................................399 Cleaning and Inspection.....................................................................403 Assembly....................................................................................404 INSTALLATION....................................................................................405 CHECKS AND ADJUSTMENTS..............................................................................405 CHECKING FOR LEAKS IN THE LIFT SYSTEM...........................................................405 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE..................................406 LIFT CHAIN ADJUSTMENTS..........................................................................406 MAST ADJUSTMENTS................................................................................407 Guide Shoe Adjustment.......................................................................408 CARRIAGE ADJUSTMENT.............................................................................410 TROUBLESHOOTING.....................................................................................412 4000135.................................................................................................413 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................413 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................413 LIFT CYLINDERS......................................................................................416 GENERAL.........................................................................................416 DESCRIPTION.....................................................................................416 Lowering Control Valve......................................................................416 Cylinders (General).........................................................................419 Cylinders (H520-620B,H700-800A).............................................................421 Cylinders (H360-460B).......................................................................422 Cylinders (Two-Speed).......................................................................422 REPAIRS.............................................................................................423 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..........................................423 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....423 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.....................427 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...............425 DISASSEMBLY.....................................................................................425 ASSEMBLY........................................................................................427 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...................................................427 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....427 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead............427 CHEVRON PACKING.................................................................................428 LIFT CYLINDERS FOR VISTA MASTS......................................................................431 DESCRIPTION.....................................................................................431 Lowering Control Valve......................................................................433 REMOVAL.........................................................................................434 DISASSEMBLY.....................................................................................434 ASSEMBLY........................................................................................434 INSTALLATION....................................................................................435 Main Lift Cylinders.........................................................................435 Free-Lift Cylinders.........................................................................435 CHECKS AND ADJUSTMENTS..............................................................................436 CHECK FOR LEAKS IN LIFT SYSTEM..................................................................436 TROUBLESHOOTING.....................................................................................437 SPECIFICATIONS......................................................................................438 4000167.................................................................................................439 INTRODUCTION........................................................................................439 GENERAL.........................................................................................439 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)...............................441 FULL FREE-LIFT MASTS............................................................................441 THREE-STAGE MASTS...............................................................................443 FOUR-STAGE MASTS................................................................................444 SEQUENCE VALVE..................................................................................444 4000197.................................................................................................446 INTRODUCTION........................................................................................446 GENERAL.........................................................................................446 VISTA TWO-STAGE MASTS...............................................................................448 DESCRIPTION.....................................................................................448 OPERATION.......................................................................................451 VISTA THREE-STAGE MASTS.............................................................................451 DESCRIPTION.....................................................................................451 OPERATION.......................................................................................453 SEQUENCE VALVE..................................................................................455 4000198.................................................................................................458 INTRODUCTION........................................................................................458 GENERAL.........................................................................................458 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................458 REPAIRS.............................................................................................459 FORKS...........................................................................................459 Removal.....................................................................................459 CARRIAGE........................................................................................459 Removal (Two-Stage and Later Production Three-Stage Carriages)..............................459 Removal (Carriages with Removable Stop Block)...............................................460 Installation (Two-Stage and Later Production Three-Stage Carriages).........................461 Installation (Carriages With Removable Stop Block)..........................................461 TWO-STAGE MASTS.....................................................................................463 REMOVAL.........................................................................................463 DISASSEMBLY.....................................................................................464 CLEANING AND INSPECTION.........................................................................465 ASSEMBLY........................................................................................466 INSTALLATION....................................................................................467 THREE-STAGE MASTS...................................................................................467 REMOVAL.........................................................................................467 DISASSEMBLY.....................................................................................467 CLEANING AND INSPECTION.........................................................................469 ASSEMBLY........................................................................................469 INSTALLATION....................................................................................470 LIFT AND TILT CYLINDERS.........................................................................471 SIDE SHIFT CARRIAGE.............................................................................471 Removal.....................................................................................471 Repairs.....................................................................................471 Installation................................................................................471 SEQUENCE VALVE..................................................................................472 Removal and Disassembly.....................................................................475 Cleaning....................................................................................475 Assembly and Installation...................................................................475 CHECKS AND ADJUSTMENTS..............................................................................476 CHECKING FOR LEAKS IN THE LIFT SYSTEM...........................................................476 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE..................................476 LIFTING CHAIN ADJUSTMENTS.......................................................................477 MAST ADJUSTMENTS................................................................................478 CARRIAGE ADJUSTMENT.............................................................................479 HEADER HOSE ROLLER ADJUSTMENT, 2-STAGE..........................................................480 TROUBLESHOOTING.....................................................................................481 TORQUE SPECIFICATIONS...............................................................................482 VISTA MASTS.........................................................................................483 8000180.................................................................................................484 INTRODUCTION........................................................................................484 General.........................................................................................484 MAINTENANCE SCHEDULE................................................................................484 MAINTENANCE PROCEDURES Every 8 Hours or Daily.......................................................487 Checks with the Engine Stopped..................................................................487 Hydraulic System............................................................................487 Air Cleaner.................................................................................487 Engine Oil..................................................................................487 Fuel Filter (Diesel)........................................................................487 Battery.....................................................................................488 Cooling System..............................................................................488 Drive Belts.................................................................................488 Tires and Wheels............................................................................489 Lift Mechanism..............................................................................490 Forks.......................................................................................490 Lift Chains.................................................................................490 Upright.....................................................................................491 Carriage....................................................................................491 Load Backrest Extension.....................................................................491 Powershift Transmission.....................................................................491 Checks with the Engine Running..................................................................491 Guages and Lights...........................................................................492 Powershift Transmission.....................................................................492 Brakes......................................................................................492 Steering System.............................................................................492 Hydraulic System............................................................................494 Uprights....................................................................................494 Attachments.................................................................................494 Every 350 Hours or Two Months...................................................................495 Engine Oil and Filter.......................................................................495 Brake Fluid.................................................................................495 Hydraulic Tank Breather.....................................................................495 Forks.......................................................................................495 Uprights....................................................................................496 Other Lubrication Points....................................................................497 Every 1000 Hours or Six Months..................................................................497 Final Fuel Filter (Diesel)..................................................................497 Removing Air From The Diesel Fuel System....................................................497 Ignition System (Gas Engine.................................................................498 PCV Valve (Gas Engine)......................................................................498 Every 2000 Hours or Yearly......................................................................499 PCV Valve (Gas Engine)......................................................................499 PCV Valve (Diesel Engine)...................................................................499 Differential................................................................................500 Adjusting The Oil Clutch Pedal..............................................................500 Hydraulic System............................................................................500 Changing The Gasoline Fuel System...........................................................501 Changing The Fuel Filter for LPG............................................................501 WHEELS AND TIRES....................................................................................502 Drive Tires.....................................................................................502 Steering Tires..................................................................................505 8000181.................................................................................................506 8000182.................................................................................................509 8000231.................................................................................................515 INTRODUCTION........................................................................................515 NOMENCLATURE, THREADS...........................................................................515 STRENGTH IDENTIFICATION.........................................................................516 TABLE 1. BOLTS AND SCREWS...........................................................................516 TABLE 2. STUDS AND NUTS.............................................................................517 TABLE 3. TORQUE NUTS................................................................................518 TABLE 4. TORQUE NUTS WITH NYLON INSERT..............................................................519 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...........................................................520 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.........................................................521
HYSTER F003 (H2.00-3.00JS EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
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