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Hyster F003 (H40-50J, H60JS) Service Manual – PDF DOWNLOAD
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Description
Hyster F003 (H40-50J, H60JS) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster F003 (H40-50J, H60JS) Service Manual – PDF DOWNLOAD
Language : English
Pages : 531
Downloadable : Yes
File Type : PDF
Size: 16.9 MB
TABLE OF CONTENTS:
Hyster F003 (H40-50J, H60JS) Service Manual – PDF DOWNLOAD
Alternator................................................................................................... 1 INTRODUCTION............................................................................................. 1 GENERAL.............................................................................................. 1 DESCRIPTION.......................................................................................... 1 REPAIRS.................................................................................................. 3 GENERAL.............................................................................................. 3 REMOVAL AND DISASSEMBLY (Type A)..................................................................... 3 CLEANING............................................................................................. 3 ASSEMBLY (Type A).................................................................................... 4 REMOVAL AND DISAASSEMBLY (Type B).................................................................... 6 CLEANING............................................................................................. 8 ASSEMBLY (Type B).................................................................................... 8 INSTALLATION (Type A and Type B)..................................................................... 9 CHECKS AND ADJUSTMENTS................................................................................... 9 GENERAL.............................................................................................. 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)............................................... 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B).............................................. 11 CHECK THE CIRCUIT FOR THE BRUSHES.................................................................... 13 Delco Alternators................................................................................ 13 Motorola Alternators............................................................................. 13 CHECK THE DIODES..................................................................................... 13 CHECK THE DIODE BRIDGE............................................................................... 13 Delco and Leece–Neville Alternators.............................................................. 13 Motorola Alternators............................................................................. 13 CHECK THE FIELD WINDING FOR THE ROTOR................................................................ 14 CHECK THE WINDINGS IN THE STATOR..................................................................... 14 CHECK THE VOLTAGE REGULATOR.......................................................................... 15 TROUBLESHOOTING.......................................................................................... 15 Brake System................................................................................................. 16 INTRODUCTION............................................................................................. 16 GENERAL.............................................................................................. 16 DESCRIPTION AND OPERATION............................................................................ 17 REPAIRS.................................................................................................. 17 REMOVAL AND DISASSEMBLY.............................................................................. 17 CLEANING............................................................................................. 18 INSPECTION........................................................................................... 19 ASSEMBLY............................................................................................. 19 CHECKS AND ADJUSTMENTS................................................................................... 21 BRAKE SHOES.......................................................................................... 21 Parking Brake.................................................................................... 21 Seat Actuated Park Brake, J40–60AS............................................................... 21 Removing The Air From The Brake System........................................................... 22 TROUBLESHOOTING.......................................................................................... 23 Capacities & Specifications.................................................................................. 26 Cooling System............................................................................................... 29 COOLING SYSTEM........................................................................................... 29 INTRODUCTION......................................................................................... 29 DESCRIPTION.......................................................................................... 29 RADIATOR............................................................................................. 29 RADIATOR CAP......................................................................................... 29 THERMOSTAT........................................................................................... 29 WATER PUMP........................................................................................... 30 FAN AND FAN SHROUD................................................................................... 30 REPAIRS.................................................................................................. 30 COOLING SYSTEM CHECKS................................................................................ 30 Exhaust Leaks.................................................................................... 30 RADIATOR............................................................................................. 30 Checks........................................................................................... 30 Cleaning The Radiator............................................................................ 30 Drain The Cooling System......................................................................... 32 Fill The Cooling System.......................................................................... 32 WATER PUMP........................................................................................... 32 Checks........................................................................................... 32 THERMOSTAT........................................................................................... 33 Checks........................................................................................... 33 FAN AND FAN SHROUD................................................................................... 33 TROUBLESHOOTING.......................................................................................... 34 Digrams...................................................................................................... 35 Drive Axle................................................................................................... 41 INTRODUCTION............................................................................................. 41 GENERAL.............................................................................................. 41 DESCRIPTION.......................................................................................... 41 REPAIRS.................................................................................................. 41 DISASSEMBLY.......................................................................................... 42 CLEANING............................................................................................. 44 ASSEMBLY............................................................................................. 44 TROUBLESHOOTING.......................................................................................... 46 Electrical System Troubleshooting............................................................................ 47 ELECTRICAL SYSTEM COMPLETELY DEAD........................................................................ 47 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN .................................................... 48 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER.............................................. 50 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK............................................. 51 STARTER CRANKS SLOWLY.................................................................................... 53 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START................................................ 54 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND.............................................................. 56 CHARGING SYSTEM DOES NOT FUNCTION........................................................................ 57 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW..................................................... 60 BATTERY IS BEING OVERCHARGED............................................................................. 63 ONE OR MORE DASH GAUGES DO NOT WORK...................................................................... 64 HORN DOES NOT BLOW....................................................................................... 68 POWERSHIFT TRANSMISSION WILL NOT ENGAGE.................................................................. 69 ELECTRICAL SCHEMATIC S20-30A, H20-30E.................................................................... 70 ELECTRICAL S30-50C....................................................................................... 71 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG.............................................................. 72 ELECTRICAL SCHEMATIC H30-60H DIESEL...................................................................... 74 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG.............................................................. 76 ELECTRICAL SCHEMATIC H60-90C DIESEL...................................................................... 77 ELECTRICAL SCHEMATIC S30-60ES............................................................................ 78 ELECTRICAL SCHEMATIC S60-120E............................................................................ 79 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG............................................................ 80 ELECTRICAL SCHEMATIC S125-150A DIESEL.................................................................... 81 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG............................................................ 82 ELECTRICAL SCHEMATIC H110-150F DIESEL.................................................................... 83 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG.................................................. 84 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL......................................................... 85 ELECTRICAL SCHEMATIC H300A............................................................................... 86 ELECTRICAL SCHEMATIC H300-350B........................................................................... 87 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL............................................................ 88 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL............................................................ 89 ELECTRICAL SCHEMATIC H700-800A........................................................................... 90 ELECTRICAL SCHEMATIC P40-50A GASOLINE.................................................................... 92 ELECTRICAL SCHEMATIC P40-50A DIESEL...................................................................... 93 ELECTRICAL SCHEMATIC P60-80A GASOLINE.................................................................... 94 ELECTRICAL SCHEMATIC P60-80A DIESEL...................................................................... 95 ELECTRICAL SCHEMATIC KE GAS GASOLINE..................................................................... 96 ELECTRICAL SCHEMATIC KE DIESEL........................................................................... 97 ELECTRICAL SCHEMATIC M200-400H GASOLINE.................................................................. 98 ELECTRICAL SCHEMATIC M200-400H DIESEL....................................................................100 ELECTRICAL SCHEMATIC M600A...............................................................................102 Electrical Warning Devices...................................................................................104 ELECTRICAL WARNING DEVICES...............................................................................104 GENERAL..............................................................................................104 DESCRIPTION..........................................................................................104 Operator Controlled Horns........................................................................104 System Warning Lights, Buzzers and Bells.........................................................104 Reverse Warning Horns............................................................................105 Warning Lights...................................................................................105 REPLACEMENT..........................................................................................106 General..........................................................................................106 Replacing Horns or Bells.........................................................................106 Replacing Horn Relay or Buzzer...................................................................106 Replacing Warning Lights.........................................................................106 Light Assemblies.................................................................................107 Replacing Flashing Units.........................................................................107 Frame........................................................................................................108 INTRODUCTION.............................................................................................108 General..............................................................................................108 Description..........................................................................................108 DISASSEMBLY AND ASSEMBLY.................................................................................109 Overhead Guard.......................................................................................109 Hood and Seat Removal................................................................................110 Counterweight........................................................................................110 Engine and Transmission..............................................................................110 REPAIRS..................................................................................................112 Fuel and Hydraulic Tanks.............................................................................112 Decal Replacement....................................................................................113 GM Engine....................................................................................................117 INTRODUCTION.............................................................................................117 GENERAL..............................................................................................117 DESCRIPTION..........................................................................................118 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................118 CYLINDER HEAD AND MECHANISM..........................................................................118 Cylinder Head, Removal...........................................................................118 Cylinder Head, Disassembly.......................................................................119 Cleaning And Inspection..........................................................................120 Valve And Valve Seats............................................................................121 Studs For The Rocker Arms........................................................................121 Hydraulic Valve Lifters, Replacement.............................................................121 Hydraulic Valve Lifters, Cleaning And Inspection.................................................122 Cylinder Head, Assembly..........................................................................122 Cylinder Head, Installation......................................................................122 Rocker Arm Cover, Installation...................................................................123 TIMING GEAR COVER....................................................................................124 Removal..........................................................................................124 Installation.....................................................................................124 CAMSHAFT.............................................................................................125 Removal..........................................................................................125 Inspection.......................................................................................126 Camshaft Bearings, Removal.......................................................................126 Camshaft Bearings, Installation..................................................................126 DISTRIBUTOR..........................................................................................127 Removal..........................................................................................127 Installation.....................................................................................127 LUBRICATION SYSTEM...................................................................................128 Oil Sump, Removal................................................................................128 Oil Sump, Installation...........................................................................128 Oil Pump, Removal................................................................................128 Oil Pump, Disassembly and Repair.................................................................128 Oil Pump, Assembly...............................................................................129 Oil Pump, Installation...........................................................................129 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................129 Connecting Rod Bearings, Replacement.............................................................129 Piston And Connecting Rod Assemblies, Removal....................................................130 Disassembly......................................................................................131 Piston, Cleaning And Inspection..................................................................131 Cylinder Bores, Inspection And Repair............................................................131 Piston Rings.....................................................................................132 Assembly.........................................................................................133 Piston And Connecting Rod Assemblies, Installation...............................................133 CRANKSHAFT...........................................................................................134 Main Bearings, Replacement.......................................................................134 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................135 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........135 Crankshaft, Removal..............................................................................136 Inspection and Repair............................................................................137 How To Check The Clearance Between The Main Bearings And Their Journals..........................137 Installation.....................................................................................138 FLYWHEEL AND FLYWHEEL HOUSING........................................................................139 Flywheel, Removal................................................................................139 Ring Gear, Replacement...........................................................................140 Flywheel, Installation...........................................................................140 COOLING SYSTEM.......................................................................................140 Coolant Pump.....................................................................................140 Fan Drive........................................................................................141 Viscous Fan Drive................................................................................141 ENGINE SPECIFICATIONS....................................................................................142 ENGINE DATA..........................................................................................142 CYLINDER HEAD........................................................................................142 HYDRAULIC VALVE LIFTER...............................................................................143 CAMSHAFT.............................................................................................143 PISTONS..............................................................................................143 CYLINDER BORE........................................................................................144 CRANKSHAFT...........................................................................................144 CONNECTING RODS......................................................................................144 COOLING SYSTEM.......................................................................................145 LUBRICATION SYSTEM...................................................................................145 TORQUE SPECIFICATIONS....................................................................................145 High Engery Ignition System (HEI)............................................................................148 HIGH ENERGY IGNITION (HEI)...............................................................................148 DESCRIPTION..........................................................................................148 REPAIRS..................................................................................................150 DISTRIBUTOR..........................................................................................150 Removal..........................................................................................150 Disassembly......................................................................................150 Assembly.........................................................................................155 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................156 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................157 IGNITION COIL........................................................................................157 Removal, Some 4 And 6 Cylinder Models............................................................157 Installation, Some 4 And 6 Cylinder Models.......................................................158 Removal, V8, Some 4 And 6 Cylinder Models........................................................158 Installation, V8, Some 4 And 6 Cylinder Models...................................................159 ELECTRONIC MODULE....................................................................................160 Removal..........................................................................................160 Installation.....................................................................................160 SENSING COIL.........................................................................................161 Removal..........................................................................................161 Installation.....................................................................................161 SPARK PLUGS..........................................................................................161 Removal..........................................................................................161 Installation.....................................................................................162 CHECKS AND ADJUSTMENTS...............................................................................162 Visual Checks....................................................................................162 Check The High Voltage Wires.....................................................................162 Checking The Ignition Coil.......................................................................162 Coil In Distributor Cap Design...................................................................162 Separate Coil Design.............................................................................163 Checking The Sensing Coil........................................................................163 Check The Electronic Module......................................................................164 Ignition Timing Adjustment.......................................................................164 Ignition System, GM V8-366 (6-litre).............................................................165 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................165 SPECIFICATIONS...........................................................................................165 TROUBLESHOOTING..........................................................................................166 Hydraulic Drive Pump Assembly................................................................................167 INTRODUCTION.............................................................................................167 GENERAL..............................................................................................167 DESCRIPTION..........................................................................................167 REPAIRS..................................................................................................167 REMOVAL AND DISASSEMBLY..............................................................................167 CLEANING.............................................................................................169 INSPECTION...........................................................................................169 ASSEMBLY AND INSTALLATION............................................................................169 TROUBLESHOOTING..........................................................................................171 GENERAL..............................................................................................171 Hydraulic Gear Pump..........................................................................................172 INTRODUCTION.............................................................................................172 DESCRIPTION..........................................................................................172 OPERATION............................................................................................172 Flow Control Valve...............................................................................174 Relief Valve.....................................................................................174 REPAIRS..................................................................................................175 REMOVAL..............................................................................................175 DISASSEMBLY..........................................................................................175 CLEANING.............................................................................................177 INSPECTION...........................................................................................177 ASSEMBLY.............................................................................................178 INSTALLATION.........................................................................................179 CHECKS AND ADUSTMENTS....................................................................................180 CHECK THE OUTPUT OF THE PUMP.........................................................................180 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................180 TROUBLESHOOTING..........................................................................................182 Hydraulic System.............................................................................................185 INTRODUCTION.............................................................................................185 General..............................................................................................185 Description..........................................................................................185 Hydraulic Control Valve..............................................................................191 REPAIRS..................................................................................................195 Disassembly..........................................................................................195 Cleaning.............................................................................................195 Inspection...........................................................................................195 Assembly.............................................................................................196 CHECKS AND ADJUSTMENT....................................................................................197 Relief Valve.........................................................................................197 TROUBLESHOOTING..........................................................................................199 INCH (SAE) & Metric Fasteners................................................................................201 INTRODUCTION.............................................................................................201 NOMENCLATURE, THREADS................................................................................201 STRENGTH IDENTIFICATION..............................................................................202 TABLE 1. BOLTS AND SCREWS................................................................................202 TABLE 2. STUDS AND NUTS..................................................................................203 TABLE 3. TORQUE NUTS.....................................................................................204 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................205 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................206 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................207 Instrument panel Indicators & Senders........................................................................210 INTRODUCTION.............................................................................................210 GENERAL..............................................................................................210 DESCRIPTION..............................................................................................210 GENERAL..............................................................................................210 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................213 LED DISPLAY PANEL....................................................................................213 Battery Discharge Indicators.....................................................................213 Brush Wear Indicators............................................................................214 Motor Temperature Indicators.....................................................................215 "LX" SERIES DISPLAY PANEL............................................................................216 Hourmeter Functions..............................................................................217 Battery Indicator Function.......................................................................217 Status Code Function.............................................................................217 "ZX" SERIES DISPLAY PANELS...........................................................................217 Display Panel....................................................................................218 Basic Display Panels.............................................................................218 Performance Display..............................................................................220 Brush Wear Indicators............................................................................223 CHECKS AND ADJUSTMENTS...................................................................................223 GENERAL..............................................................................................223 REPLACEMENT..............................................................................................224 GENERAL..............................................................................................224 METER REPLACEMENT....................................................................................224 SENDER REPLACEMENT...................................................................................225 Fuel Level Sender................................................................................225 Pressure And Temperature Sender..................................................................225 I.T.W. DISPLAY PANEL.................................................................................226 Removal..........................................................................................226 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................227 Removal..........................................................................................227 Replacing Display Panel Assembly.................................................................227 Indicator LEDs...................................................................................227 Battery Indicators...............................................................................227 Digital Display (Performance Disply Panel Only)..................................................227 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....227 Replacing Parts Of The Basic Display Panel.......................................................228 Replacing Parts Of The Performance Display Panel.................................................230 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................230 Removal And Replacement..........................................................................230 SPECIFICATIONS...........................................................................................231 TROUBLESHOOTING..........................................................................................232 Lift Cylinders...............................................................................................233 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................233 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................233 LIFT CYLINDERS...........................................................................................236 GENERAL..............................................................................................236 DESCRIPTION..........................................................................................236 Lowering Control Valve...........................................................................236 Cylinders (General)..............................................................................239 Cylinders (H520-620B,H700-800A)..................................................................241 Cylinders (H360-460B)............................................................................242 Cylinders (Two-Speed)............................................................................242 REPAIRS..................................................................................................243 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................243 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........243 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................247 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................245 DISASSEMBLY..........................................................................................245 ASSEMBLY.............................................................................................247 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................247 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........247 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................247 CHEVRON PACKING......................................................................................248 LIFT CYLINDERS FOR VISTA MASTS...........................................................................251 DESCRIPTION..........................................................................................251 Lowering Control Valve...........................................................................253 REMOVAL..............................................................................................254 DISASSEMBLY..........................................................................................254 ASSEMBLY.............................................................................................254 INSTALLATION.........................................................................................255 Main Lift Cylinders..............................................................................255 Free-Lift Cylinders..............................................................................255 CHECKS AND ADJUSTMENTS...................................................................................256 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................256 TROUBLESHOOTING..........................................................................................257 SPECIFICATIONS...........................................................................................258 LPG Fuel System..............................................................................................259 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................259 GENERAL..............................................................................................259 DESCRIPTION..........................................................................................259 Fuel Tank........................................................................................260 Fuel Filter And Fuel Valve Unit..................................................................261 Vaporizer........................................................................................261 The IMPCO CA 100 Carbureto.......................................................................263 IMPCO CA 50 Carburetor...........................................................................265 The Governor (GM Engines Only)...................................................................266 Governor With Electronic Controller..............................................................267 REPAIRS..................................................................................................268 LPG TANK.............................................................................................268 Removal..........................................................................................268 Installation.....................................................................................269 REPLACE THE HOSES....................................................................................269 HYDROSTATIC RELIEF VALVE.............................................................................269 Removal and Installation.........................................................................269 FILTER UNIT..........................................................................................270 Replacement Of the Fuel Filter Element...........................................................270 Replacement of the Diaphragm and Fuel Valve......................................................271 VAPORIZER............................................................................................271 Removal..........................................................................................271 Disassembly......................................................................................271 Cleaning.........................................................................................271 Inspection.......................................................................................271 Assembly.........................................................................................273 Installation.....................................................................................273 CARBURETOR (IMPCO CA 100)............................................................................275 Removal..........................................................................................275 Disassembly......................................................................................275 Cleaning.........................................................................................275 Assembly.........................................................................................275 Installation.....................................................................................278 CARBURETER (IMPCO CA 50).............................................................................277 Removal..........................................................................................277 Disassembly......................................................................................277 Cleaning.........................................................................................278 Inspection.......................................................................................278 Assembly (See FIGURE 26.)........................................................................278 Installation.....................................................................................278 CHECKS AND ADJUSTMENTS...................................................................................279 CHECK THE FILTER UNIT................................................................................279 CHECK THE VAPORIZER..................................................................................279 Pressure Reducer Valve...........................................................................279 Vapor Valve......................................................................................279 ADJUST THE CARBURETOR................................................................................279 Idle Mixture.....................................................................................279 Idle Speed.......................................................................................279 Power Mixture....................................................................................279 ADJUST THE GOVERNOR (GM Engines Only)................................................................280 Checks...........................................................................................280 Main Adjusting Screw.............................................................................280 Secondary Adjusting Screw........................................................................280 AISAN Governor...................................................................................281 Adjustment, AISAN Governor.......................................................................281 TROUBLESHOOTING..........................................................................................282 Mast Description.............................................................................................286 INTRODUCTION.............................................................................................286 GENERAL..............................................................................................286 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................288 FULL FREE-LIFT MASTS.................................................................................288 THREE-STAGE MASTS....................................................................................290 FOUR-STAGE MASTS.....................................................................................291 SEQUENCE VALVE.......................................................................................291 Mast Repair..................................................................................................293 INTRODUCTION.............................................................................................293 GENERAL..............................................................................................293 REPAIRS..................................................................................................293 FORKS................................................................................................293 CARRIAGE.............................................................................................293 Removal..........................................................................................293 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................294 Installation.....................................................................................295 MASTS................................................................................................297 Removal..........................................................................................297 Disassembly......................................................................................299 Cleaning and Inspection..........................................................................303 Assembly.........................................................................................304 INSTALLATION.........................................................................................305 CHECKS AND ADJUSTMENTS...................................................................................305 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................305 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................306 LIFT CHAIN ADJUSTMENTS...............................................................................306 MAST ADJUSTMENTS.....................................................................................307 Guide Shoe Adjustment............................................................................308 CARRIAGE ADJUSTMENT..................................................................................310 TROUBLESHOOTING..........................................................................................312 Master Cylinder..............................................................................................313 INTRODUCTION.............................................................................................313 GENERAL..............................................................................................313 DESCRIPTION..........................................................................................313 REPAIRS..................................................................................................313 REMOVAL AND DISASSEMBLY..............................................................................313 CLEANING ............................................................................................314 ASSEMBLY.............................................................................................314 CHECKS AND ADJUSTMENTS...................................................................................314 CHECKS...............................................................................................314 Oil Clutch Transmission......................................................................................315 INTRODUCTION.............................................................................................315 GENERAL..............................................................................................315 DESCRIPTION..........................................................................................315 REPAIRS..................................................................................................318 REMOVAL..............................................................................................318 DISASSEMBLY..........................................................................................318 CLEANING.............................................................................................325 INSPECTION...........................................................................................325 ASSEMBLY.............................................................................................325 INSTALLATION.........................................................................................333 TROUBLESHOOTING..........................................................................................333 SPECIFICATIONS...........................................................................................334 Oil Clutch...................................................................................................335 INTRODUCTION.............................................................................................335 GENERAL..............................................................................................335 DESCRIPTION AND OPERATION ...........................................................................335 REPAIRS..................................................................................................336 REMOVAL..............................................................................................336 INSPECTION...........................................................................................336 INSTALLATION.........................................................................................337 ADJUSTMENTS..............................................................................................339 ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL.............................................................339 ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS....................339 TROUBLESHOOTING..........................................................................................340 Periodic Maintenance.........................................................................................342 INTRODUCTION.............................................................................................342 General..............................................................................................342 MAINTENANCE SCHEDULE.....................................................................................342 MAINTENANCE PROCEDURES Every 8 Hours or Daily............................................................345 Checks with the Engine Stopped.......................................................................345 Hydraulic System.................................................................................345 Air Cleaner......................................................................................345 Engine Oil.......................................................................................345 Fuel Filter (Diesel).............................................................................345 Battery..........................................................................................346 Cooling System...................................................................................346 Drive Belts......................................................................................346 Tires and Wheels.................................................................................347 Lift Mechanism...................................................................................348 Forks............................................................................................348 Lift Chains......................................................................................348 Upright..........................................................................................349 Carriage.........................................................................................349 Load Backrest Extension..........................................................................349 Powershift Transmission..........................................................................349 Checks with the Engine Running.......................................................................349 Guages and Lights................................................................................350 Powershift Transmission..........................................................................350 Brakes...........................................................................................350 Steering System..................................................................................350 Hydraulic System.................................................................................352 Uprights.........................................................................................352 Attachments......................................................................................352 Every 350 Hours or Two Months........................................................................353 Engine Oil and Filter............................................................................353 Brake Fluid......................................................................................353 Hydraulic Tank Breather..........................................................................353 Forks............................................................................................353 Uprights.........................................................................................354 Other Lubrication Points.........................................................................355 Every 1000 Hours or Six Months.......................................................................355 Final Fuel Filter (Diesel).......................................................................355 Removing Air From The Diesel Fuel System.........................................................355 Ignition System (Gas Engine......................................................................356 PCV Valve (Gas Engine)...........................................................................356 Every 2000 Hours or Yearly...........................................................................357 PCV Valve (Gas Engine)...........................................................................357 PCV Valve (Diesel Engine)........................................................................357 Differential.....................................................................................358 Adjusting The Oil Clutch Pedal...................................................................358 Hydraulic System.................................................................................358 Changing The Gasoline Fuel System................................................................359 Changing The Fuel Filter for LPG.................................................................359 WHEELS AND TIRES.........................................................................................360 Drive Tires..........................................................................................360 Steering Tires.......................................................................................363 Perkins Engine 4.2032........................................................................................364 INTRODUCTION.............................................................................................364 General..............................................................................................364 Description..........................................................................................364 ENGINE REPAIRS...........................................................................................364 REMOVAL AND INSTALLATION.................................................................................364 CYLINDER HEAD............................................................................................364 Removal..............................................................................................364 Installation.........................................................................................364 CYLINDER HEAD REPAIRS....................................................................................366 Valve Seats..............................................................................................366 Valve Springs............................................................................................366 Cylinder Head........................................................................................366 Valves...............................................................................................367 Valve Guides.........................................................................................367 ROCKER ARM ASSEMBLY......................................................................................367 Disassembly and Repair...............................................................................367 Assembly and Installation............................................................................368 COMBUSTION CHAMBER PLUGS.................................................................................368 TIMING GEAR CASE AND TIMING GEARS........................................................................368 Removal..............................................................................................368 Installation.........................................................................................369 PISTONS AND CONNECTING RODS..............................................................................371 Removal..............................................................................................371 Disassembly..........................................................................................371 Inspection...........................................................................................372 Assembly.............................................................................................372 Installation.........................................................................................373 CRANKCASE, MAIN BEARINGS AND CYLINDER LINERS.............................................................373 Removal of the Crankshaft............................................................................373 Inspection...........................................................................................374 Installation.........................................................................................375 Cylinder Liners......................................................................................376 Removal..........................................................................................376 Installation.....................................................................................376 CAMSHAFT AND CAM FOLLOWERS...............................................................................377 Removal..............................................................................................377 Inspection...........................................................................................377 Assembly and Installation............................................................................377 FUEL SYSTEM..............................................................................................378 Fuel Pump............................................................................................378 Removal..........................................................................................378 Installation.....................................................................................379 Fuel Injection Pump..................................................................................379 Removal..........................................................................................379 Repairs..........................................................................................379 Installation.....................................................................................380 Fuel Injectors.......................................................................................380 Removal..........................................................................................380 Repairs..........................................................................................380 Installation.....................................................................................380 Cold Start aid.......................................................................................380 Description......................................................................................380 Removal..........................................................................................380 Installation.....................................................................................381 COOLING SYSTEM...........................................................................................381 Thermostat...........................................................................................381 Water Pump...........................................................................................381 Removal..........................................................................................381 Installation.....................................................................................382 OIL PUMP.................................................................................................383 Removal..............................................................................................383 Installation.........................................................................................384 FLYWHEEL AND FLYWHEEL HOUSING............................................................................384 Removal..............................................................................................384 Installation.........................................................................................384 CHECKS AND ADJUSTMENTS...................................................................................385 Checking the Fuel Injector...........................................................................385 Removing the Air from the Fuel System................................................................385 Timing of the Fuel Injection Pump....................................................................386 Checking the Timing for Old Style Pumps..........................................................386 Making New Timing Mark on a New Timing Gear Case.................................................388 Checking the Timing Mark of a New Fuel Injection Pump............................................389 Valve Clearance Adjustment...........................................................................389 Adjusting the Throttle Linkage.......................................................................390 TROUBLESHOOTING..........................................................................................391 SPECIFICATIONS...........................................................................................392 Rochester Carburetor.........................................................................................395 INTRODUCTION.............................................................................................395 GENERAL..............................................................................................395 DESCRIPTION..........................................................................................395 OPERATION............................................................................................396 The Float System.................................................................................396 The Idle System..................................................................................396 The Main Metering System (GM 6-250)..............................................................397 The Power System (GM 6-250)......................................................................398 The Accelerator Pump System......................................................................398 Choke System.....................................................................................398 REPAIRS..................................................................................................399 REMOVAL..............................................................................................399 DISASSEMBLY..........................................................................................399 Cleaning.............................................................................................399 ASSEMBLY.............................................................................................399 INSTALLATION.........................................................................................399 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)......................................................404 GOVERNOR (PNEUMATIC) (Early Units)...................................................................405 CHECKS AND ADJUSTMENTS...................................................................................406 GENERAL..............................................................................................406 ADJUST THE CHOKE CONTROL.............................................................................406 ADJUST THE IDLE SPEED................................................................................406 ADJSUT THE IDLE MIXTURE..............................................................................407 ADJUST THE FAST IDLE.................................................................................407 ADJUST THE THROTTLE LINKAGE,(Later Models)...........................................................408 ADJUST THE THROTTLE LINKAGE,(Early Models)...........................................................409 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)........................................409 Check the Governor...............................................................................409 GOVERNOR (AISAN Type) (Early GM Engines Only)........................................................410 Checks...........................................................................................411 Adjustments......................................................................................411 GOVERNOR (HOOF Type) (Early GM Engines Only).........................................................411 Adjust the Governor..............................................................................411 TROUBLESHOOTING..........................................................................................413 Single-SPD PS Trans-Repair...................................................................................414 INTRODUCTION.............................................................................................414 General..............................................................................................414 REPAIRS..................................................................................................415 REMOVAL..................................................................................................415 DISASSEMBLY..............................................................................................415 CLEANING.................................................................................................423 INSPECTION...............................................................................................424 ASSEMBLY.................................................................................................424 Assembling the Control Valve.........................................................................424 Assembling the Differential..........................................................................427 Assembling the Transmission..........................................................................435 Installation.........................................................................................439 MONOTROL Pedal.......................................................................................439 CHECKS AND ADJUSTMENTS...................................................................................440 Checking the MONOTROL Pedal for Leakage..............................................................440 MONOTROL Pedal.......................................................................................440 Stall Test...........................................................................................440 Checking the Oil Pressures...........................................................................441 MONOTROL Pressure................................................................................442 Clutch Apply Pressure............................................................................444 Inching Spool Operation..........................................................................445 Torque Converter and Oil Cooler Pressure.........................................................445 CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT...............................................................445 CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER.....................................................446 ADJUSTING THE OIL SUMP TUBE..............................................................................447 TROUBLESHOOTING..........................................................................................447 Pressure Tests.......................................................................................450 Troubleshooting the Differential.....................................................................451 Starter......................................................................................................453 INTRODUCTION.............................................................................................453 GENERAL..............................................................................................453 DESCRIPTION AND OPERATION............................................................................453 REPAIRS..................................................................................................455 REMOVAL..............................................................................................455 DISSASEMBLY..........................................................................................455 CLEANING.............................................................................................456 ASSEMBLY.............................................................................................456 INSTALLATION.........................................................................................456 CHECKS AND ADJUSTMENTS...................................................................................457 GENERAL..............................................................................................457 TROUBLESHOOTING..........................................................................................459 Steer Axle...................................................................................................461 INTRODUCTION.............................................................................................461 DESCRIPTION..........................................................................................461 GENERAL..............................................................................................461 REPAIRS..................................................................................................462 STEERING AXLE........................................................................................462 Removal..............................................................................................462 Installation.........................................................................................463 STEERING CYLINDER....................................................................................463 Removal..............................................................................................463 Service..............................................................................................464 Installation.........................................................................................464 HUBS.................................................................................................464 Removal..............................................................................................464 Installation.........................................................................................465 SPINDLES.............................................................................................465 Removal..............................................................................................465 Installation.........................................................................................466 CHECKS AND ADJUSTMENTS...................................................................................466 REMOVE THE AIR FROM THE STEERING SYSTEM..............................................................466 SET THE PRESSURE RELIEF VALVE........................................................................466 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)..............................................466 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION...................................................466 H2.00-3.00J (H40-60J) With Powershift Transmission...................................................466 TROUBLESHOOTING..........................................................................................468 Steering control Unit........................................................................................469 INTRODUCTION.............................................................................................469 GENERAL..............................................................................................469 DESCRIPTION..........................................................................................469 OPERATION............................................................................................469 REPAIRS..................................................................................................469 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................469 TYPE "A" STEERING COLUMN ASSEMBLY....................................................................471 Removal And Disassembly..........................................................................471 Assembly And Installation........................................................................471 TYPE "A" STEERING COLUMN.............................................................................472 TYPE "A" STEERING COLUMN.............................................................................473 TYPE "B" STEERING COLUMN.............................................................................474 Removal And Disassembly..........................................................................474 Assembly And Installation........................................................................474 TYPE "B" STEERING COLUMN.............................................................................475 Disassembly of Steering Control Unit.............................................................476 Cleaning of Steering Control Unit................................................................476 Assembly of Steering Control Unit................................................................478 CHECKS AND ADJUSTMENTS...................................................................................481 REMOVE AIR FROM THE SYSTEM...........................................................................481 TROUBLESHOOTING..........................................................................................482 Tilt Cylinders...............................................................................................483 INTRODUCTION.............................................................................................483 GENERAL..............................................................................................483 DESCRIPTION..........................................................................................483 REPAIRS..................................................................................................483 REMOVAL..............................................................................................483 DISASSEMBLY..........................................................................................483 CLEANING.............................................................................................483 ASSEMBLY.............................................................................................483 Tilt Cylinders with O-Rings or Single Lip Seals..................................................483 Tilt Cylinders for the XM and XMS Models.........................................................484 Tilt Cylinders for H700 800A and Early Model H700 920B...........................................486 INSTALLATION.........................................................................................486 Tilt Cylinders Using Chevron Packing.............................................................487 CHECKS AND ADJUSTMENTS...................................................................................489 CHECK THE TILT CYLINDERS FOR LEAKS...................................................................489 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..............................................489 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.................................................490 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS................................................491 TROUBLESHOOTING..........................................................................................493 Vista Uprights Description & Operation.......................................................................494 INTRODUCTION.............................................................................................494 GENERAL..............................................................................................494 VISTA TWO-STAGE MASTS....................................................................................496 DESCRIPTION..........................................................................................496 OPERATION............................................................................................499 VISTA THREE-STAGE MASTS..................................................................................499 DESCRIPTION..........................................................................................499 OPERATION............................................................................................501 SEQUENCE VALVE.......................................................................................503 Vista Uprights-Repair........................................................................................506 INTRODUCTION.............................................................................................506 GENERAL..............................................................................................506 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................506 REPAIRS..................................................................................................507 FORKS................................................................................................507 Removal..........................................................................................507 CARRIAGE.............................................................................................507 Removal (Two-Stage and Later Production Three-Stage Carriages)...................................507 Removal (Carriages with Removable Stop Block)....................................................508 Installation (Two-Stage and Later Production Three-Stage Carriages)..............................509 Installation (Carriages With Removable Stop Block)...............................................509 TWO-STAGE MASTS..........................................................................................511 REMOVAL..............................................................................................511 DISASSEMBLY..........................................................................................512 CLEANING AND INSPECTION..............................................................................513 ASSEMBLY.............................................................................................514 INSTALLATION.........................................................................................515 THREE-STAGE MASTS........................................................................................515 REMOVAL..............................................................................................515 DISASSEMBLY..........................................................................................515 CLEANING AND INSPECTION..............................................................................517 ASSEMBLY.............................................................................................517 INSTALLATION.........................................................................................518 LIFT AND TILT CYLINDERS..............................................................................519 SIDE SHIFT CARRIAGE..................................................................................519 Removal..........................................................................................519 Repairs..........................................................................................519 Installation.....................................................................................519 SEQUENCE VALVE.......................................................................................520 Removal and Disassembly..........................................................................523 Cleaning.........................................................................................523 Assembly and Installation........................................................................523 CHECKS AND ADJUSTMENTS...................................................................................524 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................524 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................524 LIFTING CHAIN ADJUSTMENTS............................................................................525 MAST ADJUSTMENTS.....................................................................................526 CARRIAGE ADJUSTMENT..................................................................................527 HEADER HOSE ROLLER ADJUSTMENT, 2-STAGE...............................................................528 TROUBLESHOOTING..........................................................................................529 TORQUE SPECIFICATIONS....................................................................................530 VISTA MASTS..............................................................................................531
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