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Hyster Forklift S30 50E, S60ES service manual – PDF DOWNLOAD
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Description
Hyster Forklift S30 50E, S60ES service manual
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Hyster Forklift S30 50E, S60ES service manual
Language : English
Pages : 355
Size : 9.70 MB
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Format : PDF
HYSTER FORKLIFT S30 50E, S60ES SERVICE MANUAL – PDF DOWNLOAD:
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Hyster Forklift S30 50E, S60ES service manual
- NOTE: For this SRM section, the alternators are in two groups, Type A and Type B. The two types are very similar, but the Type A alternators have a set of three diodes (diode set) as well as the diode bridge. The Type B alternator has zener diodes as part of the diodes in the diode bridge.
- This alternator does not have a diode set, but does have an additional fan inside the rear housing. The basic operation of both types is very similar. The alternator generates an alternating current when the engine is running. The alternator is either ON or OFF. The alternator generates maximum current when it is ON and no current when it is OFF. The regulator switches the alternator between ON and OFF to get the average current needed to charge the battery.
- Alternator output is directly changed by engine speed and rotor field current. The alternating current is changed to a direct current by the diode bridge inside the alternator.
Table of Contents:
Hyster Forklift S30 50E, S60ES service manual
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 INTRODUCTION............................................................................................. 16 GENERAL.............................................................................................. 16 DESCRIPTION AND OPERATION............................................................................ 16 REPAIRS.................................................................................................. 20 CLEANING PROCEDURES.................................................................................. 20 REMOVAL AND DISASSEMBLY.............................................................................. 20 INSPECTION........................................................................................... 21 ASSEMBLY............................................................................................. 22 CHECKS AND ADJUSTMENTS................................................................................... 24 ADJUSTING THE SERVICE BRAKES......................................................................... 24 ADJUSTING THE PARKING BRAKE.......................................................................... 24 REMOVING THE AIR FROM THE BRAKE SYSTEM............................................................... 24 ADJUSTING THE SERVICE BRAKE PEDAL.................................................................... 25 TROUBLESHOOTING.......................................................................................... 26 INTRODUCTION............................................................................................. 31 GENERAL.............................................................................................. 31 DESCRIPTION.......................................................................................... 31 REPAIRS.................................................................................................. 34 FAN ASSEMBLY......................................................................................... 34 Removal (S30–120E)............................................................................... 34 Removal (H60–110E)............................................................................... 34 Disassembly (S30–120E)........................................................................... 34 Disassembly (H60–110E)........................................................................... 35 Assembly (Both Series)........................................................................... 35 Fan Belt Adjustment.............................................................................. 38 Installation..................................................................................... 38 RADIATOR............................................................................................. 39 Removal.......................................................................................... 39 Installation..................................................................................... 39 Cleaning and Inspection.......................................................................... 40 TROUBLESHOOTING.......................................................................................... 41 INTRODUCTION............................................................................................. 48 General.............................................................................................. 48 Description.......................................................................................... 48 REPAIRS.................................................................................................. 49 Removal.............................................................................................. 49 Installation......................................................................................... 50 Axle Housing For S30-100E And S40-50F Lift Trucks.................................................... 51 Wheels And Tires..................................................................................... 53 TROUBLESHOOTING.......................................................................................... 55 SPECIFICATIONS........................................................................................... 56 HIGH ENERGY IGNITION (HEI)............................................................................... 58 DESCRIPTION.......................................................................................... 58 REPAIRS.................................................................................................. 60 DISTRIBUTOR.......................................................................................... 60 Removal.......................................................................................... 60 Disassembly...................................................................................... 60 Assembly......................................................................................... 65 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED......................... 66 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED.......................... 67 IGNITION COIL........................................................................................ 67 Removal, Some 4 And 6 Cylinder Models............................................................ 67 Installation, Some 4 And 6 Cylinder Models....................................................... 68 Removal, V8, Some 4 And 6 Cylinder Models........................................................ 68 Installation, V8, Some 4 And 6 Cylinder Models................................................... 69 ELECTRONIC MODULE.................................................................................... 70 Removal.......................................................................................... 70 Installation..................................................................................... 70 SENSING COIL......................................................................................... 71 Removal.......................................................................................... 71 Installation..................................................................................... 71 SPARK PLUGS.......................................................................................... 71 Removal.......................................................................................... 71 Installation..................................................................................... 72 CHECKS AND ADJUSTMENTS............................................................................... 72 Visual Checks.................................................................................... 72 Check The High Voltage Wires..................................................................... 72 Checking The Ignition Coil....................................................................... 72 Coil In Distributor Cap Design................................................................... 72 Separate Coil Design............................................................................. 73 Checking The Sensing Coil........................................................................ 73 Check The Electronic Module...................................................................... 74 Ignition Timing Adjustment....................................................................... 74 Ignition System, GM V8-366 (6-litre)............................................................. 75 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)................................. 75 SPECIFICATIONS........................................................................................... 75 TROUBLESHOOTING.......................................................................................... 76 ELECTRICAL WARNING DEVICES............................................................................... 77 GENERAL.............................................................................................. 77 DESCRIPTION.......................................................................................... 77 Operator Controlled Horns........................................................................ 77 System Warning Lights, Buzzers and Bells......................................................... 77 Reverse Warning Horns............................................................................ 78 Warning Lights................................................................................... 78 REPLACEMENT.......................................................................................... 79 General.......................................................................................... 79 Replacing Horns or Bells......................................................................... 79 Replacing Horn Relay or Buzzer................................................................... 79 Replacing Warning Lights......................................................................... 79 Light Assemblies................................................................................. 80 Replacing Flashing Units......................................................................... 80 INTRODUCTION............................................................................................. 81 General.............................................................................................. 81 Description.......................................................................................... 81 Operation............................................................................................ 81 Flow Regulator Valve............................................................................. 82 Steering Relief Valve............................................................................ 83 Relief Valve for Cold Oil........................................................................ 84 REPAIRS.................................................................................................. 84 Removal.............................................................................................. 84 Disassembly.......................................................................................... 84 Cleaning and Inspection.............................................................................. 84 Assembly and Installation............................................................................ 84 CHECKS AND ADJUSTMENTS................................................................................... 85 Removing air from the Hydraulic System............................................................... 85 Adjusting the Setting of the Relief Valve............................................................ 85 INTRODUCTION............................................................................................. 87 General.............................................................................................. 87 Description.......................................................................................... 87 DISASSEMBLY AND ASSEMBLY................................................................................. 88 Counterweight........................................................................................ 88 Hood and Seat........................................................................................ 90 Operator Restraint System............................................................................ 91 Exhaust System....................................................................................... 92 Overhead Guard....................................................................................... 92 Engine (Removal and Installation).................................................................... 95 REPAIRS.................................................................................................. 97 Fuel and Hydraulic Tanks............................................................................. 97 Decal Replacement.................................................................................... 98 INTRODUCTION.............................................................................................100 GENERAL..............................................................................................100 DESCRIPTION..........................................................................................101 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................101 CYLINDER HEAD AND MECHANISM..........................................................................101 Cylinder Head, Removal...........................................................................101 Cylinder Head, Disassembly.......................................................................102 Cleaning And Inspection..........................................................................103 Valve And Valve Seats............................................................................104 Studs For The Rocker Arms........................................................................104 Hydraulic Valve Lifters, Replacement.............................................................104 Hydraulic Valve Lifters, Cleaning And Inspection.................................................105 Cylinder Head, Assembly..........................................................................105 Cylinder Head, Installation......................................................................105 Rocker Arm Cover, Installation...................................................................106 TIMING GEAR COVER....................................................................................107 Removal..........................................................................................107 Installation.....................................................................................107 CAMSHAFT.............................................................................................108 Removal..........................................................................................108 Inspection.......................................................................................109 Camshaft Bearings, Removal.......................................................................109 Camshaft Bearings, Installation..................................................................109 DISTRIBUTOR..........................................................................................110 Removal..........................................................................................110 Installation.....................................................................................110 LUBRICATION SYSTEM...................................................................................111 Oil Sump, Removal................................................................................111 Oil Sump, Installation...........................................................................111 Oil Pump, Removal................................................................................111 Oil Pump, Disassembly and Repair.................................................................111 Oil Pump, Assembly...............................................................................112 Oil Pump, Installation...........................................................................112 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................112 Connecting Rod Bearings, Replacement.............................................................112 Piston And Connecting Rod Assemblies, Removal....................................................113 Disassembly......................................................................................114 Piston, Cleaning And Inspection..................................................................114 Cylinder Bores, Inspection And Repair............................................................114 Piston Rings.....................................................................................115 Assembly.........................................................................................116 Piston And Connecting Rod Assemblies, Installation...............................................116 CRANKSHAFT...........................................................................................117 Main Bearings, Replacement.......................................................................117 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................118 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........118 Crankshaft, Removal..............................................................................119 Inspection and Repair............................................................................120 How To Check The Clearance Between The Main Bearings And Their Journals..........................120 Installation.....................................................................................121 FLYWHEEL AND FLYWHEEL HOUSING........................................................................122 Flywheel, Removal................................................................................122 Ring Gear, Replacement...........................................................................123 Flywheel, Installation...........................................................................123 COOLING SYSTEM.......................................................................................123 Coolant Pump.....................................................................................123 Fan Drive........................................................................................124 Viscous Fan Drive................................................................................124 ENGINE SPECIFICATIONS....................................................................................125 ENGINE DATA..........................................................................................125 CYLINDER HEAD........................................................................................125 HYDRAULIC VALVE LIFTER...............................................................................126 CAMSHAFT.............................................................................................126 PISTONS..............................................................................................126 CYLINDER BORE........................................................................................127 CRANKSHAFT...........................................................................................127 CONNECTING RODS......................................................................................127 COOLING SYSTEM.......................................................................................128 LUBRICATION SYSTEM...................................................................................128 TORQUE SPECIFICATIONS....................................................................................128 HIGH ENERGY IGNITION (HEI)...............................................................................131 DESCRIPTION..........................................................................................131 REPAIRS..................................................................................................133 DISTRIBUTOR..........................................................................................133 Removal..........................................................................................133 Disassembly......................................................................................133 Assembly.........................................................................................138 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................139 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................140 IGNITION COIL........................................................................................140 Removal, Some 4 And 6 Cylinder Models............................................................140 Installation, Some 4 And 6 Cylinder Models.......................................................141 Removal, V8, Some 4 And 6 Cylinder Models........................................................141 Installation, V8, Some 4 And 6 Cylinder Models...................................................142 ELECTRONIC MODULE....................................................................................143 Removal..........................................................................................143 Installation.....................................................................................143 SENSING COIL.........................................................................................144 Removal..........................................................................................144 Installation.....................................................................................144 SPARK PLUGS..........................................................................................144 Removal..........................................................................................144 Installation.....................................................................................145 CHECKS AND ADJUSTMENTS...............................................................................145 Visual Checks....................................................................................145 Check The High Voltage Wires.....................................................................145 Checking The Ignition Coil.......................................................................145 Coil In Distributor Cap Design...................................................................145 Separate Coil Design.............................................................................146 Checking The Sensing Coil........................................................................146 Check The Electronic Module......................................................................147 Ignition Timing Adjustment.......................................................................147 Ignition System, GM V8-366 (6-litre).............................................................148 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................148 SPECIFICATIONS...........................................................................................148 TROUBLESHOOTING..........................................................................................149 INTRODUCTION.............................................................................................150 DESCRIPTION..........................................................................................150 OPERATION............................................................................................150 Flow Control Valve...............................................................................152 Relief Valve.....................................................................................152 REPAIRS..................................................................................................153 REMOVAL..............................................................................................153 DISASSEMBLY..........................................................................................153 CLEANING.............................................................................................155 INSPECTION...........................................................................................155 ASSEMBLY.............................................................................................156 INSTALLATION.........................................................................................157 CHECKS AND ADUSTMENTS....................................................................................158 CHECK THE OUTPUT OF THE PUMP.........................................................................158 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................158 TROUBLESHOOTING..........................................................................................160 INTRODUCTION.............................................................................................163 GENERAL..............................................................................................163 DESCRIPTION..........................................................................................163 REPAIRS..................................................................................................163 REMOVAL AND DISASSEMBLY..............................................................................163 CLEANING.............................................................................................165 INSPECTION...........................................................................................165 ASSEMBLY AND INSTALLATION............................................................................165 TROUBLESHOOTING..........................................................................................167 GENERAL..............................................................................................167 INTRODUCTION.............................................................................................168 GENERAL..............................................................................................168 DESCRIPTION..............................................................................................168 GENERAL..............................................................................................168 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................171 LED DISPLAY PANEL....................................................................................171 Battery Discharge Indicators.....................................................................171 Brush Wear Indicators............................................................................172 Motor Temperature Indicators.....................................................................173 "LX" SERIES DISPLAY PANEL............................................................................174 Hourmeter Functions..............................................................................175 Battery Indicator Function.......................................................................175 Status Code Function.............................................................................175 "ZX" SERIES DISPLAY PANELS...........................................................................175 Display Panel....................................................................................176 Basic Display Panels.............................................................................176 Performance Display..............................................................................178 Brush Wear Indicators............................................................................181 CHECKS AND ADJUSTMENTS...................................................................................181 GENERAL..............................................................................................181 REPLACEMENT..............................................................................................182 GENERAL..............................................................................................182 METER REPLACEMENT....................................................................................182 SENDER REPLACEMENT...................................................................................183 Fuel Level Sender................................................................................183 Pressure And Temperature Sender..................................................................183 I.T.W. DISPLAY PANEL.................................................................................184 Removal..........................................................................................184 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................185 Removal..........................................................................................185 Replacing Display Panel Assembly.................................................................185 Indicator LEDs...................................................................................185 Battery Indicators...............................................................................185 Digital Display (Performance Disply Panel Only)..................................................185 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....185 Replacing Parts Of The Basic Display Panel.......................................................186 Replacing Parts Of The Performance Display Panel.................................................188 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................188 Removal And Replacement..........................................................................188 SPECIFICATIONS...........................................................................................189 TROUBLESHOOTING..........................................................................................190 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................191 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................191 LIFT CYLINDERS...........................................................................................194 GENERAL..............................................................................................194 DESCRIPTION..........................................................................................194 Lowering Control Valve...........................................................................194 Cylinders (General)..............................................................................197 Cylinders (H520-620B,H700-800A)..................................................................199 Cylinders (H360-460B)............................................................................200 Cylinders (Two-Speed)............................................................................200 REPAIRS..................................................................................................201 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................201 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........201 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................205 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................203 DISASSEMBLY..........................................................................................203 ASSEMBLY.............................................................................................205 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................205 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........205 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................205 CHEVRON PACKING......................................................................................206 LIFT CYLINDERS FOR VISTA MASTS...........................................................................209 DESCRIPTION..........................................................................................209 Lowering Control Valve...........................................................................211 REMOVAL..............................................................................................212 DISASSEMBLY..........................................................................................212 ASSEMBLY.............................................................................................212 INSTALLATION.........................................................................................213 Main Lift Cylinders..............................................................................213 Free-Lift Cylinders..............................................................................213 CHECKS AND ADJUSTMENTS...................................................................................214 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................214 TROUBLESHOOTING..........................................................................................215 SPECIFICATIONS...........................................................................................216 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................217 GENERAL..............................................................................................217 DESCRIPTION..........................................................................................217 Fuel Tank........................................................................................218 Fuel Filter And Fuel Valve Unit..................................................................219 Vaporizer........................................................................................219 The IMPCO CA 100 Carbureto.......................................................................221 IMPCO CA 50 Carburetor...........................................................................223 The Governor (GM Engines Only)...................................................................224 Governor With Electronic Controller..............................................................225 REPAIRS..................................................................................................226 LPG TANK.............................................................................................226 Removal..........................................................................................226 Installation.....................................................................................227 REPLACE THE HOSES....................................................................................227 HYDROSTATIC RELIEF VALVE.............................................................................227 Removal and Installation.........................................................................227 FILTER UNIT..........................................................................................228 Replacement Of the Fuel Filter Element...........................................................228 Replacement of the Diaphragm and Fuel Valve......................................................229 VAPORIZER............................................................................................229 Removal..........................................................................................229 Disassembly......................................................................................229 Cleaning.........................................................................................229 Inspection.......................................................................................229 Assembly.........................................................................................231 Installation.....................................................................................231 CARBURETOR (IMPCO CA 100)............................................................................233 Removal..........................................................................................233 Disassembly......................................................................................233 Cleaning.........................................................................................233 Assembly.........................................................................................233 Installation.....................................................................................236 CARBURETER (IMPCO CA 50).............................................................................235 Removal..........................................................................................235 Disassembly......................................................................................235 Cleaning.........................................................................................236 Inspection.......................................................................................236 Assembly (See FIGURE 26.)........................................................................236 Installation.....................................................................................236 CHECKS AND ADJUSTMENTS...................................................................................237 CHECK THE FILTER UNIT................................................................................237 CHECK THE VAPORIZER..................................................................................237 Pressure Reducer Valve...........................................................................237 Vapor Valve......................................................................................237 ADJUST THE CARBURETOR................................................................................237 Idle Mixture.....................................................................................237 Idle Speed.......................................................................................237 Power Mixture....................................................................................237 ADJUST THE GOVERNOR (GM Engines Only)................................................................238 Checks...........................................................................................238 Main Adjusting Screw.............................................................................238 Secondary Adjusting Screw........................................................................238 AISAN Governor...................................................................................239 Adjustment, AISAN Governor.......................................................................239 TROUBLESHOOTING..........................................................................................240 INTRODUCTION.............................................................................................244 GENERAL..............................................................................................244 DESCRIPTION..........................................................................................244 OPERATION............................................................................................246 Lift Spool.......................................................................................246 Tilt Spool.......................................................................................246 Relief Valve, Single–Stage.......................................................................249 Relief Valve, Two–Stage..........................................................................250 REPAIRS..................................................................................................250 REMOVAL AND DISASSEMBLY..............................................................................250 CLEANING AND INSPECTION..............................................................................251 ASSEMBLY.............................................................................................251 INSTALLATION.........................................................................................251 CHECKS AND ADJUSTMENTS...................................................................................251 ADJUST THE SINGLE–STAGE RELIEF VALVE.................................................................251 ADJUST THE TWO–STAGE RELIEF VALVE....................................................................252 ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY................................253 TROUBLESHOOTING..........................................................................................253 INTRODUCTION.............................................................................................255 GENERAL..............................................................................................255 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................257 FULL FREE-LIFT MASTS.................................................................................257 THREE-STAGE MASTS....................................................................................259 FOUR-STAGE MASTS.....................................................................................260 SEQUENCE VALVE.......................................................................................260 INTRODUCTION.............................................................................................262 GENERAL..............................................................................................262 REPAIRS..................................................................................................262 FORKS................................................................................................262 CARRIAGE.............................................................................................262 Removal..........................................................................................262 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................263 Installation.....................................................................................264 MASTS................................................................................................266 Removal..........................................................................................266 Disassembly......................................................................................268 Cleaning and Inspection..........................................................................272 Assembly.........................................................................................273 INSTALLATION.........................................................................................274 CHECKS AND ADJUSTMENTS...................................................................................274 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................274 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................275 LIFT CHAIN ADJUSTMENTS...............................................................................275 MAST ADJUSTMENTS.....................................................................................276 Guide Shoe Adjustment............................................................................277 CARRIAGE ADJUSTMENT..................................................................................279 TROUBLESHOOTING..........................................................................................281 INTRODUCTION.............................................................................................282 GENERAL..............................................................................................282 DESCRIPTION..........................................................................................282 REPAIRS..................................................................................................282 REMOVAL AND DISASSEMBLY..............................................................................282 CLEANING ............................................................................................283 ASSEMBLY.............................................................................................283 CHECKS AND ADJUSTMENTS...................................................................................283 CHECKS...............................................................................................283 INTRODUCTION.............................................................................................284 General..............................................................................................284 Description..........................................................................................284 REAPAIRS.................................................................................................286 Removal..............................................................................................286 Cleaning.............................................................................................286 Inspection...........................................................................................286 Installation.........................................................................................286 CHECKS AND ADJUSTMENTS...................................................................................288 Adjusting the Clutch Pedal Height....................................................................288 Adjusting the Clearance of the Release Mechanism.....................................................288 TROUBLESHOOTING..........................................................................................289 INTRODUCTION.............................................................................................291 General..............................................................................................291 Maintenance Schedule.................................................................................291 MAINTENANCE PROCEDURES...................................................................................294 EVERY 8 HOURS OR DAILY...................................................................................294 Checks With The Engine Running.......................................................................298 Checks With The Engine Stopped.......................................................................294 EVERY 350 HOURS OR TWO MONTHS............................................................................299 Engine Oil And Filter ...............................................................................299 Fuel Filter (Diesel).................................................................................299 Removing Air From The Diesel Fuel System.............................................................300 Brake Fluid..........................................................................................300 Hydraulic Tank Breather..............................................................................300 Cooling Fan..........................................................................................301 Other Lubrication Points.............................................................................301 Uprights.............................................................................................301 Forks................................................................................................302 EVERY 1000 HOURS OR SIX MONTHS...........................................................................303 Ignition System (Gas Engine).........................................................................303 PCV Valve (Gas Engine)...............................................................................303 EVERY 2000 HOURS OR YEARLY...............................................................................303 PCV Valve (Gas Engine)...............................................................................303 Differential.........................................................................................303 Adjusting The Oil Clutch Pedal.......................................................................304 Oil Filter For The Powershift Transmission Or The Oil Clutch.........................................304 Hydraulic System.....................................................................................304 Changing The Gasoline Fuel Filter....................................................................304 Changing The Fule Filter For LPG.....................................................................304 WHEELS AND TIRES.........................................................................................305 Changing Tires.......................................................................................305 INTRODUCTION.............................................................................................306 General..............................................................................................306 Description..........................................................................................306 ENGINE REPAIRS...........................................................................................306 REMOVAL AND INSTALLATION.................................................................................306 CYLINDER HEAD............................................................................................306 Removal..............................................................................................306 Installation.........................................................................................306 CYLINDER HEAD REPAIRS....................................................................................308 Valve Seats..............................................................................................308 Valve Springs............................................................................................308 Cylinder Head........................................................................................308 Valves...............................................................................................309 Valve Guides.........................................................................................309 ROCKER ARM ASSEMBLY......................................................................................309 Disassembly and Repair...............................................................................309 Assembly and Installation............................................................................310 COMBUSTION CHAMBER PLUGS.................................................................................310 TIMING GEAR CASE AND TIMING GEARS........................................................................310 Removal..............................................................................................310 Installation.........................................................................................311 PISTONS AND CONNECTING RODS..............................................................................313 Removal..............................................................................................313 Disassembly..........................................................................................313 Inspection...........................................................................................314 Assembly.............................................................................................314 Installation.........................................................................................315 CRANKCASE, MAIN BEARINGS AND CYLINDER LINERS.............................................................315 Removal of the Crankshaft............................................................................315 Inspection...........................................................................................316 Installation.........................................................................................317 Cylinder Liners......................................................................................318 Removal..........................................................................................318 Installation.....................................................................................318 CAMSHAFT AND CAM FOLLOWERS...............................................................................319 Removal..............................................................................................319 Inspection...........................................................................................319 Assembly and Installation............................................................................319 FUEL SYSTEM..............................................................................................320 Fuel Pump............................................................................................320 Removal..........................................................................................320 Installation.....................................................................................321 Fuel Injection Pump..................................................................................321 Removal..........................................................................................321 Repairs..........................................................................................321 Installation.....................................................................................322 Fuel Injectors.......................................................................................322 Removal..........................................................................................322 Repairs..........................................................................................322 Installation.....................................................................................322 Cold Start aid.......................................................................................322 Description......................................................................................322 Removal..........................................................................................322 Installation.....................................................................................323 COOLING SYSTEM...........................................................................................323 Thermostat...........................................................................................323 Water Pump...........................................................................................323 Removal..........................................................................................323 Installation.....................................................................................324 OIL PUMP.................................................................................................325 Removal..............................................................................................325 Installation.........................................................................................326 FLYWHEEL AND FLYWHEEL HOUSING............................................................................326 Removal..............................................................................................326 Installation.........................................................................................326 CHECKS AND ADJUSTMENTS...................................................................................327 Checking the Fuel Injector...........................................................................327 Removing the Air from the Fuel System................................................................327 Timing of the Fuel Injection Pump....................................................................328 Checking the Timing for Old Style Pumps..........................................................328 Making New Timing Mark on a New Timing Gear Case.................................................330 Checking the Timing Mark of a New Fuel Injection Pump............................................331 Valve Clearance Adjustment...........................................................................331 Adjusting the Throttle Linkage.......................................................................332 TROUBLESHOOTING..........................................................................................333 SPECIFICATIONS...........................................................................................334 INTRODUCTION.............................................................................................337 GENERAL..............................................................................................337 DESCRIPTION..........................................................................................337 OPERATION............................................................................................338 The Float System.................................................................................338 The Idle System..................................................................................338 The Main Metering System (GM 6-250)..............................................................339 The Power System (GM 6-250)......................................................................340 The Accelerator Pump System......................................................................340 Choke System.....................................................................................340 REPAIRS..................................................................................................341 REMOVAL..............................................................................................341 DISASSEMBLY..........................................................................................341 Cleaning.............................................................................................341 ASSEMBLY.............................................................................................341 INSTALLATION.........................................................................................341 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)......................................................346 GOVERNOR (PNEUMATIC) (Early Units)...................................................................347 CHECKS AND ADJUSTMENTS...................................................................................348 GENERAL..............................................................................................348 ADJUST THE CHOKE CONTROL.............................................................................348 ADJUST THE IDLE SPEED................................................................................348 ADJSUT THE IDLE MIXTURE..............................................................................349 ADJUST THE FAST IDLE.................................................................................349 ADJUST THE THROTTLE LINKAGE,(Later Models)...........................................................350 ADJUST THE THROTTLE LINKAGE,(Early Models)...........................................................351 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)........................................351 Check the Governor...............................................................................351 GOVERNOR (AISAN Type) (Early GM Engines Only)........................................................352 Checks...........................................................................................353 Adjustments......................................................................................353 GOVERNOR (HOOF Type) (Early GM Engines Only).........................................................353 Adjust the Governor..............................................................................353 TROUBLESHOOTING..........................................................................................355
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
