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Hyster Forklift S40 50F service manual – PDF DOWNLOAD
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Description
Hyster Forklift S40 50F service manual
File Details:
Hyster Forklift S40 50F service manual
Language : English
Pages : 405
Size : 12.2 MB
Downloadable : Yes
Format : PDF
HYSTER FORKLIFT S40 50F SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster Forklift S40 50F service manual
- GENERAL This section has a description and the repair procedures for the alternator with a voltage regulator as part of the alternator. CAUTION When using an arc welder, always disconnect the ground lead from the lift truck battery to prevent alternator or battery damage.
- Attach the welding ground clamp as close to the weld area as possible to prevent welding current from damaging the bearings. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors in the electrical system. • Do not disconnect an electric wire before the engine is stopped and the switches are “OFF”. •
- Do not cause a short–circuit by connecting the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected. • Make sure a battery is the correct voltage and polarity before it is connected. • Do not check for current flow by making a spark because the electronic components can be damaged. NOTE: Information on alternators manufactured outside the United States is in the SRM (service repair manual) sections for lift trucks that use those alternators
- . DESCRIPTION (See FIGURE 1. and FIGURE 2.) 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 S40 50F 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 COOLING SYSTEM........................................................................................... 28 INTRODUCTION......................................................................................... 28 DESCRIPTION.......................................................................................... 28 RADIATOR............................................................................................. 28 RADIATOR CAP......................................................................................... 28 THERMOSTAT........................................................................................... 28 WATER PUMP........................................................................................... 29 FAN AND FAN SHROUD................................................................................... 29 REPAIRS.................................................................................................. 29 COOLING SYSTEM CHECKS................................................................................ 29 Exhaust Leaks.................................................................................... 29 RADIATOR............................................................................................. 29 Checks........................................................................................... 29 Cleaning The Radiator............................................................................ 29 Drain The Cooling System......................................................................... 31 Fill The Cooling System.......................................................................... 31 WATER PUMP........................................................................................... 31 Checks........................................................................................... 31 THERMOSTAT........................................................................................... 32 Checks........................................................................................... 32 FAN AND FAN SHROUD................................................................................... 32 TROUBLESHOOTING.......................................................................................... 33 FIGURE 1. SCHEMATIC FOR THE LIFT AND TILT SYSTEM......................................................... 34 FIGURE 2. ELECTRICAL SCHEMATIC........................................................................... 36 FIGURE 3. STEERING SYSTEM AND TRANSMISSION SCHEMATIC..................................................... 37 INTRODUCTION............................................................................................. 38 General.............................................................................................. 38 Description.......................................................................................... 38 REPAIRS.................................................................................................. 39 Removal.............................................................................................. 39 Installation......................................................................................... 40 Axle Housing For S30-100E And S40-50F Lift Trucks.................................................... 41 Wheels And Tires..................................................................................... 43 TROUBLESHOOTING.......................................................................................... 45 SPECIFICATIONS........................................................................................... 46 ELECTRICAL SYSTEM COMPLETELY DEAD........................................................................ 48 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN .................................................... 49 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER.............................................. 51 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK............................................. 52 STARTER CRANKS SLOWLY.................................................................................... 54 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START................................................ 55 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND.............................................................. 57 CHARGING SYSTEM DOES NOT FUNCTION........................................................................ 58 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW..................................................... 61 BATTERY IS BEING OVERCHARGED............................................................................. 64 ONE OR MORE DASH GAUGES DO NOT WORK...................................................................... 65 HORN DOES NOT BLOW....................................................................................... 69 POWERSHIFT TRANSMISSION WILL NOT ENGAGE.................................................................. 70 ELECTRICAL SCHEMATIC S20-30A, H20-30E.................................................................... 71 ELECTRICAL S30-50C....................................................................................... 72 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG.............................................................. 73 ELECTRICAL SCHEMATIC H30-60H DIESEL...................................................................... 75 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG.............................................................. 77 ELECTRICAL SCHEMATIC H60-90C DIESEL...................................................................... 78 ELECTRICAL SCHEMATIC S30-60ES............................................................................ 79 ELECTRICAL SCHEMATIC S60-120E............................................................................ 80 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG............................................................ 81 ELECTRICAL SCHEMATIC S125-150A DIESEL.................................................................... 82 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG............................................................ 83 ELECTRICAL SCHEMATIC H110-150F DIESEL.................................................................... 84 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG.................................................. 85 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL......................................................... 86 ELECTRICAL SCHEMATIC H300A............................................................................... 87 ELECTRICAL SCHEMATIC H300-350B........................................................................... 88 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL............................................................ 89 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL............................................................ 90 ELECTRICAL SCHEMATIC H700-800A........................................................................... 91 ELECTRICAL SCHEMATIC P40-50A GASOLINE.................................................................... 93 ELECTRICAL SCHEMATIC P40-50A DIESEL...................................................................... 94 ELECTRICAL SCHEMATIC P60-80A GASOLINE.................................................................... 95 ELECTRICAL SCHEMATIC P60-80A DIESEL...................................................................... 96 ELECTRICAL SCHEMATIC KE GAS GASOLINE..................................................................... 97 ELECTRICAL SCHEMATIC KE DIESEL........................................................................... 98 ELECTRICAL SCHEMATIC M200-400H GASOLINE.................................................................. 99 ELECTRICAL SCHEMATIC M200-400H DIESEL....................................................................101 ELECTRICAL SCHEMATIC M600A...............................................................................103 ELECTRICAL WARNING DEVICES...............................................................................105 GENERAL..............................................................................................105 DESCRIPTION..........................................................................................105 Operator Controlled Horns........................................................................105 System Warning Lights, Buzzers and Bells.........................................................105 Reverse Warning Horns............................................................................106 Warning Lights...................................................................................106 REPLACEMENT..........................................................................................107 General..........................................................................................107 Replacing Horns or Bells.........................................................................107 Replacing Horn Relay or Buzzer...................................................................107 Replacing Warning Lights.........................................................................107 Light Assemblies.................................................................................108 Replacing Flashing Units.........................................................................108 INTRODUCTION.............................................................................................109 General..............................................................................................109 Description..........................................................................................109 Operation............................................................................................109 Flow Regulator Valve.............................................................................110 Steering Relief Valve............................................................................111 Relief Valve for Cold Oil........................................................................112 REPAIRS..................................................................................................112 Removal..............................................................................................112 Disassembly..........................................................................................112 Cleaning and Inspection..............................................................................112 Assembly and Installation............................................................................112 CHECKS AND ADJUSTMENTS...................................................................................113 Removing air from the Hydraulic System...............................................................113 Adjusting the Setting of the Relief Valve............................................................113 INTRODUCTION.............................................................................................115 GENERAL..............................................................................................115 DESCRIPTION..........................................................................................116 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................116 CYLINDER HEAD AND MECHANISM..........................................................................116 Cylinder Head, Removal...........................................................................116 Cylinder Head, Disassembly.......................................................................117 Cleaning And Inspection..........................................................................118 Valve And Valve Seats............................................................................119 Studs For The Rocker Arms........................................................................119 Hydraulic Valve Lifters, Replacement.............................................................119 Hydraulic Valve Lifters, Cleaning And Inspection.................................................120 Cylinder Head, Assembly..........................................................................120 Cylinder Head, Installation......................................................................120 Rocker Arm Cover, Installation...................................................................121 TIMING GEAR COVER....................................................................................122 Removal..........................................................................................122 Installation.....................................................................................122 CAMSHAFT.............................................................................................123 Removal..........................................................................................123 Inspection.......................................................................................124 Camshaft Bearings, Removal.......................................................................124 Camshaft Bearings, Installation..................................................................124 DISTRIBUTOR..........................................................................................125 Removal..........................................................................................125 Installation.....................................................................................125 LUBRICATION SYSTEM...................................................................................126 Oil Sump, Removal................................................................................126 Oil Sump, Installation...........................................................................126 Oil Pump, Removal................................................................................126 Oil Pump, Disassembly and Repair.................................................................126 Oil Pump, Assembly...............................................................................127 Oil Pump, Installation...........................................................................127 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................127 Connecting Rod Bearings, Replacement.............................................................127 Piston And Connecting Rod Assemblies, Removal....................................................128 Disassembly......................................................................................129 Piston, Cleaning And Inspection..................................................................129 Cylinder Bores, Inspection And Repair............................................................129 Piston Rings.....................................................................................130 Assembly.........................................................................................131 Piston And Connecting Rod Assemblies, Installation...............................................131 CRANKSHAFT...........................................................................................132 Main Bearings, Replacement.......................................................................132 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................133 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........133 Crankshaft, Removal..............................................................................134 Inspection and Repair............................................................................135 How To Check The Clearance Between The Main Bearings And Their Journals..........................135 Installation.....................................................................................136 FLYWHEEL AND FLYWHEEL HOUSING........................................................................137 Flywheel, Removal................................................................................137 Ring Gear, Replacement...........................................................................138 Flywheel, Installation...........................................................................138 COOLING SYSTEM.......................................................................................138 Coolant Pump.....................................................................................138 Fan Drive........................................................................................139 Viscous Fan Drive................................................................................139 ENGINE SPECIFICATIONS....................................................................................140 ENGINE DATA..........................................................................................140 CYLINDER HEAD........................................................................................140 HYDRAULIC VALVE LIFTER...............................................................................141 CAMSHAFT.............................................................................................141 PISTONS..............................................................................................141 CYLINDER BORE........................................................................................142 CRANKSHAFT...........................................................................................142 CONNECTING RODS......................................................................................142 COOLING SYSTEM.......................................................................................143 LUBRICATION SYSTEM...................................................................................143 TORQUE SPECIFICATIONS....................................................................................143 HIGH ENERGY IGNITION (HEI)...............................................................................146 DESCRIPTION..........................................................................................146 REPAIRS..................................................................................................148 DISTRIBUTOR..........................................................................................148 Removal..........................................................................................148 Disassembly......................................................................................148 Assembly.........................................................................................153 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................154 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................155 IGNITION COIL........................................................................................155 Removal, Some 4 And 6 Cylinder Models............................................................155 Installation, Some 4 And 6 Cylinder Models.......................................................156 Removal, V8, Some 4 And 6 Cylinder Models........................................................156 Installation, V8, Some 4 And 6 Cylinder Models...................................................157 ELECTRONIC MODULE....................................................................................158 Removal..........................................................................................158 Installation.....................................................................................158 SENSING COIL.........................................................................................159 Removal..........................................................................................159 Installation.....................................................................................159 SPARK PLUGS..........................................................................................159 Removal..........................................................................................159 Installation.....................................................................................160 CHECKS AND ADJUSTMENTS...............................................................................160 Visual Checks....................................................................................160 Check The High Voltage Wires.....................................................................160 Checking The Ignition Coil.......................................................................160 Coil In Distributor Cap Design...................................................................160 Separate Coil Design.............................................................................161 Checking The Sensing Coil........................................................................161 Check The Electronic Module......................................................................162 Ignition Timing Adjustment.......................................................................162 Ignition System, GM V8-366 (6-litre).............................................................163 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................163 SPECIFICATIONS...........................................................................................163 TROUBLESHOOTING..........................................................................................164 INTRODUCTION.............................................................................................165 DESCRIPTION..........................................................................................165 OPERATION............................................................................................165 Flow Control Valve...............................................................................167 Relief Valve.....................................................................................167 REPAIRS..................................................................................................168 REMOVAL..............................................................................................168 DISASSEMBLY..........................................................................................168 CLEANING.............................................................................................170 INSPECTION...........................................................................................170 ASSEMBLY.............................................................................................171 INSTALLATION.........................................................................................172 CHECKS AND ADUSTMENTS....................................................................................173 CHECK THE OUTPUT OF THE PUMP.........................................................................173 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................173 TROUBLESHOOTING..........................................................................................175 INTRODUCTION.............................................................................................178 GENERAL..............................................................................................178 DESCRIPTION..........................................................................................178 REPAIRS..................................................................................................178 REMOVAL AND DISASSEMBLY..............................................................................178 CLEANING.............................................................................................180 INSPECTION...........................................................................................180 ASSEMBLY AND INSTALLATION............................................................................180 TROUBLESHOOTING..........................................................................................182 GENERAL..............................................................................................182 INTRODUCTION.............................................................................................183 GENERAL..............................................................................................183 DESCRIPTION..............................................................................................183 GENERAL..............................................................................................183 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................186 LED DISPLAY PANEL....................................................................................186 Battery Discharge Indicators.....................................................................186 Brush Wear Indicators............................................................................187 Motor Temperature Indicators.....................................................................188 "LX" SERIES DISPLAY PANEL............................................................................189 Hourmeter Functions..............................................................................190 Battery Indicator Function.......................................................................190 Status Code Function.............................................................................190 "ZX" SERIES DISPLAY PANELS...........................................................................190 Display Panel....................................................................................191 Basic Display Panels.............................................................................191 Performance Display..............................................................................193 Brush Wear Indicators............................................................................196 CHECKS AND ADJUSTMENTS...................................................................................196 GENERAL..............................................................................................196 REPLACEMENT..............................................................................................197 GENERAL..............................................................................................197 METER REPLACEMENT....................................................................................197 SENDER REPLACEMENT...................................................................................198 Fuel Level Sender................................................................................198 Pressure And Temperature Sender..................................................................198 I.T.W. DISPLAY PANEL.................................................................................199 Removal..........................................................................................199 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................200 Removal..........................................................................................200 Replacing Display Panel Assembly.................................................................200 Indicator LEDs...................................................................................200 Battery Indicators...............................................................................200 Digital Display (Performance Disply Panel Only)..................................................200 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....200 Replacing Parts Of The Basic Display Panel.......................................................201 Replacing Parts Of The Performance Display Panel.................................................203 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................203 Removal And Replacement..........................................................................203 SPECIFICATIONS...........................................................................................204 TROUBLESHOOTING..........................................................................................205 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................206 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................206 LIFT CYLINDERS...........................................................................................209 GENERAL..............................................................................................209 DESCRIPTION..........................................................................................209 Lowering Control Valve...........................................................................209 Cylinders (General)..............................................................................212 Cylinders (H520-620B,H700-800A)..................................................................214 Cylinders (H360-460B)............................................................................215 Cylinders (Two-Speed)............................................................................215 REPAIRS..................................................................................................216 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................216 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........216 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................220 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................218 DISASSEMBLY..........................................................................................218 ASSEMBLY.............................................................................................220 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................220 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........220 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................220 CHEVRON PACKING......................................................................................221 LIFT CYLINDERS FOR VISTA MASTS...........................................................................224 DESCRIPTION..........................................................................................224 Lowering Control Valve...........................................................................226 REMOVAL..............................................................................................227 DISASSEMBLY..........................................................................................227 ASSEMBLY.............................................................................................227 INSTALLATION.........................................................................................228 Main Lift Cylinders..............................................................................228 Free-Lift Cylinders..............................................................................228 CHECKS AND ADJUSTMENTS...................................................................................229 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................229 TROUBLESHOOTING..........................................................................................230 SPECIFICATIONS...........................................................................................231 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................232 GENERAL..............................................................................................232 DESCRIPTION..........................................................................................232 Fuel Tank........................................................................................233 Fuel Filter And Fuel Valve Unit..................................................................234 Vaporizer........................................................................................234 The IMPCO CA 100 Carbureto.......................................................................236 IMPCO CA 50 Carburetor...........................................................................238 The Governor (GM Engines Only)...................................................................239 Governor With Electronic Controller..............................................................240 REPAIRS..................................................................................................241 LPG TANK.............................................................................................241 Removal..........................................................................................241 Installation.....................................................................................242 REPLACE THE HOSES....................................................................................242 HYDROSTATIC RELIEF VALVE.............................................................................242 Removal and Installation.........................................................................242 FILTER UNIT..........................................................................................243 Replacement Of the Fuel Filter Element...........................................................243 Replacement of the Diaphragm and Fuel Valve......................................................244 VAPORIZER............................................................................................244 Removal..........................................................................................244 Disassembly......................................................................................244 Cleaning.........................................................................................244 Inspection.......................................................................................244 Assembly.........................................................................................246 Installation.....................................................................................246 CARBURETOR (IMPCO CA 100)............................................................................248 Removal..........................................................................................248 Disassembly......................................................................................248 Cleaning.........................................................................................248 Assembly.........................................................................................248 Installation.....................................................................................251 CARBURETER (IMPCO CA 50).............................................................................250 Removal..........................................................................................250 Disassembly......................................................................................250 Cleaning.........................................................................................251 Inspection.......................................................................................251 Assembly (See FIGURE 26.)........................................................................251 Installation.....................................................................................251 CHECKS AND ADJUSTMENTS...................................................................................252 CHECK THE FILTER UNIT................................................................................252 CHECK THE VAPORIZER..................................................................................252 Pressure Reducer Valve...........................................................................252 Vapor Valve......................................................................................252 ADJUST THE CARBURETOR................................................................................252 Idle Mixture.....................................................................................252 Idle Speed.......................................................................................252 Power Mixture....................................................................................252 ADJUST THE GOVERNOR (GM Engines Only)................................................................253 Checks...........................................................................................253 Main Adjusting Screw.............................................................................253 Secondary Adjusting Screw........................................................................253 AISAN Governor...................................................................................254 Adjustment, AISAN Governor.......................................................................254 TROUBLESHOOTING..........................................................................................255 INTRODUCTION.............................................................................................259 GENERAL..............................................................................................259 DESCRIPTION..........................................................................................259 OPERATION............................................................................................261 Lift Spool.......................................................................................261 Tilt Spool.......................................................................................261 Relief Valve, Single–Stage.......................................................................264 Relief Valve, Two–Stage..........................................................................265 REPAIRS..................................................................................................265 REMOVAL AND DISASSEMBLY..............................................................................265 CLEANING AND INSPECTION..............................................................................266 ASSEMBLY.............................................................................................266 INSTALLATION.........................................................................................266 CHECKS AND ADJUSTMENTS...................................................................................266 ADJUST THE SINGLE–STAGE RELIEF VALVE.................................................................266 ADJUST THE TWO–STAGE RELIEF VALVE....................................................................267 ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY................................268 TROUBLESHOOTING..........................................................................................268 INTRODUCTION.............................................................................................270 GENERAL..............................................................................................270 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................272 FULL FREE-LIFT MASTS.................................................................................272 THREE-STAGE MASTS....................................................................................274 FOUR-STAGE MASTS.....................................................................................275 SEQUENCE VALVE.......................................................................................275 INTRODUCTION.............................................................................................277 GENERAL..............................................................................................277 REPAIRS..................................................................................................277 FORKS................................................................................................277 CARRIAGE.............................................................................................277 Removal..........................................................................................277 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................278 Installation.....................................................................................279 MASTS................................................................................................281 Removal..........................................................................................281 Disassembly......................................................................................283 Cleaning and Inspection..........................................................................287 Assembly.........................................................................................288 INSTALLATION.........................................................................................289 CHECKS AND ADJUSTMENTS...................................................................................289 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................289 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................290 LIFT CHAIN ADJUSTMENTS...............................................................................290 MAST ADJUSTMENTS.....................................................................................291 Guide Shoe Adjustment............................................................................292 CARRIAGE ADJUSTMENT..................................................................................294 TROUBLESHOOTING..........................................................................................296 INTRODUCTION.............................................................................................297 GENERAL..............................................................................................297 DESCRIPTION..........................................................................................297 REPAIRS..................................................................................................297 REMOVAL AND DISASSEMBLY..............................................................................297 CLEANING ............................................................................................298 ASSEMBLY.............................................................................................298 CHECKS AND ADJUSTMENTS...................................................................................298 CHECKS...............................................................................................298 INTRODUCTION.............................................................................................299 GENERAL..............................................................................................299 DESCRIPTION..........................................................................................299 OPERATION............................................................................................300 The Float System.................................................................................300 The Idle System..................................................................................300 The Main Metering System (GM 6-250)..............................................................301 The Power System (GM 6-250)......................................................................302 The Accelerator Pump System......................................................................302 Choke System.....................................................................................302 REPAIRS..................................................................................................303 REMOVAL..............................................................................................303 DISASSEMBLY..........................................................................................303 Cleaning.............................................................................................303 ASSEMBLY.............................................................................................303 INSTALLATION.........................................................................................303 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)......................................................308 GOVERNOR (PNEUMATIC) (Early Units)...................................................................309 CHECKS AND ADJUSTMENTS...................................................................................310 GENERAL..............................................................................................310 ADJUST THE CHOKE CONTROL.............................................................................310 ADJUST THE IDLE SPEED................................................................................310 ADJSUT THE IDLE MIXTURE..............................................................................311 ADJUST THE FAST IDLE.................................................................................311 ADJUST THE THROTTLE LINKAGE,(Later Models)...........................................................312 ADJUST THE THROTTLE LINKAGE,(Early Models)...........................................................313 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)........................................313 Check the Governor...............................................................................313 GOVERNOR (AISAN Type) (Early GM Engines Only)........................................................314 Checks...........................................................................................315 Adjustments......................................................................................315 GOVERNOR (HOOF Type) (Early GM Engines Only).........................................................315 Adjust the Governor..............................................................................315 TROUBLESHOOTING..........................................................................................317 INTRODUCTION.............................................................................................318 NOMENCLATURE, THREADS................................................................................318 STRENGTH IDENTIFICATION..............................................................................319 TABLE 1. BOLTS AND SCREWS................................................................................319 TABLE 2. STUDS AND NUTS..................................................................................320 TABLE 3. TORQUE NUTS.....................................................................................321 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................322 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................323 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................324 INTRODUCTION.............................................................................................327 GENERAL..............................................................................................327 DESCRIPTION..............................................................................................327 OPERATION................................................................................................329 THE TORQUE CONVERTER.................................................................................329 THE PLANETARY GEAR SET...............................................................................331 CLUTCHES.............................................................................................333 HYDRAULIC SYSTEM.....................................................................................333 H60-110E.........................................................................................333 S40-50F, S30-120E................................................................................334 CONTROL VALVE........................................................................................335 Monotrol Regulator...............................................................................335 Clutch Regulator.................................................................................335 Torque Converter Regulator.......................................................................336 Direction Spool..................................................................................337 Modulation Spool, All Models Except S100-120E....................................................337 Modulation Spool and Accumulator Valve, S100-120E................................................337 The Valve For The Parking Brake Solenoid.........................................................338 The Inching Valve................................................................................338 THE ELECTRICAL CIRCUIT...............................................................................339 Electrical Circuit For the Direction.............................................................339 OIL FLOW DIAGRAMS....................................................................................340 PARK or NEUTRAL..................................................................................340 "1" Circuit Monotrol.............................................................................340 "2" Circuit - Clutch Apply.......................................................................340 "3" Circuit - Torque Converter...................................................................340 FORWARD..............................................................................................340 "1" Circuit - Monotrol...........................................................................340 "2" Circuit......................................................................................341 FORWARD - INCHING....................................................................................341 REVERSE..............................................................................................341 TROUBLESHOOTING..........................................................................................350 INTRODUCTION.............................................................................................351 General..............................................................................................351 REPAIRS..................................................................................................352 Removal..............................................................................................352 Disassembly..........................................................................................352 Inspection...........................................................................................356 Transmission.....................................................................................356 Torque Converter.................................................................................356 Repairing the Control Valve..........................................................................356 DIFFERENTIAL.............................................................................................359 Removal..............................................................................................359 Disassembly..........................................................................................361 Cleaning and Inspection..............................................................................361 Assembly.............................................................................................361 Adjusting the Differential...........................................................................362 Installation.........................................................................................364 Assembly of Transmission.............................................................................364 Installation of the Transmission.....................................................................370 Monotrol Pedal.......................................................................................371 Removal and Disassembly..............................................................................371 Assembly and Installation............................................................................371 CHECKS AND ADJUSTMENTS...................................................................................371 Checking the Monotrol Pedal for Leakage..............................................................371 Monotrol Linkage.....................................................................................371 Stall Test...........................................................................................372 Checking the Oil Pressures...........................................................................373 Monotrol Pressure................................................................................373 Clutch Pressure..................................................................................375 Inching Pressure.................................................................................375 Torque Converter Pressure........................................................................376 Modulator Spool/Clutch Engage Pressure...........................................................376 Checking the Powershift Electrical Circuit...........................................................376 Checking the Circuit for the Direction Control Lever.................................................377 TROUBLESHOOTING..........................................................................................378 INTRODUCTION.............................................................................................385 GENERAL..............................................................................................385 DESCRIPTION AND OPERATION............................................................................385 REPAIRS..................................................................................................387 REMOVAL..............................................................................................387 DISSASEMBLY..........................................................................................387 CLEANING.............................................................................................388 ASSEMBLY.............................................................................................388 INSTALLATION.........................................................................................388 CHECKS AND ADJUSTMENTS...................................................................................389 GENERAL..............................................................................................389 TROUBLESHOOTING..........................................................................................391 INTRODUCTION.............................................................................................393 GENERAL..............................................................................................393 DESCRIPTION..........................................................................................393 REPAIRS..................................................................................................394 STEERING AXLES WITH STUB SHAFT MOUNTS................................................................394 Removal..........................................................................................395 Installation.....................................................................................395 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS...............................................................396 Removal..........................................................................................396 Installation.....................................................................................397 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)............................398 Removal..........................................................................................398 Installation.....................................................................................399 WHEELS AND HUBS......................................................................................399 Removal and Disassembly..........................................................................399 Cleaning.........................................................................................399 Assembly And Installation........................................................................399 SPINDLES, BEARING AND TIE RODS.......................................................................399 Removal And Disassembly..........................................................................399 Cleaning.........................................................................................399 Assembly And Installation........................................................................399 STEERING CYLINDER....................................................................................401 Removal And Disassembly..........................................................................401 Cleaning.........................................................................................402 Assembly And Installation........................................................................402 CHECKS AND ADJUSTMENTS...................................................................................404 STEERING CYLINDER....................................................................................404 CENTER PIVOT OR RUBBER MOUNTS........................................................................404 SPINDLE AND HUB......................................................................................404 TROUBLESHOOTING..........................................................................................405
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]
1 review for Hyster Forklift S40 50F service manual – PDF DOWNLOAD
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Saul Thaddeus –
Great site, too easy.