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Hyster Forklift S60 120E service manual – PDF DOWNLOAD
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Description
Hyster Forklift S60 120E service manual
File Details:
Hyster Forklift S60 120E service manual
Language : English
Pages : 376
Size : 11.0 MB
Downloadable : Yes
Format : PDF
HYSTER FORKLIFT S60 120E SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster Forklift S60 120E service manual
- The input shaft has splines on its end for the clutch disc. The other end of the shaft has the forward and reverse gears and a sliding sleeve with splines. The forward and reverse gears are in a fixed position and they turn freely on the shaft. The sliding sleeve with splines must always turn with the shaft. Each gear can be locked to the input shaft by the sliding sleeve with splines. The sliding sleeve moves along the shaft by the fork which is controlled by the direction control lever.
- The forward idler gear and the range idler gear transfer power from the input shaft to the output shaft. The output shaft has the range gears, a sliding sleeve with splines and a pinion. The operation of the range gears is similar to the forward and reverse gears except the sliding sleeve has a synchronizer. During engagement of the range gears, the synchronizer assembly makes the rotating speed of the gear the same as the output shaft. This function permits smooth selection of the range gears.
- OPERATION (SEE FIGURES 1 AND 2) When the clutch is engaged, the power from the engine is transferred to the input shaft. When the direction control lever is in the NEUTRAL position, both the forward and reverse gears turn freely on the input shaft. They cannot transfer power to the output shaft. When forward gear is selected, the fork moves the sliding sleeve toward the forward gear. The teeth of the sliding sleeve engage with the teeth
Table of Contents:
Hyster Forklift S60 120E service manual
INTRODUCTION............................................................................................. 1 General.............................................................................................. 1 Description.......................................................................................... 1 Operation............................................................................................ 2 REPAIRS.................................................................................................. 3 Removal.............................................................................................. 3 Installation......................................................................................... 3 Disassembly.......................................................................................... 4 Cleaning............................................................................................. 5 Inspection........................................................................................... 5 Assembly............................................................................................. 5 DIFFERENTIAL............................................................................................. 10 Removal.............................................................................................. 10 Disassembly.......................................................................................... 11 Cleaning and Inspection.............................................................................. 11 Assembly............................................................................................. 11 Adjusting the Differential........................................................................... 12 Installation......................................................................................... 14 TROUBLESHOOTING.......................................................................................... 14 INTRODUCTION............................................................................................. 18 GENERAL.............................................................................................. 18 DESCRIPTION.......................................................................................... 18 REPAIRS.................................................................................................. 20 GENERAL.............................................................................................. 20 REMOVAL AND DISASSEMBLY (Type A)..................................................................... 20 CLEANING............................................................................................. 20 ASSEMBLY (Type A).................................................................................... 21 REMOVAL AND DISAASSEMBLY (Type B).................................................................... 23 CLEANING............................................................................................. 25 ASSEMBLY (Type B).................................................................................... 25 INSTALLATION (Type A and Type B)..................................................................... 26 CHECKS AND ADJUSTMENTS................................................................................... 26 GENERAL.............................................................................................. 26 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)............................................... 27 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B).............................................. 28 CHECK THE CIRCUIT FOR THE BRUSHES.................................................................... 30 Delco Alternators................................................................................ 30 Motorola Alternators............................................................................. 30 CHECK THE DIODES..................................................................................... 30 CHECK THE DIODE BRIDGE............................................................................... 30 Delco and Leece–Neville Alternators.............................................................. 30 Motorola Alternators............................................................................. 30 CHECK THE FIELD WINDING FOR THE ROTOR................................................................ 31 CHECK THE WINDINGS IN THE STATOR..................................................................... 31 CHECK THE VOLTAGE REGULATOR.......................................................................... 32 TROUBLESHOOTING.......................................................................................... 32 INTRODUCTION............................................................................................. 33 GENERAL.............................................................................................. 33 DESCRIPTION AND OPERATION............................................................................ 33 REPAIRS.................................................................................................. 37 CLEANING PROCEDURES.................................................................................. 37 REMOVAL AND DISASSEMBLY.............................................................................. 37 INSPECTION........................................................................................... 38 ASSEMBLY............................................................................................. 39 CHECKS AND ADJUSTMENTS................................................................................... 41 ADJUSTING THE SERVICE BRAKES......................................................................... 41 ADJUSTING THE PARKING BRAKE.......................................................................... 41 REMOVING THE AIR FROM THE BRAKE SYSTEM............................................................... 41 ADJUSTING THE SERVICE BRAKE PEDAL.................................................................... 42 TROUBLESHOOTING.......................................................................................... 43 INTRODUCTION............................................................................................. 48 GENERAL.............................................................................................. 48 DESCRIPTION.......................................................................................... 48 REPAIRS.................................................................................................. 51 FAN ASSEMBLY......................................................................................... 51 Removal (S30–120E)............................................................................... 51 Removal (H60–110E)............................................................................... 51 Disassembly (S30–120E)........................................................................... 51 Disassembly (H60–110E)........................................................................... 52 Assembly (Both Series)........................................................................... 52 Fan Belt Adjustment.............................................................................. 55 Installation..................................................................................... 55 RADIATOR............................................................................................. 56 Removal.......................................................................................... 56 Installation..................................................................................... 56 Cleaning and Inspection.......................................................................... 57 TROUBLESHOOTING.......................................................................................... 58 INTRODUCTION............................................................................................. 65 General.............................................................................................. 65 Description.......................................................................................... 65 REPAIRS.................................................................................................. 66 Removal.............................................................................................. 66 Installation......................................................................................... 67 Axle Housing For S30-100E And S40-50F Lift Trucks.................................................... 68 Wheels And Tires..................................................................................... 70 TROUBLESHOOTING.......................................................................................... 72 SPECIFICATIONS........................................................................................... 73 ELECTRICAL SYSTEM COMPLETELY DEAD........................................................................ 75 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN .................................................... 76 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER.............................................. 78 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK............................................. 79 STARTER CRANKS SLOWLY.................................................................................... 81 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START................................................ 82 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND.............................................................. 84 CHARGING SYSTEM DOES NOT FUNCTION........................................................................ 85 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW..................................................... 88 BATTERY IS BEING OVERCHARGED............................................................................. 91 ONE OR MORE DASH GAUGES DO NOT WORK...................................................................... 92 HORN DOES NOT BLOW....................................................................................... 96 POWERSHIFT TRANSMISSION WILL NOT ENGAGE.................................................................. 97 ELECTRICAL SCHEMATIC S20-30A, H20-30E.................................................................... 98 ELECTRICAL S30-50C....................................................................................... 99 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG..............................................................100 ELECTRICAL SCHEMATIC H30-60H DIESEL......................................................................102 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG..............................................................104 ELECTRICAL SCHEMATIC H60-90C DIESEL......................................................................105 ELECTRICAL SCHEMATIC S30-60ES............................................................................106 ELECTRICAL SCHEMATIC S60-120E............................................................................107 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG............................................................108 ELECTRICAL SCHEMATIC S125-150A DIESEL....................................................................109 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG............................................................110 ELECTRICAL SCHEMATIC H110-150F DIESEL....................................................................111 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG..................................................112 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL.........................................................113 ELECTRICAL SCHEMATIC H300A...............................................................................114 ELECTRICAL SCHEMATIC H300-350B...........................................................................115 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL............................................................116 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL............................................................117 ELECTRICAL SCHEMATIC H700-800A...........................................................................118 ELECTRICAL SCHEMATIC P40-50A GASOLINE....................................................................120 ELECTRICAL SCHEMATIC P40-50A DIESEL......................................................................121 ELECTRICAL SCHEMATIC P60-80A GASOLINE....................................................................122 ELECTRICAL SCHEMATIC P60-80A DIESEL......................................................................123 ELECTRICAL SCHEMATIC KE GAS GASOLINE.....................................................................124 ELECTRICAL SCHEMATIC KE DIESEL...........................................................................125 ELECTRICAL SCHEMATIC M200-400H GASOLINE..................................................................126 ELECTRICAL SCHEMATIC M200-400H DIESEL....................................................................128 ELECTRICAL SCHEMATIC M600A...............................................................................130 ELECTRICAL WARNING DEVICES...............................................................................132 GENERAL..............................................................................................132 DESCRIPTION..........................................................................................132 Operator Controlled Horns........................................................................132 System Warning Lights, Buzzers and Bells.........................................................132 Reverse Warning Horns............................................................................133 Warning Lights...................................................................................133 REPLACEMENT..........................................................................................134 General..........................................................................................134 Replacing Horns or Bells.........................................................................134 Replacing Horn Relay or Buzzer...................................................................134 Replacing Warning Lights.........................................................................134 Light Assemblies.................................................................................135 Replacing Flashing Units.........................................................................135 INTRODUCTION.............................................................................................136 General..............................................................................................136 Description..........................................................................................136 Operation............................................................................................136 Flow Regulator Valve.............................................................................137 Steering Relief Valve............................................................................138 Relief Valve for Cold Oil........................................................................139 REPAIRS..................................................................................................139 Removal..............................................................................................139 Disassembly..........................................................................................139 Cleaning and Inspection..............................................................................139 Assembly and Installation............................................................................139 CHECKS AND ADJUSTMENTS...................................................................................140 Removing air from the Hydraulic System...............................................................140 Adjusting the Setting of the Relief Valve............................................................140 INTRODUCTION.............................................................................................142 General..............................................................................................142 Description..........................................................................................142 DISASSEMBLY AND ASSEMBLY.................................................................................143 Counterweight........................................................................................143 Hood and Seat........................................................................................145 Operator Restraint System............................................................................146 Exhaust System.......................................................................................147 Overhead Guard.......................................................................................147 Engine (Removal and Installation)....................................................................150 REPAIRS..................................................................................................152 Fuel and Hydraulic Tanks.............................................................................152 Decal Replacement....................................................................................153 INTRODUCTION.............................................................................................155 GENERAL..............................................................................................155 DESCRIPTION..........................................................................................156 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................156 CYLINDER HEAD AND MECHANISM..........................................................................156 Cylinder Head, Removal...........................................................................156 Cylinder Head, Disassembly.......................................................................157 Cleaning And Inspection..........................................................................158 Valve And Valve Seats............................................................................159 Studs For The Rocker Arms........................................................................159 Hydraulic Valve Lifters, Replacement.............................................................159 Hydraulic Valve Lifters, Cleaning And Inspection.................................................160 Cylinder Head, Assembly..........................................................................160 Cylinder Head, Installation......................................................................160 Rocker Arm Cover, Installation...................................................................161 TIMING GEAR COVER....................................................................................162 Removal..........................................................................................162 Installation.....................................................................................162 CAMSHAFT.............................................................................................163 Removal..........................................................................................163 Inspection.......................................................................................164 Camshaft Bearings, Removal.......................................................................164 Camshaft Bearings, Installation..................................................................164 DISTRIBUTOR..........................................................................................165 Removal..........................................................................................165 Installation.....................................................................................165 LUBRICATION SYSTEM...................................................................................166 Oil Sump, Removal................................................................................166 Oil Sump, Installation...........................................................................166 Oil Pump, Removal................................................................................166 Oil Pump, Disassembly and Repair.................................................................166 Oil Pump, Assembly...............................................................................167 Oil Pump, Installation...........................................................................167 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................167 Connecting Rod Bearings, Replacement.............................................................167 Piston And Connecting Rod Assemblies, Removal....................................................168 Disassembly......................................................................................169 Piston, Cleaning And Inspection..................................................................169 Cylinder Bores, Inspection And Repair............................................................169 Piston Rings.....................................................................................170 Assembly.........................................................................................171 Piston And Connecting Rod Assemblies, Installation...............................................171 CRANKSHAFT...........................................................................................172 Main Bearings, Replacement.......................................................................172 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................173 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........173 Crankshaft, Removal..............................................................................174 Inspection and Repair............................................................................175 How To Check The Clearance Between The Main Bearings And Their Journals..........................175 Installation.....................................................................................176 FLYWHEEL AND FLYWHEEL HOUSING........................................................................177 Flywheel, Removal................................................................................177 Ring Gear, Replacement...........................................................................178 Flywheel, Installation...........................................................................178 COOLING SYSTEM.......................................................................................178 Coolant Pump.....................................................................................178 Fan Drive........................................................................................179 Viscous Fan Drive................................................................................179 ENGINE SPECIFICATIONS....................................................................................180 ENGINE DATA..........................................................................................180 CYLINDER HEAD........................................................................................180 HYDRAULIC VALVE LIFTER...............................................................................181 CAMSHAFT.............................................................................................181 PISTONS..............................................................................................181 CYLINDER BORE........................................................................................182 CRANKSHAFT...........................................................................................182 CONNECTING RODS......................................................................................182 COOLING SYSTEM.......................................................................................183 LUBRICATION SYSTEM...................................................................................183 TORQUE SPECIFICATIONS....................................................................................183 HIGH ENERGY IGNITION (HEI)...............................................................................186 DESCRIPTION..........................................................................................186 REPAIRS..................................................................................................188 DISTRIBUTOR..........................................................................................188 Removal..........................................................................................188 Disassembly......................................................................................188 Assembly.........................................................................................193 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................194 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................195 IGNITION COIL........................................................................................195 Removal, Some 4 And 6 Cylinder Models............................................................195 Installation, Some 4 And 6 Cylinder Models.......................................................196 Removal, V8, Some 4 And 6 Cylinder Models........................................................196 Installation, V8, Some 4 And 6 Cylinder Models...................................................197 ELECTRONIC MODULE....................................................................................198 Removal..........................................................................................198 Installation.....................................................................................198 SENSING COIL.........................................................................................199 Removal..........................................................................................199 Installation.....................................................................................199 SPARK PLUGS..........................................................................................199 Removal..........................................................................................199 Installation.....................................................................................200 CHECKS AND ADJUSTMENTS...............................................................................200 Visual Checks....................................................................................200 Check The High Voltage Wires.....................................................................200 Checking The Ignition Coil.......................................................................200 Coil In Distributor Cap Design...................................................................200 Separate Coil Design.............................................................................201 Checking The Sensing Coil........................................................................201 Check The Electronic Module......................................................................202 Ignition Timing Adjustment.......................................................................202 Ignition System, GM V8-366 (6-litre).............................................................203 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................203 SPECIFICATIONS...........................................................................................203 TROUBLESHOOTING..........................................................................................204 INTRODUCTION.............................................................................................205 DESCRIPTION..........................................................................................205 OPERATION............................................................................................205 Flow Control Valve...............................................................................207 Relief Valve.....................................................................................207 REPAIRS..................................................................................................208 REMOVAL..............................................................................................208 DISASSEMBLY..........................................................................................208 CLEANING.............................................................................................210 INSPECTION...........................................................................................210 ASSEMBLY.............................................................................................211 INSTALLATION.........................................................................................212 CHECKS AND ADUSTMENTS....................................................................................213 CHECK THE OUTPUT OF THE PUMP.........................................................................213 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................213 TROUBLESHOOTING..........................................................................................215 INTRODUCTION.............................................................................................218 GENERAL..............................................................................................218 DESCRIPTION..........................................................................................218 REPAIRS..................................................................................................218 REMOVAL AND DISASSEMBLY..............................................................................218 CLEANING.............................................................................................220 INSPECTION...........................................................................................220 ASSEMBLY AND INSTALLATION............................................................................220 TROUBLESHOOTING..........................................................................................222 GENERAL..............................................................................................222 INTRODUCTION.............................................................................................223 NOMENCLATURE, THREADS................................................................................223 STRENGTH IDENTIFICATION..............................................................................224 TABLE 1. BOLTS AND SCREWS................................................................................224 TABLE 2. STUDS AND NUTS..................................................................................225 TABLE 3. TORQUE NUTS.....................................................................................226 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................227 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................228 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................229 INTRODUCTION.............................................................................................232 GENERAL..............................................................................................232 DESCRIPTION..............................................................................................232 GENERAL..............................................................................................232 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................235 LED DISPLAY PANEL....................................................................................235 Battery Discharge Indicators.....................................................................235 Brush Wear Indicators............................................................................236 Motor Temperature Indicators.....................................................................237 "LX" SERIES DISPLAY PANEL............................................................................238 Hourmeter Functions..............................................................................239 Battery Indicator Function.......................................................................239 Status Code Function.............................................................................239 "ZX" SERIES DISPLAY PANELS...........................................................................239 Display Panel....................................................................................240 Basic Display Panels.............................................................................240 Performance Display..............................................................................242 Brush Wear Indicators............................................................................245 CHECKS AND ADJUSTMENTS...................................................................................245 GENERAL..............................................................................................245 REPLACEMENT..............................................................................................246 GENERAL..............................................................................................246 METER REPLACEMENT....................................................................................246 SENDER REPLACEMENT...................................................................................247 Fuel Level Sender................................................................................247 Pressure And Temperature Sender..................................................................247 I.T.W. DISPLAY PANEL.................................................................................248 Removal..........................................................................................248 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................249 Removal..........................................................................................249 Replacing Display Panel Assembly.................................................................249 Indicator LEDs...................................................................................249 Battery Indicators...............................................................................249 Digital Display (Performance Disply Panel Only)..................................................249 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....249 Replacing Parts Of The Basic Display Panel.......................................................250 Replacing Parts Of The Performance Display Panel.................................................252 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................252 Removal And Replacement..........................................................................252 SPECIFICATIONS...........................................................................................253 TROUBLESHOOTING..........................................................................................254 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................255 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................255 LIFT CYLINDERS...........................................................................................258 GENERAL..............................................................................................258 DESCRIPTION..........................................................................................258 Lowering Control Valve...........................................................................258 Cylinders (General)..............................................................................261 Cylinders (H520-620B,H700-800A)..................................................................263 Cylinders (H360-460B)............................................................................264 Cylinders (Two-Speed)............................................................................264 REPAIRS..................................................................................................265 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................265 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........265 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................269 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................267 DISASSEMBLY..........................................................................................267 ASSEMBLY.............................................................................................269 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................269 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........269 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................269 CHEVRON PACKING......................................................................................270 LIFT CYLINDERS FOR VISTA MASTS...........................................................................273 DESCRIPTION..........................................................................................273 Lowering Control Valve...........................................................................275 REMOVAL..............................................................................................276 DISASSEMBLY..........................................................................................276 ASSEMBLY.............................................................................................276 INSTALLATION.........................................................................................277 Main Lift Cylinders..............................................................................277 Free-Lift Cylinders..............................................................................277 CHECKS AND ADJUSTMENTS...................................................................................278 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................278 TROUBLESHOOTING..........................................................................................279 SPECIFICATIONS...........................................................................................280 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................281 GENERAL..............................................................................................281 DESCRIPTION..........................................................................................281 Fuel Tank........................................................................................282 Fuel Filter And Fuel Valve Unit..................................................................283 Vaporizer........................................................................................283 The IMPCO CA 100 Carbureto.......................................................................285 IMPCO CA 50 Carburetor...........................................................................287 The Governor (GM Engines Only)...................................................................288 Governor With Electronic Controller..............................................................289 REPAIRS..................................................................................................290 LPG TANK.............................................................................................290 Removal..........................................................................................290 Installation.....................................................................................291 REPLACE THE HOSES....................................................................................291 HYDROSTATIC RELIEF VALVE.............................................................................291 Removal and Installation.........................................................................291 FILTER UNIT..........................................................................................292 Replacement Of the Fuel Filter Element...........................................................292 Replacement of the Diaphragm and Fuel Valve......................................................293 VAPORIZER............................................................................................293 Removal..........................................................................................293 Disassembly......................................................................................293 Cleaning.........................................................................................293 Inspection.......................................................................................293 Assembly.........................................................................................295 Installation.....................................................................................295 CARBURETOR (IMPCO CA 100)............................................................................297 Removal..........................................................................................297 Disassembly......................................................................................297 Cleaning.........................................................................................297 Assembly.........................................................................................297 Installation.....................................................................................300 CARBURETER (IMPCO CA 50).............................................................................299 Removal..........................................................................................299 Disassembly......................................................................................299 Cleaning.........................................................................................300 Inspection.......................................................................................300 Assembly (See FIGURE 26.)........................................................................300 Installation.....................................................................................300 CHECKS AND ADJUSTMENTS...................................................................................301 CHECK THE FILTER UNIT................................................................................301 CHECK THE VAPORIZER..................................................................................301 Pressure Reducer Valve...........................................................................301 Vapor Valve......................................................................................301 ADJUST THE CARBURETOR................................................................................301 Idle Mixture.....................................................................................301 Idle Speed.......................................................................................301 Power Mixture....................................................................................301 ADJUST THE GOVERNOR (GM Engines Only)................................................................302 Checks...........................................................................................302 Main Adjusting Screw.............................................................................302 Secondary Adjusting Screw........................................................................302 AISAN Governor...................................................................................303 Adjustment, AISAN Governor.......................................................................303 TROUBLESHOOTING..........................................................................................304 INTRODUCTION.............................................................................................308 GENERAL..............................................................................................308 DESCRIPTION..........................................................................................308 OPERATION............................................................................................310 Lift Spool.......................................................................................310 Tilt Spool.......................................................................................310 Relief Valve, Single–Stage.......................................................................313 Relief Valve, Two–Stage..........................................................................314 REPAIRS..................................................................................................314 REMOVAL AND DISASSEMBLY..............................................................................314 CLEANING AND INSPECTION..............................................................................315 ASSEMBLY.............................................................................................315 INSTALLATION.........................................................................................315 CHECKS AND ADJUSTMENTS...................................................................................315 ADJUST THE SINGLE–STAGE RELIEF VALVE.................................................................315 ADJUST THE TWO–STAGE RELIEF VALVE....................................................................316 ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY................................317 TROUBLESHOOTING..........................................................................................317 INTRODUCTION.............................................................................................319 GENERAL..............................................................................................319 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................321 FULL FREE-LIFT MASTS.................................................................................321 THREE-STAGE MASTS....................................................................................323 FOUR-STAGE MASTS.....................................................................................324 SEQUENCE VALVE.......................................................................................324 INTRODUCTION.............................................................................................326 GENERAL..............................................................................................326 REPAIRS..................................................................................................326 FORKS................................................................................................326 CARRIAGE.............................................................................................326 Removal..........................................................................................326 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................327 Installation.....................................................................................328 MASTS................................................................................................330 Removal..........................................................................................330 Disassembly......................................................................................332 Cleaning and Inspection..........................................................................336 Assembly.........................................................................................337 INSTALLATION.........................................................................................338 CHECKS AND ADJUSTMENTS...................................................................................338 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................338 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................339 LIFT CHAIN ADJUSTMENTS...............................................................................339 MAST ADJUSTMENTS.....................................................................................340 Guide Shoe Adjustment............................................................................341 CARRIAGE ADJUSTMENT..................................................................................343 TROUBLESHOOTING..........................................................................................345 INTRODUCTION.............................................................................................346 GENERAL..............................................................................................346 DESCRIPTION..........................................................................................346 REPAIRS..................................................................................................346 REMOVAL AND DISASSEMBLY..............................................................................346 CLEANING ............................................................................................347 ASSEMBLY.............................................................................................347 CHECKS AND ADJUSTMENTS...................................................................................347 CHECKS...............................................................................................347 INTRODUCTION.............................................................................................348 General..............................................................................................348 Description..........................................................................................348 REAPAIRS.................................................................................................350 Removal..............................................................................................350 Cleaning.............................................................................................350 Inspection...........................................................................................350 Installation.........................................................................................350 CHECKS AND ADJUSTMENTS...................................................................................352 Adjusting the Clutch Pedal Height....................................................................352 Adjusting the Clearance of the Release Mechanism.....................................................352 TROUBLESHOOTING..........................................................................................353 INTRODUCTION.............................................................................................355 General..............................................................................................355 MAINTENANCE SCHEDULE.....................................................................................355 MAINTENANCE PROCEDURES Every 8 Hours or Daily............................................................358 Checks with the Engine Stopped.......................................................................358 Hydraulic System.................................................................................358 Air Cleaner......................................................................................358 Engine Oil.......................................................................................358 Fuel Filter (Diesel).............................................................................358 Battery..........................................................................................359 Cooling System...................................................................................359 Drive Belts......................................................................................359 Tires and Wheels.................................................................................360 Lift Mechanism...................................................................................361 Forks............................................................................................361 Lift Chains......................................................................................361 Upright..........................................................................................362 Carriage.........................................................................................362 Load Backrest Extension..........................................................................362 Powershift Transmission..........................................................................362 Checks with the Engine Running.......................................................................362 Guages and Lights................................................................................363 Powershift Transmission..........................................................................363 Brakes...........................................................................................363 Steering System..................................................................................363 Hydraulic System.................................................................................365 Uprights.........................................................................................365 Attachments......................................................................................365 Every 350 Hours or Two Months........................................................................366 Engine Oil and Filter............................................................................366 Brake Fluid......................................................................................366 Hydraulic Tank Breather..........................................................................366 Forks............................................................................................366 Uprights.........................................................................................367 Other Lubrication Points.........................................................................368 Every 1000 Hours or Six Months.......................................................................368 Final Fuel Filter (Diesel).......................................................................368 Removing Air From The Diesel Fuel System.........................................................368 Ignition System (Gas Engine......................................................................369 PCV Valve (Gas Engine)...........................................................................369 Every 2000 Hours or Yearly...........................................................................370 PCV Valve (Gas Engine)...........................................................................370 PCV Valve (Diesel Engine)........................................................................370 Differential.....................................................................................371 Adjusting The Oil Clutch Pedal...................................................................371 Hydraulic System.................................................................................371 Changing The Gasoline Fuel System................................................................372 Changing The Fuel Filter for LPG.................................................................372 WHEELS AND TIRES.........................................................................................373 Drive Tires..........................................................................................373 Steering Tires.......................................................................................376
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]
