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Hyster H30 60H Ser#E3 service manual – PDF DOWNLOAD
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Description
Hyster H30 60H Ser#E3 service manual
File Details:
Hyster H30 60H Ser#E3 service manual
Language : English
Pages : 383
Size : 12.6 MB
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Format : PDF
HYSTER H30 60H SER#E3 SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster H30 60H Ser#E3 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 H30 60H Ser#E3 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............................................................................ 17 REPAIRS.................................................................................................. 17 REMOVAL AND DISASSEMBLY.............................................................................. 17 CLEANING............................................................................................. 18 INSPECTION........................................................................................... 19 ASSEMBLY............................................................................................. 19 CHECKS AND ADJUSTMENTS................................................................................... 21 BRAKE SHOES.......................................................................................... 21 Parking Brake.................................................................................... 21 Seat Actuated Park Brake, J40–60AS............................................................... 21 Removing The Air From The Brake System........................................................... 22 TROUBLESHOOTING.......................................................................................... 23 COOLING SYSTEM........................................................................................... 29 INTRODUCTION......................................................................................... 29 DESCRIPTION.......................................................................................... 29 RADIATOR............................................................................................. 29 RADIATOR CAP......................................................................................... 29 THERMOSTAT........................................................................................... 29 WATER PUMP........................................................................................... 30 FAN AND FAN SHROUD................................................................................... 30 REPAIRS.................................................................................................. 30 COOLING SYSTEM CHECKS................................................................................ 30 Exhaust Leaks.................................................................................... 30 RADIATOR............................................................................................. 30 Checks........................................................................................... 30 Cleaning The Radiator............................................................................ 30 Drain The Cooling System......................................................................... 32 Fill The Cooling System.......................................................................... 32 WATER PUMP........................................................................................... 32 Checks........................................................................................... 32 THERMOSTAT........................................................................................... 33 Checks........................................................................................... 33 FAN AND FAN SHROUD................................................................................... 33 TROUBLESHOOTING.......................................................................................... 34 INTRODUCTION............................................................................................. 41 GENERAL.............................................................................................. 41 DESCRIPTION.......................................................................................... 41 REPAIRS.................................................................................................. 41 DISASSEMBLY.......................................................................................... 42 CLEANING............................................................................................. 44 ASSEMBLY............................................................................................. 44 TROUBLESHOOTING.......................................................................................... 46 ELECTRICAL SYSTEM COMPLETELY DEAD........................................................................ 47 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN .................................................... 48 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER.............................................. 50 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK............................................. 51 STARTER CRANKS SLOWLY.................................................................................... 53 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START................................................ 54 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND.............................................................. 56 CHARGING SYSTEM DOES NOT FUNCTION........................................................................ 57 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW..................................................... 60 BATTERY IS BEING OVERCHARGED............................................................................. 63 ONE OR MORE DASH GAUGES DO NOT WORK...................................................................... 64 HORN DOES NOT BLOW....................................................................................... 68 POWERSHIFT TRANSMISSION WILL NOT ENGAGE.................................................................. 69 ELECTRICAL SCHEMATIC S20-30A, H20-30E.................................................................... 70 ELECTRICAL S30-50C....................................................................................... 71 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG.............................................................. 72 ELECTRICAL SCHEMATIC H30-60H DIESEL...................................................................... 74 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG.............................................................. 76 ELECTRICAL SCHEMATIC H60-90C DIESEL...................................................................... 77 ELECTRICAL SCHEMATIC S30-60ES............................................................................ 78 ELECTRICAL SCHEMATIC S60-120E............................................................................ 79 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG............................................................ 80 ELECTRICAL SCHEMATIC S125-150A DIESEL.................................................................... 81 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG............................................................ 82 ELECTRICAL SCHEMATIC H110-150F DIESEL.................................................................... 83 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG.................................................. 84 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL......................................................... 85 ELECTRICAL SCHEMATIC H300A............................................................................... 86 ELECTRICAL SCHEMATIC H300-350B........................................................................... 87 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL............................................................ 88 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL............................................................ 89 ELECTRICAL SCHEMATIC H700-800A........................................................................... 90 ELECTRICAL SCHEMATIC P40-50A GASOLINE.................................................................... 92 ELECTRICAL SCHEMATIC P40-50A DIESEL...................................................................... 93 ELECTRICAL SCHEMATIC P60-80A GASOLINE.................................................................... 94 ELECTRICAL SCHEMATIC P60-80A DIESEL...................................................................... 95 ELECTRICAL SCHEMATIC KE GAS GASOLINE..................................................................... 96 ELECTRICAL SCHEMATIC KE DIESEL........................................................................... 97 ELECTRICAL SCHEMATIC M200-400H GASOLINE.................................................................. 98 ELECTRICAL SCHEMATIC M200-400H DIESEL....................................................................100 ELECTRICAL SCHEMATIC M600A...............................................................................102 ELECTRICAL WARNING DEVICES...............................................................................104 GENERAL..............................................................................................104 DESCRIPTION..........................................................................................104 Operator Controlled Horns........................................................................104 System Warning Lights, Buzzers and Bells.........................................................104 Reverse Warning Horns............................................................................105 Warning Lights...................................................................................105 REPLACEMENT..........................................................................................106 General..........................................................................................106 Replacing Horns or Bells.........................................................................106 Replacing Horn Relay or Buzzer...................................................................106 Replacing Warning Lights.........................................................................106 Light Assemblies.................................................................................107 Replacing Flashing Units.........................................................................107 INTRODUCTION.............................................................................................108 GENERAL..............................................................................................108 DESCRIPTION..........................................................................................108 Main Frame.......................................................................................108 Fuel Tank........................................................................................108 Hydraulic Tank...................................................................................108 REMOVAL AND DISASSEMBLY..................................................................................109 COUNTERWEIGHT REMOVAL................................................................................109 FUEL TANK REMOVAL....................................................................................109 HYDRAULIC TANK REMOVAL...............................................................................110 HOOD AND SEAT REMOVAL................................................................................110 OVERHEAD GUARD REMOVAL...............................................................................110 ENGINE AND TRANSMISSION REMOVAL......................................................................110 REPAIRS..................................................................................................111 FUEL OR HYDRAULIC TANK...............................................................................111 Small Leaks......................................................................................111 Large Leaks......................................................................................112 PAINTING INSTRUCTIONS................................................................................113 LABEL REPLACEMENT....................................................................................114 ASSEMBLY AND INSTALLATION................................................................................114 GENERAL..............................................................................................114 COUNTERWEIGHT INSTALLATION...........................................................................114 FUEL TANK INSTALLATION...............................................................................114 HYDRAULIC TANK INSTALLATION..........................................................................114 ENGINE AND TRANSMISSION INSTALLATION.................................................................115 INTRODUCTION.............................................................................................116 GENERAL..............................................................................................116 DESCRIPTION..........................................................................................117 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................117 CYLINDER HEAD AND MECHANISM..........................................................................117 Cylinder Head, Removal...........................................................................117 Cylinder Head, Disassembly.......................................................................118 Cleaning And Inspection..........................................................................119 Valve And Valve Seats............................................................................120 Studs For The Rocker Arms........................................................................120 Hydraulic Valve Lifters, Replacement.............................................................120 Hydraulic Valve Lifters, Cleaning And Inspection.................................................121 Cylinder Head, Assembly..........................................................................121 Cylinder Head, Installation......................................................................121 Rocker Arm Cover, Installation...................................................................122 TIMING GEAR COVER....................................................................................123 Removal..........................................................................................123 Installation.....................................................................................123 CAMSHAFT.............................................................................................124 Removal..........................................................................................124 Inspection.......................................................................................125 Camshaft Bearings, Removal.......................................................................125 Camshaft Bearings, Installation..................................................................125 DISTRIBUTOR..........................................................................................126 Removal..........................................................................................126 Installation.....................................................................................126 LUBRICATION SYSTEM...................................................................................127 Oil Sump, Removal................................................................................127 Oil Sump, Installation...........................................................................127 Oil Pump, Removal................................................................................127 Oil Pump, Disassembly and Repair.................................................................127 Oil Pump, Assembly...............................................................................128 Oil Pump, Installation...........................................................................128 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................128 Connecting Rod Bearings, Replacement.............................................................128 Piston And Connecting Rod Assemblies, Removal....................................................129 Disassembly......................................................................................130 Piston, Cleaning And Inspection..................................................................130 Cylinder Bores, Inspection And Repair............................................................130 Piston Rings.....................................................................................131 Assembly.........................................................................................132 Piston And Connecting Rod Assemblies, Installation...............................................132 CRANKSHAFT...........................................................................................133 Main Bearings, Replacement.......................................................................133 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................134 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........134 Crankshaft, Removal..............................................................................135 Inspection and Repair............................................................................136 How To Check The Clearance Between The Main Bearings And Their Journals..........................136 Installation.....................................................................................137 FLYWHEEL AND FLYWHEEL HOUSING........................................................................138 Flywheel, Removal................................................................................138 Ring Gear, Replacement...........................................................................139 Flywheel, Installation...........................................................................139 COOLING SYSTEM.......................................................................................139 Coolant Pump.....................................................................................139 Fan Drive........................................................................................140 Viscous Fan Drive................................................................................140 ENGINE SPECIFICATIONS....................................................................................141 ENGINE DATA..........................................................................................141 CYLINDER HEAD........................................................................................141 HYDRAULIC VALVE LIFTER...............................................................................142 CAMSHAFT.............................................................................................142 PISTONS..............................................................................................142 CYLINDER BORE........................................................................................143 CRANKSHAFT...........................................................................................143 CONNECTING RODS......................................................................................143 COOLING SYSTEM.......................................................................................144 LUBRICATION SYSTEM...................................................................................144 TORQUE SPECIFICATIONS....................................................................................144 HIGH ENERGY IGNITION (HEI)...............................................................................147 DESCRIPTION..........................................................................................147 REPAIRS..................................................................................................149 DISTRIBUTOR..........................................................................................149 Removal..........................................................................................149 Disassembly......................................................................................149 Assembly.........................................................................................154 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................155 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................156 IGNITION COIL........................................................................................156 Removal, Some 4 And 6 Cylinder Models............................................................156 Installation, Some 4 And 6 Cylinder Models.......................................................157 Removal, V8, Some 4 And 6 Cylinder Models........................................................157 Installation, V8, Some 4 And 6 Cylinder Models...................................................158 ELECTRONIC MODULE....................................................................................159 Removal..........................................................................................159 Installation.....................................................................................159 SENSING COIL.........................................................................................160 Removal..........................................................................................160 Installation.....................................................................................160 SPARK PLUGS..........................................................................................160 Removal..........................................................................................160 Installation.....................................................................................161 CHECKS AND ADJUSTMENTS...............................................................................161 Visual Checks....................................................................................161 Check The High Voltage Wires.....................................................................161 Checking The Ignition Coil.......................................................................161 Coil In Distributor Cap Design...................................................................161 Separate Coil Design.............................................................................162 Checking The Sensing Coil........................................................................162 Check The Electronic Module......................................................................163 Ignition Timing Adjustment.......................................................................163 Ignition System, GM V8-366 (6-litre).............................................................164 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................164 SPECIFICATIONS...........................................................................................164 TROUBLESHOOTING..........................................................................................165 INTRODUCTION.............................................................................................166 DESCRIPTION..........................................................................................166 OPERATION............................................................................................166 Flow Control Valve...............................................................................168 Relief Valve.....................................................................................168 REPAIRS..................................................................................................169 REMOVAL..............................................................................................169 DISASSEMBLY..........................................................................................169 CLEANING.............................................................................................171 INSPECTION...........................................................................................171 ASSEMBLY.............................................................................................172 INSTALLATION.........................................................................................173 CHECKS AND ADUSTMENTS....................................................................................174 CHECK THE OUTPUT OF THE PUMP.........................................................................174 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................174 TROUBLESHOOTING..........................................................................................176 INTRODUCTION.............................................................................................179 GENERAL..............................................................................................179 DESCRIPTION..........................................................................................179 REPAIRS..................................................................................................179 REMOVAL AND DISASSEMBLY..............................................................................179 CLEANING.............................................................................................181 INSPECTION...........................................................................................181 ASSEMBLY AND INSTALLATION............................................................................181 TROUBLESHOOTING..........................................................................................183 GENERAL..............................................................................................183 INTRODUCTION.............................................................................................184 General..............................................................................................184 Description..........................................................................................184 Hydraulic Control Valve..............................................................................190 REPAIRS..................................................................................................194 Disassembly..........................................................................................194 Cleaning.............................................................................................194 Inspection...........................................................................................194 Assembly.............................................................................................195 CHECKS AND ADJUSTMENT....................................................................................196 Relief Valve.........................................................................................196 TROUBLESHOOTING..........................................................................................198 INTRODUCTION.............................................................................................200 NOMENCLATURE, THREADS................................................................................200 STRENGTH IDENTIFICATION..............................................................................201 TABLE 1. BOLTS AND SCREWS................................................................................201 TABLE 2. STUDS AND NUTS..................................................................................202 TABLE 3. TORQUE NUTS.....................................................................................203 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................204 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................205 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................206 INTRODUCTION.............................................................................................209 GENERAL..............................................................................................209 DESCRIPTION..............................................................................................209 GENERAL..............................................................................................209 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................212 LED DISPLAY PANEL....................................................................................212 Battery Discharge Indicators.....................................................................212 Brush Wear Indicators............................................................................213 Motor Temperature Indicators.....................................................................214 "LX" SERIES DISPLAY PANEL............................................................................215 Hourmeter Functions..............................................................................216 Battery Indicator Function.......................................................................216 Status Code Function.............................................................................216 "ZX" SERIES DISPLAY PANELS...........................................................................216 Display Panel....................................................................................217 Basic Display Panels.............................................................................217 Performance Display..............................................................................219 Brush Wear Indicators............................................................................222 CHECKS AND ADJUSTMENTS...................................................................................222 GENERAL..............................................................................................222 REPLACEMENT..............................................................................................223 GENERAL..............................................................................................223 METER REPLACEMENT....................................................................................223 SENDER REPLACEMENT...................................................................................224 Fuel Level Sender................................................................................224 Pressure And Temperature Sender..................................................................224 I.T.W. DISPLAY PANEL.................................................................................225 Removal..........................................................................................225 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................226 Removal..........................................................................................226 Replacing Display Panel Assembly.................................................................226 Indicator LEDs...................................................................................226 Battery Indicators...............................................................................226 Digital Display (Performance Disply Panel Only)..................................................226 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....226 Replacing Parts Of The Basic Display Panel.......................................................227 Replacing Parts Of The Performance Display Panel.................................................229 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................229 Removal And Replacement..........................................................................229 SPECIFICATIONS...........................................................................................230 TROUBLESHOOTING..........................................................................................231 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................232 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................232 LIFT CYLINDERS...........................................................................................235 GENERAL..............................................................................................235 DESCRIPTION..........................................................................................235 Lowering Control Valve...........................................................................235 Cylinders (General)..............................................................................238 Cylinders (H520-620B,H700-800A)..................................................................240 Cylinders (H360-460B)............................................................................241 Cylinders (Two-Speed)............................................................................241 REPAIRS..................................................................................................242 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................242 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........242 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................246 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................244 DISASSEMBLY..........................................................................................244 ASSEMBLY.............................................................................................246 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................246 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........246 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................246 CHEVRON PACKING......................................................................................247 LIFT CYLINDERS FOR VISTA MASTS...........................................................................250 DESCRIPTION..........................................................................................250 Lowering Control Valve...........................................................................252 REMOVAL..............................................................................................253 DISASSEMBLY..........................................................................................253 ASSEMBLY.............................................................................................253 INSTALLATION.........................................................................................254 Main Lift Cylinders..............................................................................254 Free-Lift Cylinders..............................................................................254 CHECKS AND ADJUSTMENTS...................................................................................255 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................255 TROUBLESHOOTING..........................................................................................256 SPECIFICATIONS...........................................................................................257 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................258 GENERAL..............................................................................................258 DESCRIPTION..........................................................................................258 Fuel Tank........................................................................................259 Fuel Filter And Fuel Valve Unit..................................................................260 Vaporizer........................................................................................260 The IMPCO CA 100 Carbureto.......................................................................262 IMPCO CA 50 Carburetor...........................................................................264 The Governor (GM Engines Only)...................................................................265 Governor With Electronic Controller..............................................................266 REPAIRS..................................................................................................267 LPG TANK.............................................................................................267 Removal..........................................................................................267 Installation.....................................................................................268 REPLACE THE HOSES....................................................................................268 HYDROSTATIC RELIEF VALVE.............................................................................268 Removal and Installation.........................................................................268 FILTER UNIT..........................................................................................269 Replacement Of the Fuel Filter Element...........................................................269 Replacement of the Diaphragm and Fuel Valve......................................................270 VAPORIZER............................................................................................270 Removal..........................................................................................270 Disassembly......................................................................................270 Cleaning.........................................................................................270 Inspection.......................................................................................270 Assembly.........................................................................................272 Installation.....................................................................................272 CARBURETOR (IMPCO CA 100)............................................................................274 Removal..........................................................................................274 Disassembly......................................................................................274 Cleaning.........................................................................................274 Assembly.........................................................................................274 Installation.....................................................................................277 CARBURETER (IMPCO CA 50).............................................................................276 Removal..........................................................................................276 Disassembly......................................................................................276 Cleaning.........................................................................................277 Inspection.......................................................................................277 Assembly (See FIGURE 26.)........................................................................277 Installation.....................................................................................277 CHECKS AND ADJUSTMENTS...................................................................................278 CHECK THE FILTER UNIT................................................................................278 CHECK THE VAPORIZER..................................................................................278 Pressure Reducer Valve...........................................................................278 Vapor Valve......................................................................................278 ADJUST THE CARBURETOR................................................................................278 Idle Mixture.....................................................................................278 Idle Speed.......................................................................................278 Power Mixture....................................................................................278 ADJUST THE GOVERNOR (GM Engines Only)................................................................279 Checks...........................................................................................279 Main Adjusting Screw.............................................................................279 Secondary Adjusting Screw........................................................................279 AISAN Governor...................................................................................280 Adjustment, AISAN Governor.......................................................................280 TROUBLESHOOTING..........................................................................................281 INTRODUCTION.............................................................................................285 GENERAL..............................................................................................285 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................287 FULL FREE-LIFT MASTS.................................................................................287 THREE-STAGE MASTS....................................................................................289 FOUR-STAGE MASTS.....................................................................................290 SEQUENCE VALVE.......................................................................................290 INTRODUCTION.............................................................................................292 GENERAL..............................................................................................292 REPAIRS..................................................................................................292 FORKS................................................................................................292 CARRIAGE.............................................................................................292 Removal..........................................................................................292 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................293 Installation.....................................................................................294 MASTS................................................................................................296 Removal..........................................................................................296 Disassembly......................................................................................298 Cleaning and Inspection..........................................................................302 Assembly.........................................................................................303 INSTALLATION.........................................................................................304 CHECKS AND ADJUSTMENTS...................................................................................304 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................304 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................305 LIFT CHAIN ADJUSTMENTS...............................................................................305 MAST ADJUSTMENTS.....................................................................................306 Guide Shoe Adjustment............................................................................307 CARRIAGE ADJUSTMENT..................................................................................309 TROUBLESHOOTING..........................................................................................311 INTRODUCTION.............................................................................................312 GENERAL..............................................................................................312 DESCRIPTION..........................................................................................312 REPAIRS..................................................................................................312 REMOVAL AND DISASSEMBLY..............................................................................312 CLEANING ............................................................................................313 ASSEMBLY.............................................................................................313 CHECKS AND ADJUSTMENTS...................................................................................313 CHECKS...............................................................................................313 INTRODUCTION.............................................................................................314 GENERAL..............................................................................................314 DESCRIPTION..........................................................................................314 REPAIRS..................................................................................................317 REMOVAL..............................................................................................317 DISASSEMBLY..........................................................................................317 CLEANING.............................................................................................324 INSPECTION...........................................................................................324 ASSEMBLY.............................................................................................324 INSTALLATION.........................................................................................332 TROUBLESHOOTING..........................................................................................332 SPECIFICATIONS...........................................................................................333 INTRODUCTION.............................................................................................334 GENERAL..............................................................................................334 DESCRIPTION AND OPERATION ...........................................................................334 REPAIRS..................................................................................................335 REMOVAL..............................................................................................335 INSPECTION...........................................................................................335 INSTALLATION.........................................................................................336 ADJUSTMENTS..............................................................................................338 ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL.............................................................338 ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS....................338 TROUBLESHOOTING..........................................................................................339 INTRODUCTION.............................................................................................341 General..............................................................................................341 MAINTENANCE SCHEDULE.....................................................................................341 MAINTENANCE PROCEDURES...................................................................................343 Every 8 Hours or Daily...............................................................................343 Engine Oil.......................................................................................343 Air Cleaner......................................................................................343 Cooling System...................................................................................344 Fuel Filter......................................................................................344 Hydraulic Oil....................................................................................344 Battery..........................................................................................344 Tires............................................................................................345 Forks............................................................................................345 Lift Chains......................................................................................346 Drive Belts......................................................................................347 Brake Fluid......................................................................................347 Every 150 Hours or Monthly...........................................................................347 Uprights.........................................................................................347 Steering Axle....................................................................................349 Every 200 Hours......................................................................................349 Engine Oil (Perkins).............................................................................349 Every 350 Hours or Two Months........................................................................350 Engine Oil (GM) .................................................................................350 Fuel Filters.....................................................................................350 Every 1000 Hours or Six Months.......................................................................351 Fuel Filters.....................................................................................351 Ignition System..................................................................................351 Brakes...........................................................................................351 Every 2000 Hours or Yearly...........................................................................352 Differential/Transmission........................................................................352 Clutch Pedal.....................................................................................352 Hydraulic System.................................................................................352 PCV Valve........................................................................................354 INTRODUCTION.............................................................................................355 General..............................................................................................355 Description..........................................................................................355 ENGINE...................................................................................................355 Removal..............................................................................................355 Installation.........................................................................................356 CYLINDER HEAD AND VALVE MECHANISM........................................................................356 Cylinder Head........................................................................................356 Removal..........................................................................................356 Repairs..........................................................................................357 Installation.....................................................................................357 Valve Guides.....................................................................................359 Valve Mechanism......................................................................................359 Valves...........................................................................................359 Valve Springs....................................................................................359 Rocker Arm Assembly..............................................................................359 LUBRICATION..............................................................................................360 Oil Pump.............................................................................................360 Removal and Disassembly..........................................................................360 Repairs..........................................................................................360 Assembly and Installation........................................................................360 Relief Valve.....................................................................................361 TIMING GEAR CASE AND CAMSHAFT............................................................................361 Timing Gear Cover....................................................................................361 Removal..........................................................................................361 Installation.....................................................................................361 Idle Gears...........................................................................................361 Removal..........................................................................................361 Installation.....................................................................................362 Camshaft Gear and Camshaft...........................................................................362 Removal..........................................................................................362 Installation.....................................................................................363 Fuel Pump Gear.......................................................................................363 Removal..........................................................................................363 Installation.....................................................................................364 Timing Gear Case.....................................................................................364 Removal..........................................................................................364 Installation.....................................................................................364 CRANKSHAFT AND MAIN BEARINGS.............................................................................365 Removal..............................................................................................365 Installation.........................................................................................365 PISTONS AND PISTON RODS..................................................................................366 Removal..............................................................................................366 Disassembly..........................................................................................366 Repairs..............................................................................................367 Assembly.............................................................................................367 Installation.........................................................................................368 CYLINDER LINERS..........................................................................................369 Removal .............................................................................................369 Installation.........................................................................................369 FLYWHEEL AND FLYWHEEL HOUSING............................................................................369 Removal..............................................................................................369 Installation.........................................................................................369 FUEL PUMP................................................................................................369 Removal..............................................................................................369 Installation.........................................................................................370 FUEL INJECTION PUMP......................................................................................370 Removal..............................................................................................370 Installation.........................................................................................370 FUEL INJECTORS...........................................................................................371 Checks...............................................................................................371 Installation.........................................................................................371 COOLING SYSTEM...........................................................................................372 Thermostat...........................................................................................372 Removal..........................................................................................372 Installation.....................................................................................372 Water Pump...........................................................................................372 Removal..........................................................................................372 Assembly.........................................................................................373 CHECKS AND ADJUSTMENTS...................................................................................373 Removing Air From The Fuel System....................................................................373 Timing...............................................................................................374 Fuel Injection Pump..............................................................................374 Valve Clearance Adjustment...........................................................................377 Adjusting The Throttle Linkage.......................................................................377 TROUBLESHOOTING..........................................................................................379 SPECIFICATIONS...........................................................................................380
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]
