Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster H40 50J, H60JS service manual – PDF DOWNLOAD
Original price was: $92.95.$32.95Current price is: $32.95.
Hyster H40 50J, H60JS service manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster H40 50J, H60JS service manual
File Details:
Hyster H40 50J, H60JS service manual
Language : English
Pages : 394
Size : 12.2 MB
Downloadable : Yes
Format : PDF
HYSTER H40 50J, H60JS SERVICE MANUAL – PDF DOWNLOAD:
Image Preview:
Description:
Hyster H40 50J, H60JS 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 H40 50J, H60JS 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 DISASSEMBLY AND ASSEMBLY.................................................................................109 Overhead Guard.......................................................................................109 Hood and Seat Removal................................................................................110 Counterweight........................................................................................110 Engine and Transmission..............................................................................110 REPAIRS..................................................................................................112 Fuel and Hydraulic Tanks.............................................................................112 Decal Replacement....................................................................................113 INTRODUCTION.............................................................................................117 GENERAL..............................................................................................117 DESCRIPTION..........................................................................................118 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................118 CYLINDER HEAD AND MECHANISM..........................................................................118 Cylinder Head, Removal...........................................................................118 Cylinder Head, Disassembly.......................................................................119 Cleaning And Inspection..........................................................................120 Valve And Valve Seats............................................................................121 Studs For The Rocker Arms........................................................................121 Hydraulic Valve Lifters, Replacement.............................................................121 Hydraulic Valve Lifters, Cleaning And Inspection.................................................122 Cylinder Head, Assembly..........................................................................122 Cylinder Head, Installation......................................................................122 Rocker Arm Cover, Installation...................................................................123 TIMING GEAR COVER....................................................................................124 Removal..........................................................................................124 Installation.....................................................................................124 CAMSHAFT.............................................................................................125 Removal..........................................................................................125 Inspection.......................................................................................126 Camshaft Bearings, Removal.......................................................................126 Camshaft Bearings, Installation..................................................................126 DISTRIBUTOR..........................................................................................127 Removal..........................................................................................127 Installation.....................................................................................127 LUBRICATION SYSTEM...................................................................................128 Oil Sump, Removal................................................................................128 Oil Sump, Installation...........................................................................128 Oil Pump, Removal................................................................................128 Oil Pump, Disassembly and Repair.................................................................128 Oil Pump, Assembly...............................................................................129 Oil Pump, Installation...........................................................................129 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................129 Connecting Rod Bearings, Replacement.............................................................129 Piston And Connecting Rod Assemblies, Removal....................................................130 Disassembly......................................................................................131 Piston, Cleaning And Inspection..................................................................131 Cylinder Bores, Inspection And Repair............................................................131 Piston Rings.....................................................................................132 Assembly.........................................................................................133 Piston And Connecting Rod Assemblies, Installation...............................................133 CRANKSHAFT...........................................................................................134 Main Bearings, Replacement.......................................................................134 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................135 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........135 Crankshaft, Removal..............................................................................136 Inspection and Repair............................................................................137 How To Check The Clearance Between The Main Bearings And Their Journals..........................137 Installation.....................................................................................138 FLYWHEEL AND FLYWHEEL HOUSING........................................................................139 Flywheel, Removal................................................................................139 Ring Gear, Replacement...........................................................................140 Flywheel, Installation...........................................................................140 COOLING SYSTEM.......................................................................................140 Coolant Pump.....................................................................................140 Fan Drive........................................................................................141 Viscous Fan Drive................................................................................141 ENGINE SPECIFICATIONS....................................................................................142 ENGINE DATA..........................................................................................142 CYLINDER HEAD........................................................................................142 HYDRAULIC VALVE LIFTER...............................................................................143 CAMSHAFT.............................................................................................143 PISTONS..............................................................................................143 CYLINDER BORE........................................................................................144 CRANKSHAFT...........................................................................................144 CONNECTING RODS......................................................................................144 COOLING SYSTEM.......................................................................................145 LUBRICATION SYSTEM...................................................................................145 TORQUE SPECIFICATIONS....................................................................................145 HIGH ENERGY IGNITION (HEI)...............................................................................148 DESCRIPTION..........................................................................................148 REPAIRS..................................................................................................150 DISTRIBUTOR..........................................................................................150 Removal..........................................................................................150 Disassembly......................................................................................150 Assembly.........................................................................................155 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................156 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................157 IGNITION COIL........................................................................................157 Removal, Some 4 And 6 Cylinder Models............................................................157 Installation, Some 4 And 6 Cylinder Models.......................................................158 Removal, V8, Some 4 And 6 Cylinder Models........................................................158 Installation, V8, Some 4 And 6 Cylinder Models...................................................159 ELECTRONIC MODULE....................................................................................160 Removal..........................................................................................160 Installation.....................................................................................160 SENSING COIL.........................................................................................161 Removal..........................................................................................161 Installation.....................................................................................161 SPARK PLUGS..........................................................................................161 Removal..........................................................................................161 Installation.....................................................................................162 CHECKS AND ADJUSTMENTS...............................................................................162 Visual Checks....................................................................................162 Check The High Voltage Wires.....................................................................162 Checking The Ignition Coil.......................................................................162 Coil In Distributor Cap Design...................................................................162 Separate Coil Design.............................................................................163 Checking The Sensing Coil........................................................................163 Check The Electronic Module......................................................................164 Ignition Timing Adjustment.......................................................................164 Ignition System, GM V8-366 (6-litre).............................................................165 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................165 SPECIFICATIONS...........................................................................................165 TROUBLESHOOTING..........................................................................................166 INTRODUCTION.............................................................................................167 GENERAL..............................................................................................167 DESCRIPTION..........................................................................................167 REPAIRS..................................................................................................167 REMOVAL AND DISASSEMBLY..............................................................................167 CLEANING.............................................................................................169 INSPECTION...........................................................................................169 ASSEMBLY AND INSTALLATION............................................................................169 TROUBLESHOOTING..........................................................................................171 GENERAL..............................................................................................171 INTRODUCTION.............................................................................................172 DESCRIPTION..........................................................................................172 OPERATION............................................................................................172 Flow Control Valve...............................................................................174 Relief Valve.....................................................................................174 REPAIRS..................................................................................................175 REMOVAL..............................................................................................175 DISASSEMBLY..........................................................................................175 CLEANING.............................................................................................177 INSPECTION...........................................................................................177 ASSEMBLY.............................................................................................178 INSTALLATION.........................................................................................179 CHECKS AND ADUSTMENTS....................................................................................180 CHECK THE OUTPUT OF THE PUMP.........................................................................180 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................180 TROUBLESHOOTING..........................................................................................182 INTRODUCTION.............................................................................................185 General..............................................................................................185 Description..........................................................................................185 Hydraulic Control Valve..............................................................................191 REPAIRS..................................................................................................195 Disassembly..........................................................................................195 Cleaning.............................................................................................195 Inspection...........................................................................................195 Assembly.............................................................................................196 CHECKS AND ADJUSTMENT....................................................................................197 Relief Valve.........................................................................................197 TROUBLESHOOTING..........................................................................................199 INTRODUCTION.............................................................................................201 NOMENCLATURE, THREADS................................................................................201 STRENGTH IDENTIFICATION..............................................................................202 TABLE 1. BOLTS AND SCREWS................................................................................202 TABLE 2. STUDS AND NUTS..................................................................................203 TABLE 3. TORQUE NUTS.....................................................................................204 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................205 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................206 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................207 INTRODUCTION.............................................................................................210 GENERAL..............................................................................................210 DESCRIPTION..............................................................................................210 GENERAL..............................................................................................210 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................213 LED DISPLAY PANEL....................................................................................213 Battery Discharge Indicators.....................................................................213 Brush Wear Indicators............................................................................214 Motor Temperature Indicators.....................................................................215 "LX" SERIES DISPLAY PANEL............................................................................216 Hourmeter Functions..............................................................................217 Battery Indicator Function.......................................................................217 Status Code Function.............................................................................217 "ZX" SERIES DISPLAY PANELS...........................................................................217 Display Panel....................................................................................218 Basic Display Panels.............................................................................218 Performance Display..............................................................................220 Brush Wear Indicators............................................................................223 CHECKS AND ADJUSTMENTS...................................................................................223 GENERAL..............................................................................................223 REPLACEMENT..............................................................................................224 GENERAL..............................................................................................224 METER REPLACEMENT....................................................................................224 SENDER REPLACEMENT...................................................................................225 Fuel Level Sender................................................................................225 Pressure And Temperature Sender..................................................................225 I.T.W. DISPLAY PANEL.................................................................................226 Removal..........................................................................................226 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................227 Removal..........................................................................................227 Replacing Display Panel Assembly.................................................................227 Indicator LEDs...................................................................................227 Battery Indicators...............................................................................227 Digital Display (Performance Disply Panel Only)..................................................227 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....227 Replacing Parts Of The Basic Display Panel.......................................................228 Replacing Parts Of The Performance Display Panel.................................................230 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................230 Removal And Replacement..........................................................................230 SPECIFICATIONS...........................................................................................231 TROUBLESHOOTING..........................................................................................232 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................233 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................233 LIFT CYLINDERS...........................................................................................236 GENERAL..............................................................................................236 DESCRIPTION..........................................................................................236 Lowering Control Valve...........................................................................236 Cylinders (General)..............................................................................239 Cylinders (H520-620B,H700-800A)..................................................................241 Cylinders (H360-460B)............................................................................242 Cylinders (Two-Speed)............................................................................242 REPAIRS..................................................................................................243 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................243 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........243 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................247 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................245 DISASSEMBLY..........................................................................................245 ASSEMBLY.............................................................................................247 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................247 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........247 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................247 CHEVRON PACKING......................................................................................248 LIFT CYLINDERS FOR VISTA MASTS...........................................................................251 DESCRIPTION..........................................................................................251 Lowering Control Valve...........................................................................253 REMOVAL..............................................................................................254 DISASSEMBLY..........................................................................................254 ASSEMBLY.............................................................................................254 INSTALLATION.........................................................................................255 Main Lift Cylinders..............................................................................255 Free-Lift Cylinders..............................................................................255 CHECKS AND ADJUSTMENTS...................................................................................256 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................256 TROUBLESHOOTING..........................................................................................257 SPECIFICATIONS...........................................................................................258 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................259 GENERAL..............................................................................................259 DESCRIPTION..........................................................................................259 Fuel Tank........................................................................................260 Fuel Filter And Fuel Valve Unit..................................................................261 Vaporizer........................................................................................261 The IMPCO CA 100 Carbureto.......................................................................263 IMPCO CA 50 Carburetor...........................................................................265 The Governor (GM Engines Only)...................................................................266 Governor With Electronic Controller..............................................................267 REPAIRS..................................................................................................268 LPG TANK.............................................................................................268 Removal..........................................................................................268 Installation.....................................................................................269 REPLACE THE HOSES....................................................................................269 HYDROSTATIC RELIEF VALVE.............................................................................269 Removal and Installation.........................................................................269 FILTER UNIT..........................................................................................270 Replacement Of the Fuel Filter Element...........................................................270 Replacement of the Diaphragm and Fuel Valve......................................................271 VAPORIZER............................................................................................271 Removal..........................................................................................271 Disassembly......................................................................................271 Cleaning.........................................................................................271 Inspection.......................................................................................271 Assembly.........................................................................................273 Installation.....................................................................................273 CARBURETOR (IMPCO CA 100)............................................................................275 Removal..........................................................................................275 Disassembly......................................................................................275 Cleaning.........................................................................................275 Assembly.........................................................................................275 Installation.....................................................................................278 CARBURETER (IMPCO CA 50).............................................................................277 Removal..........................................................................................277 Disassembly......................................................................................277 Cleaning.........................................................................................278 Inspection.......................................................................................278 Assembly (See FIGURE 26.)........................................................................278 Installation.....................................................................................278 CHECKS AND ADJUSTMENTS...................................................................................279 CHECK THE FILTER UNIT................................................................................279 CHECK THE VAPORIZER..................................................................................279 Pressure Reducer Valve...........................................................................279 Vapor Valve......................................................................................279 ADJUST THE CARBURETOR................................................................................279 Idle Mixture.....................................................................................279 Idle Speed.......................................................................................279 Power Mixture....................................................................................279 ADJUST THE GOVERNOR (GM Engines Only)................................................................280 Checks...........................................................................................280 Main Adjusting Screw.............................................................................280 Secondary Adjusting Screw........................................................................280 AISAN Governor...................................................................................281 Adjustment, AISAN Governor.......................................................................281 TROUBLESHOOTING..........................................................................................282 INTRODUCTION.............................................................................................286 GENERAL..............................................................................................286 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................288 FULL FREE-LIFT MASTS.................................................................................288 THREE-STAGE MASTS....................................................................................290 FOUR-STAGE MASTS.....................................................................................291 SEQUENCE VALVE.......................................................................................291 INTRODUCTION.............................................................................................293 GENERAL..............................................................................................293 REPAIRS..................................................................................................293 FORKS................................................................................................293 CARRIAGE.............................................................................................293 Removal..........................................................................................293 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................294 Installation.....................................................................................295 MASTS................................................................................................297 Removal..........................................................................................297 Disassembly......................................................................................299 Cleaning and Inspection..........................................................................303 Assembly.........................................................................................304 INSTALLATION.........................................................................................305 CHECKS AND ADJUSTMENTS...................................................................................305 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................305 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................306 LIFT CHAIN ADJUSTMENTS...............................................................................306 MAST ADJUSTMENTS.....................................................................................307 Guide Shoe Adjustment............................................................................308 CARRIAGE ADJUSTMENT..................................................................................310 TROUBLESHOOTING..........................................................................................312 INTRODUCTION.............................................................................................313 GENERAL..............................................................................................313 DESCRIPTION..........................................................................................313 REPAIRS..................................................................................................313 REMOVAL AND DISASSEMBLY..............................................................................313 CLEANING ............................................................................................314 ASSEMBLY.............................................................................................314 CHECKS AND ADJUSTMENTS...................................................................................314 CHECKS...............................................................................................314 INTRODUCTION.............................................................................................315 GENERAL..............................................................................................315 DESCRIPTION..........................................................................................315 REPAIRS..................................................................................................318 REMOVAL..............................................................................................318 DISASSEMBLY..........................................................................................318 CLEANING.............................................................................................325 INSPECTION...........................................................................................325 ASSEMBLY.............................................................................................325 INSTALLATION.........................................................................................333 TROUBLESHOOTING..........................................................................................333 SPECIFICATIONS...........................................................................................334 INTRODUCTION.............................................................................................335 GENERAL..............................................................................................335 DESCRIPTION AND OPERATION ...........................................................................335 REPAIRS..................................................................................................336 REMOVAL..............................................................................................336 INSPECTION...........................................................................................336 INSTALLATION.........................................................................................337 ADJUSTMENTS..............................................................................................339 ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL.............................................................339 ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS....................339 TROUBLESHOOTING..........................................................................................340 INTRODUCTION.............................................................................................342 General..............................................................................................342 MAINTENANCE SCHEDULE.....................................................................................342 MAINTENANCE PROCEDURES Every 8 Hours or Daily............................................................345 Checks with the Engine Stopped.......................................................................345 Hydraulic System.................................................................................345 Air Cleaner......................................................................................345 Engine Oil.......................................................................................345 Fuel Filter (Diesel).............................................................................345 Battery..........................................................................................346 Cooling System...................................................................................346 Drive Belts......................................................................................346 Tires and Wheels.................................................................................347 Lift Mechanism...................................................................................348 Forks............................................................................................348 Lift Chains......................................................................................348 Upright..........................................................................................349 Carriage.........................................................................................349 Load Backrest Extension..........................................................................349 Powershift Transmission..........................................................................349 Checks with the Engine Running.......................................................................349 Guages and Lights................................................................................350 Powershift Transmission..........................................................................350 Brakes...........................................................................................350 Steering System..................................................................................350 Hydraulic System.................................................................................352 Uprights.........................................................................................352 Attachments......................................................................................352 Every 350 Hours or Two Months........................................................................353 Engine Oil and Filter............................................................................353 Brake Fluid......................................................................................353 Hydraulic Tank Breather..........................................................................353 Forks............................................................................................353 Uprights.........................................................................................354 Other Lubrication Points.........................................................................355 Every 1000 Hours or Six Months.......................................................................355 Final Fuel Filter (Diesel).......................................................................355 Removing Air From The Diesel Fuel System.........................................................355 Ignition System (Gas Engine......................................................................356 PCV Valve (Gas Engine)...........................................................................356 Every 2000 Hours or Yearly...........................................................................357 PCV Valve (Gas Engine)...........................................................................357 PCV Valve (Diesel Engine)........................................................................357 Differential.....................................................................................358 Adjusting The Oil Clutch Pedal...................................................................358 Hydraulic System.................................................................................358 Changing The Gasoline Fuel System................................................................359 Changing The Fuel Filter for LPG.................................................................359 WHEELS AND TIRES.........................................................................................360 Drive Tires..........................................................................................360 Steering Tires.......................................................................................363 INTRODUCTION.............................................................................................364 General..............................................................................................364 Description..........................................................................................364 ENGINE REPAIRS...........................................................................................364 REMOVAL AND INSTALLATION.................................................................................364 CYLINDER HEAD............................................................................................364 Removal..............................................................................................364 Installation.........................................................................................364 CYLINDER HEAD REPAIRS....................................................................................366 Valve Seats..............................................................................................366 Valve Springs............................................................................................366 Cylinder Head........................................................................................366 Valves...............................................................................................367 Valve Guides.........................................................................................367 ROCKER ARM ASSEMBLY......................................................................................367 Disassembly and Repair...............................................................................367 Assembly and Installation............................................................................368 COMBUSTION CHAMBER PLUGS.................................................................................368 TIMING GEAR CASE AND TIMING GEARS........................................................................368 Removal..............................................................................................368 Installation.........................................................................................369 PISTONS AND CONNECTING RODS..............................................................................371 Removal..............................................................................................371 Disassembly..........................................................................................371 Inspection...........................................................................................372 Assembly.............................................................................................372 Installation.........................................................................................373 CRANKCASE, MAIN BEARINGS AND CYLINDER LINERS.............................................................373 Removal of the Crankshaft............................................................................373 Inspection...........................................................................................374 Installation.........................................................................................375 Cylinder Liners......................................................................................376 Removal..........................................................................................376 Installation.....................................................................................376 CAMSHAFT AND CAM FOLLOWERS...............................................................................377 Removal..............................................................................................377 Inspection...........................................................................................377 Assembly and Installation............................................................................377 FUEL SYSTEM..............................................................................................378 Fuel Pump............................................................................................378 Removal..........................................................................................378 Installation.....................................................................................379 Fuel Injection Pump..................................................................................379 Removal..........................................................................................379 Repairs..........................................................................................379 Installation.....................................................................................380 Fuel Injectors.......................................................................................380 Removal..........................................................................................380 Repairs..........................................................................................380 Installation.....................................................................................380 Cold Start aid.......................................................................................380 Description......................................................................................380 Removal..........................................................................................380 Installation.....................................................................................381 COOLING SYSTEM...........................................................................................381 Thermostat...........................................................................................381 Water Pump...........................................................................................381 Removal..........................................................................................381 Installation.....................................................................................382 OIL PUMP.................................................................................................383 Removal..............................................................................................383 Installation.........................................................................................384 FLYWHEEL AND FLYWHEEL HOUSING............................................................................384 Removal..............................................................................................384 Installation.........................................................................................384 CHECKS AND ADJUSTMENTS...................................................................................385 Checking the Fuel Injector...........................................................................385 Removing the Air from the Fuel System................................................................385 Timing of the Fuel Injection Pump....................................................................386 Checking the Timing for Old Style Pumps..........................................................386 Making New Timing Mark on a New Timing Gear Case.................................................388 Checking the Timing Mark of a New Fuel Injection Pump............................................389 Valve Clearance Adjustment...........................................................................389 Adjusting the Throttle Linkage.......................................................................390 TROUBLESHOOTING..........................................................................................391 SPECIFICATIONS...........................................................................................392
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]
