Complete service repair manual for Hyster C007 (H150-275HP150-200B & H7.00-12.50HP7.00-9.00B Europe), with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
Hyster C007 (H150-275HP150-200B & H7.00-12.50HP7.00-9.00B Europe) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 1,076 pages
File Format: PDF
Language: English
Hyster C007 (H150-275HP150-200B & H7.00-12.50HP7.00-9.00B Europe) Service Manual.pdf
C007 (H150-275HP150-200B)….2
100141….4
INTRODUCTION….4
General….4
Description….4
Frame….4
Fuel Tank….4
Hydraulic tank….4
REPAIRS….5
Counterweight….5
Removal….5
Installation….5
Fenders….6
Removal….6
Installation….6
Seat….6
Removal….6
Installation….6
Hood….6
Hydraulic Tank….7
Removal….7
Service Procedures….7
Installation….8
Fuel Tank….8
Removal….8
Service Procedures….8
Installation….8
Housing (Steering Control Unit)….8
Removal….8
Installation….8
Painting Instructions….9
Decal Installation….9
Cab….9
120022….13
INTRODUCTION….13
GENERAL….13
DESCRIPTION….13
Oil Clutch….13
Jet Pump….13
REPAIRS….14
OIL CLUTCH ASSEMBLY….14
Removal And Disassembly….14
Cleaning….14
Inspection….14
Assembly And Installation….15
JET PUMP….15
Removal And Disassembly….15
CLEANING….15
Assembly And Installation….15
CHECKS AND ADJUSTMENTS….15
ADJUSTING THE LINKAGE FOR THE CLUTCH PEDAL….15
CHECKING THE ALIGNMENT OF THE CLUTCH DISC….16
TROUBLESHOOTING….17
1300142….18
INTRODUCTION….18
General….18
REPAIRS….18
Torque Converter….18
Transmission….18
Control Valve….33
Monotrol Pedal….35
CHECKS AND ADJUSTMENTS….36
Stall Speed of the Torque Converter….36
Leakage in the Monotrol Pedal….36
Oil Pressure of the Transmission….36
Linkages….39
TROUBLESHOOTING….41
SPECIFICATIONS….44
130033….46
INTRODUCTION….47
MECHANICAL SECTION….48
TORQUE CONVERTER….49
FORWARD-REVERSE SECTION….49
PLANETARY GEARS: HOW THEY WORK….51
WHEN THE SUN GEAR IS DRIVEN….51
WHEN PLANET PINION CARRIER IS DRIVEN….51
DOUBLE PLANET PINION SET….51
REVERSE….52
FORWARD….52
RANGE SECTION….53
LOW….53
MEDIUM….53
HIGH….56
HYDRAULIC SYSTEM….57
INTRODUCTION TO HYDRAULIC SYSTEM….57
PUMP AND SUMP….58
OIL FILTER….58
MONOTROL ASSEMBLY….59
OIL COOLERS….60
CONTROL VALVE ASSEMBLY….61
RANGE SPOOL….61
INCHING VALVE….61
DIRECTIONAL SPOOL….64
PRESSURE REGULATORS….66
CUSHION VALVE….66
SCHEMATIC AND FLOW DIAGRAMS….68
NEUTRAL-REVERSE….68
DRIVE-HIGH-REVERSE….71
DRIVE-MEDIUM-FORWARD….72
INCHING-LOW-FORWARD….73
130039….74
INTRODUCTION….74
General….74
Description….74
REPAIRS….75
Removal….75
Disassembly….75
Cleaning….75
Installation….75
CHECKS AND ADJUSTMENTS….85
Forward/Reverse Linkage….85
TROUBLESHOOTING….85
130044….87
INTRODUCTION….87
GENERAL….87
DESCRIPTION….87
REPAIRS….87
REMOVAL….87
DISASSEMBLY….88
CLEANING….88
ASSEMBLY AND INSTALLATION….88
TROUBLESHOOTING….88
140046….89
General….91
Description….91
Differential Repair….91
Remove….91
Disassemble….91
Assemble….91
Pinion, Bearings, and Pinion Carrier, Assemble….91
Pinion Bearings, Adjust Preload….93
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….93
Differential and Ring Gear, Assemble….95
Differential Pinion and Side Gear Assembly, Assemble….97
Differential Gears Rotating Torque, Check….98
Differential and Ring Gear Assembly, Install….99
Differential Bearings, Preload Adjust….100
Ring Gear, Runout Check….100
Gear Clearance, Adjust….101
Gear Set, Tooth Contact Pattern Check….101
Install into Axle Housing….101
Specifications….104
General Specifications….104
Rivet Installation Pressure….104
Pinion Preload Pressure….104
Pinion Adjustment….104
Troubleshooting….107
160054….109
INTRODUCTION….109
GENERAL….109
DESCRIPTION….109
OPERATION….109
REPAIRS….109
STEERING WHEEL AND COLUMN ASSEMBLY….109
TYPE "A" STEERING COLUMN ASSEMBLY….111
Removal And Disassembly….111
Assembly And Installation….111
TYPE "A" STEERING COLUMN….112
TYPE "A" STEERING COLUMN….113
TYPE "B" STEERING COLUMN….114
Removal And Disassembly….114
Assembly And Installation….114
TYPE "B" STEERING COLUMN….115
Disassembly of Steering Control Unit….116
Cleaning of Steering Control Unit….116
Assembly of Steering Control Unit….118
CHECKS AND ADJUSTMENTS….121
REMOVE AIR FROM THE SYSTEM….121
TROUBLESHOOTING….122
160071….123
INTRODUCTION….123
GENERAL ….123
DESCRIPTION….123
REPAIRS….124
STEERING AXLE….124
Removal….124
Installation….124
STEERING CYLINDER….124
Removal….124
Inspection….126
Assembly….126
Installation….126
HUBS, H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B (P150-200B)….127
Removal….127
Installation….127
HUBS, H360-620B, H16.00-30.00C, H17.00-32.00C, H700-800A, H36.00-44.00B, H36.00-48.00C, H20.00-32.00F….128
Removal….128
Installation….128
SPINDLES….128
Removal….128
Installation….128
CHECKS AND ADJUSTMENTS….130
REMOVE THE AIR FROM THE STEERING SYSTEM….130
ADJUST THE CYLINDER STOPS….130
1800146….131
INTRODUCTION….131
General….131
Description….131
REPAIRS….131
Removal and Disassembly….131
Cleaning….132
Assembly and Installation….132
1800150….134
INTRODUCTION….134
General….134
Description….134
Operation….134
REPAIRS….134
Removal….134
Disassembly….134
Cleaning….135
Assembly….135
Installation….137
TROUBLESHOOTING….138
180083….140
INTRODUCTION….140
GENERAL….140
DESCRIPTION….140
CONTROL VALVE OPERATION….141
REPAIRS….141
BRAKE SHOE ASSEMBLIES….141
Removal….141
Cleaning….141
Inspection….142
Installation….142
AIR CHAMBER….143
Removal and Disassembly….143
Assembly and Installation….143
CONTROL VALVE….143
Removal….143
Disassembly….144
Assembly….145
Installation….145
AIR TANK….145
CHECKS AND ADJUSTMENTS….146
ADJUSTING THE BRAKES….146
RELIEF VALVE….146
TROUBLESHOOTING….147
180084….149
INTRODUCTION….149
General….149
Description….149
Brake Valve….149
Service Brake Assembly….152
REPAIRS….153
Brake Shoe Assemblies….153
Removal….153
Cleaning….154
Assembly….154
Brake Valve Assemblies….155
Master Cylinder….156
Removal….156
Disassembly….157
Assembly….157
Relief Valve Assembly….158
Disassembly….158
Assembly….158
Actuator….159
Disassembly….160
Assembly….160
CHECKS AND ADJUSTMENTS….161
Adjust the Brake Shoes….161
Adjust the Brake Pedal….161
Remove Air from the Brake System….162
Adjust the Relief Valve In The Actuator….162
SPECIFICATIONS….163
TROUBLESHOOTING….163
1900147….166
190097….168
INTRODUCTION….168
DESCRIPTION….168
OPERATION….168
Flow Control Valve….170
Relief Valve….170
REPAIRS….171
REMOVAL….171
DISASSEMBLY….171
CLEANING….173
INSPECTION….173
ASSEMBLY….174
INSTALLATION….175
CHECKS AND ADUSTMENTS….176
CHECK THE OUTPUT OF THE PUMP….176
CHECK FOR AIR IN THE HYDRAULIC SYSTEM….176
TROUBLESHOOTING….178
2000100….181
INTRODUCTION….181
GENERAL….181
DESCRIPTION….181
OPERATION….182
Lifting, No Load or Light Load….182
Lifting, Capacity Load….182
Lowering….183
Tilting….184
Relief Valve….184
By-Pass Fitting….184
Flow Control Fitting….184
REPAIRS….185
REMOVAL AND DISASSEMBLY….185
CLEANING….185
ASSEMBLY….185
INSTALLATION….186
CHECKS AND ADJUSTMENTS….186
ADJUSTING THE PRESSURE OF THE RELIEF VALVE….186
CHECK AND ADJUST THE PRESSURE OF THE TWO SPEED VALVE….187
TROUBLESHOOTING….187
200099….188
INTRODUCTION….188
GENERAL….188
DESCRIPTION….188
OPERATION….189
LIFTING, NO LOAD OR LIGHT LOAD….189
LIFTING, CAPACITY LOAD….189
LOWERING….189
TILTING….190
RELIEF VALVE….190
BY-PASS FITTING….190
FLOW CONTROL FITTING….191
REPAIRS….191
REMOVAL AND DISASSEMBLY….191
CLEANING….192
ASSEMBLY….192
INSTALLATION….193
CHECKS AND ADJUSTMENTS….193
ADJUSTING THE PRESSURE OF THE RELIEF VALVE….193
SETTINGS FOR THE PRESSURE OF THE RELIEF VALVE….193
CHECKING AND ADJUSTING THE PRESSURE OF THE TWO SPEED VALVE….193
TROUBLESHOOTING….195
2100102….196
INTRODUCTION….196
GENERAL….196
DESCRIPTION AND OPERATION….196
Tilt Forward….196
Tilt Backward….197
REPAIRS….199
REMOVAL….199
DISASSEMBLY….199
CLEANING….199
ASSEMBLY….199
INSTILLATION….200
TROUBLESHOOTING….200
2100103….201
General….203
Description….203
Tilt Cylinder….203
Remove….203
Disassemble….203
Clean….203
Assemble….203
Tilt Cylinders with O-Ring or Single-Lip Seals….203
Tilt Cylinders for XM and XMS Models….205
Tilt Cylinders for H700-800A and Early Model H700-920B….206
Install….207
Tilt Cylinders Using Chevron Packing….208
Install….209
Tilt Cylinder Leak Check….211
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….212
Torque Specifications….212
Piston Rod Nut….212
Retainer….214
Troubleshooting….215
2200106….218
General….220
Description and Operation….220
Starter Repair….222
Remove….222
Disassemble….222
Clean….223
Assemble….223
Install….224
General Checks and Adjustments….224
Troubleshooting….227
2200107….231
toc….231
High Energy Ignition (HEI) System….231
Safety Precautions Maintenance and Repair….232
Description….235
Distributor Repair….237
Remove….237
Disassemble….237
Assemble….242
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo….243
Install, If Crankshaft WAS Rotated when Distributor was Removed….243
Ignition Coil Replacement….244
Some Four- and Six-Cylinder Models….244
Remove….244
Install….245
V8, Some Four- and Six-Cylinder Models….245
Remove….245
Install….246
Electronic Module Replacement….247
Remove….247
Install….247
Sensing Coil Replacement….248
Remove….248
Install….248
Spark Plugs Replacement….248
Remove….248
Install….249
Visual Check….249
High Voltage Wires Check….249
Ignition Coil Check….250
Coil in Distributor Cap Design….250
Separate Coil Design….250
Sensing Coil, Check….251
Electronic Module Check….251
Ignition Timing Adjustment….251
GM V8-366 (6-liter) Ignition System Check….253
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ….253
Specifications….253
Troubleshooting….254
2200143….259
INTRODUCTION….259
GENERAL….259
DESCRIPTION….259
GENERAL….259
STEERING COLUMN GAUGES, METERS AND INDICATORS….262
LED DISPLAY PANEL….262
Battery Discharge Indicators….262
Brush Wear Indicators….263
Motor Temperature Indicators….264
"LX" SERIES DISPLAY PANEL….265
Hourmeter Functions….266
Battery Indicator Function….266
Status Code Function….266
"ZX" SERIES DISPLAY PANELS….266
Display Panel….267
Basic Display Panels….267
Performance Display….269
Brush Wear Indicators….272
CHECKS AND ADJUSTMENTS….272
GENERAL….272
REPLACEMENT….273
GENERAL….273
METER REPLACEMENT….273
SENDER REPLACEMENT….274
Fuel Level Sender….274
Pressure And Temperature Sender….274
I.T.W. DISPLAY PANEL….275
Removal….275
DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT….276
Removal….276
Replacing Display Panel Assembly….276
Indicator LEDs….276
Battery Indicators….276
Digital Display (Performance Disply Panel Only)….276
Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)….276
Replacing Parts Of The Basic Display Panel….277
Replacing Parts Of The Performance Display Panel….279
DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT….279
Removal And Replacement….279
SPECIFICATIONS….280
TROUBLESHOOTING….281
2200144….282
ELECTRICAL WARNING DEVICES….282
GENERAL….282
DESCRIPTION….282
Operator Controlled Horns….282
System Warning Lights, Buzzers and Bells….282
Reverse Warning Horns….283
Warning Lights….283
REPLACEMENT….284
General….284
Replacing Horns or Bells….284
Replacing Horn Relay or Buzzer….284
Replacing Warning Lights….284
Light Assemblies….285
Replacing Flashing Units….285
2200153….286
ELECTRICAL SYSTEM COMPLETELY DEAD….286
STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN ….287
STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER….289
STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK….290
STARTER CRANKS SLOWLY….292
STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START….293
BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND….295
CHARGING SYSTEM DOES NOT FUNCTION….296
ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW….299
BATTERY IS BEING OVERCHARGED….302
ONE OR MORE DASH GAUGES DO NOT WORK….303
HORN DOES NOT BLOW….307
POWERSHIFT TRANSMISSION WILL NOT ENGAGE….308
ELECTRICAL SCHEMATIC S20-30A, H20-30E….309
ELECTRICAL S30-50C….310
ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG….311
ELECTRICAL SCHEMATIC H30-60H DIESEL….313
ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG….315
ELECTRICAL SCHEMATIC H60-90C DIESEL….316
ELECTRICAL SCHEMATIC S30-60ES….317
ELECTRICAL SCHEMATIC S60-120E….318
ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG….319
ELECTRICAL SCHEMATIC S125-150A DIESEL….320
ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG….321
ELECTRICAL SCHEMATIC H110-150F DIESEL….322
ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG….323
ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL….324
ELECTRICAL SCHEMATIC H300A….325
ELECTRICAL SCHEMATIC H300-350B….326
ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL….327
ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL….328
ELECTRICAL SCHEMATIC H700-800A….329
ELECTRICAL SCHEMATIC P40-50A GASOLINE….331
ELECTRICAL SCHEMATIC P40-50A DIESEL….332
ELECTRICAL SCHEMATIC P60-80A GASOLINE….333
ELECTRICAL SCHEMATIC P60-80A DIESEL….334
ELECTRICAL SCHEMATIC KE GAS GASOLINE….335
ELECTRICAL SCHEMATIC KE DIESEL….336
ELECTRICAL SCHEMATIC M200-400H GASOLINE….337
ELECTRICAL SCHEMATIC M200-400H DIESEL….339
ELECTRICAL SCHEMATIC M600A….341
22002….343
General….345
Description….345
Alternator Repair….347
Alternator Type A….347
Remove and Disassemble….347
Clean….348
Assemble….348
Install….349
Alternator Type B….352
Remove and Disassemble….352
Clean….352
Assemble….353
Install….354
General Check and Adjustment….355
Low Output Check (Type A or Type B)….355
High Output Check (Type A or Type B)….357
Brushes Circuit Check….358
Delco Alternators….358
Motorola Alternators….359
Diodes Check….360
Diodes Bridge Check….360
Delco and Leece-Neville Alternators….360
Motorola Alternators….360
Rotor Field Winding Check….361
Stator Windings Check….362
Voltage Regulator Check….362
Troubleshooting….363
4000127….365
INTRODUCTION….365
General….365
Description….365
Upright….365
Carriage….365
Lift Cylinder….365
REPAIRS….366
Upright….366
Removal….366
Disassembly….367
Cleaning….367
Assembly….367
Installation….368
Carriage….369
Removal….369
Installation….369
Lift Cylinder….370
Removal….370
Disassembly….371
Assembly….371
Installation….372
Forks….373
Removal….373
Intallation….373
LAYDOWN TILT….373
General….373
Lowering Procedure….373
Transportation….375
Raising Procedure….375
Special Equipment….376
CHECKS AND ADJUSTMENTS….378
Lift Chains….378
Checking and Adjusting the Side Rollers….378
Checking and Adjusting the Back Rollers….379
SPECIFICATIONS….380
5000154….382
INTRODUCTION….382
General….382
Description….382
REPAIRS….385
Removal….385
Disassembly….385
Cleaning….385
Assembly….385
Installation….385
CHECKS AND ADJUSTMENTS….385
The Lifting Chains….385
Checking and Adjusting The Side Rollers….386
Checking and Adjusting The Bumper Roller….386
600104….387
GM 4.3 LITRE V-6 AND 5.7 LITRE V-8 ENGINES….387
DESCRIPTION….387
ENGINE, REMOVAL AND INSTALLATION….387
CYLINDER HEAD….387
Removal And Disassembly….387
Cleaning And Inspection….387
Repairs, Valve Guides and Seats….387
Studs For The Rocker Arms….388
Valve Springs….388
ASSEMBLY AND INSTALLATION….389
CYLINDER BLOCK, CLEANING AND INSPECTION….390
PISTON BORE PREPARTION….390
ENGINE MOUNTS….390
LUBRICATION SYSTEM….390
Oil Pump, Removal and Disassembly….390
Cleaning and Inspection….390
Oil Pump, Assembly and Installation….390
TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS….391
Timing Cover, Removal….391
Installation….391
Timing Sprockets, Removal….392
Timing Sprockets, Installation….392
Camshaft, Removal….392
Camshaft, Inspection….392
Camshaft, Installation….393
Hydraulic Valve Lifters, Removal….393
Hydraulic Valve Lifters, Disassembly….393
Hydraulic Valve Lifters, Cleaning And Inspection….393
Hydraulic Valve Lifters, Assembly….394
CRANKSHAFT….394
Removal….394
Inspection and Repair….395
How To Check The Clearance Between The Main Bearings And Their Journals….395
Installation….396
PISTON AND CONNECTING ROD ASSEMBLIES….397
Connecting Rod Bearings, Replacement….397
Piston And Connecting Rod Assemblies, Removal….398
Disassembly….398
Piston, Cleaning And Inspection….399
Cylinder Bores, Inspection And Repair….399
Piston Rings….400
Assembly….400
Piston And Connecting Rod Assemblies, Installation….401
FLYWHEEL AND FLYWEEL HOUSING….401
Flywheel Repair For V-6 Engines….401
Flywheel For V-6 Engines, Installation….401
Flywheel Housing, H3.5-5.00XL (H70-110XL)….401
Engine Adapter, H6.00-7.00XL (H135-155XL)….401
Ring Gear Replacement (Flywheel) For V-8 Engines….402
Flywheel For V-8 Engines, Flywheel Housing….402
COOLANT PUMP….403
FAN MOUNT….403
CHECKS AND ADJUSTEMENTS….404
Valve Clearance Adjustment….404
ENGINE SPECIFICATIONS….404
ENGINE SPECIFICATIONS….404
Engine Data….404
Cylinder head….404
Hydraulic Valve Lifter….405
Camshaft….405
Pistons….405
Crankshaft….406
Connecting Rods….406
Cooling System….406
Lubrication System….406
TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS….407
TROUBLESHOOTING….408
6007….410
INTRODUCTION….410
GENERAL….410
DESCRIPTION….410
CYLINDER HEAD AND VALVE MECHANISM….411
CYLINDER HEAD….411
Removal….411
Repairs….412
Installation….412
VALVE MECHANISM….414
Repairs….414
LUBRICATION SYSTEM….415
OIL PUMP….415
Removal And Disassembly….415
Repairs….415
Assembly And Installation….415
Relief Valve For The Oil Pressure….416
Oil Cooler (T6.3544 Engine Only)….416
Cooling Jets For The Pistons….417
TIMING GEARS AND CAMSHAFT….418
TIMING GEAR CASE….418
Removal….418
Installation….418
Idler Gears And Hubs Removal….421
Camshaft And Cam Followers….421
Auxiliary Drive Shaft And The Drive Shaft For The Fuel Injection Pump….422
CRANKSHAFT….424
REMOVAL….424
REPAIR….425
INSTALLATION….425
PISTONS AND PISTON RODS….427
REMOVAL….427
DISASSEMBLY….427
REPAIRS….428
ASSEMBLY….428
INSTALLATION….429
CYLINDER LINERS….430
REMOVAL AND INSTALLATION….430
FLYWHEEL AND FLYWHEEL HOUSING….430
REPAIRS….430
INSTALLATION….430
TURBOCHARGER….431
REMOVAL….431
DISASSEMBLY….431
INSPECTION….431
ASSEMBLY….431
INSTALLATION….432
FUEL SYSTEM….432
FUEL PUMP….433
Removal….433
Disassembly….433
Assembly….433
Installation….433
FUEL INJECTION PUMP….433
Removal….433
Repairs….434
Installation….434
FUEL INJECTORS….434
Checks….434
Removal….434
Repairs….434
Installation….434
COLD START AID….435
Description….435
Removal….435
Installation….435
COOLING SYSTEM….435
THERMOSTATS….435
Removal….435
Installation….435
WATER PUMP….435
Removal….435
Disassembly….435
Assembly….436
Installation….437
CHECKS AND ADJUSTMENTS….437
REMOVING AIR FROM FUEL SYSTEM….437
TIMING….438
Fuel Injection Pump….438
Checking The Timing Angle For The Fuel Injection Pump (Using The Timing Tool)….440
VALVE CLEARANCE ADJUSTMENT….441
ADJUSTING THE THROTTLE LINKAGE….442
CHECKING THE FUEL INJECTORS….443
TROUBLESHOOTING….444
SPECIFICATIONS….445
TORQUE SPECIFICATIONS….449
700626….450
General….452
Description….453
Radiator….453
Radiator Cap….453
Thermostat….453
Water Pump….454
Fan and Fan Shroud….454
Cooling System Checks….454
Radiator….454
Thermostat….454
Water Pump….455
Exhaust Leaks….455
Fan and Fan Shroud….455
Radiator Cleaning….455
Drain….455
Clean….455
Fill….456
Troubleshooting….457
8000148….459
FIGURE 1. GRAPHIC SYMBOLS (Sheet 1 of 2)….459
FIGURE 1. GRAPHIC SYMBOLS (Sheet 2 of 2)….460
FIGURE 2. HYDRAULIC SYSTEM SCHEMATIC….461
FIGURE 3. POWERSHIFT TRANSMISSION….462
FIGURE 4. ELECTRICAL WIRING DIAGRAM….463
FIGURE 5. INSTRUMENT PANEL ELECTRICAL CONNECTIONS….464
FIGURE 6. ENGINE CABLING DIAGRAM….466
FIGURE 7. CAB ELETRICAL AND HEATER CONNECTIONS….467
8000151….468
INTRODUCTION….468
General….468
How To Move A Disabled Lift Truck….468
How To Put A Lift Truck On Blocks….469
MAINTENANCE SCHEDULE….470
MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY….474
How To Make Checks With The Engine Stopped….474
Engine Oil ….474
Fuel System….474
Drive Belts….475
Battery….475
Primary Fuel Filter, Diesel….476
Upright, Forks, And Lift Chains….476
Lift Chain Adjustments….476
Tires And Wheels….478
Operator Restraint System….479
How To Make Checks With The Engine Running….480
Guages, Lights, Horn And Fuses….480
Control Levers And Pedals….480
Lift System Operation….480
Service Brakes….480
Parking Brake….481
Steering System….481
FIRST 100 HOURS ON NEW LIFT TRUCKS….481
EVERY 150 HOURS OR MONTHLY….482
Engine Oil And Filter….482
Lift Chains….482
Lubrication….482
Air Cleaner….483
EVERY 350 HOURS OR 2 MONTHS….483
Forks….483
Brake Fluid….483
Pedal Adjustment….483
Engine Speed….486
Accelerator Linkage Adjustment, Diesel….486
Governor Adjustment, Gasoline And LPG Engines….488
Accelerator Linkage Adjustment, Gasoline And LPG Engines….488
Battery….488
Wheel Nuts….489
Upright Lubrication….489
Fork Pins And Fork Guides….489
Other Lubrication….490
Fuel Filters, Diesel….490
EVERY 1000 HOURS OR 6 MONTHS….492
Checks For Leaks In The Lift And Tilt System….492
Ignition System, GM V8-350….492
Timing, Diesel Engines….493
Oil Level, Manual Transmission….493
Oil Level, Final Drives….494
Valve Clearance Adjustment….494
Check The PCV Valve, GM V8-350….494
Primary Fuel Filter, Diesel….495
EVERY 2000 HOURS OR YEARLY….495
Fuel Filter, Gasoline And LPG….495
Changing The Coolant In The Coolant System….495
Changing The Hydraulic Oil, Hydraulic Filter, And The Hydraulic Tank Breather….496
Changing The Oil In The Final Drive….496
Changing The Oil And Filter In The Powershift Transmission….496
Change The Oil In the Manual Transmission….497
Lubricate the Wheel Bearings, Steering Axle….497
Lubricate The Wheel Bearings, Hypoid Drive Axle….497
GENERAL PROCEDURES….499
Checking The Fuel Injectors….499
Wheels And Tires….499
8000152….504
8000231….510
General….512
Nomenclature, Threads….512
Strength Identification….513
Fastener Torque Tables….517
Conversion Table….519
90012….521
INTRODUCTION….521
GENERAL….521
DESCRIPTION….521
CARBURETOR….521
GOVERNOR….521
REPAIRS….521
CARBURETOR….521
REMOVAL AND DISASSEMBLY….521
CLEANING….521
ASSEMBLY….521
INSTALLATION….523
GOVENOR….523
CHECKS AND ADJUSTMENTS….523
ADJUSTING THE CARBURETOR….523
ADJUSTING THE GOVERNOR….524
ADJUSTING THE THROTTLE LINKAGE….524
TROUBLESHOOTING….525
90016….526
INTRODUCTION….526
GENERAL….526
DESCRIPTION….526
PROCEDURES FOR LPG FUEL TANKS….527
Installation….527
HYDROSTATIC RELIEF VALVE….527
Removal and Installation….527
CARBURETOR….528
Removal and Dissembly….528
Cleaning….528
Assembly and Installation….528
GOVERNOR….529
FUEL FILTER AND SHUT-OFF VALVE….529
Replace The Filter Element….529
Install A New Diaphragm and Fuel Valve….529
Check The Filter Unit….530
VAPORIZER….531
Description….531
Removal….532
Disassembly….532
Cleaning….534
Inspection….534
Assembly….534
Installation….534
Check The Pressure Reducer Valve….534
Check The Vapor Valve….534
INSTALLATION OF NEW HOSES….534
CHECKS AND ADJUSTMENTS….537
CHECK THE FILTER AND SHUT-OFF VALVE….537
CHECK THE VAPORIZER/REGULATOR….537
Pressure Reducer Valve….537
Check the Low Pressure Valve….537
Check the Low Pressure Diaphragm….537
ADJUST THE CARBURETOR….537
Idle Mixture….537
Idle Speed….537
Power Mixture….537
ADJUST THE GOVERNOR….538
ADJUST THE THROTTLE LINKAGE….538
TROUBLESHOOTING….539
900347….543
WEBER CARBURETOR WITH GOVERNOR….543
GENERAL….543
DESCRIPTION….543
Carburetor….543
Governor….543
OPERATION….544
Carburetor, Float System….544
Carburetor, Idle System….544
Carburetor, Main Metering System….544
Carburetor, Power System….545
Carburetor, Accelerator Pump System….545
Carburetor, Choke System….546
GOVERNOR….547
REPAIRS….548
CARBURETOR….548
Removal….548
Disassembly….548
Cleaning….548
Assembly….548
Installation….549
GOVERNOR….549
CHECKS AND ADJUSTMENTS….550
GENERAL….550
CHOKE SYSTEM….550
ELECTRIC CHOKE….550
IDLE MIXTURE ADJUSTMENT….551
IDLE SPEED ADJUSTMENT….551
THROTTLE LINKAGE ADJUSTMENT….552
TROUBLESHOOTING….553
myManual[1]….554
INTRODUCTION….554
GENERAL….554
DESCRIPTION….554
REPAIRS….554
DISASSEMBLY….555
CLEANING….557
ASSEMBLY….557
TROUBLESHOOTING….559
C007 (H7.00-12.50HP7.00-9.00B Europe)….560
100141….562
INTRODUCTION….562
General….562
Description….562
Frame….562
Fuel Tank….562
Hydraulic tank….562
REPAIRS….563
Counterweight….563
Removal….563
Installation….563
Fenders….564
Removal….564
Installation….564
Seat….564
Removal….564
Installation….564
Hood….564
Hydraulic Tank….565
Removal….565
Service Procedures….565
Installation….566
Fuel Tank….566
Removal….566
Service Procedures….566
Installation….566
Housing (Steering Control Unit)….566
Removal….566
Installation….566
Painting Instructions….567
Decal Installation….567
Cab….567
120022….571
INTRODUCTION….571
GENERAL….571
DESCRIPTION….571
Oil Clutch….571
Jet Pump….571
REPAIRS….572
OIL CLUTCH ASSEMBLY….572
Removal And Disassembly….572
Cleaning….572
Inspection….572
Assembly And Installation….573
JET PUMP….573
Removal And Disassembly….573
CLEANING….573
Assembly And Installation….573
CHECKS AND ADJUSTMENTS….573
ADJUSTING THE LINKAGE FOR THE CLUTCH PEDAL….573
CHECKING THE ALIGNMENT OF THE CLUTCH DISC….574
TROUBLESHOOTING….575
1300142….576
INTRODUCTION….576
General….576
REPAIRS….576
Torque Converter….576
Transmission….576
Control Valve….591
Monotrol Pedal….593
CHECKS AND ADJUSTMENTS….594
Stall Speed of the Torque Converter….594
Leakage in the Monotrol Pedal….594
Oil Pressure of the Transmission….594
Linkages….597
TROUBLESHOOTING….599
SPECIFICATIONS….602
130033….604
INTRODUCTION….605
MECHANICAL SECTION….606
TORQUE CONVERTER….607
FORWARD-REVERSE SECTION….607
PLANETARY GEARS: HOW THEY WORK….609
WHEN THE SUN GEAR IS DRIVEN….609
WHEN PLANET PINION CARRIER IS DRIVEN….609
DOUBLE PLANET PINION SET….609
REVERSE….610
FORWARD….610
RANGE SECTION….611
LOW….611
MEDIUM….611
HIGH….614
HYDRAULIC SYSTEM….615
INTRODUCTION TO HYDRAULIC SYSTEM….615
PUMP AND SUMP….616
OIL FILTER….616
MONOTROL ASSEMBLY….617
OIL COOLERS….618
CONTROL VALVE ASSEMBLY….619
RANGE SPOOL….619
INCHING VALVE….619
DIRECTIONAL SPOOL….622
PRESSURE REGULATORS….624
CUSHION VALVE….624
SCHEMATIC AND FLOW DIAGRAMS….626
NEUTRAL-REVERSE….626
DRIVE-HIGH-REVERSE….629
DRIVE-MEDIUM-FORWARD….630
INCHING-LOW-FORWARD….631
130039….632
INTRODUCTION….632
General….632
Description….632
REPAIRS….633
Removal….633
Disassembly….633
Cleaning….633
Installation….633
CHECKS AND ADJUSTMENTS….643
Forward/Reverse Linkage….643
TROUBLESHOOTING….643
130044….645
INTRODUCTION….645
GENERAL….645
DESCRIPTION….645
REPAIRS….645
REMOVAL….645
DISASSEMBLY….646
CLEANING….646
ASSEMBLY AND INSTALLATION….646
TROUBLESHOOTING….646
140046….647
DIFFERENTIAL….647
GENERAL….647
DESCRIPTION….647
REPAIRS….648
REMOVAL….648
DISASSEMBLY….648
ASSEMBLY….648
Assemble The Pinion, Bearings And Pinion Carrier….648
Adjust Preload For Pinion Bearings….648
Adjust Thickness Of Shim Set For The Pinion Carrier (Depth Of Pinion)….649
Assemble The Differential And Ring Gear….651
Assemble Differential Pinion And Side Gear Assembly….652
Check The Rotating Torque Of Differential Gears….653
Install The Differential And Ring Gear Assembly….654
Adjust Preload Of The Differential Bearings….655
Check Runout Of Ring Gear….655
Adjust The Gear Clearance….655
Check Tooth Contact Pattern Of The Gear Set….656
Installation Into The Axle Housing….656
SPECIFICATIONS….659
TABLE 1. GENERAL SPECIFICATIONS….659
TABLE 2. RIVET INSTALLATION PRESSURE….659
TABLE 3. PINION PRELOAD PRESSURE….659
TABLE 4. PINION ADJUSTMENT….659
TABLE 5. TORQUE SPECIFICATIONS….660
TROUBLESHOOTING….661
140047….662
INTRODUCTION….662
GENERAL….662
DESCRIPTION….662
OPERATION….662
REPAIRS….663
REMOVAL….663
DISASSEMBLY….666
ASSEMBLY AND INSTALLATION….668
TROUBLESHOOTING….671
140049….674
INTRODUCTION….674
GENERAL….674
DESCRIPTION….674
REPAIRS….674
DISASSEMBLY….675
CLEANING….677
ASSEMBLY….677
TROUBLESHOOTING….679
160054….680
INTRODUCTION….680
GENERAL….680
DESCRIPTION….680
OPERATION….680
REPAIRS….680
STEERING WHEEL AND COLUMN ASSEMBLY….680
TYPE "A" STEERING COLUMN ASSEMBLY….682
Removal And Disassembly….682
Assembly And Installation….682
TYPE "A" STEERING COLUMN….683
TYPE "A" STEERING COLUMN….684
TYPE "B" STEERING COLUMN….685
Removal And Disassembly….685
Assembly And Installation….685
TYPE "B" STEERING COLUMN….686
Disassembly of Steering Control Unit….687
Cleaning of Steering Control Unit….687
Assembly of Steering Control Unit….689
CHECKS AND ADJUSTMENTS….692
REMOVE AIR FROM THE SYSTEM….692
TROUBLESHOOTING….693
160071….694
INTRODUCTION….694
GENERAL ….694
DESCRIPTION….694
REPAIRS….695
STEERING AXLE….695
Removal….695
Installation….695
STEERING CYLINDER….695
Removal….695
Inspection….697
Assembly….697
Installation….697
HUBS, H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B (P150-200B)….698
Removal….698
Installation….698
HUBS, H360-620B, H16.00-30.00C, H17.00-32.00C, H700-800A, H36.00-44.00B, H36.00-48.00C, H20.00-32.00F….699
Removal….699
Installation….699
SPINDLES….699
Removal….699
Installation….699
CHECKS AND ADJUSTMENTS….701
REMOVE THE AIR FROM THE STEERING SYSTEM….701
ADJUST THE CYLINDER STOPS….701
1800146….702
INTRODUCTION….702
General….702
Description….702
REPAIRS….702
Removal and Disassembly….702
Cleaning….703
Assembly and Installation….703
1800150….705
INTRODUCTION….705
General….705
Description….705
Operation….705
REPAIRS….705
Removal….705
Disassembly….705
Cleaning….706
Assembly….706
Installation….708
TROUBLESHOOTING….709
180083….711
INTRODUCTION….711
GENERAL….711
DESCRIPTION….711
CONTROL VALVE OPERATION….712
REPAIRS….712
BRAKE SHOE ASSEMBLIES….712
Removal….712
Cleaning….712
Inspection….713
Installation….713
AIR CHAMBER….714
Removal and Disassembly….714
Assembly and Installation….714
CONTROL VALVE….714
Removal….714
Disassembly….715
Assembly….716
Installation….716
AIR TANK….716
CHECKS AND ADJUSTMENTS….717
ADJUSTING THE BRAKES….717
RELIEF VALVE….717
TROUBLESHOOTING….718
180084….720
INTRODUCTION….720
General….720
Description….720
Brake Valve….720
Service Brake Assembly….723
REPAIRS….724
Brake Shoe Assemblies….724
Removal….724
Cleaning….725
Assembly….725
Brake Valve Assemblies….726
Master Cylinder….727
Removal….727
Disassembly….728
Assembly….728
Relief Valve Assembly….729
Disassembly….729
Assembly….729
Actuator….730
Disassembly….731
Assembly….731
CHECKS AND ADJUSTMENTS….732
Adjust the Brake Shoes….732
Adjust the Brake Pedal….732
Remove Air from the Brake System….733
Adjust the Relief Valve In The Actuator….733
SPECIFICATIONS….734
TROUBLESHOOTING….734
1900147….737
190097….739
INTRODUCTION….739
DESCRIPTION….739
OPERATION….739
Flow Control Valve….741
Relief Valve….741
REPAIRS….742
REMOVAL….742
DISASSEMBLY….742
CLEANING….744
INSPECTION….744
ASSEMBLY….745
INSTALLATION….746
CHECKS AND ADUSTMENTS….747
CHECK THE OUTPUT OF THE PUMP….747
CHECK FOR AIR IN THE HYDRAULIC SYSTEM….747
TROUBLESHOOTING….749
2000100….752
INTRODUCTION….752
GENERAL….752
DESCRIPTION….752
OPERATION….753
Lifting, No Load or Light Load….753
Lifting, Capacity Load….753
Lowering….754
Tilting….755
Relief Valve….755
By-Pass Fitting….755
Flow Control Fitting….755
REPAIRS….756
REMOVAL AND DISASSEMBLY….756
CLEANING….756
ASSEMBLY….756
INSTALLATION….757
CHECKS AND ADJUSTMENTS….757
ADJUSTING THE PRESSURE OF THE RELIEF VALVE….757
CHECK AND ADJUST THE PRESSURE OF THE TWO SPEED VALVE….758
TROUBLESHOOTING….758
200099….759
INTRODUCTION….759
GENERAL….759
DESCRIPTION….759
OPERATION….760
LIFTING, NO LOAD OR LIGHT LOAD….760
LIFTING, CAPACITY LOAD….760
LOWERING….760
TILTING….761
RELIEF VALVE….761
BY-PASS FITTING….761
FLOW CONTROL FITTING….762
REPAIRS….762
REMOVAL AND DISASSEMBLY….762
CLEANING….763
ASSEMBLY….763
INSTALLATION….764
CHECKS AND ADJUSTMENTS….764
ADJUSTING THE PRESSURE OF THE RELIEF VALVE….764
SETTINGS FOR THE PRESSURE OF THE RELIEF VALVE….764
CHECKING AND ADJUSTING THE PRESSURE OF THE TWO SPEED VALVE….764
TROUBLESHOOTING….766
2100102….767
INTRODUCTION….767
GENERAL….767
DESCRIPTION AND OPERATION….767
Tilt Forward….767
Tilt Backward….768
REPAIRS….770
REMOVAL….770
DISASSEMBLY….770
CLEANING….770
ASSEMBLY….770
INSTILLATION….771
TROUBLESHOOTING….771
2100103….772
INTRODUCTION….775
GENERAL….775
DESCRIPTION….775
REPAIRS….775
REMOVAL….775
DISASSEMBLY….775
CLEANING….775
ASSEMBLY….775
Tilt Cylinders for the XM and XMS Models….775
Tilt Cylinders with O-Ring or Single Lip Seals….777
Tilt Cylinders for H700-800A and Early Model H700-920B….777
INSTALLATION….777
Tilt Cylinders with Chevron Packing….777
CHECKS AND ADJUSTMENTS….781
CHECK THE TILT CYLINDERS FOR LEAKS….781
ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE….781
TROUBLESHOOTING….784
2200106….787
INTRODUCTION….787
GENERAL….787
DESCRIPTION AND OPERATION….787
REPAIRS….789
REMOVAL….789
DISSASEMBLY….789
CLEANING….790
ASSEMBLY….790
INSTALLATION….790
CHECKS AND ADJUSTMENTS….791
GENERAL….791
TROUBLESHOOTING….793
2200107….795
HIGH ENERGY IGNITION (HEI)….795
DESCRIPTION….795
REPAIRS….797
DISTRIBUTOR….797
Removal….797
Disassembly….797
Assembly….802
INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED….803
INSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED….804
IGNITION COIL….804
Removal, Some 4 and 6 Cylinder Models….804
Installation, Some 4 and 6 Cylinder Models….805
Removal, V8, Some 4 and 6 Cylinder Models….805
Installation, V8, Some 4 and 6 Cylinder Models….806
ELECTRONIC MODULE….807
Removal….807
Installation….807
SENSING COIL….808
Removal….808
Installation….808
SPARK PLUGS….808
Removal….808
Installation….809
CHECKS AND ADJUSTMENTS….809
Visual Checks….809
Check The High Voltage Wires….809
Checking The Ignition Coil….809
Coil In Distributor Cap Design….809
Separate Coil Design….810
Checking The Sensing Coil….810
Check The Electronic Module….811
Ignition Timing Adjustment….811
Ignition System, GM V8-366 (6-litre)….812
Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)….812
SPECIFICATIONS….812
TROUBLESHOOTING….813
2200143….814
INTRODUCTION….814
GENERAL….814
DESCRIPTION….814
GENERAL….814
STEERING COLUMN GAUGES, METERS AND INDICATORS….817
LED DISPLAY PANEL….817
Battery Discharge Indicators ….817
Brush Wear Indicators….818
Motor Temperature Indicators….819
"LX" SERIES INSTRUMENT PANEL DISPLAY….820
Hourmeter Functions….821
Battery Indicator Function….821
Status Code Function….821
CHECKS AND ADJUSTMENTS….821
GENERAL….821
REPLACEMENT….822
GENERAL….822
METER REPLACEMENT….822
SENDER REPLACEMENT….823
Fuel Level Sender….823
Pressure And Temperature Sender….824
I.T.W. DISPLAY PANEL….824
Removal….824
SPECIFICATIONS….825
TROUBLESHOOTING….826
2200144….827
ELECTRICAL WARNING DEVICES….827
GENERAL….827
DESCRIPTION….827
Operator Controlled Horns….827
System Warning Lights, Buzzers and Bells….827
Reverse Warning Horns….828
Warning Lights….828
REPLACEMENT….829
General….829
Replacing Horns or Bells….829
Replacing Horn Relay or Buzzer….829
Replacing Warning Lights….829
Light Assemblies….830
Replacing Flashing Units….830
2200153….831
ELECTRICAL SYSTEM COMPLETELY DEAD….831
STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN ….832
STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER….834
STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK….835
STARTER CRANKS SLOWLY….837
STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START….838
BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND….840
CHARGING SYSTEM DOES NOT FUNCTION….841
ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW….844
BATTERY IS BEING OVERCHARGED….847
ONE OR MORE DASH GAUGES DO NOT WORK….848
HORN DOES NOT BLOW….852
POWERSHIFT TRANSMISSION WILL NOT ENGAGE….853
ELECTRICAL SCHEMATIC S20-30A, H20-30E….854
ELECTRICAL S30-50C….855
ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG….856
ELECTRICAL SCHEMATIC H30-60H DIESEL….858
ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG….860
ELECTRICAL SCHEMATIC H60-90C DIESEL….861
ELECTRICAL SCHEMATIC S30-60ES….862
ELECTRICAL SCHEMATIC S60-120E….863
ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG….864
ELECTRICAL SCHEMATIC S125-150A DIESEL….865
ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG….866
ELECTRICAL SCHEMATIC H110-150F DIESEL….867
ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG….868
ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL….869
ELECTRICAL SCHEMATIC H300A….870
ELECTRICAL SCHEMATIC H300-350B….871
ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL….872
ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL….873
ELECTRICAL SCHEMATIC H700-800A….874
ELECTRICAL SCHEMATIC P40-50A GASOLINE….876
ELECTRICAL SCHEMATIC P40-50A DIESEL….877
ELECTRICAL SCHEMATIC P60-80A GASOLINE….878
ELECTRICAL SCHEMATIC P60-80A DIESEL….879
ELECTRICAL SCHEMATIC KE GAS GASOLINE….880
ELECTRICAL SCHEMATIC KE DIESEL….881
ELECTRICAL SCHEMATIC M200-400H GASOLINE….882
ELECTRICAL SCHEMATIC M200-400H DIESEL….884
ELECTRICAL SCHEMATIC M600A….886
22002….888
INTRODUCTION….888
GENERAL….888
DESCRIPTION….888
REPAIRS….890
GENERAL….890
REMOVAL AND DISASSEMBLY (Type A)….890
CLEANING….890
ASSEMBLY (Type A)….891
REMOVAL AND DISAASSEMBLY (Type B)….893
CLEANING….895
ASSEMBLY (Type B)….895
INSTALLATION (Type A and Type B)….896
CHECKS AND ADJUSTMENTS….896
GENERAL….896
CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)….897
CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)….898
CHECK THE CIRCUIT FOR THE BRUSHES….900
Delco Alternators….900
Motorola Alternators….900
CHECK THE DIODES….900
CHECK THE DIODE BRIDGE….900
Delco and Leece–Neville Alternators….900
Motorola Alternators….900
CHECK THE FIELD WINDING FOR THE ROTOR….901
CHECK THE WINDINGS IN THE STATOR….901
CHECK THE VOLTAGE REGULATOR….902
TROUBLESHOOTING….902
4000127….903
INTRODUCTION….903
General….903
Description….903
Upright….903
Carriage….903
Lift Cylinder….903
REPAIRS….904
Upright….904
Removal….904
Disassembly….905
Cleaning….905
Assembly….905
Installation….906
Carriage….907
Removal….907
Installation….907
Lift Cylinder….908
Removal….908
Disassembly….909
Assembly….909
Installation….910
Forks….911
Removal….911
Intallation….911
LAYDOWN TILT….911
General….911
Lowering Procedure….911
Transportation….913
Raising Procedure….913
Special Equipment….914
CHECKS AND ADJUSTMENTS….916
Lift Chains….916
Checking and Adjusting the Side Rollers….916
Checking and Adjusting the Back Rollers….917
SPECIFICATIONS….918
5000154….920
INTRODUCTION….920
General….920
Description….920
REPAIRS….923
Removal….923
Disassembly….923
Cleaning….923
Assembly….923
Installation….923
CHECKS AND ADJUSTMENTS….923
The Lifting Chains….923
Checking and Adjusting The Side Rollers….924
Checking and Adjusting The Bumper Roller….924
600104….925
GM 4.3 LITRE V-6 AND 5.7 LITRE V-8 ENGINES….925
DESCRIPTION….925
ENGINE, REMOVAL AND INSTALLATION….925
CYLINDER HEAD….925
Removal And Disassembly….925
Cleaning And Inspection….925
Repairs, Valve Guides and Seats….925
Studs For The Rocker Arms….926
Valve Springs….926
ASSEMBLY AND INSTALLATION….927
CYLINDER BLOCK, CLEANING AND INSPECTION….928
PISTON BORE PREPARTION….928
ENGINE MOUNTS….928
LUBRICATION SYSTEM….928
Oil Pump, Removal and Disassembly….928
Cleaning and Inspection….928
Oil Pump, Assembly and Installation….928
TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS….929
Timing Cover, Removal….929
Installation….929
Timing Sprockets, Removal….930
Timing Sprockets, Installation….930
Camshaft, Removal….930
Camshaft, Inspection….930
Camshaft, Installation….931
Hydraulic Valve Lifters, Removal….931
Hydraulic Valve Lifters, Disassembly….931
Hydraulic Valve Lifters, Cleaning And Inspection….931
Hydraulic Valve Lifters, Assembly….932
CRANKSHAFT….932
Removal….932
Inspection and Repair….933
How To Check The Clearance Between The Main Bearings And Their Journals….933
Installation….934
PISTON AND CONNECTING ROD ASSEMBLIES….935
Connecting Rod Bearings, Replacement….935
Piston And Connecting Rod Assemblies, Removal….936
Disassembly….936
Piston, Cleaning And Inspection….937
Cylinder Bores, Inspection And Repair….937
Piston Rings….938
Assembly….938
Piston And Connecting Rod Assemblies, Installation….939
FLYWHEEL AND FLYWEEL HOUSING….939
Flywheel Repair For V-6 Engines….939
Flywheel For V-6 Engines, Installation….939
Flywheel Housing, H3.5-5.00XL (H70-110XL)….939
Engine Adapter, H6.00-7.00XL (H135-155XL)….939
Ring Gear Replacement (Flywheel) For V-8 Engines….940
Flywheel For V-8 Engines, Flywheel Housing….940
COOLANT PUMP….941
FAN MOUNT….941
CHECKS AND ADJUSTEMENTS….942
Valve Clearance Adjustment….942
ENGINE SPECIFICATIONS….942
ENGINE SPECIFICATIONS….942
Engine Data….942
Cylinder head….942
Hydraulic Valve Lifter….943
Camshaft….943
Pistons….943
Crankshaft….944
Connecting Rods….944
Cooling System….944
Lubrication System….944
TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS….945
TROUBLESHOOTING….946
6007….948
INTRODUCTION….948
GENERAL….948
DESCRIPTION….948
CYLINDER HEAD AND VALVE MECHANISM….949
CYLINDER HEAD….949
Removal….949
Repairs….950
Installation….950
VALVE MECHANISM….952
Repairs….952
LUBRICATION SYSTEM….953
OIL PUMP….953
Removal And Disassembly….953
Repairs….953
Assembly And Installation….953
Relief Valve For The Oil Pressure….954
Oil Cooler (T6.3544 Engine Only)….954
Cooling Jets For The Pistons….955
TIMING GEARS AND CAMSHAFT….956
TIMING GEAR CASE….956
Removal….956
Installation….956
Idler Gears And Hubs Removal….959
Camshaft And Cam Followers….959
Auxiliary Drive Shaft And The Drive Shaft For The Fuel Injection Pump….960
CRANKSHAFT….962
REMOVAL….962
REPAIR….963
INSTALLATION….963
PISTONS AND PISTON RODS….965
REMOVAL….965
DISASSEMBLY….965
REPAIRS….966
ASSEMBLY….966
INSTALLATION….967
CYLINDER LINERS….968
REMOVAL AND INSTALLATION….968
FLYWHEEL AND FLYWHEEL HOUSING….968
REPAIRS….968
INSTALLATION….968
TURBOCHARGER….969
REMOVAL….969
DISASSEMBLY….969
INSPECTION….969
ASSEMBLY….969
INSTALLATION….970
FUEL SYSTEM….970
FUEL PUMP….971
Removal….971
Disassembly….971
Assembly….971
Installation….971
FUEL INJECTION PUMP….971
Removal….971
Repairs….972
Installation….972
FUEL INJECTORS….972
Checks….972
Removal….972
Repairs….972
Installation….972
COLD START AID….973
Description….973
Removal….973
Installation….973
COOLING SYSTEM….973
THERMOSTATS….973
Removal….973
Installation….973
WATER PUMP….973
Removal….973
Disassembly….973
Assembly….974
Installation….975
CHECKS AND ADJUSTMENTS….975
REMOVING AIR FROM FUEL SYSTEM….975
TIMING….976
Fuel Injection Pump….976
Checking The Timing Angle For The Fuel Injection Pump (Using The Timing Tool)….978
VALVE CLEARANCE ADJUSTMENT….979
ADJUSTING THE THROTTLE LINKAGE….980
CHECKING THE FUEL INJECTORS….981
TROUBLESHOOTING….982
SPECIFICATIONS….983
TORQUE SPECIFICATIONS….987
700626….988
COOLING SYSTEM….988
INTRODUCTION….988
DESCRIPTION….988
RADIATOR….988
RADIATOR CAP….988
THERMOSTAT….988
WATER PUMP….989
FAN AND FAN SHROUD ….989
REPAIRS….989
COOLING SYSTEM CHECKS….989
Exhaust Leaks….989
RADIATOR….989
Checks….989
Cleaning The Radiator….989
Drain The Cooling System….991
Fill The Cooling System….991
WATER PUMP….991
Checks….991
THERMOSTAT….992
Checks….992
FAN AND FAN SHROUD ….992
TROUBLESHOOTING….993
8000148….994
FIGURE 1. GRAPHIC SYMBOLS (Sheet 1 of 2)….994
FIGURE 1. GRAPHIC SYMBOLS (Sheet 2 of 2)….995
FIGURE 2. HYDRAULIC SYSTEM SCHEMATIC….996
FIGURE 3. POWERSHIFT TRANSMISSION….997
FIGURE 4. ELECTRICAL WIRING DIAGRAM….998
FIGURE 5. INSTRUMENT PANEL ELECTRICAL CONNECTIONS….999
FIGURE 6. ENGINE CABLING DIAGRAM….1001
FIGURE 7. CAB ELETRICAL AND HEATER CONNECTIONS….1002
8000151….1003
INTRODUCTION….1003
General….1003
How To Move A Disabled Lift Truck….1003
How To Put A Lift Truck On Blocks….1004
MAINTENANCE SCHEDULE….1005
MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY….1009
How To Make Checks With The Engine Stopped….1009
Engine Oil ….1009
Fuel System….1009
Drive Belts….1010
Battery….1010
Primary Fuel Filter, Diesel….1011
Upright, Forks, And Lift Chains….1011
Lift Chain Adjustments….1011
Tires And Wheels….1013
Operator Restraint System….1014
How To Make Checks With The Engine Running….1015
Guages, Lights, Horn And Fuses….1015
Control Levers And Pedals….1015
Lift System Operation….1015
Service Brakes….1015
Parking Brake….1016
Steering System….1016
FIRST 100 HOURS ON NEW LIFT TRUCKS….1016
EVERY 150 HOURS OR MONTHLY….1017
Engine Oil And Filter….1017
Lift Chains….1017
Lubrication….1017
Air Cleaner….1018
EVERY 350 HOURS OR 2 MONTHS….1018
Forks….1018
Brake Fluid….1018
Pedal Adjustment….1018
Engine Speed….1021
Accelerator Linkage Adjustment, Diesel….1021
Governor Adjustment, Gasoline And LPG Engines….1023
Accelerator Linkage Adjustment, Gasoline And LPG Engines….1023
Battery….1023
Wheel Nuts….1024
Upright Lubrication….1024
Fork Pins And Fork Guides….1024
Other Lubrication….1025
Fuel Filters, Diesel….1025
EVERY 1000 HOURS OR 6 MONTHS….1027
Checks For Leaks In The Lift And Tilt System….1027
Ignition System, GM V8-350….1027
Timing, Diesel Engines….1028
Oil Level, Manual Transmission….1028
Oil Level, Final Drives….1029
Valve Clearance Adjustment….1029
Check The PCV Valve, GM V8-350….1029
Primary Fuel Filter, Diesel….1030
EVERY 2000 HOURS OR YEARLY….1030
Fuel Filter, Gasoline And LPG….1030
Changing The Coolant In The Coolant System….1030
Changing The Hydraulic Oil, Hydraulic Filter, And The Hydraulic Tank Breather….1031
Changing The Oil In The Final Drive….1031
Changing The Oil And Filter In The Powershift Transmission….1031
Change The Oil In the Manual Transmission….1032
Lubricate the Wheel Bearings, Steering Axle….1032
Lubricate The Wheel Bearings, Hypoid Drive Axle….1032
GENERAL PROCEDURES….1034
Checking The Fuel Injectors….1034
Wheels And Tires….1034
8000152….1039
8000231….1045
INTRODUCTION….1045
NOMENCLATURE, THREADS….1045
STRENGTH IDENTIFICATION….1046
TABLE 1. BOLTS AND SCREWS….1046
TABLE 2. STUDS AND NUTS….1047
TABLE 3. TORQUE NUTS….1048
TABLE 4. TORQUE NUTS WITH NYLON INSERT….1049
TABLE 5. TORQUE VALUES FOR INCH FASTENERS….1050
TABLE 6. TORQUE VALUES FOR METRIC FASTENERS….1051
90012….1054
INTRODUCTION….1054
GENERAL….1054
DESCRIPTION….1054
CARBURETOR….1054
GOVERNOR….1054
REPAIRS….1054
CARBURETOR….1054
REMOVAL AND DISASSEMBLY….1054
CLEANING….1054
ASSEMBLY….1054
INSTALLATION….1056
GOVENOR….1056
CHECKS AND ADJUSTMENTS….1056
ADJUSTING THE CARBURETOR….1056
ADJUSTING THE GOVERNOR….1057
ADJUSTING THE THROTTLE LINKAGE….1057
TROUBLESHOOTING….1058
90016….1059
INTRODUCTION….1059
GENERAL….1059
DESCRIPTION….1059
PROCEDURES FOR LPG FUEL TANKS….1060
Installation….1060
HYDROSTATIC RELIEF VALVE….1060
Removal and Installation….1060
CARBURETOR….1061
Removal and Dissembly….1061
Cleaning….1061
Assembly and Installation….1061
GOVERNOR….1062
FUEL FILTER AND SHUT-OFF VALVE….1062
Replace The Filter Element….1062
Install A New Diaphragm and Fuel Valve….1062
Check The Filter Unit….1063
VAPORIZER….1064
Description….1064
Removal….1065
Disassembly….1065
Cleaning….1067
Inspection….1067
Assembly….1067
Installation….1067
Check The Pressure Reducer Valve….1067
Check The Vapor Valve….1067
INSTALLATION OF NEW HOSES….1067
CHECKS AND ADJUSTMENTS….1070
CHECK THE FILTER AND SHUT-OFF VALVE….1070
CHECK THE VAPORIZER/REGULATOR….1070
Pressure Reducer Valve….1070
Check the Low Pressure Valve….1070
Check the Low Pressure Diaphragm….1070
ADJUST THE CARBURETOR….1070
Idle Mixture….1070
Idle Speed….1070
Power Mixture….1070
ADJUST THE GOVERNOR….1071
ADJUST THE THROTTLE LINKAGE….1071
TROUBLESHOOTING….1072
900347….1076
WEBER CARBURETOR WITH GOVERNOR….1076
GENERAL….1076
DESCRIPTION….1076
Carburetor….1076
Governor….1076
OPERATION….1077
Carburetor, Float System….1077
Carburetor, Idle System….1077
Carburetor, Main Metering System….1077
Carburetor, Power System….1078
Carburetor, Accelerator Pump System….1078
Carburetor, Choke System….1079
GOVERNOR….1080
REPAIRS….1081
CARBURETOR….1081
Removal….1081
Disassembly….1081
Cleaning….1081
Assembly….1081
Installation….1082
GOVERNOR….1082
CHECKS AND ADJUSTMENTS….1083
GENERAL….1083
CHOKE SYSTEM….1083
ELECTRIC CHOKE….1083
IDLE MIXTURE ADJUSTMENT….1084
IDLE SPEED ADJUSTMENT….1084
THROTTLE LINKAGE ADJUSTMENT….1085
TROUBLESHOOTING….1086
Hyster C007 (H150-275HP150-200B & H7.00-12.50HP7.00-9.00B Europe) Repair Service Manuals