Complete service repair manual for Hyster F003 (H40-60JS & H2.00-3.00JS Europe) Forklift Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster F003 (H40-60JS & H2.00-3.00JS 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.
Hyster F003 (H40-60JS & H2.00-3.00JS Europe) Service Manual.pdf
Total Pages: 577 + 525 pages
File Format: PDF
Language: English
F003 (H2.00-3.00JS Europe)…2
100179…4
INTRODUCTION…4
General…4
Description…4
DISASSEMBLY AND ASSEMBLY…5
Overhead Guard…5
Hood and Seat Removal…6
Counterweight…6
Engine and Transmission…6
REPAIRS…8
Fuel and Hydraulic Tanks…8
Decal Replacement…9
120018…13
INTRODUCTION…13
GENERAL…13
DESCRIPTION AND OPERATION …13
REPAIRS…14
REMOVAL…14
INSPECTION…14
INSTALLATION…15
ADJUSTMENTS…17
ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL…17
ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS…17
TROUBLESHOOTING…18
130043…20
INTRODUCTION…20
General…20
REPAIRS…21
REMOVAL…21
DISASSEMBLY…21
CLEANING…29
INSPECTION…30
ASSEMBLY…30
Assembling the Control Valve…30
Assembling the Differential…33
Assembling the Transmission…41
Installation…45
MONOTROL Pedal…45
CHECKS AND ADJUSTMENTS…46
Checking the MONOTROL Pedal for Leakage…46
MONOTROL Pedal…46
Stall Test…46
Checking the Oil Pressures…47
MONOTROL Pressure…48
Clutch Apply Pressure…50
Inching Spool Operation…51
Torque Converter and Oil Cooler Pressure…51
CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT…51
CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER…52
ADJUSTING THE OIL SUMP TUBE…53
TROUBLESHOOTING…53
Pressure Tests…56
Troubleshooting the Differential…57
130059…59
INTRODUCTION…59
GENERAL…59
DESCRIPTION…59
REPAIRS…62
REMOVAL…62
DISASSEMBLY…62
CLEANING…69
INSPECTION…69
ASSEMBLY…69
INSTALLATION…77
TROUBLESHOOTING…77
SPECIFICATIONS…78
140049…79
INTRODUCTION…79
GENERAL…79
DESCRIPTION…79
REPAIRS…79
DISASSEMBLY…80
CLEANING…82
ASSEMBLY…82
TROUBLESHOOTING…84
160010…85
INTRODUCTION…85
DESCRIPTION…85
GENERAL…85
REPAIRS…86
STEERING AXLE…86
Removal…86
Installation…87
STEERING CYLINDER…87
Removal…87
Service…88
Installation…88
HUBS…88
Removal…88
Installation…89
SPINDLES…89
Removal…89
Installation…90
CHECKS AND ADJUSTMENTS…90
REMOVE THE AIR FROM THE STEERING SYSTEM…90
SET THE PRESSURE RELIEF VALVE…90
S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)…90
H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION…90
H2.00-3.00J (H40-60J) With Powershift Transmission…90
TROUBLESHOOTING…92
160054…93
INTRODUCTION…93
GENERAL…93
DESCRIPTION…93
OPERATION…93
REPAIRS…93
STEERING WHEEL AND COLUMN ASSEMBLY…93
TYPE "A" STEERING COLUMN ASSEMBLY…95
Removal And Disassembly…95
Assembly And Installation…95
TYPE "A" STEERING COLUMN…96
TYPE "A" STEERING COLUMN…97
TYPE "B" STEERING COLUMN…98
Removal And Disassembly…98
Assembly And Installation…98
TYPE "B" STEERING COLUMN…99
Disassembly of Steering Control Unit…100
Cleaning of Steering Control Unit…100
Assembly of Steering Control Unit…102
CHECKS AND ADJUSTMENTS…105
REMOVE AIR FROM THE SYSTEM…105
TROUBLESHOOTING…106
180013…107
INTRODUCTION…107
GENERAL…107
DESCRIPTION…107
REPAIRS…107
REMOVAL AND DISASSEMBLY…107
CLEANING …108
ASSEMBLY…108
CHECKS AND ADJUSTMENTS…108
CHECKS…108
180080…109
INTRODUCTION…109
GENERAL…109
DESCRIPTION AND OPERATION…110
REPAIRS…110
REMOVAL AND DISASSEMBLY…110
CLEANING…111
INSPECTION…112
ASSEMBLY…112
CHECKS AND ADJUSTMENTS…114
BRAKE SHOES…114
Parking Brake…114
Seat Actuated Park Brake, J40–60AS…114
Removing The Air From The Brake System…115
TROUBLESHOOTING…116
190064…119
INTRODUCTION…119
GENERAL…119
DESCRIPTION…119
REPAIRS…119
REMOVAL AND DISASSEMBLY…119
CLEANING…121
INSPECTION…121
ASSEMBLY AND INSTALLATION…121
TROUBLESHOOTING…123
GENERAL…123
190097…124
INTRODUCTION…124
DESCRIPTION…124
OPERATION…124
Flow Control Valve…126
Relief Valve…126
REPAIRS…127
REMOVAL…127
DISASSEMBLY…127
CLEANING…129
INSPECTION…129
ASSEMBLY…130
INSTALLATION…131
CHECKS AND ADUSTMENTS…132
CHECK THE OUTPUT OF THE PUMP…132
CHECK FOR AIR IN THE HYDRAULIC SYSTEM…132
TROUBLESHOOTING…134
200065…137
INTRODUCTION…137
General…137
Description…137
Hydraulic Control Valve…143
REPAIRS…147
Disassembly…147
Cleaning…147
Inspection…147
Assembly…148
CHECKS AND ADJUSTMENT…149
Relief Valve…149
TROUBLESHOOTING…151
2100103…153
INTRODUCTION…156
GENERAL…156
DESCRIPTION…156
REPAIRS…156
REMOVAL…156
DISASSEMBLY…156
CLEANING…156
ASSEMBLY…156
Tilt Cylinders for the XM and XMS Models…156
Tilt Cylinders with O-Ring or Single Lip Seals…158
Tilt Cylinders for H700-800A and Early Model H700-920B…158
INSTALLATION…158
Tilt Cylinders with Chevron Packing…158
CHECKS AND ADJUSTMENTS…162
CHECK THE TILT CYLINDERS FOR LEAKS…162
ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE…162
TROUBLESHOOTING…165
2200106…168
INTRODUCTION…168
GENERAL…168
DESCRIPTION AND OPERATION…168
REPAIRS…170
REMOVAL…170
DISSASEMBLY…170
CLEANING…171
ASSEMBLY…171
INSTALLATION…171
CHECKS AND ADJUSTMENTS…172
GENERAL…172
TROUBLESHOOTING…174
2200107…176
HIGH ENERGY IGNITION (HEI)…176
DESCRIPTION…176
REPAIRS…178
DISTRIBUTOR…178
Removal…178
Disassembly…178
Assembly…183
INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED…184
INSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED…185
IGNITION COIL…185
Removal, Some 4 and 6 Cylinder Models…185
Installation, Some 4 and 6 Cylinder Models…186
Removal, V8, Some 4 and 6 Cylinder Models…186
Installation, V8, Some 4 and 6 Cylinder Models…187
ELECTRONIC MODULE…188
Removal…188
Installation…188
SENSING COIL…189
Removal…189
Installation…189
SPARK PLUGS…189
Removal…189
Installation…190
CHECKS AND ADJUSTMENTS…190
Visual Checks…190
Check The High Voltage Wires…190
Checking The Ignition Coil…190
Coil In Distributor Cap Design…190
Separate Coil Design…191
Checking The Sensing Coil…191
Check The Electronic Module…192
Ignition Timing Adjustment…192
Ignition System, GM V8-366 (6-litre)…193
Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)…193
SPECIFICATIONS…193
TROUBLESHOOTING…194
2200143…195
INTRODUCTION…195
GENERAL…195
DESCRIPTION…195
GENERAL…195
STEERING COLUMN GAUGES, METERS AND INDICATORS…198
LED DISPLAY PANEL…198
Battery Discharge Indicators …198
Brush Wear Indicators…199
Motor Temperature Indicators…200
"LX" SERIES INSTRUMENT PANEL DISPLAY…201
Hourmeter Functions…202
Battery Indicator Function…202
Status Code Function…202
CHECKS AND ADJUSTMENTS…202
GENERAL…202
REPLACEMENT…203
GENERAL…203
METER REPLACEMENT…203
SENDER REPLACEMENT…204
Fuel Level Sender…204
Pressure And Temperature Sender…205
I.T.W. DISPLAY PANEL…205
Removal…205
SPECIFICATIONS…206
TROUBLESHOOTING…207
2200144…208
ELECTRICAL WARNING DEVICES…208
GENERAL…208
DESCRIPTION…208
Operator Controlled Horns…208
System Warning Lights, Buzzers and Bells…208
Reverse Warning Horns…209
Warning Lights…209
REPLACEMENT…210
General…210
Replacing Horns or Bells…210
Replacing Horn Relay or Buzzer…210
Replacing Warning Lights…210
Light Assemblies…211
Replacing Flashing Units…211
2200153…212
ELECTRICAL SYSTEM COMPLETELY DEAD…212
STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN …213
STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER…215
STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK…216
STARTER CRANKS SLOWLY…218
STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START…219
BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND…221
CHARGING SYSTEM DOES NOT FUNCTION…222
ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW…225
BATTERY IS BEING OVERCHARGED…228
ONE OR MORE DASH GAUGES DO NOT WORK…229
HORN DOES NOT BLOW…233
POWERSHIFT TRANSMISSION WILL NOT ENGAGE…234
ELECTRICAL SCHEMATIC S20-30A, H20-30E…235
ELECTRICAL S30-50C…236
ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG…237
ELECTRICAL SCHEMATIC H30-60H DIESEL…239
ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG…241
ELECTRICAL SCHEMATIC H60-90C DIESEL…242
ELECTRICAL SCHEMATIC S30-60ES…243
ELECTRICAL SCHEMATIC S60-120E…244
ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG…245
ELECTRICAL SCHEMATIC S125-150A DIESEL…246
ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG…247
ELECTRICAL SCHEMATIC H110-150F DIESEL…248
ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG…249
ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL…250
ELECTRICAL SCHEMATIC H300A…251
ELECTRICAL SCHEMATIC H300-350B…252
ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL…253
ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL…254
ELECTRICAL SCHEMATIC H700-800A…255
ELECTRICAL SCHEMATIC P40-50A GASOLINE…257
ELECTRICAL SCHEMATIC P40-50A DIESEL…258
ELECTRICAL SCHEMATIC P60-80A GASOLINE…259
ELECTRICAL SCHEMATIC P60-80A DIESEL…260
ELECTRICAL SCHEMATIC KE GAS GASOLINE…261
ELECTRICAL SCHEMATIC KE DIESEL…262
ELECTRICAL SCHEMATIC M200-400H GASOLINE…263
ELECTRICAL SCHEMATIC M200-400H DIESEL…265
ELECTRICAL SCHEMATIC M600A…267
22002…269
INTRODUCTION…269
GENERAL…269
DESCRIPTION…269
REPAIRS…271
GENERAL…271
REMOVAL AND DISASSEMBLY (Type A)…271
CLEANING…271
ASSEMBLY (Type A)…272
REMOVAL AND DISAASSEMBLY (Type B)…274
CLEANING…276
ASSEMBLY (Type B)…276
INSTALLATION (Type A and Type B)…277
CHECKS AND ADJUSTMENTS…277
GENERAL…277
CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)…278
CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)…279
CHECK THE CIRCUIT FOR THE BRUSHES…281
Delco Alternators…281
Motorola Alternators…281
CHECK THE DIODES…281
CHECK THE DIODE BRIDGE…281
Delco and Leece–Neville Alternators…281
Motorola Alternators…281
CHECK THE FIELD WINDING FOR THE ROTOR…282
CHECK THE WINDINGS IN THE STATOR…282
CHECK THE VOLTAGE REGULATOR…283
TROUBLESHOOTING…283
4000115…284
INTRODUCTION…284
GENERAL…284
REPAIRS…284
FORKS…284
CARRIAGE…284
Removal…284
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…285
Installation…286
MASTS…288
Removal…288
Disassembly…290
Cleaning and Inspection…294
Assembly…295
INSTALLATION…296
CHECKS AND ADJUSTMENTS…296
CHECKING FOR LEAKS IN THE LIFT SYSTEM…296
ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…297
LIFT CHAIN ADJUSTMENTS…297
MAST ADJUSTMENTS…298
Guide Shoe Adjustment…299
CARRIAGE ADJUSTMENT…301
TROUBLESHOOTING…303
4000135…304
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…304
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…304
LIFT CYLINDERS…307
GENERAL…307
DESCRIPTION…307
Lowering Control Valve…307
Cylinders (General)…310
Cylinders (H520-620B,H700-800A)…312
Cylinders (H360-460B)…313
Cylinders (Two-Speed)…313
REPAIRS…314
REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST…314
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…314
Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead…318
Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder…316
DISASSEMBLY…316
ASSEMBLY…318
INSTALLATION OF THE LIFT CYLINDER IN THE MAST…318
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…318
Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead…318
CHEVRON PACKING…319
LIFT CYLINDERS FOR VISTA MASTS…322
DESCRIPTION…322
Lowering Control Valve…324
REMOVAL…325
DISASSEMBLY…325
ASSEMBLY…325
INSTALLATION…326
Main Lift Cylinders…326
Free-Lift Cylinders…326
CHECKS AND ADJUSTMENTS…327
CHECK FOR LEAKS IN LIFT SYSTEM…327
TROUBLESHOOTING…328
SPECIFICATIONS…329
4000167…330
INTRODUCTION…330
GENERAL…330
STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)…332
FULL FREE-LIFT MASTS…332
THREE-STAGE MASTS…334
FOUR-STAGE MASTS…335
SEQUENCE VALVE…335
4000197…337
INTRODUCTION…337
GENERAL…337
VISTA TWO-STAGE MASTS…339
DESCRIPTION…339
OPERATION…342
VISTA THREE-STAGE MASTS…342
DESCRIPTION…342
OPERATION…344
SEQUENCE VALVE…346
4000198…349
INTRODUCTION…349
GENERAL…349
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…349
REPAIRS…350
FORKS…350
Removal…350
CARRIAGE…350
Removal (Two-Stage and Later Production Three-Stage Carriages)…350
Removal (Carriages with Removable Stop Block)…351
Installation (Two-Stage and Later Production Three-Stage Carriages)…352
Installation (Carriages With Removable Stop Block)…352
TWO-STAGE MASTS…354
REMOVAL…354
DISASSEMBLY…355
CLEANING AND INSPECTION…356
ASSEMBLY…357
INSTALLATION…358
THREE-STAGE MASTS…358
REMOVAL…358
DISASSEMBLY…358
CLEANING AND INSPECTION…360
ASSEMBLY…360
INSTALLATION…361
LIFT AND TILT CYLINDERS…362
SIDE SHIFT CARRIAGE…362
Removal…362
Repairs…362
Installation…362
SEQUENCE VALVE…363
Removal and Disassembly…366
Cleaning…366
Assembly and Installation…366
CHECKS AND ADJUSTMENTS…367
CHECKING FOR LEAKS IN THE LIFT SYSTEM…367
ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…367
LIFTING CHAIN ADJUSTMENTS…368
MAST ADJUSTMENTS…369
CARRIAGE ADJUSTMENT…370
HEADER HOSE ROLLER ADJUSTMENT, 2-STAGE…371
TROUBLESHOOTING…372
TORQUE SPECIFICATIONS…373
VISTA MASTS…374
600169…375
INTRODUCTION…375
General…375
Description…375
ENGINE…375
Removal…375
Installation…376
CYLINDER HEAD AND VALVE MECHANISM…376
Cylinder Head…376
Removal…376
Repairs…377
Installation…377
Valve Guides…379
Valve Mechanism…379
Valves…379
Valve Springs…379
Rocker Arm Assembly…379
LUBRICATION…380
Oil Pump…380
Removal and Disassembly…380
Repairs…380
Assembly and Installation…380
Relief Valve…381
TIMING GEAR CASE AND CAMSHAFT…381
Timing Gear Cover…381
Removal…381
Installation…381
Idle Gears…381
Removal…381
Installation…382
Camshaft Gear and Camshaft…382
Removal…382
Installation…383
Fuel Pump Gear…383
Removal…383
Installation…384
Timing Gear Case…384
Removal…384
Installation…384
CRANKSHAFT AND MAIN BEARINGS…385
Removal…385
Installation…385
PISTONS AND PISTON RODS…386
Removal…386
Disassembly…386
Repairs…387
Assembly…387
Installation…388
CYLINDER LINERS…389
Removal …389
Installation…389
FLYWHEEL AND FLYWHEEL HOUSING…389
Removal…389
Installation…389
FUEL PUMP…389
Removal…389
Installation…390
FUEL INJECTION PUMP…390
Removal…390
Installation…390
FUEL INJECTORS…391
Checks…391
Installation…391
COOLING SYSTEM…392
Thermostat…392
Removal…392
Installation…392
Water Pump…392
Removal…392
Assembly…393
CHECKS AND ADJUSTMENTS…393
Removing Air From The Fuel System…393
Timing…394
Fuel Injection Pump…394
Valve Clearance Adjustment…397
Adjusting The Throttle Linkage…397
TROUBLESHOOTING…399
SPECIFICATIONS…400
6003…404
INTRODUCTION…404
GENERAL…404
DESCRIPTION…405
REMOVAL AND INSTALLATION OF THE ENGINE…405
CYLINDER HEAD AND MECHANISM…405
Cylinder Head, Removal…405
Cylinder Head, Disassembly…406
Cleaning And Inspection…407
Valve And Valve Seats…408
Studs For The Rocker Arms…408
Hydraulic Valve Lifters, Replacement…408
Hydraulic Valve Lifters, Cleaning And Inspection…409
Cylinder Head, Assembly…409
Cylinder Head, Installation…409
Rocker Arm Cover, Installation…410
TIMING GEAR COVER…411
Removal…411
Installation…411
CAMSHAFT…412
Removal…412
Inspection…413
Camshaft Bearings, Removal…413
Camshaft Bearings, Installation…413
DISTRIBUTOR…414
Removal…414
Installation…414
LUBRICATION SYSTEM…415
Oil Sump, Removal…415
Oil Sump, Installation…415
Oil Pump, Removal…415
Oil Pump, Disassembly and Repair…415
Oil Pump, Assembly…416
Oil Pump, Installation…416
PISTON AND CONNECTING ROD ASSEMBLIES…416
Connecting Rod Bearings, Replacement…416
Piston And Connecting Rod Assemblies, Removal…417
Disassembly…418
Piston, Cleaning And Inspection…418
Cylinder Bores, Inspection And Repair…418
Piston Rings…419
Assembly…420
Piston And Connecting Rod Assemblies, Installation…420
CRANKSHAFT…421
Main Bearings, Replacement…421
Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only)…422
Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal)…422
Crankshaft, Removal…423
Inspection and Repair…424
How To Check The Clearance Between The Main Bearings And Their Journals…424
Installation…425
FLYWHEEL AND FLYWHEEL HOUSING…426
Flywheel, Removal…426
Ring Gear, Replacement…427
Flywheel, Installation…427
COOLING SYSTEM…427
Coolant Pump…427
Fan Drive…428
Viscous Fan Drive…428
ENGINE SPECIFICATIONS…429
ENGINE DATA…429
CYLINDER HEAD…429
HYDRAULIC VALVE LIFTER…430
CAMSHAFT…430
PISTONS…430
CYLINDER BORE…431
CRANKSHAFT…431
CONNECTING RODS…431
COOLING SYSTEM…432
LUBRICATION SYSTEM…432
TORQUE SPECIFICATIONS…432
700626…435
COOLING SYSTEM…435
INTRODUCTION…435
DESCRIPTION…435
RADIATOR…435
RADIATOR CAP…435
THERMOSTAT…435
WATER PUMP…436
FAN AND FAN SHROUD …436
REPAIRS…436
COOLING SYSTEM CHECKS…436
Exhaust Leaks…436
RADIATOR…436
Checks…436
Cleaning The Radiator…436
Drain The Cooling System…438
Fill The Cooling System…438
WATER PUMP…438
Checks…438
THERMOSTAT…439
Checks…439
FAN AND FAN SHROUD …439
TROUBLESHOOTING…440
8000180…441
INTRODUCTION…441
General…441
MAINTENANCE SCHEDULE…441
MAINTENANCE PROCEDURES Every 8 Hours or Daily…444
Checks with the Engine Stopped…444
Hydraulic System…444
Air Cleaner…444
Engine Oil…444
Fuel Filter (Diesel)…444
Battery…445
Cooling System…445
Drive Belts…445
Tires and Wheels…446
Lift Mechanism…447
Forks…447
Lift Chains…447
Upright…448
Carriage…448
Load Backrest Extension…448
Powershift Transmission…448
Checks with the Engine Running…448
Guages and Lights…449
Powershift Transmission…449
Brakes…449
Steering System…449
Hydraulic System…451
Uprights…451
Attachments…451
Every 350 Hours or Two Months…452
Engine Oil and Filter…452
Brake Fluid…452
Hydraulic Tank Breather…452
Forks…452
Uprights…453
Other Lubrication Points…454
Every 1000 Hours or Six Months…454
Final Fuel Filter (Diesel)…454
Removing Air From The Diesel Fuel System…454
Ignition System (Gas Engine…455
PCV Valve (Gas Engine)…455
Every 2000 Hours or Yearly…456
PCV Valve (Gas Engine)…456
PCV Valve (Diesel Engine)…456
Differential…457
Adjusting The Oil Clutch Pedal…457
Hydraulic System…457
Changing The Gasoline Fuel System…458
Changing The Fuel Filter for LPG…458
WHEELS AND TIRES…459
Drive Tires…459
Steering Tires…462
8000181…463
8000182…466
8000231…472
INTRODUCTION…472
NOMENCLATURE, THREADS…472
STRENGTH IDENTIFICATION…473
TABLE 1. BOLTS AND SCREWS…473
TABLE 2. STUDS AND NUTS…474
TABLE 3. TORQUE NUTS…475
TABLE 4. TORQUE NUTS WITH NYLON INSERT…476
TABLE 5. TORQUE VALUES FOR INCH FASTENERS…477
TABLE 6. TORQUE VALUES FOR METRIC FASTENERS…478
90011…481
INTRODUCTION…481
GENERAL…481
DESCRIPTION…481
OPERATION…482
The Float System…482
The Idle System…482
The Main Metering System (GM 6-250)…483
The Power System (GM 6-250)…484
The Accelerator Pump System…484
Choke System…484
REPAIRS…485
REMOVAL…485
DISASSEMBLY…485
Cleaning…485
ASSEMBLY…485
INSTALLATION…485
GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)…490
GOVERNOR (PNEUMATIC) (Early Units)…491
CHECKS AND ADJUSTMENTS…492
GENERAL…492
ADJUST THE CHOKE CONTROL…492
ADJUST THE IDLE SPEED…492
ADJSUT THE IDLE MIXTURE…493
ADJUST THE FAST IDLE…493
ADJUST THE THROTTLE LINKAGE,(Later Models)…494
ADJUST THE THROTTLE LINKAGE,(Early Models)…495
GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)…495
Check the Governor…495
GOVERNOR (AISAN Type) (Early GM Engines Only)…496
Checks…497
Adjustments…497
GOVERNOR (HOOF Type) (Early GM Engines Only)…497
Adjust the Governor…497
TROUBLESHOOTING…499
90015…500
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)…500
GENERAL…500
DESCRIPTION…500
Fuel Tank…501
Fuel Filter And Fuel Valve Unit…502
Vaporizer…502
The IMPCO CA 100 Carbureto…504
IMPCO CA 50 Carburetor…506
The Governor (GM Engines Only)…507
Governor With Electronic Controller…508
REPAIRS…509
LPG TANK…509
Removal…509
Installation…510
REPLACE THE HOSES…510
HYDROSTATIC RELIEF VALVE…510
Removal and Installation…510
FILTER UNIT…511
Replacement Of the Fuel Filter Element…511
Replacement of the Diaphragm and Fuel Valve…512
VAPORIZER…512
Removal…512
Disassembly…512
Cleaning…512
Inspection…512
Assembly…514
Installation…514
CARBURETOR (IMPCO CA 100)…516
Removal…516
Disassembly…516
Cleaning…516
Assembly…516
Installation…519
CARBURETER (IMPCO CA 50)…518
Removal…518
Disassembly…518
Cleaning…519
Inspection…519
Assembly (See FIGURE 26.)…519
Installation…519
CHECKS AND ADJUSTMENTS…520
CHECK THE FILTER UNIT…520
CHECK THE VAPORIZER…520
Pressure Reducer Valve…520
Vapor Valve…520
ADJUST THE CARBURETOR…520
Idle Mixture…520
Idle Speed…520
Power Mixture…520
ADJUST THE GOVERNOR (GM Engines Only)…521
Checks…521
Main Adjusting Screw…521
Secondary Adjusting Screw…521
AISAN Governor…522
Adjustment, AISAN Governor…522
TROUBLESHOOTING…523
F003 (H40-60JS)…527
100179…529
INTRODUCTION…529
General…529
Description…529
DISASSEMBLY AND ASSEMBLY…530
Overhead Guard…530
Hood and Seat Removal…531
Counterweight…531
Engine and Transmission…531
REPAIRS…533
Fuel and Hydraulic Tanks…533
Decal Replacement…534
120018…538
INTRODUCTION…538
GENERAL…538
DESCRIPTION AND OPERATION …538
REPAIRS…539
REMOVAL…539
INSPECTION…539
INSTALLATION…540
ADJUSTMENTS…542
ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL…542
ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS…542
TROUBLESHOOTING…543
130043…545
INTRODUCTION…545
General…545
REPAIRS…546
REMOVAL…546
DISASSEMBLY…546
CLEANING…554
INSPECTION…555
ASSEMBLY…555
Assembling the Control Valve…555
Assembling the Differential…558
Assembling the Transmission…566
Installation…570
MONOTROL Pedal…570
CHECKS AND ADJUSTMENTS…571
Checking the MONOTROL Pedal for Leakage…571
MONOTROL Pedal…571
Stall Test…571
Checking the Oil Pressures…572
MONOTROL Pressure…573
Clutch Apply Pressure…575
Inching Spool Operation…576
Torque Converter and Oil Cooler Pressure…576
CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT…576
CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER…577
ADJUSTING THE OIL SUMP TUBE…578
TROUBLESHOOTING…578
Pressure Tests…581
Troubleshooting the Differential…582
130059…584
INTRODUCTION…584
GENERAL…584
DESCRIPTION…584
REPAIRS…587
REMOVAL…587
DISASSEMBLY…587
CLEANING…594
INSPECTION…594
ASSEMBLY…594
INSTALLATION…602
TROUBLESHOOTING…602
SPECIFICATIONS…603
140049…604
INTRODUCTION…604
GENERAL…604
DESCRIPTION…604
REPAIRS…604
DISASSEMBLY…605
CLEANING…607
ASSEMBLY…607
TROUBLESHOOTING…609
160010…610
INTRODUCTION…610
DESCRIPTION…610
GENERAL…610
REPAIRS…611
STEERING AXLE…611
Removal…611
Installation…612
STEERING CYLINDER…612
Removal…612
Service…613
Installation…613
HUBS…613
Removal…613
Installation…614
SPINDLES…614
Removal…614
Installation…615
CHECKS AND ADJUSTMENTS…615
REMOVE THE AIR FROM THE STEERING SYSTEM…615
SET THE PRESSURE RELIEF VALVE…615
S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)…615
H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION…615
H2.00-3.00J (H40-60J) With Powershift Transmission…615
TROUBLESHOOTING…617
160054…618
INTRODUCTION…618
GENERAL…618
DESCRIPTION…618
OPERATION…618
REPAIRS…618
STEERING WHEEL AND COLUMN ASSEMBLY…618
TYPE "A" STEERING COLUMN ASSEMBLY…620
Removal And Disassembly…620
Assembly And Installation…620
TYPE "A" STEERING COLUMN…621
TYPE "A" STEERING COLUMN…622
TYPE "B" STEERING COLUMN…623
Removal And Disassembly…623
Assembly And Installation…623
TYPE "B" STEERING COLUMN…624
Disassembly of Steering Control Unit…625
Cleaning of Steering Control Unit…625
Assembly of Steering Control Unit…627
CHECKS AND ADJUSTMENTS…630
REMOVE AIR FROM THE SYSTEM…630
TROUBLESHOOTING…631
180013…632
INTRODUCTION…632
GENERAL…632
DESCRIPTION…632
REPAIRS…632
REMOVAL AND DISASSEMBLY…632
CLEANING …633
ASSEMBLY…633
CHECKS AND ADJUSTMENTS…633
CHECKS…633
180080…634
INTRODUCTION…634
GENERAL…634
DESCRIPTION AND OPERATION…635
REPAIRS…635
REMOVAL AND DISASSEMBLY…635
CLEANING…636
INSPECTION…637
ASSEMBLY…637
CHECKS AND ADJUSTMENTS…639
BRAKE SHOES…639
Parking Brake…639
Seat Actuated Park Brake, J40–60AS…639
Removing The Air From The Brake System…640
TROUBLESHOOTING…641
190064…644
INTRODUCTION…644
GENERAL…644
DESCRIPTION…644
REPAIRS…644
REMOVAL AND DISASSEMBLY…644
CLEANING…646
INSPECTION…646
ASSEMBLY AND INSTALLATION…646
TROUBLESHOOTING…648
GENERAL…648
190097…649
INTRODUCTION…649
DESCRIPTION…649
OPERATION…649
Flow Control Valve…651
Relief Valve…651
REPAIRS…652
REMOVAL…652
DISASSEMBLY…652
CLEANING…654
INSPECTION…654
ASSEMBLY…655
INSTALLATION…656
CHECKS AND ADUSTMENTS…657
CHECK THE OUTPUT OF THE PUMP…657
CHECK FOR AIR IN THE HYDRAULIC SYSTEM…657
TROUBLESHOOTING…659
200065…662
INTRODUCTION…662
General…662
Description…662
Hydraulic Control Valve…668
REPAIRS…672
Disassembly…672
Cleaning…672
Inspection…672
Assembly…673
CHECKS AND ADJUSTMENT…674
Relief Valve…674
TROUBLESHOOTING…676
2100103…678
General…680
Description…680
Tilt Cylinder…680
Remove…680
Disassemble…680
Clean…680
Assemble…680
Tilt Cylinders with O-Ring or Single-Lip Seals…680
Tilt Cylinders for XM and XMS Models…682
Tilt Cylinders for H700-800A and Early Model H700-920B…683
Install…684
Tilt Cylinders Using Chevron Packing…685
Install…686
Tilt Cylinder Leak Check…688
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…689
Torque Specifications…689
Piston Rod Nut…689
Retainer…691
Troubleshooting…692
2200106…695
General…697
Description and Operation…697
Starter Repair…699
Remove…699
Disassemble…699
Clean…700
Assemble…700
Install…701
General Checks and Adjustments…701
Troubleshooting…704
2200107…708
toc…708
High Energy Ignition (HEI) System…708
Safety Precautions Maintenance and Repair…709
Description…712
Distributor Repair…714
Remove…714
Disassemble…714
Assemble…719
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…720
Install, If Crankshaft WAS Rotated when Distributor was Removed…720
Ignition Coil Replacement…721
Some Four- and Six-Cylinder Models…721
Remove…721
Install…722
V8, Some Four- and Six-Cylinder Models…722
Remove…722
Install…723
Electronic Module Replacement…724
Remove…724
Install…724
Sensing Coil Replacement…725
Remove…725
Install…725
Spark Plugs Replacement…725
Remove…725
Install…726
Visual Check…726
High Voltage Wires Check…726
Ignition Coil Check…727
Coil in Distributor Cap Design…727
Separate Coil Design…727
Sensing Coil, Check…728
Electronic Module Check…728
Ignition Timing Adjustment…728
GM V8-366 (6-liter) Ignition System Check…730
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …730
Specifications…730
Troubleshooting…731
2200143…736
INTRODUCTION…736
GENERAL…736
DESCRIPTION…736
GENERAL…736
STEERING COLUMN GAUGES, METERS AND INDICATORS…739
LED DISPLAY PANEL…739
Battery Discharge Indicators…739
Brush Wear Indicators…740
Motor Temperature Indicators…741
"LX" SERIES DISPLAY PANEL…742
Hourmeter Functions…743
Battery Indicator Function…743
Status Code Function…743
"ZX" SERIES DISPLAY PANELS…743
Display Panel…744
Basic Display Panels…744
Performance Display…746
Brush Wear Indicators…749
CHECKS AND ADJUSTMENTS…749
GENERAL…749
REPLACEMENT…750
GENERAL…750
METER REPLACEMENT…750
SENDER REPLACEMENT…751
Fuel Level Sender…751
Pressure And Temperature Sender…751
I.T.W. DISPLAY PANEL…752
Removal…752
DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT…753
Removal…753
Replacing Display Panel Assembly…753
Indicator LEDs…753
Battery Indicators…753
Digital Display (Performance Disply Panel Only)…753
Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)…753
Replacing Parts Of The Basic Display Panel…754
Replacing Parts Of The Performance Display Panel…756
DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT…756
Removal And Replacement…756
SPECIFICATIONS…757
TROUBLESHOOTING…758
2200144…759
ELECTRICAL WARNING DEVICES…759
GENERAL…759
DESCRIPTION…759
Operator Controlled Horns…759
System Warning Lights, Buzzers and Bells…759
Reverse Warning Horns…760
Warning Lights…760
REPLACEMENT…761
General…761
Replacing Horns or Bells…761
Replacing Horn Relay or Buzzer…761
Replacing Warning Lights…761
Light Assemblies…762
Replacing Flashing Units…762
2200153…763
ELECTRICAL SYSTEM COMPLETELY DEAD…763
STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN …764
STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER…766
STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK…767
STARTER CRANKS SLOWLY…769
STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START…770
BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND…772
CHARGING SYSTEM DOES NOT FUNCTION…773
ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW…776
BATTERY IS BEING OVERCHARGED…779
ONE OR MORE DASH GAUGES DO NOT WORK…780
HORN DOES NOT BLOW…784
POWERSHIFT TRANSMISSION WILL NOT ENGAGE…785
ELECTRICAL SCHEMATIC S20-30A, H20-30E…786
ELECTRICAL S30-50C…787
ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG…788
ELECTRICAL SCHEMATIC H30-60H DIESEL…790
ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG…792
ELECTRICAL SCHEMATIC H60-90C DIESEL…793
ELECTRICAL SCHEMATIC S30-60ES…794
ELECTRICAL SCHEMATIC S60-120E…795
ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG…796
ELECTRICAL SCHEMATIC S125-150A DIESEL…797
ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG…798
ELECTRICAL SCHEMATIC H110-150F DIESEL…799
ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG…800
ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL…801
ELECTRICAL SCHEMATIC H300A…802
ELECTRICAL SCHEMATIC H300-350B…803
ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL…804
ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL…805
ELECTRICAL SCHEMATIC H700-800A…806
ELECTRICAL SCHEMATIC P40-50A GASOLINE…808
ELECTRICAL SCHEMATIC P40-50A DIESEL…809
ELECTRICAL SCHEMATIC P60-80A GASOLINE…810
ELECTRICAL SCHEMATIC P60-80A DIESEL…811
ELECTRICAL SCHEMATIC KE GAS GASOLINE…812
ELECTRICAL SCHEMATIC KE DIESEL…813
ELECTRICAL SCHEMATIC M200-400H GASOLINE…814
ELECTRICAL SCHEMATIC M200-400H DIESEL…816
ELECTRICAL SCHEMATIC M600A…818
22002…820
General…822
Description…822
Alternator Repair…824
Alternator Type A…824
Remove and Disassemble…824
Clean…825
Assemble…825
Install…826
Alternator Type B…829
Remove and Disassemble…829
Clean…829
Assemble…830
Install…831
General Check and Adjustment…832
Low Output Check (Type A or Type B)…832
High Output Check (Type A or Type B)…834
Brushes Circuit Check…835
Delco Alternators…835
Motorola Alternators…836
Diodes Check…837
Diodes Bridge Check…837
Delco and Leece-Neville Alternators…837
Motorola Alternators…837
Rotor Field Winding Check…838
Stator Windings Check…839
Voltage Regulator Check…839
Troubleshooting…840
4000115…842
INTRODUCTION…842
GENERAL…842
REPAIRS…842
FORKS…842
CARRIAGE…842
Removal…842
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…843
Installation…844
MASTS…846
Removal…846
Disassembly…848
Cleaning and Inspection…852
Assembly…853
INSTALLATION…854
CHECKS AND ADJUSTMENTS…854
CHECKING FOR LEAKS IN THE LIFT SYSTEM…854
ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…855
LIFT CHAIN ADJUSTMENTS…855
MAST ADJUSTMENTS…856
Guide Shoe Adjustment…857
CARRIAGE ADJUSTMENT…859
TROUBLESHOOTING…861
4000135…862
Safety Procedures When Working Near Mast…864
General…869
Description…869
Lowering Control Valve…869
Cylinders (General)…872
Cylinders (H520-620B, H700-800A)…872
Retainer, Install…872
Cylinders (H360-460B)…874
Cylinders (Two-Speed)…877
Lift Cylinder Repair…878
Lift Cylinder Removal Without Removing Mast…878
Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast…878
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead…879
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder…880
Disasemble…880
Assemble…880
Lift Cylinder Installation in Mast…882
Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast…882
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead…882
Chevron-Style Packing…882
Chevron-Style Packing Installation on Piston…883
Chevron-Style Packing Installation in Packing Gland…885
Lift Cylinders for Vista Masts…886
Description…886
Lowering Control Valve…886
Remove…888
Disassemble…889
Assemble…890
Install…891
Main Lift Cylinders…891
Free-Lift Cylinder…891
Lift System Leak Check…891
Specifications…892
Troubleshooting…893
4000167…896
INTRODUCTION…896
GENERAL…896
STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)…898
FULL FREE-LIFT MASTS…898
THREE-STAGE MASTS…900
FOUR-STAGE MASTS…901
SEQUENCE VALVE…901
4000197…903
INTRODUCTION…903
GENERAL…903
VISTA TWO-STAGE MASTS…905
DESCRIPTION…905
OPERATION…908
VISTA THREE-STAGE MASTS…908
DESCRIPTION…908
OPERATION…910
SEQUENCE VALVE…912
4000198…915
…915
…916
…917
…918
…919
…920
…921
…922
…923
…924
…925
…926
…927
…928
…929
…930
…931
…932
…933
…934
…935
…936
…937
…938
…939
…940
…941
…942
…943
…944
…945
…946
600169…947
INTRODUCTION…947
General…947
Description…947
ENGINE…947
Removal…947
Installation…948
CYLINDER HEAD AND VALVE MECHANISM…948
Cylinder Head…948
Removal…948
Repairs…949
Installation…949
Valve Guides…951
Valve Mechanism…951
Valves…951
Valve Springs…951
Rocker Arm Assembly…951
LUBRICATION…952
Oil Pump…952
Removal and Disassembly…952
Repairs…952
Assembly and Installation…952
Relief Valve…953
TIMING GEAR CASE AND CAMSHAFT…953
Timing Gear Cover…953
Removal…953
Installation…953
Idle Gears…953
Removal…953
Installation…954
Camshaft Gear and Camshaft…954
Removal…954
Installation…955
Fuel Pump Gear…955
Removal…955
Installation…956
Timing Gear Case…956
Removal…956
Installation…956
CRANKSHAFT AND MAIN BEARINGS…957
Removal…957
Installation…957
PISTONS AND PISTON RODS…958
Removal…958
Disassembly…958
Repairs…959
Assembly…959
Installation…960
CYLINDER LINERS…961
Removal …961
Installation…961
FLYWHEEL AND FLYWHEEL HOUSING…961
Removal…961
Installation…961
FUEL PUMP…961
Removal…961
Installation…962
FUEL INJECTION PUMP…962
Removal…962
Installation…962
FUEL INJECTORS…963
Checks…963
Installation…963
COOLING SYSTEM…964
Thermostat…964
Removal…964
Installation…964
Water Pump…964
Removal…964
Assembly…965
CHECKS AND ADJUSTMENTS…965
Removing Air From The Fuel System…965
Timing…966
Fuel Injection Pump…966
Valve Clearance Adjustment…969
Adjusting The Throttle Linkage…969
TROUBLESHOOTING…971
SPECIFICATIONS…972
6003…976
INTRODUCTION…976
GENERAL…976
DESCRIPTION…977
REMOVAL AND INSTALLATION OF THE ENGINE…977
CYLINDER HEAD AND MECHANISM…977
Cylinder Head, Removal…977
Cylinder Head, Disassembly…978
Cleaning And Inspection…979
Valve And Valve Seats…980
Studs For The Rocker Arms…980
Hydraulic Valve Lifters, Replacement…980
Hydraulic Valve Lifters, Cleaning And Inspection…981
Cylinder Head, Assembly…981
Cylinder Head, Installation…981
Rocker Arm Cover, Installation…982
TIMING GEAR COVER…983
Removal…983
Installation…983
CAMSHAFT…984
Removal…984
Inspection…985
Camshaft Bearings, Removal…985
Camshaft Bearings, Installation…985
DISTRIBUTOR…986
Removal…986
Installation…986
LUBRICATION SYSTEM…987
Oil Sump, Removal…987
Oil Sump, Installation…987
Oil Pump, Removal…987
Oil Pump, Disassembly and Repair…987
Oil Pump, Assembly…988
Oil Pump, Installation…988
PISTON AND CONNECTING ROD ASSEMBLIES…988
Connecting Rod Bearings, Replacement…988
Piston And Connecting Rod Assemblies, Removal…989
Disassembly…990
Piston, Cleaning And Inspection…990
Cylinder Bores, Inspection And Repair…990
Piston Rings…991
Assembly…992
Piston And Connecting Rod Assemblies, Installation…992
CRANKSHAFT…993
Main Bearings, Replacement…993
Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only)…994
Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal)…994
Crankshaft, Removal…995
Inspection and Repair…996
How To Check The Clearance Between The Main Bearings And Their Journals…996
Installation…997
FLYWHEEL AND FLYWHEEL HOUSING…998
Flywheel, Removal…998
Ring Gear, Replacement…999
Flywheel, Installation…999
COOLING SYSTEM…999
Coolant Pump…999
Fan Drive…1000
Viscous Fan Drive…1000
ENGINE SPECIFICATIONS…1001
ENGINE DATA…1001
CYLINDER HEAD…1001
HYDRAULIC VALVE LIFTER…1002
CAMSHAFT…1002
PISTONS…1002
CYLINDER BORE…1003
CRANKSHAFT…1003
CONNECTING RODS…1003
COOLING SYSTEM…1004
LUBRICATION SYSTEM…1004
TORQUE SPECIFICATIONS…1004
700626…1007
General…1009
Description…1010
Radiator…1010
Radiator Cap…1010
Thermostat…1010
Water Pump…1011
Fan and Fan Shroud…1011
Cooling System Checks…1011
Radiator…1011
Thermostat…1011
Water Pump…1012
Exhaust Leaks…1012
Fan and Fan Shroud…1012
Radiator Cleaning…1012
Drain…1012
Clean…1012
Fill…1013
Troubleshooting…1014
8000180…1016
INTRODUCTION…1016
General…1016
MAINTENANCE SCHEDULE…1016
MAINTENANCE PROCEDURES Every 8 Hours or Daily…1019
Checks with the Engine Stopped…1019
Hydraulic System…1019
Air Cleaner…1019
Engine Oil…1019
Fuel Filter (Diesel)…1019
Battery…1020
Cooling System…1020
Drive Belts…1020
Tires and Wheels…1021
Lift Mechanism…1022
Forks…1022
Lift Chains…1022
Upright…1023
Carriage…1023
Load Backrest Extension…1023
Powershift Transmission…1023
Checks with the Engine Running…1023
Guages and Lights…1024
Powershift Transmission…1024
Brakes…1024
Steering System…1024
Hydraulic System…1026
Uprights…1026
Attachments…1026
Every 350 Hours or Two Months…1027
Engine Oil and Filter…1027
Brake Fluid…1027
Hydraulic Tank Breather…1027
Forks…1027
Uprights…1028
Other Lubrication Points…1029
Every 1000 Hours or Six Months…1029
Final Fuel Filter (Diesel)…1029
Removing Air From The Diesel Fuel System…1029
Ignition System (Gas Engine…1030
PCV Valve (Gas Engine)…1030
Every 2000 Hours or Yearly…1031
PCV Valve (Gas Engine)…1031
PCV Valve (Diesel Engine)…1031
Differential…1032
Adjusting The Oil Clutch Pedal…1032
Hydraulic System…1032
Changing The Gasoline Fuel System…1033
Changing The Fuel Filter for LPG…1033
WHEELS AND TIRES…1034
Drive Tires…1034
Steering Tires…1037
8000181…1038
8000182…1041
8000231…1047
General…1049
Nomenclature, Threads…1049
Strength Identification…1050
Fastener Torque Tables…1054
Conversion Table…1056
90011…1058
INTRODUCTION…1058
GENERAL…1058
DESCRIPTION…1058
OPERATION…1059
The Float System…1059
The Idle System…1059
The Main Metering System (GM 6-250)…1060
The Power System (GM 6-250)…1061
The Accelerator Pump System…1061
Choke System…1061
REPAIRS…1062
REMOVAL…1062
DISASSEMBLY…1062
Cleaning…1062
ASSEMBLY…1062
INSTALLATION…1062
GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)…1067
GOVERNOR (PNEUMATIC) (Early Units)…1068
CHECKS AND ADJUSTMENTS…1069
GENERAL…1069
ADJUST THE CHOKE CONTROL…1069
ADJUST THE IDLE SPEED…1069
ADJSUT THE IDLE MIXTURE…1070
ADJUST THE FAST IDLE…1070
ADJUST THE THROTTLE LINKAGE,(Later Models)…1071
ADJUST THE THROTTLE LINKAGE,(Early Models)…1072
GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)…1072
Check the Governor…1072
GOVERNOR (AISAN Type) (Early GM Engines Only)…1073
Checks…1074
Adjustments…1074
GOVERNOR (HOOF Type) (Early GM Engines Only)…1074
Adjust the Governor…1074
TROUBLESHOOTING…1076
90015…1077
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)…1077
GENERAL…1077
DESCRIPTION…1077
Fuel Tank…1078
Fuel Filter And Fuel Valve Unit…1079
Vaporizer…1079
The IMPCO CA 100 Carbureto…1081
IMPCO CA 50 Carburetor…1083
The Governor (GM Engines Only)…1084
Governor With Electronic Controller…1085
REPAIRS…1086
LPG TANK…1086
Removal…1086
Installation…1087
REPLACE THE HOSES…1087
HYDROSTATIC RELIEF VALVE…1087
Removal and Installation…1087
FILTER UNIT…1088
Replacement Of the Fuel Filter Element…1088
Replacement of the Diaphragm and Fuel Valve…1089
VAPORIZER…1089
Removal…1089
Disassembly…1089
Cleaning…1089
Inspection…1089
Assembly…1091
Installation…1091
CARBURETOR (IMPCO CA 100)…1093
Removal…1093
Disassembly…1093
Cleaning…1093
Assembly…1093
Installation…1096
CARBURETER (IMPCO CA 50)…1095
Removal…1095
Disassembly…1095
Cleaning…1096
Inspection…1096
Assembly (See FIGURE 26.)…1096
Installation…1096
CHECKS AND ADJUSTMENTS…1097
CHECK THE FILTER UNIT…1097
CHECK THE VAPORIZER…1097
Pressure Reducer Valve…1097
Vapor Valve…1097
ADJUST THE CARBURETOR…1097
Idle Mixture…1097
Idle Speed…1097
Power Mixture…1097
ADJUST THE GOVERNOR (GM Engines Only)…1098
Checks…1098
Main Adjusting Screw…1098
Secondary Adjusting Screw…1098
AISAN Governor…1099
Adjustment, AISAN Governor…1099
TROUBLESHOOTING…1100
Hyster Forklift Trucks F003 (H40-60JS & H2.00-3.00JS Europe) Repair Service Manuals