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