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