Hyster 2.6L, 3.0L, 3.3L Yanmar Diesel Engines Maintenance And Repair

Description

• Model List:
  • 2.6L, 3.0L, 3.3L Yanmar Diesel Engines

• 1. RM1205-(09-2021)-UK-EN
• 1.1. General
• 1.1.1. Engine Identification
• 1.2. Engine Removal and Installation
• 1.3. Cylinder Head Assembly Repair
• 1.3.1. Glow Plugs
• 1.3.2. Install
• 1.3.3. Valve Cover
• 1.3.4. Rocker Arm Assembly
• 1.3.5. Valve Clearance Adjustments
• 1.3.6. Cylinder Head Assembly
• 1.4. Timing Gear Case and Timing Gears Repair
• 1.4.1. Timing Gear Case Cover
• 1.4.2. Timing Gears
• 1.4.3. Timing Gear Case
• 1.5. Drive Train, Camshaft, and Cylinder Block Repair
• 1.5.1. Disassemble
• 1.5.2. Clean and Inspect
• 1.5.3. Assemble
• 1.5.4. Install
• 1.6. Lubrication System Repair
• 1.6.1. Engine Oil and Oil Filter Change
• 1.6.2. Oil Pan
• 1.6.3. Oil Suction Tube
• 1.6.4. Oil Pump
• 1.7. Fuel System Repair
• 1.7.1. Fuel Injectors
• 1.7.2. Inspect
• 1.7.3. Electronic Throttle System
• 1.7.4. Manual Throttle System
• 1.7.5. Fuel Injection Pump
• 1.8. Cooling System Repair
• 1.8.1. Water Pump
• 1.8.2. Thermostat
• 1.9. Flywheel and Flywheel Housing
• 1.9.1. Flywheel
• 1.9.2. Flywheel Housing
• 1.10. Electrical Equipment Repair
• 1.10.1. Alternator
• 1.10.2. Starter
• 1.11. Engine Specifications
• 1.11.1. Engine Data
• 1.11.2. Engine Tuning
• 1.11.3. Cylinder Head
• 1.11.4. Intake/Exhaust Valve and Guide
• 1.11.5. Valve Spring
• 1.11.6. Rocker Arm and Shaft
• 1.11.7. Push Rod
• 1.11.8. Gear Train and Camshaft
• 1.11.9. Cylinder Block
• 1.11.10. Crankshaft
• 1.11.11. Thrust Bearing
• 1.11.12. Piston Ring
• 1.11.13. Connecting Rod
• 1.11.14. Oil Pump
• 1.12. Standard Torque Specifications
• 1.12.1. Standard Torque Chart
• 1.13. Special Torque Specifications
• 1.14. Special Tools
• 2. RM1755-(01-2022)-UK-EN
• 2.1. General
• 2.2. Engine Removal and Installation
• 2.3. Cylinder Head Assembly Repair
• 2.4. Drive Train and Lubrication System
• 2.4.1. Disassemble
• 2.4.2. Oil Pan
• 2.4.3. Oil Pump (Front Cover)
• 2.4.4. Clean and Inspect
• 2.4.5. Assemble
• 2.4.6. Install
• 2.5. Crankshaft and Cylinder Block Repair
• 2.5.1. Remove Major Attaching Components
• 2.5.2. Crankshaft and Cylinder Block
• 2.5.3. Piston and Connecting Rod
• 2.5.4. Install Major Attaching Components
• 2.6. Fuel System Repair
• 2.7. Cooling System Repair
• 2.8. Electrical Equipment Repair
• 2.9. Flywheel and Flywheel Housing
• 2.9.1. Flywheel
• 2.9.2. Flywheel Housing
• 2.10. POWER TAKE OFF (PTO), REMOVE AND INSTALL
• 2.10.1. REMOVE COVER
• 2.10.2. INSTALL COVER
• 2.11. Engine Specifications
• 2.11.1. Engine Data
• 2.11.2. Engine Tuning
• 2.11.3. Cylinder Head
• 2.11.4. Intake/Exhaust Valve and Guide
• 2.11.5. Valve Spring
• 2.11.6. Gear Train and Camshaft
• 2.11.7. Cylinder Block
• 2.11.8. Crankshaft
• 2.11.9. Piston Ring
• 2.11.10. Connecting Rod
• 2.11.11. Oil Pump
• 2.12. Torque Specifications
• 2.13. Special Tools
• 3. RM1921-(09-2021)-UK-EN
• 3.1. General
• 3.1.1. Engine Identification
• 3.2. Engine Removal and Installation
• 3.3. Cylinder Head Assembly Repair
• 3.3.1. Valve Covers and Fuel Injectors
• 3.3.2. Rocker Arm Assembly
• 3.3.3. Valve Clearance Adjustments
• 3.3.4. Compression Test
• 3.3.5. Cylinder Head Assembly
• 3.4. Timing Gear Case and Timing Gears Repair
• 3.4.1. Timing Gear Case Cover
• 3.4.2. Timing Gears
• 3.5. Drive Train, Camshaft, and Cylinder Block Repair
• 3.5.1. Disassemble
• 3.5.2. Clean and Inspect
• 3.5.3. Assemble
• 3.5.4. Install
• 3.6. Lubrication System Repair
• 3.6.1. Engine Oil and Oil Filter Change
• 3.6.2. Oil Pan
• 3.6.3. Oil Suction Tube
• 3.6.4. Oil Pump
• 3.7. Fuel System Repair
• 3.7.1. Fuel Injectors
• 3.7.2. Fuel Injection Pump/Supply Pump
• 3.8. Cooling System Repair
• 3.8.1. Accessory Drive Belt
• 3.8.2. Water Pump
• 3.8.3. Thermostat
• 3.9. Flywheel and Flywheel Housing
• 3.9.1. Flywheel
• 3.9.2. Flywheel Housing
• 3.10. Electrical Equipment Repair
• 3.10.1. Alternator
• 3.10.2. Starter
• 3.11. Engine Specifications
• 3.11.1. Engine Data
• 3.11.2. Engine Tuning
• 3.11.3. Cylinder Head
• 3.11.4. Intake/Exhaust Valve and Guide
• 3.11.5. Valve Spring
• 3.11.6. Rocker Arm and Shaft
• 3.11.7. Push Rod
• 3.11.8. Gear Train and Camshaft
• 3.11.9. Cylinder Block
• 3.11.10. Crankshaft
• 3.11.11. Piston Ring
• 3.11.12. Connecting Rod
• 3.11.13. Oil Pump
• 3.12. Standard Torque Specifications
• 3.12.1. Standard Torque Chart
• 3.13. Special Torque Specifications
• 3.14. Special Tools
• 4. RM2199-(04-2022)-UK-EN
• 4.1. Forklift Truck Main Parts
• 4.1.1. Description of Forklift Truck Main Parts
• 4.2. Forklift Main Technical Parameters
• 4.2.1. Main Technical Parameters
• 4.3. Power System
• 4.3.1. Engine System
• 4.4. Hydraulic Transmission Case and Torque Converter
• 4.4.1. Overview
• 4.4.2. Torque Converter
• 4.4.3. Hydraulic Clutch
• 4.4.4. Control Valve, Safety Valve, and Inching Valve
• 4.4.5. Transmission Case
• 4.4.6. Transmission Pump
• 4.4.7. Transmission hydraulic schematic
• 4.4.8. Speed Reducer and Speed Differential
• 4.4.9. Towing the Lift Truck
• 4.4.10. Oil Inlet/Outlet Connection Location
• 4.5. Drive Axle
• 4.5.1. Overview
• 4.5.2. Maintenance of Drive Axle
• 4.6. Steering System
• 4.6.1. Steering System
• 4.7. Steering and Drive Axle Information
• 4.7.1. Steering Axle
• 4.8. Brake System
• 4.8.1. Overview
• 4.8.2. Brake Master Cylinder
• 4.8.3. Wheel Brake
• 4.8.4. Automatic Brake Adjuster
• 4.8.5. Manual Brake
• 4.8.6. Adjustment of Brake Pedal
• 4.8.7. Maintenance
• 4.9. Hydraulic System
• 4.9.1. Overview
• 4.9.2. Steering Control Unit
• 4.9.3. Multi-way Valve and Priority spool
• 4.9.4. Hydraulic System Main Oil Circuit
• 4.9.5. Lift Cylinder
• 4.9.6. Velocity Fuse
• 4.9.7. Tilt Cylinder
• 4.9.8. Maintenance of Hydraulic Pump
• 4.9.9. Troubleshoot Hydraulic System
• 4.10. Lifting System
• 4.10.1. Safety Procedures When Working Near Mast
• 4.10.2. Overview
• 4.10.3. Inside and Outside Masts
• 4.10.4. Carriage
• 4.10.5. Adjustment of Lifting System
• 4.11. Electrical System
• 4.11.1. Overview
• 4.11.2. Electrical Box
• 4.11.3. Battery
• 4.11.4. Description and Summary of Basic Truck Operations
• 4.11.5. Introduction to the Power Distribution Module (PDM)
• 4.11.6. Electrical Schematics
• 4.11.7. Troubleshoot Electrical System
• 4.12. Drive, Operation, and Routine Maintenance of Forklift Truck
• 4.12.1. Cooling System Troubleshooting and Service
• 4.12.2. Oils Used for Forklift Truck
• 4.12.3. Hydraulic Oil Gauge and Hydraulic Oil fill
• 4.12.4. Lubrication System
• 4.13. PDM Schematics
• 5. RM2415-(02-2022)-UK-EN
• 5.1. General
• 5.2. Description
• 5.3. Hood, Seat, and Side Covers Replacement
• 5.3.1. Disassemble
• 5.3.2. Re-assemble
• 5.4. Steering Column
• 5.4.1. Description
• 5.4.2. Steering Column Repair
• 5.5. Counterweight Replacement
• 5.5.1. Install
• 5.6. Overhead Guard Replacement
• 5.6.1. Remove and Install
• 5.7. Operator Restraint System Replacement
• 5.7.1. Description
• 5.8. Engine and Transmission Replacement
• 5.8.1. Engine and Transmission Disassembly
• 5.9. Exhaust System Repair
• 5.9.1. Remove and Re-assemble
• 5.9.2. Inspect
• 5.10. Cooling System
• 5.10.1. Description
• 5.11. Hydraulic Filter Assembly Repair
• 5.11.1. Disassemble
• 5.11.2. Clean and Inspect
• 5.11.3. Re-assemble
• 5.12. Fuel and Hydraulic Tanks Repair
• 5.12.1. Inspect
• 5.12.2. Additional Preparations for Repair
• 5.12.3. Small Leaks, Repair
• 5.12.4. Large Leaks, Repair
• 5.12.5. Preparations for Use After Repair
• 5.13. Safety Labels
• 6. RM2413-(02-2022)-UK-EN
• 6.1. General
• 6.2. Cooling System Checks
• 6.2.1. Exhaust Leaks Into Cooling System
• 6.2.2. Water Flow Restrictions in Radiator
• 6.2.3. Radiator Hoses
• 6.2.4. Water Pump
• 6.3. Flushing the Cooling System
• 6.3.1. Cooling System, Clean
• 6.4. Radiator Replacement
• 6.4.1. Radiator, Remove
• 6.4.2. Radiator, Install
• 6.5. Fan Assembly Replacement
• 6.5.1. Fan Removal
• 6.5.2. Inspect
• 6.5.3. Fan Installation
• 7. RM2416-(10-2022)-UK-EN
• 7.1. General
• 7.2. Intake-Air System
• 7.2.1. Intake-Air System Manifold Vacuum Check
• 7.2.2. Throttle Body
• 7.2.3. Intake Manifold
• 7.3. LPG Tank and Bracket Replacement with Swing-Out Bracket
• 7.3.1. Remove LPG Tank
• 7.3.2. Install LPG Tank
• 7.3.3. Remove LPG Bracket
• 7.3.4. Install LPG Bracket
• 7.4. Fuel Filter and Fuel Level Sensor Repair
• 7.4.1. FUEL FILTER ELEMENT
• 7.4.2. Fuel Level Sensor
• 7.5. Electronic Throttle Body Repair
• 7.5.1. Install
• 7.6. LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair
• 7.6.1. Install
• 7.7. Control System
• 7.7.1. Engine Control Module (ECM)
• 7.8. LPG Converter
• 7.9. LPG Lock-Off Valve
• 7.9.1. Install
• 7.10. Exhaust System
• 7.10.1. Counterweight Exhaust System
• 7.10.2. Oxygen Sensor
• 8. RM2419-(07-2021)-UK-EN
• 8.1. GENERAL
• 8.2. TRANSMISSION
• 8.2.1. CLEAN AND INSPECT
• 8.2.2. INSTALL
• 8.3. PEDAL REPAIR
• 8.3.1. REMOVE AND DISASSEMBLE
• 8.3.2. CLEAN AND INSPECT
• 8.3.3. ASSEMBLE AND INSTALL
• 9. RM2409-(02-2022)-UK-EN
• 9.1. General
• 9.2. Drive Axle Repair
• 9.2.1. Remove and Disassemble
• 9.2.2. Clean and Inspect
• 9.2.3. Re-assemble and Install
• 10. RM2410-(07-2021)-UK-EN
• 10.1. General
• 10.2. Steering Axle Assembly Repair
• 10.2.1. Disassemble
• 10.2.2. Inspect
• 10.2.3. Re-assemble
• 10.2.4. Install
• 10.3. Spindles, Bearings, and Tie Rods Repair
• 10.3.1. Remove and Disassemble
• 10.3.2. Inspect
• 10.3.3. Install and Assemble
• 10.4. Steering Cylinder Repair
• 10.4.1. Remove and Disassemble
• 10.4.2. Clean and Inspect
• 10.4.3. Assemble and Install
• 11. RM2411-(07-2021)-UK-EN
• 11.1. GENERAL
• 11.2. SERVICE BRAKE REPAIR
• 11.2.1. REMOVE AND DISASSEMBLE
• 11.2.2. INSPECT
• 11.2.3. ASSEMBLE AND INSTALL
• 11.3. PARKING BRAKE REPAIR
• 11.3.1. REMOVE AND DISASSEMBLE
• 11.3.2. ASSEMBLE AND INSTALL
• 11.4. MASTER CYLINDER REPAIR
• 11.4.1. DISASSEMBLE
• 11.4.2. CLEAN AND INSPECT
• 11.4.3. ASSEMBLE
• 11.4.4. BENCH BLEED MASTER CYLINDER
• 11.4.5. INSTALL
• 11.4.6. SERVICE BRAKE ADJUSTMENT
• 11.4.7. SERVICE BRAKE AIR REMOVAL
• 12. RM2417-(10-2022)-UK-EN
• 12.1. Cylinder
• 12.1.1. General
• 12.1.2. Safety Procedures When Working Near Mast
• 12.1.3. Integral Sideshift Cylinder Repair
• 12.1.4. Free-Lift Cylinder
• 12.1.5. Main Lift Cylinder Repair
• 12.1.6. Tilt Cylinder Repair
• 12.2. Hydraulic Gear Pump
• 12.2.1. General
• 12.2.2. Hydraulic Gear Pump Repair
• 12.3. Main Control Valve
• 12.3.1. General
• 12.3.2. Main Control Valve
• 13. RM2414-(10-2022)-UK-EN
• 13.1. General
• 13.2. Combination Switch
• 13.2.1. Remove and Install
• 13.3. Display and Rocker Switch
• 13.3.1. Remove and Install
• 13.4. Battery and Power Distribution Module
• 13.4.1. Remove and Install
• 13.5. Auxiliary Relay and Fuse Box
• 13.5.1. Remove and Install
• 13.6. Sensors and Switches
• 13.6.1. General
• 13.6.2. Accelerator Pedal Position Sensor
• 13.6.3. Parking Brake Sensor
• 13.6.4. Fuel Level Sensor
• 13.6.5. Torque Converter Temperature Sensor
• 13.6.6. Engine Coolant Temperature Sensor
• 13.6.7. CAM Sensor
• 13.6.8. Crank Sensor
• 13.6.9. Map Sensor
• 13.6.10. Oil Pressure Sensor
• 13.6.11. Oxygen Sensors
• 13.6.12. Fuel Shut-off Valve, Fuel filter, Fuel Pump, and Fuel Temperature Sensor
• 13.6.13. Remove and Install
• 13.7. Main Harness and OPS Harness
• 14. RM2418-(04-2022)-UK-EN
• 14.1. General
• 14.2. Safety Procedures When Working Near Mast
• 14.3. Fork Replacement
• 14.3.1. Standard Carriage and Integral Sideshift Carriage
• 14.4. Carriages Repair, Three-Stage FFL Mast
• 14.4.1. Standard Carriage
• 14.4.2. Integral Sideshift Carriage
• 14.5. Three-Stage Mast With Full Free-Lift Repair
• 14.5.1. Disassemble and Re-assemble
• 14.5.2. Clean and Inspect
• 14.6. Carriage Adjustments
• 14.7. Lift Chains Adjustment
• 14.8. Mast Adjustments
• 14.8.1. Load Roller, Adjust
• 14.8.2. Mast Side Kicking, Adjust
• 15. RM2407-(10-2022)-UK-EN
• 15.1. Electrical Schematics
• 15.2. Hydraulic Schematics
• 15.3. Operator Presence System (OPS) Schematic
• 15.4. Power Distribution Module (PDM) Schematics
• 16. RM2408-(10-2022)-UK-EN
• 16.1. General
• 16.1.1. How to Move a Disabled Lift Truck
• 16.1.2. How to Put a Lift Truck on Blocks
• 16.1.3. HOW TO CLEAN A LIFT TRUCK
• 16.2. Maintenance Schedule
• 16.3. Maintenance Procedures Every 8 Hours or Daily
• 16.3.1. How to Make Checks With Engine Stopped
• 16.3.2. How to Make Checks With Engine Running
• 16.4. Maintenance Procedures Every 250 Hours or 4 Months