Hyster C001 (H1.25-1.75XL) Service Manual

Description

• Model List:
  • C001 (H1.25-1.75XL)

• 1. INTRODUCTION
• 2. General
• 3. Removal of The Transmission
• 4. Installation of the Transmission
• 5. REPAIRS
• 6. Torque Converter
• 7. Front Cover and Oil Pump
• 8. Clutch Assemblies
• 9. Differential
• 10. Control Valve
• 11. CHECKS AND ADJUSTMENTS
• 12. Stall Test
• 13. Adjusting the Direction Control Linkage
• 14. Adjusting the Brake and Inching Pedals
• 15. Checking the Oil Pressures
• 16. SPECIFICATIONS
• 17. TROUBLESHOOTING
• 18. MAZDA M4-121G ENGINE
• 19. GENERAL
• 20. DESCRIPTION
• 21. REMOVAL AND INSTALLATION OF THE ENGINE
• 22. CYLINDER HEAD AND VALVE MECHANISM
• 23. Cylinder Head, Removal
• 24. Cylinder Head, Inspection and Repairs
• 25. Rocker Arm Assembly
• 26. Valve Guides
• 27. Valve Seats
• 28. Valve Springs
• 29. Cylinder Head, Installation
• 30. TIMING GEAR CASE, REMOVAL
• 31. TIMING GEAR CASE, INSTALLATION
• 32. CAMSHAFT
• 33. Removal
• 34. Inspection
• 35. Cam Followers, Inspection
• 36. Installation
• 37. CRANKSHAFT AND MAIN BEARINGS
• 38. Crankshaft, Removal
• 39. Crankshaft, Inspection And Repair
• 40. Main Bearings
• 41. Crankshaft, Installation
• 42. PISTONS AND CONNECTING RODS
• 43. Removal
• 44. Disassembly
• 45. Pistons, Inspection And Repair
• 46. Piston Rings
• 47. Piston Pin and Bushing
• 48. Connecting Rods and Bearings, Inspection
• 49. Pistons and Connecting Rods, Assembly
• 50. Pistons and Connecting Rods, Installation
• 51. CYLINDER BLOCK AND CYLINDER LINERS
• 52. Cylinder Block, Repairs
• 53. Cylinder Liners
• 54. DISTRIBUTOR
• 55. Removal
• 56. Installation
• 57. OIL PUMP
• 58. Removal
• 59. Repairs
• 60. Installation
• 61. GOVERNOR
• 62. Description
• 63. Removal
• 64. Disassembly
• 65. Assembly
• 66. Installation
• 67. COOLANT PUMP
• 68. Removal
• 69. Disassembly and Repair
• 70. Assembly
• 71. Installation
• 72. FLYWHEEL
• 73. Repairs
• 74. Installation
• 75. CHECKS AND ADJUSTMENTS
• 76. ADJUST THE VALVES
• 77. ADJUST THE THROTTLE LINKAGE
• 78. ENGINE SPECIFICATIONS
• 79. ENGINE SPECIFICATIONS
• 80. Engine Data
• 81. Cooling System
• 82. Cylinder Head and Valve Mechanism
• 83. Camshaft
• 84. Timing Gear
• 85. Camshaft
• 86. Connecting Rods
• 87. Cylinder Liners
• 88. Pistons
• 89. Lubrication System
• 90. Fuel Pump
• 91. TORQUE SPECIFICATIONS
• 92. TROUBLESHOOTING
• 93. INTRODUCTION
• 94. GENERAL
• 95. DESCRIPTION
• 96. FUEL SYSTEM
• 97. Description
• 98. Operation, Fuel Injection Pump, Model VE
• 99. Operation, Fuel Injection Pump, Model PE4A
• 100. Pneumatic Governor For Fuel Injection Pump, Model PE4A
• 101. Inlet Manifold For Fuel Injection Pump, Model PE4A
• 102. REPAIRS
• 103. FUEL INJECTION PUMP (ALL MODELS)
• 104. Removal
• 105. Installation
• 106. REMOVAL AND INSTALLATION OF THE ENGINE
• 107. CYLINDER HEAD AND VALVE MECHANISM
• 108. Cylinder Head, Removal
• 109. Valve Guides, Replacement
• 110. Cylinder Head, Inspection And Repair
• 111. Combustion Chamber Plugs, Inspection And Repair
• 112. Combustion Chamber Plugs, Installation
• 113. Valves, Inspection And Repair
• 114. Valve Seat, Inspection
• 115. Valve Seat, Removal
• 116. Valve Seat, Installation
• 117. Valve Spring, Inspection
• 118. Rocker Arms, Inspection And Assembly
• 119. Installation Of The Cylinder Head
• 120. TIMING GEAR CASE
• 121. Removal
• 122. Installation
• 123. CAMSHAFT
• 124. Removal
• 125. Inspection
• 126. Camshaft Bearings
• 127. Cam Followers
• 128. CAMSHAFT, INSTALLATION
• 129. CRANKSHAFT AND MAIN BEARINGS
• 130. Crankshaft, Removal
• 131. Crankshaft, Inspection And Repair
• 132. Main Bearings
• 133. Pilot Bearing
• 134. Crankshaft, Installation
• 135. FLYWHEEL AND RING GEAR, H2.003.20XM (H4065XM)
• 136. Flywheel, Removal
• 137. Ring Gear, Replacement
• 138. Flywheel, Installation
• 139. PISTONS AND CONNECTING RODS
• 140. Pistons And Connecting Rods, Removal
• 141. Disassembly
• 142. Pistons, Inspection And Repair
• 143. Piston Rings, Inspection And Repair
• 144. Piston Pins, Inspection And Repair
• 145. Connecting Rods, Inspection And Repair
• 146. Pistons And Connecting Rods, Assembly And Installation
• 147. CYLINDER BLOCK AND CYLINDER LINERS
• 148. Cylinder Liners, Inspection
• 149. Replacement Of A Cylinder Liner
• 150. LUBRICATION SYSTEM
• 151. Oil Pump, Removal And Disassembly
• 152. Oil Pump, Inspection
• 153. Oil Pump, Assembly And Installation
• 154. Oil Filter
• 155. COOLING SYSTEM
• 156. Coolant Pump, Removal
• 157. Coolant Pump, Disassembly
• 158. Coolant Pump, Assembly And Installation
• 159. Thermostat, Replacement
• 160. CHECKS AND ADJUSTMENTS
• 161. VALVE CLEARANCE ADJUSTMENT
• 162. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE
• 163. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A
• 164. FUEL INJECTORS
• 165. Fuel Injectors, Removal
• 166. Fuel Injectors, Inspection
• 167. Fuel Injectors, Installation
• 168. DIESEL FUEL FILTERS
• 169. Filter Replacement, Models With A Water Separator
• 170. Filter Replacement, Models Without A Water Separator
• 171. Filter For The Fuel Injection Pump, Model PE4A
• 172. REMOVE AIR FROM THE FUEL SYSTEM
• 173. Throttle Linkage, Adjustment
• 174. Idle Speed, Adjustment
• 175. Check The Elements For The Cold Start Aid System
• 176. ENGINE SPECIFICATIONS
• 177. TORQUE SPECIFICATIONS
• 178. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
• 179. GENERAL
• 180. DESCRIPTION
• 181. Fuel Tank
• 182. Fuel Filter And Fuel Valve Unit
• 183. Vaporizer
• 184. The IMPCO CA 100 Carbureto
• 185. IMPCO CA 50 Carburetor
• 186. The Governor (GM Engines Only)
• 187. Governor With Electronic Controller
• 188. REPAIRS
• 189. LPG TANK
• 190. Removal
• 191. Installation
• 192. REPLACE THE HOSES
• 193. HYDROSTATIC RELIEF VALVE
• 194. Removal and Installation
• 195. FILTER UNIT
• 196. Replacement Of the Fuel Filter Element
• 197. Replacement of the Diaphragm and Fuel Valve
• 198. VAPORIZER
• 199. Removal
• 200. Disassembly
• 201. Cleaning
• 202. Inspection
• 203. Assembly
• 204. Installation
• 205. CARBURETOR (IMPCO CA 100)
• 206. Removal
• 207. Disassembly
• 208. Cleaning
• 209. Assembly
• 210. Installation
• 211. CARBURETER (IMPCO CA 50)
• 212. Removal
• 213. Disassembly
• 214. Cleaning
• 215. Inspection
• 216. Assembly (See FIGURE 26.)
• 217. Installation
• 218. CHECKS AND ADJUSTMENTS
• 219. CHECK THE FILTER UNIT
• 220. CHECK THE VAPORIZER
• 221. Pressure Reducer Valve
• 222. Vapor Valve
• 223. ADJUST THE CARBURETOR
• 224. Idle Mixture
• 225. Idle Speed
• 226. Power Mixture
• 227. ADJUST THE GOVERNOR (GM Engines Only)
• 228. Main Adjusting Screw
• 229. Secondary Adjusting Screw
• 230. AISAN Governor
• 231. Adjustment, AISAN Governor
• 232. TROUBLESHOOTING
• 233. INTRODUCTION
• 234. GENERAL
• 235. DESCRIPTION
• 236. REPAIRS
• 237. COUNTERWEIGHT
• 238. Removal
• 239. Installation
• 240. OVERHEAD GUARD
• 241. Removal
• 242. Installation
• 243. OPERATOR RESTRAINT SYSTEM
• 244. Removal
• 245. Installation (Engine Only)
• 246. Installation (Engine and Transmission)
• 247. RADIATOR AND MUFFLER
• 248. Removal and Installation
• 249. FUEL AND HYDRAULIC TANKS
• 250. Inspection
• 251. Repairs
• 252. LABEL REPLACEMENT
• 253. INTRODUCTION
• 254. General
• 255. DESCRIPTION AND OPERATION
• 256. General
• 257. Torque Converter
• 258. Description
• 259. Operation
• 260. Clutch Assemblies
• 261. Description
• 262. Operation
• 263. Hydraulic System
• 264. General
• 265. Oil Pump and Front Cover
• 266. Torque Converter Regulator
• 267. Oil Cooler By-Pass
• 268. Control Valve
• 269. General
• 270. Differential
• 271. Oil Flow Diagrams
• 272. Neutral
• 273. Forward
• 274. Forward-Inching
• 275. Reverse
• 276. INTRODUCTION
• 277. DESCRIPTION
• 278. GENERAL
• 279. REPAIRS
• 280. STEERING AXLE
• 281. Removal
• 282. Installation
• 283. STEERING CYLINDER
• 284. Removal
• 285. Service
• 286. Installation
• 287. Removal
• 288. Installation
• 289. SPINDLES
• 290. Removal
• 291. Installation
• 292. CHECKS AND ADJUSTMENTS
• 293. REMOVE THE AIR FROM THE STEERING SYSTEM
• 294. SET THE PRESSURE RELIEF VALVE
• 295. S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)
• 296. H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION
• 297. H2.00-3.00J (H40-60J) With Powershift Transmission
• 298. TROUBLESHOOTING
• 299. INTRODUCTION
• 300. GENERAL
• 301. DESCRIPTION
• 302. OPERATION
• 303. REPAIRS
• 304. STEERING WHEEL AND COLUMN ASSEMBLY
• 305. TYPE A STEERING COLUMN ASSEMBLY
• 306. Removal And Disassembly
• 307. Assembly And Installation
• 308. TYPE A STEERING COLUMN
• 309. TYPE A STEERING COLUMN
• 310. TYPE B STEERING COLUMN
• 311. Removal And Disassembly
• 312. Assembly And Installation
• 313. TYPE B STEERING COLUMN
• 314. Disassembly of Steering Control Unit
• 315. Cleaning of Steering Control Unit
• 316. Assembly of Steering Control Unit
• 317. CHECKS AND ADJUSTMENTS
• 318. REMOVE AIR FROM THE SYSTEM
• 319. TROUBLESHOOTING
• 320. INTRODUCTION
• 321. GENERAL
• 322. DESCRIPTION
• 323. OPERATION
• 324. Lift Section
• 325. Tilt Section
• 326. Relief Valve
• 327. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 328. Operation
• 329. REPAIRS
• 330. MAIN CONTROL VALVE
• 331. Removal and Disassembly
• 332. Cleaning and Inspection
• 333. Assembly
• 334. Installation
• 335. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 336. Removal and Disassembly
• 337. Assembly and Installation
• 338. CHECKS AND ADJUSTMENTS
• 339. PRESSURE RELIEF VALVES
• 340. Primary Relief Valve
• 341. Seconday Relief Valve
• 342. CONTROL LEVER ARRANGEMENT
• 343. TROUBLESHOOTING
• 344. SPECIFICATIONS
• 345. COOLING SYSTEM
• 346. INTRODUCTION
• 347. DESCRIPTION
• 348. RADIATOR
• 349. RADIATOR CAP
• 350. THERMOSTAT
• 351. WATER PUMP
• 352. FAN AND FAN SHROUD
• 353. REPAIRS
• 354. COOLING SYSTEM CHECKS
• 355. Exhaust Leaks
• 356. RADIATOR
• 357. Cleaning The Radiator
• 358. Drain The Cooling System
• 359. Fill The Cooling System
• 360. WATER PUMP
• 361. THERMOSTAT
• 362. FAN AND FAN SHROUD
• 363. TROUBLESHOOTING
• 364. THE CARBURETOR, (MAZDA M4-121G ENGINE)
• 365. DESCRIPTION
• 366. REPAIRS, CARBURETOR
• 367. Removal
• 368. Cleaning
• 369. Inspection
• 370. Assembly
• 371. Installation
• 372. CHECKS AND ADJUSTMENTS
• 373. Carburetor, Idle Speed And Mixture Adjustment
• 374. Adjust The Governor
• 375. ADJUST THE THROTTLE LINKAGE
• 376. SPECIFICATIONS
• 377. TROUBLESHOOTING
• 378.
• 378.1. INTRODUCTION
• 378.2. DESCRIPTION AND OPERATION
• 379.
• 379.1. INTRODUCTION
• 379.2. REPAIRS
• 379.3. CHECKS AND ADJUSTMENTS
• 379.4. TROUBLESHOOTING
• 379.5. TROUBLESHOOTING, PRESSURE TESTS
• 380.
• 380.1. INTRODUCTION
• 380.2. REPAIRS
• 380.3. TROUBLESHOOTING
• 381.
• 381.1. INTRODUCTION
• 381.2. REPAIRS
• 381.3. CHECKS AND ADJUSTMENTS
• 381.4. TROUBLESHOOTING
• 382.
• 382.1. INTRODUCTION
• 382.2. CHECKS AND ADJUSTMENTS
• 382.3. TROUBLESHOOTING
• 383.
• 383.1. INTRODUCTION
• 383.2. REPAIRS
• 383.3. CHECKS AND ADJUSTMENTS
• 383.4. TROUBLESHOOTING
• 384.
• 384.1. INTRODUCTION
• 384.2. CHECKS AND ADJUSTMENTS
• 384.3. TROBLESHOOTING
• 385.
• 385.1. INTRODUCTION
• 385.2. REPAIRS
• 385.3. TROUBLESHOOTING
• 386.
• 386.1. INTRODUCTION
• 386.2. DESCRIPTION
• 386.3. CHECKS AND ADJUSTMENTS
• 386.4. REPLACEMENT
• 386.5. SPECIFICATIONS
• 386.6. TROUBLESHOOTING
• 387.
• 387.1. ELECTRICAL WARNING DEVICES
• 388.
• 388.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 388.2. LIFT CYLINDERS
• 388.3. REPAIRS
• 388.4. LIFT CYLINDERS FOR VISTA MASTS
• 388.5. CHECKS AND ADJUSTMENTS
• 388.6. TROUBLESHOOTING
• 388.7. SPECIFICATIONS
• 389.
• 389.1. INTRODUCTION
• 389.2. VISTA TWO-STAGE MAST
• 389.3. VISTA FREE-LIFT MAST
• 389.4. VISTA THREE-STAGE MAST
• 389.5. VISTA FOUR-STAGE MAST
• 390.
• 390.1. VISTA MAST, REPAIR
• 390.2. CHECKS AND ADJUSTMENTS
• 390.3. TROUBLESHOOTING
• 391.
• 392.
• 392.1. INTRODUCTION
• 392.2. TABLE 1. BOLTS AND SCREWS
• 392.3. TABLE 2. STUDS AND NUTS
• 392.4. TABLE 3. TORQUE NUTS
• 392.5. TABLE 4. TORQUE NUTS WITH NYLON INSERT
• 392.6. TABLE 5. TORQUE VALUES FOR INCH FASTENERS
• 392.7. TABLE 6. TORQUE VALUES FOR METRIC FASTENERS
• 393.
• 393.1. PERIODIC MAINTENANCE