Hyster C007 (H150-275HP150-200B) Service Manual

Description

• Model List:
  • C007 (H150-275HP150-200B)

• 1. INTRODUCTION
• 2. GENERAL
• 3. DESCRIPTION
• 4. CYLINDER HEAD AND VALVE MECHANISM
• 5. CYLINDER HEAD
• 6. Removal
• 7. Repairs
• 8. Installation
• 9. VALVE MECHANISM
• 10. Repairs
• 11. LUBRICATION SYSTEM
• 12. OIL PUMP
• 13. Removal And Disassembly
• 14. Repairs
• 15. Assembly And Installation
• 16. Relief Valve For The Oil Pressure
• 17. Oil Cooler (T6.3544 Engine Only)
• 18. Cooling Jets For The Pistons
• 19. TIMING GEARS AND CAMSHAFT
• 20. TIMING GEAR CASE
• 21. Removal
• 22. Installation
• 23. Idler Gears And Hubs Removal
• 24. Camshaft And Cam Followers
• 25. Auxiliary Drive Shaft And The Drive Shaft For The Fuel Injection Pump
• 26. CRANKSHAFT
• 27. REMOVAL
• 28. INSTALLATION
• 29. PISTONS AND PISTON RODS
• 30. REMOVAL
• 31. DISASSEMBLY
• 32. REPAIRS
• 33. ASSEMBLY
• 34. INSTALLATION
• 35. CYLINDER LINERS
• 36. REMOVAL AND INSTALLATION
• 37. FLYWHEEL AND FLYWHEEL HOUSING
• 38. REPAIRS
• 39. INSTALLATION
• 40. TURBOCHARGER
• 41. REMOVAL
• 42. DISASSEMBLY
• 43. INSPECTION
• 44. ASSEMBLY
• 45. INSTALLATION
• 46. FUEL SYSTEM
• 47. FUEL PUMP
• 48. Removal
• 49. Disassembly
• 50. Assembly
• 51. Installation
• 52. FUEL INJECTION PUMP
• 53. Removal
• 54. Repairs
• 55. Installation
• 56. FUEL INJECTORS
• 57. Removal
• 58. Repairs
• 59. Installation
• 60. COLD START AID
• 61. Description
• 62. Removal
• 63. Installation
• 64. COOLING SYSTEM
• 65. THERMOSTATS
• 66. Removal
• 67. Installation
• 68. WATER PUMP
• 69. Removal
• 70. Disassembly
• 71. Assembly
• 72. Installation
• 73. CHECKS AND ADJUSTMENTS
• 74. REMOVING AIR FROM FUEL SYSTEM
• 75. Fuel Injection Pump
• 76. Checking The Timing Angle For The Fuel Injection Pump (Using The Timing Tool)
• 77. VALVE CLEARANCE ADJUSTMENT
• 78. ADJUSTING THE THROTTLE LINKAGE
• 79. CHECKING THE FUEL INJECTORS
• 80. TROUBLESHOOTING
• 81. SPECIFICATIONS
• 82. TORQUE SPECIFICATIONS
• 83. INTRODUCTION
• 84. GENERAL
• 85. DESCRIPTION
• 86. CARBURETOR
• 87. GOVERNOR
• 88. REPAIRS
• 89. CARBURETOR
• 90. REMOVAL AND DISASSEMBLY
• 91. CLEANING
• 92. ASSEMBLY
• 93. INSTALLATION
• 94. GOVENOR
• 95. CHECKS AND ADJUSTMENTS
• 96. ADJUSTING THE CARBURETOR
• 97. ADJUSTING THE GOVERNOR
• 98. ADJUSTING THE THROTTLE LINKAGE
• 99. TROUBLESHOOTING
• 100. INTRODUCTION
• 101. GENERAL
• 102. DESCRIPTION
• 103. PROCEDURES FOR LPG FUEL TANKS
• 104. Installation
• 105. HYDROSTATIC RELIEF VALVE
• 106. Removal and Installation
• 107. CARBURETOR
• 108. Removal and Dissembly
• 109. Cleaning
• 110. Assembly and Installation
• 111. GOVERNOR
• 112. FUEL FILTER AND SHUT-OFF VALVE
• 113. Replace The Filter Element
• 114. Install A New Diaphragm and Fuel Valve
• 115. Check The Filter Unit
• 116. VAPORIZER
• 117. Description
• 118. Removal
• 119. Disassembly
• 120. Cleaning
• 121. Inspection
• 122. Assembly
• 123. Installation
• 124. Check The Pressure Reducer Valve
• 125. Check The Vapor Valve
• 126. INSTALLATION OF NEW HOSES
• 127. CHECKS AND ADJUSTMENTS
• 128. CHECK THE FILTER AND SHUT-OFF VALVE
• 129. CHECK THE VAPORIZER/REGULATOR
• 130. Pressure Reducer Valve
• 131. Check the Low Pressure Valve
• 132. Check the Low Pressure Diaphragm
• 133. ADJUST THE CARBURETOR
• 134. Idle Mixture
• 135. Idle Speed
• 136. Power Mixture
• 137. ADJUST THE GOVERNOR
• 138. ADJUST THE THROTTLE LINKAGE
• 139. TROUBLESHOOTING
• 140. INTRODUCTION
• 141. General
• 142. Description
• 143. Fuel Tank
• 144. Hydraulic tank
• 145. REPAIRS
• 146. Counterweight
• 147. Removal
• 148. Installation
• 149. Fenders
• 150. Removal
• 151. Installation
• 152. Removal
• 153. Installation
• 154. Hydraulic Tank
• 155. Removal
• 156. Service Procedures
• 157. Installation
• 158. Fuel Tank
• 159. Removal
• 160. Service Procedures
• 161. Installation
• 162. Housing (Steering Control Unit)
• 163. Removal
• 164. Installation
• 165. Painting Instructions
• 166. Decal Installation
• 167. INTRODUCTION
• 168. GENERAL
• 169. DESCRIPTION
• 170. Oil Clutch
• 171. Jet Pump
• 172. REPAIRS
• 173. OIL CLUTCH ASSEMBLY
• 174. Removal And Disassembly
• 175. Cleaning
• 176. Inspection
• 177. Assembly And Installation
• 178. JET PUMP
• 179. Removal And Disassembly
• 180. CLEANING
• 181. Assembly And Installation
• 182. CHECKS AND ADJUSTMENTS
• 183. ADJUSTING THE LINKAGE FOR THE CLUTCH PEDAL
• 184. CHECKING THE ALIGNMENT OF THE CLUTCH DISC
• 185. TROUBLESHOOTING
• 186. INTRODUCTION
• 187. MECHANICAL SECTION
• 188. TORQUE CONVERTER
• 189. FORWARD-REVERSE SECTION
• 190. PLANETARY GEARS HOW THEY WORK
• 191. WHEN THE SUN GEAR IS DRIVEN
• 192. WHEN PLANET PINION CARRIER IS DRIVEN
• 193. DOUBLE PLANET PINION SET
• 194. REVERSE
• 195. FORWARD
• 196. RANGE SECTION
• 197. HYDRAULIC SYSTEM
• 198. INTRODUCTION TO HYDRAULIC SYSTEM
• 199. PUMP AND SUMP
• 200. OIL FILTER
• 201. MONOTROL ASSEMBLY
• 202. OIL COOLERS
• 203. CONTROL VALVE ASSEMBLY
• 204. RANGE SPOOL
• 205. INCHING VALVE
• 206. DIRECTIONAL SPOOL
• 207. PRESSURE REGULATORS
• 208. CUSHION VALVE
• 209. SCHEMATIC AND FLOW DIAGRAMS
• 210. NEUTRAL-REVERSE
• 211. DRIVE-HIGH-REVERSE
• 212. DRIVE-MEDIUM-FORWARD
• 213. INCHING-LOW-FORWARD
• 214. INTRODUCTION
• 215. General
• 216. Description
• 217. REPAIRS
• 218. Removal
• 219. Disassembly
• 220. Cleaning
• 221. Installation
• 222. CHECKS AND ADJUSTMENTS
• 223. Forward/Reverse Linkage
• 224. TROUBLESHOOTING
• 225. INTRODUCTION
• 226. GENERAL
• 227. DESCRIPTION
• 228. REPAIRS
• 229. REMOVAL
• 230. DISASSEMBLY
• 231. CLEANING
• 232. ASSEMBLY AND INSTALLATION
• 233. TROUBLESHOOTING
• 234. INTRODUCTION
• 235. GENERAL
• 236. DESCRIPTION
• 237. REPAIRS
• 238. DISASSEMBLY
• 239. CLEANING
• 240. ASSEMBLY
• 241. TROUBLESHOOTING
• 242. INTRODUCTION
• 243. GENERAL
• 244. DESCRIPTION
• 245. OPERATION
• 246. REPAIRS
• 247. STEERING WHEEL AND COLUMN ASSEMBLY
• 248. TYPE A STEERING COLUMN ASSEMBLY
• 249. Removal And Disassembly
• 250. Assembly And Installation
• 251. TYPE A STEERING COLUMN
• 252. TYPE A STEERING COLUMN
• 253. TYPE B STEERING COLUMN
• 254. Removal And Disassembly
• 255. Assembly And Installation
• 256. TYPE B STEERING COLUMN
• 257. Disassembly of Steering Control Unit
• 258. Cleaning of Steering Control Unit
• 259. Assembly of Steering Control Unit
• 260. CHECKS AND ADJUSTMENTS
• 261. REMOVE AIR FROM THE SYSTEM
• 262. TROUBLESHOOTING
• 263. INTRODUCTION
• 264. GENERAL
• 265. DESCRIPTION
• 266. REPAIRS
• 267. STEERING AXLE
• 268. Removal
• 269. Installation
• 270. STEERING CYLINDER
• 271. Removal
• 272. Inspection
• 273. Assembly
• 274. Installation
• 275. HUBS, H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B (P150-200B)
• 276. Removal
• 277. Installation
• 278. 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
• 279. Removal
• 280. Installation
• 281. SPINDLES
• 282. Removal
• 283. Installation
• 284. CHECKS AND ADJUSTMENTS
• 285. REMOVE THE AIR FROM THE STEERING SYSTEM
• 286. ADJUST THE CYLINDER STOPS
• 287. INTRODUCTION
• 288. GENERAL
• 289. DESCRIPTION
• 290. CONTROL VALVE OPERATION
• 291. REPAIRS
• 292. BRAKE SHOE ASSEMBLIES
• 293. Removal
• 294. Cleaning
• 295. Inspection
• 296. Installation
• 297. AIR CHAMBER
• 298. Removal and Disassembly
• 299. Assembly and Installation
• 300. CONTROL VALVE
• 301. Removal
• 302. Disassembly
• 303. Assembly
• 304. Installation
• 305. AIR TANK
• 306. CHECKS AND ADJUSTMENTS
• 307. ADJUSTING THE BRAKES
• 308. RELIEF VALVE
• 309. TROUBLESHOOTING
• 310. INTRODUCTION
• 311. General
• 312. Description
• 313. Brake Valve
• 314. Service Brake Assembly
• 315. REPAIRS
• 316. Brake Shoe Assemblies
• 317. Removal
• 318. Cleaning
• 319. Assembly
• 320. Brake Valve Assemblies
• 321. Master Cylinder
• 322. Removal
• 323. Disassembly
• 324. Assembly
• 325. Relief Valve Assembly
• 326. Disassembly
• 327. Assembly
• 328. Actuator
• 329. Disassembly
• 330. Assembly
• 331. CHECKS AND ADJUSTMENTS
• 332. Adjust the Brake Shoes
• 333. Adjust the Brake Pedal
• 334. Remove Air from the Brake System
• 335. Adjust the Relief Valve In The Actuator
• 336. SPECIFICATIONS
• 337. TROUBLESHOOTING
• 338. INTRODUCTION
• 339. DESCRIPTION
• 340. OPERATION
• 341. Flow Control Valve
• 342. Relief Valve
• 343. REPAIRS
• 344. REMOVAL
• 345. DISASSEMBLY
• 346. CLEANING
• 347. INSPECTION
• 348. ASSEMBLY
• 349. INSTALLATION
• 350. CHECKS AND ADUSTMENTS
• 351. CHECK THE OUTPUT OF THE PUMP
• 352. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
• 353. TROUBLESHOOTING
• 354. INTRODUCTION
• 355. GENERAL
• 356. DESCRIPTION
• 357. OPERATION
• 358. LIFTING, NO LOAD OR LIGHT LOAD
• 359. LIFTING, CAPACITY LOAD
• 360. LOWERING
• 361. TILTING
• 362. RELIEF VALVE
• 363. BY-PASS FITTING
• 364. FLOW CONTROL FITTING
• 365. REPAIRS
• 366. REMOVAL AND DISASSEMBLY
• 367. CLEANING
• 368. ASSEMBLY
• 369. INSTALLATION
• 370. CHECKS AND ADJUSTMENTS
• 371. ADJUSTING THE PRESSURE OF THE RELIEF VALVE
• 372. SETTINGS FOR THE PRESSURE OF THE RELIEF VALVE
• 373. CHECKING AND ADJUSTING THE PRESSURE OF THE TWO SPEED VALVE
• 374. TROUBLESHOOTING
• 375. GM 4.3 LITRE V-6 AND 5.7 LITRE V-8 ENGINES
• 376. DESCRIPTION
• 377. ENGINE, REMOVAL AND INSTALLATION
• 378. CYLINDER HEAD
• 379. Removal And Disassembly
• 380. Cleaning And Inspection
• 381. Repairs, Valve Guides and Seats
• 382. Studs For The Rocker Arms
• 383. Valve Springs
• 384. ASSEMBLY AND INSTALLATION
• 385. CYLINDER BLOCK, CLEANING AND INSPECTION
• 386. PISTON BORE PREPARTION
• 387. ENGINE MOUNTS
• 388. LUBRICATION SYSTEM
• 389. Oil Pump, Removal and Disassembly
• 390. Cleaning and Inspection
• 391. Oil Pump, Assembly and Installation
• 392. TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS
• 393. Timing Cover, Removal
• 394. Installation
• 395. Timing Sprockets, Removal
• 396. Timing Sprockets, Installation
• 397. Camshaft, Removal
• 398. Camshaft, Inspection
• 399. Camshaft, Installation
• 400. Hydraulic Valve Lifters, Removal
• 401. Hydraulic Valve Lifters, Disassembly
• 402. Hydraulic Valve Lifters, Cleaning And Inspection
• 403. Hydraulic Valve Lifters, Assembly
• 404. CRANKSHAFT
• 405. Removal
• 406. Inspection and Repair
• 407. How To Check The Clearance Between The Main Bearings And Their Journals
• 408. Installation
• 409. PISTON AND CONNECTING ROD ASSEMBLIES
• 410. Connecting Rod Bearings, Replacement
• 411. Piston And Connecting Rod Assemblies, Removal
• 412. Disassembly
• 413. Piston, Cleaning And Inspection
• 414. Cylinder Bores, Inspection And Repair
• 415. Piston Rings
• 416. Assembly
• 417. Piston And Connecting Rod Assemblies, Installation
• 418. FLYWHEEL AND FLYWEEL HOUSING
• 419. Flywheel Repair For V-6 Engines
• 420. Flywheel For V-6 Engines, Installation
• 421. Flywheel Housing, H3.5-5.00XL (H70-110XL)
• 422. Engine Adapter, H6.00-7.00XL (H135-155XL)
• 423. Ring Gear Replacement (Flywheel) For V-8 Engines
• 424. Flywheel For V-8 Engines, Flywheel Housing
• 425. COOLANT PUMP
• 426. FAN MOUNT
• 427. CHECKS AND ADJUSTEMENTS
• 428. Valve Clearance Adjustment
• 429. ENGINE SPECIFICATIONS
• 430. ENGINE SPECIFICATIONS
• 431. Engine Data
• 432. Cylinder head
• 433. Hydraulic Valve Lifter
• 434. Camshaft
• 435. Pistons
• 436. Crankshaft
• 437. Connecting Rods
• 438. Cooling System
• 439. Lubrication System
• 440. TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS
• 441. TROUBLESHOOTING
• 442. WEBER CARBURETOR WITH GOVERNOR
• 443. GENERAL
• 444. DESCRIPTION
• 445. Carburetor
• 446. Governor
• 447. OPERATION
• 448. Carburetor, Float System
• 449. Carburetor, Idle System
• 450. Carburetor, Main Metering System
• 451. Carburetor, Power System
• 452. Carburetor, Accelerator Pump System
• 453. Carburetor, Choke System
• 454. GOVERNOR
• 455. REPAIRS
• 456. CARBURETOR
• 457. Removal
• 458. Disassembly
• 459. Cleaning
• 460. Assembly
• 461. Installation
• 462. GOVERNOR
• 463. CHECKS AND ADJUSTMENTS
• 464. GENERAL
• 465. CHOKE SYSTEM
• 466. ELECTRIC CHOKE
• 467. IDLE MIXTURE ADJUSTMENT
• 468. IDLE SPEED ADJUSTMENT