Hyster F003 (H2.00-3.00JS) Service Manual

Description

• Model List:
  • F003 (H2.00-3.00JS)

• 1. INTRODUCTION
• 2. GENERAL
• 3. DESCRIPTION
• 4. REMOVAL AND INSTALLATION OF THE ENGINE
• 5. CYLINDER HEAD AND MECHANISM
• 6. Cylinder Head, Removal
• 7. Cylinder Head, Disassembly
• 8. Cleaning And Inspection
• 9. Valve And Valve Seats
• 10. Studs For The Rocker Arms
• 11. Hydraulic Valve Lifters, Replacement
• 12. Hydraulic Valve Lifters, Cleaning And Inspection
• 13. Cylinder Head, Assembly
• 14. Cylinder Head, Installation
• 15. Rocker Arm Cover, Installation
• 16. TIMING GEAR COVER
• 17. Removal
• 18. Installation
• 19. CAMSHAFT
• 20. Removal
• 21. Inspection
• 22. Camshaft Bearings, Removal
• 23. Camshaft Bearings, Installation
• 24. DISTRIBUTOR
• 25. Removal
• 26. Installation
• 27. LUBRICATION SYSTEM
• 28. Oil Sump, Removal
• 29. Oil Sump, Installation
• 30. Oil Pump, Removal
• 31. Oil Pump, Disassembly and Repair
• 32. Oil Pump, Assembly
• 33. Oil Pump, Installation
• 34. PISTON AND CONNECTING ROD ASSEMBLIES
• 35. Connecting Rod Bearings, Replacement
• 36. Piston And Connecting Rod Assemblies, Removal
• 37. Disassembly
• 38. Piston, Cleaning And Inspection
• 39. Cylinder Bores, Inspection And Repair
• 40. Piston Rings
• 41. Assembly
• 42. Piston And Connecting Rod Assemblies, Installation
• 43. CRANKSHAFT
• 44. Main Bearings, Replacement
• 45. Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only)
• 46. Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal)
• 47. Crankshaft, Removal
• 48. Inspection and Repair
• 49. How To Check The Clearance Between The Main Bearings And Their Journals
• 50. Installation
• 51. FLYWHEEL AND FLYWHEEL HOUSING
• 52. Flywheel, Removal
• 53. Ring Gear, Replacement
• 54. Flywheel, Installation
• 55. COOLING SYSTEM
• 56. Coolant Pump
• 57. Fan Drive
• 58. Viscous Fan Drive
• 59. ENGINE SPECIFICATIONS
• 60. ENGINE DATA
• 61. CYLINDER HEAD
• 62. HYDRAULIC VALVE LIFTER
• 63. CAMSHAFT
• 64. PISTONS
• 65. CYLINDER BORE
• 66. CRANKSHAFT
• 67. CONNECTING RODS
• 68. COOLING SYSTEM
• 69. LUBRICATION SYSTEM
• 70. TORQUE SPECIFICATIONS
• 71. INTRODUCTION
• 72. GENERAL
• 73. DESCRIPTION
• 74. REPAIRS
• 75. GENERAL
• 76. REMOVAL AND DISASSEMBLY (Type A)
• 77. CLEANING
• 78. ASSEMBLY (Type A)
• 79. REMOVAL AND DISAASSEMBLY (Type B)
• 80. CLEANING
• 81. ASSEMBLY (Type B)
• 82. INSTALLATION (Type A and Type B)
• 83. CHECKS AND ADJUSTMENTS
• 84. GENERAL
• 85. CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)
• 86. CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)
• 87. CHECK THE CIRCUIT FOR THE BRUSHES
• 88. Delco Alternators
• 89. Motorola Alternators
• 90. CHECK THE DIODES
• 91. CHECK THE DIODE BRIDGE
• 92. Delco and LeeceNeville Alternators
• 93. Motorola Alternators
• 94. CHECK THE FIELD WINDING FOR THE ROTOR
• 95. CHECK THE WINDINGS IN THE STATOR
• 96. CHECK THE VOLTAGE REGULATOR
• 97. TROUBLESHOOTING
• 98. INTRODUCTION
• 99. GENERAL
• 100. DESCRIPTION
• 101. OPERATION
• 102. The Float System
• 103. The Idle System
• 104. The Main Metering System (GM 6-250)
• 105. The Power System (GM 6-250)
• 106. The Accelerator Pump System
• 107. Choke System
• 108. REPAIRS
• 109. REMOVAL
• 110. DISASSEMBLY
• 111. Cleaning
• 112. ASSEMBLY
• 113. INSTALLATION
• 114. GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)
• 115. GOVERNOR (PNEUMATIC) (Early Units)
• 116. CHECKS AND ADJUSTMENTS
• 117. GENERAL
• 118. ADJUST THE CHOKE CONTROL
• 119. ADJUST THE IDLE SPEED
• 120. ADJSUT THE IDLE MIXTURE
• 121. ADJUST THE FAST IDLE
• 122. ADJUST THE THROTTLE LINKAGE,(Later Models)
• 123. ADJUST THE THROTTLE LINKAGE,(Early Models)
• 124. GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)
• 125. Check the Governor
• 126. GOVERNOR (AISAN Type) (Early GM Engines Only)
• 127. Adjustments
• 128. GOVERNOR (HOOF Type) (Early GM Engines Only)
• 129. Adjust the Governor
• 130. TROUBLESHOOTING
• 131. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
• 132. GENERAL
• 133. DESCRIPTION
• 134. Fuel Tank
• 135. Fuel Filter And Fuel Valve Unit
• 136. Vaporizer
• 137. The IMPCO CA 100 Carbureto
• 138. IMPCO CA 50 Carburetor
• 139. The Governor (GM Engines Only)
• 140. Governor With Electronic Controller
• 141. REPAIRS
• 142. LPG TANK
• 143. Removal
• 144. Installation
• 145. REPLACE THE HOSES
• 146. HYDROSTATIC RELIEF VALVE
• 147. Removal and Installation
• 148. FILTER UNIT
• 149. Replacement Of the Fuel Filter Element
• 150. Replacement of the Diaphragm and Fuel Valve
• 151. VAPORIZER
• 152. Removal
• 153. Disassembly
• 154. Cleaning
• 155. Inspection
• 156. Assembly
• 157. Installation
• 158. CARBURETOR (IMPCO CA 100)
• 159. Removal
• 160. Disassembly
• 161. Cleaning
• 162. Assembly
• 163. Installation
• 164. CARBURETER (IMPCO CA 50)
• 165. Removal
• 166. Disassembly
• 167. Cleaning
• 168. Inspection
• 169. Assembly (See FIGURE 26.)
• 170. Installation
• 171. CHECKS AND ADJUSTMENTS
• 172. CHECK THE FILTER UNIT
• 173. CHECK THE VAPORIZER
• 174. Pressure Reducer Valve
• 175. Vapor Valve
• 176. ADJUST THE CARBURETOR
• 177. Idle Mixture
• 178. Idle Speed
• 179. Power Mixture
• 180. ADJUST THE GOVERNOR (GM Engines Only)
• 181. Main Adjusting Screw
• 182. Secondary Adjusting Screw
• 183. AISAN Governor
• 184. Adjustment, AISAN Governor
• 185. TROUBLESHOOTING
• 186. INTRODUCTION
• 187. General
• 188. Description
• 189. DISASSEMBLY AND ASSEMBLY
• 190. Overhead Guard
• 191. Hood and Seat Removal
• 192. Counterweight
• 193. Engine and Transmission
• 194. REPAIRS
• 195. Fuel and Hydraulic Tanks
• 196. Decal Replacement
• 197. INTRODUCTION
• 198. GENERAL
• 199. DESCRIPTION AND OPERATION
• 200. REPAIRS
• 201. REMOVAL
• 202. INSPECTION
• 203. INSTALLATION
• 204. ADJUSTMENTS
• 205. ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL
• 206. ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS
• 207. TROUBLESHOOTING
• 208. INTRODUCTION
• 209. General
• 210. REPAIRS
• 211. REMOVAL
• 212. DISASSEMBLY
• 213. CLEANING
• 214. INSPECTION
• 215. ASSEMBLY
• 216. Assembling the Control Valve
• 217. Assembling the Differential
• 218. Assembling the Transmission
• 219. Installation
• 220. MONOTROL Pedal
• 221. CHECKS AND ADJUSTMENTS
• 222. Checking the MONOTROL Pedal for Leakage
• 223. MONOTROL Pedal
• 224. Stall Test
• 225. Checking the Oil Pressures
• 226. MONOTROL Pressure
• 227. Clutch Apply Pressure
• 228. Inching Spool Operation
• 229. Torque Converter and Oil Cooler Pressure
• 230. CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT
• 231. CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER
• 232. ADJUSTING THE OIL SUMP TUBE
• 233. TROUBLESHOOTING
• 234. Pressure Tests
• 235. Troubleshooting the Differential
• 236. INTRODUCTION
• 237. GENERAL
• 238. DESCRIPTION
• 239. REPAIRS
• 240. REMOVAL
• 241. DISASSEMBLY
• 242. CLEANING
• 243. INSPECTION
• 244. ASSEMBLY
• 245. INSTALLATION
• 246. TROUBLESHOOTING
• 247. SPECIFICATIONS
• 248. INTRODUCTION
• 249. GENERAL
• 250. DESCRIPTION
• 251. REPAIRS
• 252. DISASSEMBLY
• 253. CLEANING
• 254. ASSEMBLY
• 255. TROUBLESHOOTING
• 256. INTRODUCTION
• 257. DESCRIPTION
• 258. GENERAL
• 259. REPAIRS
• 260. STEERING AXLE
• 261. Removal
• 262. Installation
• 263. STEERING CYLINDER
• 264. Removal
• 265. Service
• 266. Installation
• 267. Removal
• 268. Installation
• 269. SPINDLES
• 270. Removal
• 271. Installation
• 272. CHECKS AND ADJUSTMENTS
• 273. REMOVE THE AIR FROM THE STEERING SYSTEM
• 274. SET THE PRESSURE RELIEF VALVE
• 275. S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)
• 276. H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION
• 277. H2.00-3.00J (H40-60J) With Powershift Transmission
• 278. TROUBLESHOOTING
• 279. INTRODUCTION
• 280. GENERAL
• 281. DESCRIPTION
• 282. OPERATION
• 283. REPAIRS
• 284. STEERING WHEEL AND COLUMN ASSEMBLY
• 285. TYPE A STEERING COLUMN ASSEMBLY
• 286. Removal And Disassembly
• 287. Assembly And Installation
• 288. TYPE A STEERING COLUMN
• 289. TYPE A STEERING COLUMN
• 290. TYPE B STEERING COLUMN
• 291. Removal And Disassembly
• 292. Assembly And Installation
• 293. TYPE B STEERING COLUMN
• 294. Disassembly of Steering Control Unit
• 295. Cleaning of Steering Control Unit
• 296. Assembly of Steering Control Unit
• 297. CHECKS AND ADJUSTMENTS
• 298. REMOVE AIR FROM THE SYSTEM
• 299. TROUBLESHOOTING
• 300. INTRODUCTION
• 301. GENERAL
• 302. DESCRIPTION
• 303. REPAIRS
• 304. REMOVAL AND DISASSEMBLY
• 305. CLEANING
• 306. ASSEMBLY
• 307. CHECKS AND ADJUSTMENTS
• 308. INTRODUCTION
• 309. GENERAL
• 310. DESCRIPTION AND OPERATION
• 311. REPAIRS
• 312. REMOVAL AND DISASSEMBLY
• 313. CLEANING
• 314. INSPECTION
• 315. ASSEMBLY
• 316. CHECKS AND ADJUSTMENTS
• 317. BRAKE SHOES
• 318. Parking Brake
• 319. Seat Actuated Park Brake, J4060AS
• 320. Removing The Air From The Brake System
• 321. TROUBLESHOOTING
• 322. INTRODUCTION
• 323. GENERAL
• 324. DESCRIPTION
• 325. REPAIRS
• 326. REMOVAL AND DISASSEMBLY
• 327. CLEANING
• 328. INSPECTION
• 329. ASSEMBLY AND INSTALLATION
• 330. TROUBLESHOOTING
• 331. GENERAL
• 332. INTRODUCTION
• 333. DESCRIPTION
• 334. OPERATION
• 335. Flow Control Valve
• 336. Relief Valve
• 337. REPAIRS
• 338. REMOVAL
• 339. DISASSEMBLY
• 340. CLEANING
• 341. INSPECTION
• 342. ASSEMBLY
• 343. INSTALLATION
• 344. CHECKS AND ADUSTMENTS
• 345. CHECK THE OUTPUT OF THE PUMP
• 346. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
• 347. TROUBLESHOOTING
• 348. INTRODUCTION
• 349. General
• 350. Description
• 351. Hydraulic Control Valve
• 352. REPAIRS
• 353. Disassembly
• 354. Cleaning
• 355. Inspection
• 356. Assembly
• 357. CHECKS AND ADJUSTMENT
• 358. Relief Valve
• 359. TROUBLESHOOTING
• 360. INTRODUCTION
• 361. General
• 362. Description
• 363. Removal
• 364. Installation
• 365. CYLINDER HEAD AND VALVE MECHANISM
• 366. Cylinder Head
• 367. Removal
• 368. Repairs
• 369. Installation
• 370. Valve Guides
• 371. Valve Mechanism
• 372. Valve Springs
• 373. Rocker Arm Assembly
• 374. LUBRICATION
• 375. Oil Pump
• 376. Removal and Disassembly
• 377. Repairs
• 378. Assembly and Installation
• 379. Relief Valve
• 380. TIMING GEAR CASE AND CAMSHAFT
• 381. Timing Gear Cover
• 382. Removal
• 383. Installation
• 384. Idle Gears
• 385. Removal
• 386. Installation
• 387. Camshaft Gear and Camshaft
• 388. Removal
• 389. Installation
• 390. Fuel Pump Gear
• 391. Removal
• 392. Installation
• 393. Timing Gear Case
• 394. Removal
• 395. Installation
• 396. CRANKSHAFT AND MAIN BEARINGS
• 397. Removal
• 398. Installation
• 399. PISTONS AND PISTON RODS
• 400. Removal
• 401. Disassembly
• 402. Repairs
• 403. Assembly
• 404. Installation
• 405. CYLINDER LINERS
• 406. Removal
• 407. Installation
• 408. FLYWHEEL AND FLYWHEEL HOUSING
• 409. Removal
• 410. Installation
• 411. FUEL PUMP
• 412. Removal
• 413. Installation
• 414. FUEL INJECTION PUMP
• 415. Removal
• 416. Installation
• 417. FUEL INJECTORS
• 418. Installation
• 419. COOLING SYSTEM
• 420. Thermostat
• 421. Removal
• 422. Installation
• 423. Water Pump
• 424. Removal
• 425. Assembly
• 426. CHECKS AND ADJUSTMENTS
• 427. Removing Air From The Fuel System
• 428. Fuel Injection Pump
• 429. Valve Clearance Adjustment
• 430. Adjusting The Throttle Linkage
• 431. TROUBLESHOOTING
• 432. SPECIFICATIONS
• 433. COOLING SYSTEM
• 434. INTRODUCTION
• 435. DESCRIPTION
• 436. RADIATOR
• 437. RADIATOR CAP
• 438. THERMOSTAT
• 439. WATER PUMP
• 440. FAN AND FAN SHROUD
• 441. REPAIRS
• 442. COOLING SYSTEM CHECKS
• 443. Exhaust Leaks
• 444. RADIATOR
• 445. Cleaning The Radiator
• 446. Drain The Cooling System
• 447. Fill The Cooling System
• 448. WATER PUMP
• 449. THERMOSTAT
• 450. FAN AND FAN SHROUD
• 451. TROUBLESHOOTING
• 452.
• 452.1. INTRODUCTION
• 452.2. REPAIRS
• 452.3. CHECKS AND ADJUSTMENTS
• 452.4. TROUBLESHOOTING
• 453.
• 453.1. INTRODUCTION
• 453.2. REPAIRS
• 453.3. CHECKS AND ADJUSTMENTS
• 453.4. TROUBLESHOOTING
• 454.
• 454.1. HIGH ENERGY IGNITION (HEI)
• 454.2. REPAIRS
• 454.3. SPECIFICATIONS