Hyster F003 (H40-60JS) Service Manual

Description

• Model List:
  • F003 (H40-60JS)

• 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. _2
• 72. _2
• 72.1. INTRODUCTION
• 72.1.1. GENERAL
• 72.1.2. DESCRIPTION
• 72.1.3. OPERATION
• 72.2. REPAIRS
• 72.2.1. REMOVAL
• 72.2.2. DISASSEMBLY
• 72.2.3. Cleaning
• 72.2.4. ASSEMBLY
• 72.2.5. INSTALLATION
• 72.2.6. GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)
• 72.2.7. GOVERNOR (PNEUMATIC) (Early Units)
• 72.3. CHECKS AND ADJUSTMENTS
• 72.3.1. GENERAL
• 72.3.2. ADJUST THE CHOKE CONTROL
• 72.3.3. ADJUST THE IDLE SPEED
• 72.3.4. ADJSUT THE IDLE MIXTURE
• 72.3.5. ADJUST THE FAST IDLE
• 72.3.6. ADJUST THE THROTTLE LINKAGE,(Later Models)
• 72.3.7. ADJUST THE THROTTLE LINKAGE,(Early Models)
• 72.3.8. GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)
• 72.3.9. GOVERNOR (AISAN Type) (Early GM Engines Only)
• 72.3.10. GOVERNOR (HOOF Type) (Early GM Engines Only)
• 72.4. TROUBLESHOOTING
• 73. _2
• 73.1. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
• 73.1.1. GENERAL
• 73.1.2. DESCRIPTION
• 73.2. REPAIRS
• 73.2.1. LPG TANK
• 73.2.2. REPLACE THE HOSES
• 73.2.3. HYDROSTATIC RELIEF VALVE
• 73.2.4. FILTER UNIT
• 73.2.5. VAPORIZER
• 73.2.6. CARBURETOR (IMPCO CA 100)
• 73.2.7. CARBURETER (IMPCO CA 50)
• 73.3. CHECKS AND ADJUSTMENTS
• 73.3.1. CHECK THE FILTER UNIT
• 73.3.2. CHECK THE VAPORIZER
• 73.3.3. ADJUST THE CARBURETOR
• 73.3.4. ADJUST THE GOVERNOR (GM Engines Only)
• 73.4. TROUBLESHOOTING
• 74. _2
• 74.1. INTRODUCTION
• 74.1.1. General
• 74.1.2. Description
• 74.2. DISASSEMBLY AND ASSEMBLY
• 74.2.1. Overhead Guard
• 74.2.2. Hood and Seat Removal
• 74.2.3. Counterweight
• 74.2.4. Engine and Transmission
• 74.3. REPAIRS
• 74.3.1. Fuel and Hydraulic Tanks
• 74.3.2. Decal Replacement
• 75. _2
• 75.1. INTRODUCTION
• 75.1.1. GENERAL
• 75.1.2. DESCRIPTION AND OPERATION
• 75.2. REPAIRS
• 75.2.1. REMOVAL
• 75.2.2. INSPECTION
• 75.2.3. INSTALLATION
• 75.3. ADJUSTMENTS
• 75.3.1. ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL
• 75.3.2. ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS
• 75.4. TROUBLESHOOTING
• 76. _2
• 76.1. INTRODUCTION
• 76.1.1. General
• 76.2. REPAIRS
• 76.3. REMOVAL
• 76.4. DISASSEMBLY
• 76.5. CLEANING
• 76.6. INSPECTION
• 76.7. ASSEMBLY
• 76.7.1. Assembling the Control Valve
• 76.7.2. Assembling the Differential
• 76.7.3. Assembling the Transmission
• 76.7.4. Installation
• 76.7.5. MONOTROL Pedal
• 76.8. CHECKS AND ADJUSTMENTS
• 76.8.1. Checking the MONOTROL Pedal for Leakage
• 76.8.2. MONOTROL Pedal
• 76.8.3. Stall Test
• 76.8.4. Checking the Oil Pressures
• 76.9. CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT
• 76.10. CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER
• 76.11. ADJUSTING THE OIL SUMP TUBE
• 76.12. TROUBLESHOOTING
• 76.12.1. Pressure Tests
• 76.12.2. Troubleshooting the Differential
• 77. _2
• 77.1. INTRODUCTION
• 77.1.1. GENERAL
• 77.1.2. DESCRIPTION
• 77.2. REPAIRS
• 77.2.1. REMOVAL
• 77.2.2. DISASSEMBLY
• 77.2.3. CLEANING
• 77.2.4. INSPECTION
• 77.2.5. ASSEMBLY
• 77.2.6. INSTALLATION
• 77.3. TROUBLESHOOTING
• 77.4. SPECIFICATIONS
• 78. _2
• 78.1. INTRODUCTION
• 78.1.1. GENERAL
• 78.1.2. DESCRIPTION
• 78.2. REPAIRS
• 78.2.1. DISASSEMBLY
• 78.2.2. CLEANING
• 78.2.3. ASSEMBLY
• 78.3. TROUBLESHOOTING
• 79. _2
• 79.1. INTRODUCTION
• 79.1.1. DESCRIPTION
• 79.1.2. GENERAL
• 79.2. REPAIRS
• 79.2.1. STEERING AXLE
• 79.2.2. Removal
• 79.2.3. Installation
• 79.2.4. STEERING CYLINDER
• 79.2.5. Removal
• 79.2.6. Service
• 79.2.7. Installation
• 79.2.8. Removal
• 79.2.9. Installation
• 79.2.10. SPINDLES
• 79.2.11. Removal
• 79.2.12. Installation
• 79.3. CHECKS AND ADJUSTMENTS
• 79.3.1. REMOVE THE AIR FROM THE STEERING SYSTEM
• 79.3.2. SET THE PRESSURE RELIEF VALVE
• 79.3.3. S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)
• 79.3.4. H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION
• 79.3.5. H2.00-3.00J (H40-60J) With Powershift Transmission
• 79.4. TROUBLESHOOTING
• 80. _2
• 80.1. INTRODUCTION
• 80.1.1. GENERAL
• 80.1.2. DESCRIPTION
• 80.1.3. OPERATION
• 80.2. REPAIRS
• 80.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
• 80.2.2. TYPE A STEERING COLUMN ASSEMBLY
• 80.2.3. TYPE A STEERING COLUMN
• 80.2.4. TYPE A STEERING COLUMN
• 80.2.5. TYPE B STEERING COLUMN
• 80.2.6. TYPE B STEERING COLUMN
• 80.3. CHECKS AND ADJUSTMENTS
• 80.3.1. REMOVE AIR FROM THE SYSTEM
• 80.4. TROUBLESHOOTING
• 81. _2
• 81.1. INTRODUCTION
• 81.1.1. GENERAL
• 81.1.2. DESCRIPTION
• 81.2. REPAIRS
• 81.2.1. REMOVAL AND DISASSEMBLY
• 81.2.2. CLEANING
• 81.2.3. ASSEMBLY
• 81.3. CHECKS AND ADJUSTMENTS
• 82. _2
• 82.1. INTRODUCTION
• 82.1.1. GENERAL
• 82.1.2. DESCRIPTION AND OPERATION
• 82.2. REPAIRS
• 82.2.1. REMOVAL AND DISASSEMBLY
• 82.2.2. CLEANING
• 82.2.3. INSPECTION
• 82.2.4. ASSEMBLY
• 82.3. CHECKS AND ADJUSTMENTS
• 82.3.1. BRAKE SHOES
• 82.4. TROUBLESHOOTING
• 83. _2
• 83.1. INTRODUCTION
• 83.1.1. GENERAL
• 83.1.2. DESCRIPTION
• 83.2. REPAIRS
• 83.2.1. REMOVAL AND DISASSEMBLY
• 83.2.2. CLEANING
• 83.2.3. INSPECTION
• 83.2.4. ASSEMBLY AND INSTALLATION
• 83.3. TROUBLESHOOTING
• 83.3.1. GENERAL
• 84. _2
• 84.1. INTRODUCTION
• 84.1.1. DESCRIPTION
• 84.1.2. OPERATION
• 84.2. REPAIRS
• 84.2.1. REMOVAL
• 84.2.2. DISASSEMBLY
• 84.2.3. CLEANING
• 84.2.4. INSPECTION
• 84.2.5. ASSEMBLY
• 84.2.6. INSTALLATION
• 84.3. CHECKS AND ADUSTMENTS
• 84.3.1. CHECK THE OUTPUT OF THE PUMP
• 84.3.2. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
• 84.4. TROUBLESHOOTING
• 85. _2
• 85.1. INTRODUCTION
• 85.1.1. General
• 85.1.2. Description
• 85.1.3. Hydraulic Control Valve
• 85.2. REPAIRS
• 85.2.1. Disassembly
• 85.2.2. Cleaning
• 85.2.3. Inspection
• 85.2.4. Assembly
• 85.3. CHECKS AND ADJUSTMENT
• 85.3.1. Relief Valve
• 85.4. TROUBLESHOOTING
• 86. _2
• 86.1. INTRODUCTION
• 86.1.1. General
• 86.1.2. Description
• 86.1.3. Removal
• 86.1.4. Installation
• 86.2. CYLINDER HEAD AND VALVE MECHANISM
• 86.2.1. Cylinder Head
• 86.2.2. Valve Mechanism
• 86.3. LUBRICATION
• 86.3.1. Oil Pump
• 86.4. TIMING GEAR CASE AND CAMSHAFT
• 86.4.1. Timing Gear Cover
• 86.4.2. Idle Gears
• 86.4.3. Camshaft Gear and Camshaft
• 86.4.4. Fuel Pump Gear
• 86.4.5. Timing Gear Case
• 86.5. CRANKSHAFT AND MAIN BEARINGS
• 86.5.1. Removal
• 86.5.2. Installation
• 86.6. PISTONS AND PISTON RODS
• 86.6.1. Removal
• 86.6.2. Disassembly
• 86.6.3. Repairs
• 86.6.4. Assembly
• 86.6.5. Installation
• 86.7. CYLINDER LINERS
• 86.7.1. Removal
• 86.7.2. Installation
• 86.8. FLYWHEEL AND FLYWHEEL HOUSING
• 86.8.1. Removal
• 86.8.2. Installation
• 86.9. FUEL PUMP
• 86.9.1. Removal
• 86.9.2. Installation
• 86.10. FUEL INJECTION PUMP
• 86.10.1. Removal
• 86.10.2. Installation
• 86.11. FUEL INJECTORS
• 86.11.1. Installation
• 86.12. COOLING SYSTEM
• 86.12.1. Thermostat
• 86.12.2. Water Pump
• 86.13. CHECKS AND ADJUSTMENTS
• 86.13.1. Removing Air From The Fuel System
• 86.13.2. Valve Clearance Adjustment
• 86.13.3. Adjusting The Throttle Linkage
• 86.14. TROUBLESHOOTING
• 86.15. SPECIFICATIONS
• 87. _2
• 88. _2
• 89. _2
• 90. _2
• 90.1. INTRODUCTION
• 90.1.1. GENERAL
• 90.2. DESCRIPTION
• 90.2.1. GENERAL
• 90.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
• 90.2.3. LED DISPLAY PANEL
• 90.2.4. LX SERIES DISPLAY PANEL
• 90.2.5. ZX SERIES DISPLAY PANELS
• 90.3. CHECKS AND ADJUSTMENTS
• 90.3.1. GENERAL
• 90.4. REPLACEMENT
• 90.4.1. GENERAL
• 90.4.2. METER REPLACEMENT
• 90.4.3. SENDER REPLACEMENT
• 90.4.4. DISPLAY PANEL
• 90.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
• 90.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
• 90.5. SPECIFICATIONS
• 90.6. TROUBLESHOOTING
• 91. _2
• 91.1. ELECTRICAL WARNING DEVICES
• 91.1.1. GENERAL
• 91.1.2. DESCRIPTION
• 91.1.3. REPLACEMENT
• 92. _2
• 92.1. ELECTRICAL SYSTEM COMPLETELY DEAD
• 92.2. STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN
• 92.3. STARTER DOES NOT CRANK SOLENOID PULLS IN, DOES NOT CHATTER.
• 92.4. STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK.
• 92.5. STARTER CRANKS SLOWLY
• 92.6. STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START
• 92.7. BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND
• 92.8. CHARGING SYSTEM DOES NOT FUNCTION
• 92.9. ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW
• 92.10. BATTERY IS BEING OVERCHARGED
• 92.11. ONE OR MORE DASH GAUGES DO NOT WORK
• 92.12. HORN DOES NOT BLOW
• 92.13. POWERSHIFT TRANSMISSION WILL NOT ENGAGE.
• 92.14. ELECTRICAL SCHEMATIC S20-30A, H20-30E
• 92.15. ELECTRICAL S30-50C
• 92.16. ELECTRICAL SCHEMATIC H30-60H GASOLINE LPG
• 92.17. ELECTRICAL SCHEMATIC H30-60H DIESEL
• 92.18. ELECTRICAL SCHEMATIC H60-90C GASOLINE LPG
• 92.19. ELECTRICAL SCHEMATIC H60-90C DIESEL
• 92.20. ELECTRICAL SCHEMATIC S30-60ES
• 92.21. ELECTRICAL SCHEMATIC S60-120E
• 92.22. ELECTRICAL SCHEMATIC S125-150A GASOLINE LPG
• 92.23. ELECTRICAL SCHEMATIC S125-150A DIESEL
• 92.24. ELECTRICAL SCHEMATIC H110-150F GASOLINE LPG
• 92.25. ELECTRICAL SCHEMATIC H110-150F DIESEL
• 92.26. ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE LPG
• 92.27. ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL
• 92.28. ELECTRICAL SCHEMATIC H300A
• 92.29. ELECTRICAL SCHEMATIC H300-350B
• 92.30. ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL
• 92.31. ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL
• 92.32. ELECTRICAL SCHEMATIC H700-800A
• 92.33. ELECTRICAL SCHEMATIC P40-50A GASOLINE
• 92.34. ELECTRICAL SCHEMATIC P40-50A DIESEL
• 92.35. ELECTRICAL SCHEMATIC P60-80A GASOLINE
• 92.36. ELECTRICAL SCHEMATIC P60-80A DIESEL
• 92.37. ELECTRICAL SCHEMATIC KE GAS GASOLINE
• 92.38. ELECTRICAL SCHEMATIC KE DIESEL
• 92.39. ELECTRICAL SCHEMATIC M200-400H GASOLINE
• 92.40. ELECTRICAL SCHEMATIC M200-400H DIESEL
• 92.41. ELECTRICAL SCHEMATIC M600A
• 93. _2
• 93.1. INTRODUCTION
• 93.1.1. GENERAL
• 93.2. REPAIRS
• 93.2.1. CARRIAGE
• 93.2.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 93.2.3. INSTALLATION
• 93.3. CHECKS AND ADJUSTMENTS
• 93.3.1. CHECKING FOR LEAKS IN THE LIFT SYSTEM
• 93.3.2. ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
• 93.3.3. LIFT CHAIN ADJUSTMENTS
• 93.3.4. MAST ADJUSTMENTS
• 93.3.5. CARRIAGE ADJUSTMENT
• 93.4. TROUBLESHOOTING
• 94. _2
• 95. _2
• 95.1. INTRODUCTION
• 95.1.1. GENERAL
• 95.1.2. STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)