Hyster F005 (H3.50-5.00XL) Service Manual

Description

• Model List:
  • F005 (H3.50-5.00XL)

• 1. INTRODUCTION
• 2. GENERAL
• 3. DESCRIPTION
• 4. REPAIRS
• 5. GENERAL
• 6. REMOVAL AND DISASSEMBLY (Type A)
• 7. CLEANING
• 8. ASSEMBLY (Type A)
• 9. REMOVAL AND DISAASSEMBLY (Type B)
• 10. CLEANING
• 11. ASSEMBLY (Type B)
• 12. INSTALLATION (Type A and Type B)
• 13. CHECKS AND ADJUSTMENTS
• 14. GENERAL
• 15. CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)
• 16. CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)
• 17. CHECK THE CIRCUIT FOR THE BRUSHES
• 18. Delco Alternators
• 19. Motorola Alternators
• 20. CHECK THE DIODES
• 21. CHECK THE DIODE BRIDGE
• 22. Delco and LeeceNeville Alternators
• 23. Motorola Alternators
• 24. CHECK THE FIELD WINDING FOR THE ROTOR
• 25. CHECK THE WINDINGS IN THE STATOR
• 26. CHECK THE VOLTAGE REGULATOR
• 27. TROUBLESHOOTING
• 28. THE FRAME
• 29. GENERAL
• 30. DESCRIPTION
• 31. REPAIRS
• 32. COUNTERWEIGHT
• 33. Removal
• 34. COUNTERWEIGHT
• 35. Installation
• 36. Removal
• 37. Installation
• 38. OVERHEAD GUARD
• 39. Removal
• 40. Installation
• 41. OPERATOR RESTRAINT SYSTEM
• 42. RADIATOR
• 43. Removal
• 44. Installation
• 45. EXHAUST SYSTEM
• 46. Muffler Replacement
• 47. Removal
• 48. Installation
• 49. FUEL AND HYDRAULIC TANKS
• 50. Inspection
• 51. Repairs, Small Leaks
• 52. Repairs, Large Leaks
• 53. Cleaning
• 54. Other Methods Of Preparation For Repair
• 55. SAFETY LABELS
• 56. Cab Repalacement
• 57. Window Repalcement
• 58. Windshield Wipers, Heater and Fan
• 59. Material Specifications For Cab Windows
• 60. Cab Heater Hoses
• 61. INTRODUCTION
• 62. GENERAL
• 63. DESCRIPTION
• 64. OPERATION
• 65. REPAIRS
• 66. STEERING WHEEL AND COLUMN ASSEMBLY
• 67. TYPE A STEERING COLUMN ASSEMBLY
• 68. Removal And Disassembly
• 69. Assembly And Installation
• 70. TYPE A STEERING COLUMN
• 71. TYPE A STEERING COLUMN
• 72. TYPE B STEERING COLUMN
• 73. Removal And Disassembly
• 74. Assembly And Installation
• 75. TYPE B STEERING COLUMN
• 76. Disassembly of Steering Control Unit
• 77. Cleaning of Steering Control Unit
• 78. Assembly of Steering Control Unit
• 79. CHECKS AND ADJUSTMENTS
• 80. REMOVE AIR FROM THE SYSTEM
• 81. TROUBLESHOOTING
• 82. INTRODUCTION
• 83. DESCRIPTION
• 84. OPERATION
• 85. Flow Control Valve
• 86. Relief Valve
• 87. REPAIRS
• 88. REMOVAL
• 89. DISASSEMBLY
• 90. CLEANING
• 91. INSPECTION
• 92. ASSEMBLY
• 93. INSTALLATION
• 94. CHECKS AND ADUSTMENTS
• 95. CHECK THE OUTPUT OF THE PUMP
• 96. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
• 97. TROUBLESHOOTING
• 98. INTRODUCTION
• 99. GENERAL
• 100. DESCRIPTION
• 101. OPERATION
• 102. Lift Section
• 103. Tilt Section
• 104. Relief Valve
• 105. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 106. Operation
• 107. REPAIRS
• 108. MAIN CONTROL VALVE
• 109. Removal and Disassembly
• 110. Cleaning and Inspection
• 111. Assembly
• 112. Installation
• 113. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 114. Removal and Disassembly
• 115. Assembly and Installation
• 116. CHECKS AND ADJUSTMENTS
• 117. PRESSURE RELIEF VALVES
• 118. Primary Relief Valve
• 119. Seconday Relief Valve
• 120. CONTROL LEVER ARRANGEMENT
• 121. TROUBLESHOOTING
• 122. SPECIFICATIONS
• 123. INTRODUCTION
• 124. GENERAL
• 125. DESCRIPTION
• 126. ENGINE SERIAL NUMBER CODES
• 127. REMOVAL AND INSTALLATION
• 128. CYLINDER HEAD
• 129. Removal
• 130. Installation
• 131. Cylinder Head Repairs
• 132. OIL PUMP
• 133. Removal
• 134. Disassembly
• 135. Inspection
• 136. Assembly
• 137. Installation
• 138. RELIEF VALVE
• 139. TIMING GEAR CASE AND TIMING GEARS
• 140. Removal
• 141. Installation
• 142. PISTONS AND CONNECTING RODS
• 143. Removal
• 144. Disassembly
• 145. Inspection
• 146. Assembly
• 147. Installation
• 148. CRANKSHAFT AND MAIN BEARINGS
• 149. Removal
• 150. Inspection
• 151. Assembly
• 152. CAMSHAFT AND CAM FOLLOWERS
• 153. Removal
• 154. Inspection
• 155. Assembly
• 156. FLYWHEEL AND FLYWHEEL HOUSING
• 157. Removal
• 158. Repairs
• 159. Installation
• 160. STEERING PUMP DRIVE
• 161. Removal
• 162. Installation
• 163. PCV VALVE
• 164. FUEL SYSTEM
• 165. FUEL PUMP
• 166. Removal
• 167. Disassembly
• 168. Assembly
• 169. Installation
• 170. FUEL INJECTION PUMP
• 171. Removal
• 172. Repairs
• 173. Installation
• 174. FUEL INJECTORS
• 175. Removal
• 176. Repairs
• 177. Installation
• 178. COLD START AID
• 179. Description
• 180. Removal
• 181. Installation
• 182. COOLING SYSTEM
• 183. THERMOSTAT
• 184. Removal
• 185. Inspection
• 186. Installation
• 187. WATER PUMP
• 188. Removal
• 189. Disassembly
• 190. Assembly
• 191. Installation
• 192. CHECKS AND ADJUSTMENTS
• 193. CHECKING THE INJECTORS
• 194. Repairs
• 195. Installation
• 196. REMOVING AIR FROM THE FUEL SYSTEM
• 197. CHECKING THE TIMING MARKS
• 198. Method A
• 199. Method B
• 200. CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL
• 201. VALVE CLEARANCE ADJUSTMENT
• 202. ADJUSTING THE THROTTLE LINKAGE
• 203. TROUBLESHOOTING
• 204. SPECIFICATIONS
• 205. TORQUE SPECIFICATIONS
• 206. PERKINS DIESEL ENGINES, SERIES 1000
• 207. GENERAL
• 208. GENERAL SAFETY RULES
• 209. Viton Seals
• 210. DESCRIPTION
• 211. Engine Serial Number Codes
• 212. Engine Data
• 213. 4 ENGINE
• 214. 4T ENGINE
• 215. 6 ENGINE
• 216. 6T ENGINE
• 217. REMOVAL AND INSTALLATION
• 218. CYLINDER HEAD ASSEMBLY
• 219. VALVE COVER
• 220. Removal
• 221. Installation
• 222. ROCKER ARM ASSEMBLY
• 223. Removal
• 224. Installation
• 225. Disassembly
• 226. Inspection
• 227. Assembly
• 228. VALVE CLEARANCE ADJUSTMENTS
• 229. Four Cylinder Engines
• 230. Six Cylinder Engines
• 231. VALVE SPRINGS
• 232. CYLINDER HEAD ASSEMBLY
• 233. Removal
• 234. Installation
• 235. VALVES AND VALVE SPRINGS
• 236. Removal
• 237. Inspection
• 238. Installation
• 239. VALVE GUIDES
• 240. Inspection
• 241. Removal
• 242. Installation
• 243. CYLINDER HEAD AND VALVE SEATS
• 244. Inspection
• 245. Repair
• 246. Installation Of New Valve Seats
• 247. PISTON AND CONNECTING ROD ASSEMBLIES
• 248. ROD BEARINGS
• 249. Removal
• 250. Installation
• 251. PISTON AND CONNECTING ROD ASSEMBLY
• 252. Service Note
• 253. Removal
• 254. Installation
• 255. PISTON RINGS
• 256. Removal
• 257. Inspection
• 258. Installation
• 259. PISTON AND CONNECTING ROD
• 260. Disassembly
• 261. Inspection
• 262. Installation
• 263. PISTON COOLING JETS
• 264. Removal
• 265. Installation
• 266. CRANKSHAFT ASSEMBLY
• 267. GENERAL
• 268. CRANKSHAFT PULLEY
• 269. Removal, Engines AA and AB
• 270. Installation, Engines AA and AB
• 271. Removal, Engines YA and YB
• 272. Installation, Engines YA and YB
• 273. REAR OIL SEAL
• 274. Replacement
• 275. MAIN BEARINGS
• 276. Removal
• 277. Installation
• 278. THRUST WASHERS
• 279. Check The Axial Movement Of The Crankshaft
• 280. Removal
• 281. Installation
• 282. CRANKSHAFT
• 283. Removal
• 284. Inspection
• 285. Installation
• 286. TIMING CASE AND TIMING GEARS
• 287. GENERAL
• 288. TIMING CASE COVER
• 289. Removal
• 290. Installation
• 291. FRONT OIL SEAL
• 292. Removal
• 293. Installation
• 294. IDLER GEAR AND HUB
• 295. Removal
• 296. Installation
• 297. GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR
• 298. Removal
• 299. Installation
• 300. CRANKSHAFT GEAR
• 301. Removal
• 302. Installation
• 303. TIMING CASE
• 304. Removal
• 305. Installation
• 306. CAMSHAFT AND TAPPETS
• 307. Removal
• 308. Installation
• 309. ENGINE BLOCK ASSEMBLY
• 310. DESCRIPTION
• 311. ENGINE BLOCK
• 312. Disassembly
• 313. Inspection
• 314. Assembly
• 315. CYLINDER LINER
• 316. Inspection
• 317. Hone
• 318. Removal
• 319. Installation
• 320. TURBOCHARGER, ENGINES AB AND YB
• 321. GENERAL
• 322. Removal
• 323. Installation
• 324. Clean The Impeller And Compressor Housing
• 325. LUBRICATION SYSTEM
• 326. GENERAL
• 327. OIL FILTER, REPLACEMENT
• 328. OIL SUMP
• 329. Removal
• 330. Installation
• 331. OIL PUMP
• 332. Removal
• 333. Inspection
• 334. Installation
• 335. RELIEF VALVE
• 336. Removal
• 337. Disassembly
• 338. Inspection
• 339. Installation
• 340. FUEL SYSTEM
• 341. DESCRIPTION
• 342. CAV FUEL INJECTION PUMP
• 343. Removal
• 344. Installation
• 345. CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS
• 346. Timing Gear Marks
• 347. How To Set Number 1 Piston To TDC On The Compression Stroke
• 348. Check The Valve Timing
• 349. Check The Timing Of The Fuel Injection Pump
• 350. Check The Timing Mark Of The Fuel Injection Pump
• 351. Check The Engine Timing Mark
• 352. REMOVE AIR FROM THE FUEL SYSTEM
• 353. Fuel Injection Pump With Vent Tube
• 354. Fuel Injection Pump With Vent Screw
• 355. FUEL FILTER (REPLACEMENT)
• 356. FUEL INJECTORS
• 357. Removal
• 358. Inspection
• 359. Installation
• 360. FUEL PUMP
• 361. Removal
• 362. Disassembly
• 363. Assembly
• 364. Installation
• 365. Test
• 366. COOLING SYSTEM
• 367. GENERAL
• 368. THERMOSTAT
• 369. Replacement
• 370. COOLANT PUMP
• 371. Removal
• 372. Disassembly
• 373. Assembly
• 374. Installation
• 375. FAN AND FAN DRIVE
• 376. Removal
• 377. Disassembly
• 378. Assembly
• 379. Installation
• 380. OIL COOLER
• 381. Removal, Engine AB
• 382. Removal, Engines YA and YB
• 383. Disassembly And Assembly
• 384. Installation, Engine AB
• 385. Installation, Engines YA and YB
• 386. ByPass Valve, Oil Cooler
• 387. FLYWHEEL AND FLYWHEEL HOUSING
• 388. GENERAL
• 389. FLYWHEEL
• 390. Removal
• 391. Ring Gear (Replacement)
• 392. Installation
• 393. FLYWHEEL HOUSING
• 394. Removal
• 395. Installation
• 396. ELECTRICAL EQUIPMENT
• 397. DRIVE BELTS
• 398. ALTERNATOR
• 399. STARTER MOTOR
• 400. Removal
• 401. Installation
• 402. COLD START AID
• 403. AIR COMPRESSOR, ENGINES YA AND YB
• 404. GENERAL
• 405. Air Compressor, Removal, WABCO
• 406. Compressor Drive, Inspection
• 407. Air Compressor, Installation, WABCO
• 408. Compressor Drive, Disassembly, WABCO
• 409. Compressor Drive, Assembly, WABCO
• 410. Air Compressor, Removal, BENDIX
• 411. Air Compressor, Installation, BENDIX
• 412. Compressor Drive, Disassembly, BENDIX
• 413. Compressor Drive, Assembly, BENDIX
• 414. ENGINE SPECIFICATIONS
• 415. CYLINDER HEAD ASSEMBLY
• 416. Cylinder Head
• 417. Valve Guides
• 418. Inlet Valves
• 419. Exhaust Valves
• 420. Double Valve Springs To Outer
• 421. Double Valve Springs To Inner
• 422. Single Valve Springs
• 423. Tappets
• 424. Rocker Arm Shaft
• 425. Rocker Arms And Bushings
• 426. PISTON AND CONNECTING RODS
• 427. Pistons, Engines AA And YA
• 428. Pistons, Engines AB And YB
• 429. Piston Rings, Engines AA And YA
• 430. Piston Rings, Engines AB And YB
• 431. Connecting Rods, Engines AB And YB
• 432. Connecting Rods, Engines AB And YB
• 433. Piston Pins, Engines AA And YA
• 434. Piston Pins, Engines AB and YB
• 435. Small End Bushings, Engines AA And YA
• 436. Small End Bushings, Engines AB And YB
• 437. Connecting Rod Bearings, Engines AA And YA
• 438. Connecting Rod Bearings, Engines AB And YB
• 439. Piston Cooling Jets, Engines AB And YB
• 440. CRANKSHAFT ASSEMBLY
• 441. Crankshaft
• 442. Crankshaft Heat Treatment
• 443. Crankshaft Overhaul
• 444. Main Bearings
• 445. Crankshaft Thrust Washers
• 446. TIMING CASE AND DRIVE ASSEMBLY
• 447. Camshaft
• 448. Camshaft Thrust Washer
• 449. Camshaft Gear
• 450. Gear For Fuel Injection Pump
• 451. Crankshaft Gear
• 452. Idler Gear And Hub
• 453. ENGINE BLOCK ASSEMBLY
• 454. Engine Block
• 455. Cylinder Liners
• 456. TURBOCHARGER
• 457. LUBRICATION SYSTEM
• 458. Oil Pump, Engines AA And AB
• 459. Oil Pump, Engines YA And YB
• 460. Relief Valve
• 461. Oil Filter
• 462. FUEL SYSTEM
• 463. Cav Fuel Injection Pump
• 464. FUEL INJECTORS
• 465. Fuel Pump, Engines AA And AB
• 466. Fuel Pump, Engines YA And YB
• 467. Fuel Filter
• 468. COOLING SYSTEM
• 469. Coolant Pump
• 470. Thermostat
• 471. Fan Drive Housing
• 472. FLYWHEEL AND HOUSING
• 473. Limits for flywheel run out and alignment (total indicator reading).
• 474. ELECTRICAL EQUIPMENT
• 475. Alternator