Hyster H1.50-1.75XM, H2.00XMS Frame Maintenance And Repair

Description

• Model List:
  • H1.50-1.75XM, H2.00XMS Frame

• 1. _2
• 1.1. INTRODUCTION
• 1.1.1. GENERAL
• 1.1.2. DESCRIPTION
• 1.2. REPAIRS
• 1.2.1. OPERATOR MODULE
• 1.2.2. HOOD AND SIDE COVERS
• 1.2.3. OVERHEAD GUARD
• 1.2.4. COUNTERWEIGHT
• 1.2.5. EXHAUST SYSTEM
• 1.2.6. RADIATOR AND COOLING SYSTEM
• 1.2.7. OPERATOR RESTRAINT SYSTEM
• 1.2.8. FUEL AND HYDRAULIC TANK
• 1.2.9. SAFETY LABELS
• 2. _2
• 2.1. INTRODUCTION
• 2.1.1. GENERAL
• 2.1.2. DESCRIPTION
• 2.2. REPAIRS
• 2.2.1. REMOVAL AND INSTALLATION OF THE ENGINE
• 2.2.2. CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM
• 2.2.3. CRANKSHAFT AND MAIN BEARINGS
• 2.2.4. PISTONS AND CONNECTING RODS
• 2.2.5. CYLINDER BLOCK
• 2.2.6. OIL PUMP
• 2.2.7. COOLING SYSTEM
• 2.2.8. DISTRIBUTOR
• 2.2.9. FLYWHEEL AND RING GEAR, S/H2.003.20XM (S/H4065XM)
• 2.2.10. FLYWHEEL, S/H1.501.75XM, S/H2.00XMS (S/H2535XM, S/H40XMS)
• 2.2.11. CHECKS AND ADJUSTMENTS
• 2.2.12. ADJUST THE VALVES
• 2.2.13. CHECK THE COMPRESSION PRESSURE
• 2.3. ENGINE SPECIFICATIONS
• 2.4. TORQUE SPECIFICATIONS
• 3. _2
• 3.1. INTRODUCTION
• 3.1.1. DESCRIPTION
• 3.2. REPAIRS
• 3.2.1. CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM
• 3.2.2. CRANKSHAFT AND MAIN BEARINGS
• 3.2.3. PISTONS AND CONNECTING RODS
• 3.2.4. CYLINDER BLOCK
• 3.2.5. FLYWHEEL AND RING GEAR
• 3.3. CHECKS AND ADJUSTMENTS
• 3.3.1. ADJUST THE VALVES
• 3.3.2. CHECK THE COMPRESSION PRESSURE
• 3.4. ENGINE SPECIFICATIONS
• 3.5. TORQUE SPECIFICATIONS
• 3.6. TROUBLESHOOTING
• 4. _2
• 4.1. INTRODUCTION
• 4.1.1. GENERAL
• 4.1.2. DESCRIPTION
• 4.2. REPAIRS
• 4.2.1. REMOVAL AND INSTALLATION OF THE ENGINE
• 4.2.2. CYLINDER HEAD AND VALVE MECHANISM
• 4.2.3. TIMING GEARS
• 4.2.4. CAMSHAFT
• 4.2.5. CRANKSHAFT AND MAIN BEARINGS
• 4.2.6. PISTON AND CONNECTING RODS
• 4.2.7. CYLINDER BLOCK AND LINERS
• 4.2.8. LUBRICATION SYSTEM
• 4.2.9. COOLING SYSTEM
• 4.2.10. FUEL SYSTEM
• 4.2.11. FUEL INJECTION PUMP
• 4.2.12. FUEL FILTER
• 4.2.13. REMOVE AIR FROM THE FUEL SYSTEM
• 4.2.14. FUEL INJECTORS
• 4.2.15. FLYWHEEL
• 4.3. CHECKS AND ADJUSTMENTS
• 4.3.1. ADJUST THE VALVES
• 4.3.2. CHECK THE COMPRESSION PRESSURE
• 4.3.3. ADJUST THE THROTTLE LINKAGE
• 4.3.4. CHECK THE TIMING OF THE FUEL INJECTION PUMP
• 4.4. ENGINE SPECIFICATIONS
• 4.5. TORQUE SPECIFICATIONS
• 4.6. TROUBLESHOOTING
• 5. _2
• 6. _2
• 6.1. INTRODUCTION
• 6.1.1. GENERAL
• 6.1.2. DESCRIPTION AND OPERATION.
• 6.2. REPAIRS
• 6.2.1. REPLACEMENT OF THE HOSES
• 6.2.2. LPG TANK
• 6.2.3. HYDROSTATIC RELIEF VALVE
• 6.2.4. FILTER UNIT
• 6.2.5. VAPORIZER
• 6.2.6. CARBURETOR
• 6.2.7. SOLENOID VALVE
• 6.2.8. GOVERNOR
• 6.2.9. CHECK THE VAPORIZER
• 6.3. CHECKS AND ADJUSTMENTS
• 6.3.1. CHECK THE FILTER UNIT
• 6.3.2. ADJUST THE CARBURETOR
• 6.3.3. GOVERNOR
• 6.3.4. ADJUST THE THROTTLE LINKAGE, S/H2.003.20XM (S/H4065XM)
• 6.3.5. ADJUST THE THROTTLE LINKAGE, S/H1.501.75XM, S/H2.00XMS (S/H2535XM, H40XMS)
• 6.3.6. CHECK THE MONOTROL PEDAL
• 6.4. TROUBLESHOOTING
• 7. _2
• 7.1. INTRODUCTION
• 7.1.1. DESCRIPTION
• 7.1.2. GOVERNOR
• 7.2. REPAIRS
• 7.2.1. CARBURETOR
• 7.3. CHECKS AND ADJUSTMENTS
• 7.3.1. CARBURETOR
• 7.3.2. GOVERNOR
• 7.4. TROUBLESHOOTING
• 8. _2
• 8.1. INTRODUCTION
• 8.1.1. DESCRIPTION
• 8.1.2. FUEL TANK
• 8.1.3. HYDROSTATIC RELIEF VALVE
• 8.1.4. FUEL FILTER AND FUEL VALVE UNIT
• 8.1.5. VAPORIZER
• 8.1.6. CARBURETOR
• 8.1.7. GOVERNOR
• 8.1.8. INSTALLING NEW HOSES
• 8.2. CHECKS AND ADJUSTMENTS
• 8.2.1. CARBURETOR
• 8.2.2. GOVERNOR
• 8.2.3. ADJUST THE THROTTLE LINKAGE
• 8.3. TROUBLESHOOTING
• 8.3.1. LPG Fuel System
• 8.3.2. Safety Precautions Maintenance and Repair
• 8.3.3. General
• 8.3.4. Description and Operation
• 8.3.5. Hoses Replacement
• 8.3.6. LPG Tank Repair
• 8.3.7. Relief Valve Repair
• 8.3.8. Carburetor Repair
• 8.3.9. Fuel Injector Repair
• 8.3.10. Governor Repair
• 8.3.11. Regulator Repair
• 8.3.12. Oxygen Sensor Repair
• 8.3.13. Vacuum Switches Repair
• 8.3.14. Resistor Repair
• 8.3.15. Carburetor and New Regulator Adjustment
• 8.3.16. Governor Checks and Adjustments
• 8.3.17. Throttle Linkage Adjustment
• 8.3.18. MONOTROL Pedal Check
• 8.3.19. Check Engine Light
• 8.3.20. Troubleshooting
• 8.3.21. Table 1. Adjusting Screw
• 9. _2
• 9.1. INTRODUCTION
• 9.1.1. GENERAL
• 9.1.2. TORQUE CONVERTER
• 9.1.3. CLUTCH ASSEMBLIES
• 9.1.4. HYDRAULIC SYSTEM
• 9.1.5. CONTROL VALVE
• 9.1.6. MONOTROL PEDAL
• 9.1.7. DIRECTION CONTROL LEVER
• 9.1.8. DIFFERENTIAL
• 9.2. REPAIRS
• 9.2.1. TORQUE CONVERTER AND TRANSMISSION PUMP
• 9.2.2. CLUCTH ASSEMBLIES
• 9.2.3. DIFFERENTIAL
• 9.2.4. CONTROL VALVE
• 9.2.5. MONOTROL PEDAL
• 9.2.6. DIRECTION CONTROL LEVER
• 9.3. CHECKS AND ADJUSTMENTS
• 9.3.1. TORQUE CONVERTERS STALL TEST
• 9.3.2. TRANSMISSION PRESSURE TESTS
• 9.4. TROUBLESHOOTING
• 10. _2
• 10.1. INTRODUCTION
• 10.1.1. GENERAL
• 10.1.2. DESCRIPTION
• 10.2. REPAIRS
• 10.2.1. REMOVAL AND DISASSEMBLY
• 10.2.2. CLEANING AND INSPECTION
• 10.2.3. ASSEMBLY AND INSTALLATION
• 10.3. TROUBLESHOOTING
• 10.4. TORQUE SPECIFICATIONS
• 11. _2
• 11.1. STEERING CONTROL UNIT
• 11.1.1. GENERAL
• 11.1.2. DESCRIPTION
• 11.1.3. DISASSEMBLY AND INSPECTION
• 11.1.4. ASSEMBLY
• 11.2. TROUBLESHOOTING
• 12. _2
• 12.1. INTRODUCTION
• 12.1.1. GENERAL
• 12.1.2. DESCRIPTION
• 12.2. REPAIRS
• 12.2.1. HOW TO PUT THE LIFT TRUCK ON BLOCKS
• 12.2.2. STEERING AXLE ASSEMBLY
• 12.2.3. WHEELS AND HUBS
• 12.2.4. SPINDLES, BEARINGS, AND TIE RODS
• 12.2.5. STEERING CYLINDER
• 12.3. TROUBLESHOOTING
• 12.4. TORQUE SPECIFICATIONS
• 13. _2
• 13.1. INTRODUCTION
• 13.1.1. GENERAL
• 13.1.2. DESCRIPTION
• 13.2. REPAIRS
• 13.2.1. STEERING HOUSING
• 14.
• 14.1. INTRODUCTION
• 14.1.1. GENERAL
• 14.1.2. DESCRIPTION
• 14.1.3. OPERATION
• 14.2. REPAIRS
• 14.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
• 14.3. CHECKS AND ADJUSTMENTS
• 14.3.1. REMOVE AIR FROM THE SYSTEM
• 14.4. TROUBLESHOOTING
• 15. _2
• 15.1. INTRODUCTION
• 15.1.1. GENERAL
• 15.1.2. DESCRIPTION AND OPERATION
• 15.2. SERVICE BRAKES
• 15.2.1. Removal And Disassembly
• 15.2.2. Cleaning
• 15.2.3. Inspection
• 15.2.4. Assembly And Installation
• 15.2.5. Adjustments
• 15.3. PARKING BRAKE
• 15.3.1. Removal And Disassembly
• 15.3.2. Assembly And Installation
• 15.3.3. Adjust The Parking Brake
• 15.4. MASTER CYLINDER
• 15.4.1. Removal
• 15.4.2. Disassembly
• 15.4.3. Cleaning And Inspection
• 15.4.4. Assembly
• 15.4.5. Installation
• 15.5. CHECKS AND ADJUSTMENT
• 15.5.1. ADJUST THE SERVICE BRAKES
• 15.5.2. REMOVE THE AIR FROM THE BRAKE SYSTEM
• 15.5.3. TEST THE PARKING BRAKE NOT APPLIED SWITCH
• 15.5.4. TEST THE PARKING BRAKE SWITCH(MONOTROL PEDAL ONLY)
• 15.5.5. ADJUST THE INCHING/BRAKE PEDAL
• 15.6. TROUBLESHOOTING
• 15.7. TORQUE SPECIFICATIONS
• 16. _2
• 16.1. INTRODUCTION
• 16.1.1. GENERAL
• 16.1.2. DESCRIPTION AND OPERATION
• 16.1.3. GEAR PUMP ASSEMBLY
• 16.1.4. PUMP DRIVE SHAFT
• 16.1.5. CHECK AND ADJUST STEERING RELIEF PRESSURE
• 16.1.6. CHECK GEAR PUMP FOR CORRECT FLOW
• 16.2. TROUBLESHOOTING
• 17. _2
• 17.1. INTRODUCTION
• 17.1.1. GENERAL
• 17.1.2. DESCRIPTION
• 17.1.3. OPERATION
• 17.2. REPAIRS
• 17.2.1. MAIN CONTROL VALVE
• 17.3. CHECKS AND ADJUSTMENTS
• 17.3.1. PRESSURE RELIEF VALVES
• 17.4. TROUBLESHOOTING
• 18. _2
• 19. _2
• 19.1. ELECTRICAL WARNING DEVICES
• 19.1.1. GENERAL
• 19.1.2. DESCRIPTION
• 19.1.3. REPLACEMENT
• 20. _2
• 20.1. INTRODUCTION
• 20.1.1. GENERAL
• 20.1.2. DESCRIPTION
• 20.2. REPAIRS
• 20.2.1. REMOVAL AND DISASSEMBLY
• 20.2.2. ASSEMBLY AND INSTALLATION
• 21. _2
• 21.1. INTRODUCTION
• 21.1.1. GENERAL
• 21.1.2. DESCRIPTION
• 21.2. REPAIRS
• 21.2.1. GENERAL
• 21.2.2. STARTER
• 21.2.3. COIL REPLACEMENT
• 21.2.4. DISTRIBUTOR, H1.501.75XM, H2.00XMS (S/H2535XM, S/H40XMS)
• 21.2.5. DISTRIBUTOR, S/H2.003.20XM (S/H4065XM)
• 21.2.6. ALTERNATOR
• 21.3. CHECKS AND ADJUSTMENTS
• 21.3.1. GENERAL
• 21.3.2. STARTER
• 21.3.3. IGNITION SYSTEM
• 21.3.4. CHARGING CIRCUIT
• 21.4. TROUBLESHOOTING
• 22. _2
• 22.1. INTRODUCTION
• 22.1.1. GENERAL
• 22.1.2. DESCRIPTION
• 22.2. REPAIRS
• 22.2.1. GENERAL
• 22.2.2. STARTER
• 22.2.3. COIL REPLACEMENT
• 22.2.4. DISTRIBUTOR
• 22.2.5. ALTERNATOR
• 22.3. CHECKS AND ADJUSTMENTS
• 22.3.1. GENERAL
• 22.3.2. STARTER
• 22.3.3. IGNITION SYSTEM
• 22.3.4. CHARGING CIRCUIT
• 22.4. TROUBLESHOOTING
• 23. _2
• 23.1. INTRODUCTION
• 23.1.1. GENERAL
• 23.1.2. DESCRIPTION
• 23.2. REPAIRS
• 23.2.1. GENERAL
• 23.2.2. STARTER
• 23.2.3. ALTERNATOR
• 23.3. CHECKS AND ADJUSTMENTS
• 23.3.1. GENERAL
• 23.3.2. STARTER
• 23.3.3. COLD START AID
• 23.3.4. CHARGING UNIT
• 23.4. TROUBLESHOOTING
• 24. _2
• 25. _2
• 25.1. INTRODUCTION
• 25.1.1. GENERAL
• 25.1.2. DESCRIPTION AND OPERATION
• 25.1.3. TWO-STAGE MAST, LIMITED FREE-LIFT
• 25.1.4. TWO-STAGE MAST, FULL FREE-LIFT
• 25.1.5. THREE-STAGE, FULL FREE-LIFT MAST
• 26. _2
• 26.1. INTRODUCTION
• 26.1.1. GENERAL
• 26.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 26.3. REPAIRS
• 26.3.1. Removal
• 26.3.2. Installation
• 26.3.3. CARRIAGES
• 26.3.4. LIFT CYLINDERS
• 26.3.5. HEADER HOSE ARRANGEMENTS H/S/E/J2.003.20XM (H/S/E/J4065XM) S/E/J2.003.00XL (S/E/J4060XL)
• 26.3.6. HEADER HOSE ARRANGEMENTS H/E1.501.75XM, H/S2.00XMS (H/S/E2535XM, H/S/E40XMS) and J1.602.00XMT (J3040XMT)
• 26.4. CHECKS AND ADJUSTMENTS
• 26.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 26.4.2. ADJUST THE TILT CYLINDERS
• 26.4.3. ADJUST THE LIFT CHAINS
• 26.4.4. ADJUST THE MAST
• 26.4.5. ADJUST THE CARRIAGE
• 26.5. TROUBLESHOOTING
• 27. _2
• 28. _2
• 28.1. Periodic Maintenance
• 28.2. Safety Precautions Maintenance and Repair
• 28.3. General
• 28.4. Serial Number
• 28.5. How to Move Disabled Lift Truck
• 28.6. How to Tow Lift Truck
• 28.7. How to Put Lift Truck on Blocks
• 28.8. How to Raise Drive Tires
• 28.9. How to Raise Steering Tires
• 28.10. Maintenance Schedule
• 28.11. Maintenance Procedures Every 8 Hours or Daily
• 28.12. How to Make Checks with Engine Stopped
• 28.13. Tires and Wheels
• 28.14. Forks, Mast, and Lift Chains, Inspect
• 28.15. Safety Labels
• 28.16. Operator Restraint System
• 28.17. Steering Column Latch
• 28.18. Fuel, Oil, or Coolant Leaks, Check
• 28.19. Drive Belt
• 28.20. Engine Oil
• 28.21. Hydraulic System
• 28.22. How to Make Checks with Engine Running
• 28.23. Battery
• 28.24. Gauges, Indicator Lights, Horn, Fuses, and Relays
• 28.25. Transmission Oil Level
• 28.26. Steering System
• 28.27. Service Brakes
• 28.28. Parking Brake
• 28.29. Cooling System
• 28.30. Control Levers and Pedals
• 28.31. Lift System Operation
• 28.32. Maintenance Procedures Every 250 Hours or 6 Weeks
• 28.33. Parking Brake Linkage
• 28.34. Engine Filter and Oil
• 28.35. Oil Filter and Oil
• 28.36. Air Filter
• 28.37. Gasoline and LPG Fuel Filters
• 28.38. Fuel Filter, Diesel Engine
• 28.39. How to Drain Water from Fuel Filter
• 28.40. Transmission Oil Level
• 28.41. Battery
• 28.42. Hydraulic Tank Breather
• 28.43. Wheel Nuts
• 28.44. Engine Speed
• 28.45. LPG Carburetor
• 28.46. Gasoline Carburetor
• 28.47. Lift Chains
• 28.48. Lubrication
• 28.49. Wear Check
• 28.50. Steering Axle
• 28.51. Pedals, Levers, Cables, and Other Linkages
• 28.52. Spark Plugs (Mazda M4-1.5G or M4-2.0G Engine)
• 28.53. Differential
• 28.54. Drive Belts
• 28.55. Mazda M4-1.5G Gasoline/LPG Engine
• 28.56. Mazda M4-2.0G Gasoline/LPG Engine
• 28.57. Mazda M4-2.5D Diesel Engine
• 28.58. Inching Brake
• 28.59. PCV Valve
• 28.60. Brake Fluid
• 28.61. Maintenance Procedures Every 1000 Hours or 6 Months
• 28.62. Air Filter
• 28.63. Diesel Fuel System
• 28.64. Fuel Filter Replacement
• 28.65. Fuel System, Remove Air
• 28.66. Gasoline Fuel Filter
• 28.67. LPG Fuel Filter
• 28.68. Spark Plugs
• 28.69. Ignition System
• 28.70. Mazda M4-1.5G or M4-2.0G Engine
• 28.71. Injection Pump Timing, Mazda M4-2.5D Diesel Engine
• 28.72. Valve Clearance, Check and Adjust
• 28.73. Maintenance Procedures Every 2000 Hours or Yearly
• 28.74. Throttle Cable
• 28.75. Differential
• 28.76. Hydraulic System
• 28.77. Hydraulic Oil and Filter, Replace
• 28.78. Mazda M4-2.0G Engine Timing Belt
• 28.79. PCV Valve
• 28.80. Cooling System
• 28.81. Transmission
• 28.82. Transmission Oil and Filter, Replace
• 28.83. Wheel Bearings
• 28.84. Steer Wheels
• 28.85. Drive Wheels
• 28.86. Hood Latch Check
• 28.87. Latch, Adjust
• 28.88. Safety Procedures When Working Near Mast