Hyster F003 (H40-60JS) Service Manual - Image 2

Hyster F003 (H40-60JS) Service Manual - Image 3

Hyster F003 (H40-60JS) Service Manual - Image 4

Hyster F003 (H40-60JS) Service Manual - Image 5

Hyster F003 (H40-60JS) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 547
Size: 21.0MB
Format: PDF

Category: Hyster Service Manual PDF

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.)

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