Engine Service Repair:
Comprehensive engine diagnosis, repair, and overhaul procedures for various powerplants used in the H series.
Transmission Service Repair:
Detailed information on the transmission system, including maintenance, troubleshooting, and repair of hydrostatic or powershift transmissions.
Brake System:
Coverage of brake system components, maintenance, bleeding, adjustment, and repair procedures.
Electrical System:
In-depth explanation of the electrical system, including component identification, troubleshooting, and repair of wiring harnesses and electrical components.
Wiring Diagrams:
Includes detailed electrical wiring schematics for various systems within the forklift.
Suspension:
Information related to the steering axle and drive axle systems, including maintenance and repair.
Steering System:
Procedures for steering system maintenance, repair, and alignment.
Cooling System:
Maintenance and repair of the engine's cooling system, including radiators, hoses, and thermostats.
Fuel System:
Covers the fuel delivery, injection, and return systems, including maintenance and troubleshooting.
Fuel Injection:
Specific details on fuel injection system components, calibration, and repair.
Emission System:
Information related to emission control systems and their maintenance.
Heater Air Conditioning:
Service and repair procedures for the HVAC system.
Engine Control System:
Details on electronic engine management and control units.
Chassis Body:
Information on frame, structural components, and bodywork repair.
Restraint System:
Focuses on operator restraint, such as seat belts and safety harnesses.
Interior:
Procedures related to the operator's cabin and interior components.
Differential Drive Axle:
Comprehensive coverage of the drive axle and differential assembly.
Hydraulic System:
Extensive coverage of the hydraulic system, including pumps, valves, cylinders, hoses, filters, and troubleshooting for lift, tilt, and auxiliary functions.
Mast And Forks:
Details on mast assembly, lift chains, rollers, side shift mechanisms, and fork inspection and maintenance.
General Maintenance:
Routine maintenance checks, fluid changes, filter replacements, and lubrication schedules.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon issues.
Periodic Lubrication:
Detailed lubrication points, recommended lubricants, and service intervals for optimal performance and longevity.
Operating Device Operation:
Guidance on the correct operation of the forklift's working mechanisms, including mast, forks, and hydraulics.
Travel Operation:
Instructions on safe and efficient driving and maneuvering of the forklift.
Maintenance Check List:
Pre-operation, daily, weekly, and monthly maintenance checklists.
Service Instructions:
Step-by-step repair and replacement procedures for all major components.
Tightening Torque:
Specifications for critical fastener torque values to ensure proper assembly and prevent component failure.
Component Overhaul:
Detailed procedures for the complete disassembly, inspection, repair, and reassembly of major components like engines, transmissions, hydraulic pumps, and lift cylinders.
Hydraulic System Repair:
Step-by-step guides for hydraulic system maintenance, including fluid changes, filter replacements, seal replacements in cylinders and pumps, and diagnostic procedures for performance issues.
Engine Tune Up:
Procedures for engine tuning, including ignition system checks (if applicable), fuel system adjustments, and emissions system diagnostics.
Electrical Component Replacement:
Detailed instructions for replacing electrical components such as starters, alternators, sensors, switches, and control modules.
Depth Of Coverage:
Complete factory service and repair information, suitable for professional technicians and experienced mechanics. Covers everything from basic maintenance to complex overhauls and diagnostics.
Diagrams And Illustrations:
The manual is rich with technical diagrams, schematics, and detailed illustrations of components and assembly procedures, crucial for accurate repairs.
Diagnostic Procedures:
Includes step-by-step troubleshooting guides for diagnosing faults in all major systems, often listing symptoms, probable causes, and corrective actions.
Diagnostic Codes:
If the forklifts are equipped with electronic control units (ECUs), the manual would likely include a section on diagnostic trouble codes (DTCs) and their interpretation.
Dimensions Overview:
The manual provides detailed dimensions for each model variant (H100 through H160), including overall length, width, height, mast height (low and raised), and wheelbase. Specific figures vary by model and mast configuration.
Operator Cabin Dimensions:
Details on operator comfort and control layout within the cabin, though specific interior dimensions are less common in workshop manuals compared to operational guides.
Lifting Capacities:
Crucial information on the lifting capacities of the H100, H120, H136, H140, H150, and H160 models at various load centers and mast heights. This is a key specification provided in the operating section.
Vehicle Weights:
Includes curb weight, operating weight, and axle load capacities for each model variant, essential for safe operation and transportation.
Routine Maintenance Schedule:
The manual provides detailed recommended service intervals for all major components and systems, including engine oil changes, filter replacements, hydraulic fluid checks, brake inspections, and lubrication points (e.g., every 250, 500, 1000, 2000 operating hours, depending on the component and operating conditions).
Filter Replacement Intervals:
Specific intervals for replacing hydraulic filters, fuel filters, air filters, and oil filters based on operating hours and environmental conditions.
Recommended Oils Fluids:
Specific types and grades of engine oil, hydraulic fluid, transmission fluid, coolant, and grease are detailed, often including API/ISO classifications and part numbers from reputable suppliers.
Fluid Capacities:
The manual will specify the exact fluid capacities for the engine oil sump, hydraulic reservoir, transmission, and cooling system for each model variant.
Common Wear And Tear Items:
Troubleshooting sections often implicitly or explicitly highlight common wear items and potential failure points, such as hydraulic cylinder seals, lift chain wear, brake pad wear, and cooling system leaks, providing guidance on inspection and replacement.
Preventive Maintenance Tips:
Includes advice on preventative measures to avoid common problems, such as proper cleaning, avoiding overloading, and adhering to service intervals.
Common Hydraulic Failures:
Guidance on diagnosing and rectifying issues like slow hydraulic operation, leaks, or system pressure loss.
