Hyster F001 (H30-35FT, H40FTS) Fortis Forklift Service Manual

Name: Hyster F001 (H30-35FT, H40FTS) Fortis Forklift Service Manual
Brand: MidWestTech
SKU: 1599956
Price: 469.57 USD
Availability: InStock

4,669 pages · Publication 1599956

$469.57

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Models: F001 (H30-35FT, H40FTS) Fortis
Manual type: Service Manual
Pages: 4,669
Publication: 1599956
Condition: Brand new

Hyster F001 (H30-35FT, H40FTS) Fortis Forklift Service Manual, publication 1599956

What's inside

From the manual's own table of contents: 181 sections, 471 entries. See sample pages (PDF, 355 KB)

Search the contents

Frame

Safety Precautions Maintenance and Repair

General

Description

Hood, Seat, and Side Covers Replacement2 topics

Remove
Install

Steering Column2 topics

Description
Steering Column Repair

LPG Tank and Bracket Assembly

Counterweight Replacement1 topic

Tow Pin, Remove and Install

Overhead Guard Replacement2 topics

Remove and Install
LED Tail, Backup, and Brake Lights, Replace

Operator Restraint System Replacement

Engine Replacement

Transmission Replacement4 topics

Remove Transmission with Iron Housing
Install Transmission with Iron Housing
Remove Transmission with Aluminum Housing
Install Transmission with Aluminum Housing

Throttle Pedal and Cable Adjustment5 topics

Mazda Gas/LPG Engines With Basic Power Shift Transmission and El
Mazda Gasoline Engine With Electronic Transmission
Throttle Pedal Stop Adjustment
Yanmar Diesel Engine With Basic Power Shift Transmission
Yanmar Diesel Engine With Electronic Throttle

Exhaust System Repair2 topics

Lift Trucks With Counterweight Exhaust System
Lift Trucks With Overhead Exhaust System

Cooling System

Hydraulic Filter Assembly Repair1 topic

Clean and Inspect

Fuel and Hydraulic Tanks Repair6 topics

Inspect
Clean
Additional Preparations for Repair
Small Leaks, Repair
Large Leaks, Repair
Preparations for Use After Repair

Safety Labels

Table 1. Gas Spring Installation, Lift Truck Models H1.6FT, H1.8

Table 2. Gas Spring Installation, Lift Truck Models H2.0-3.5FT (

Table 3. Weight of Counterweights, Lift Truck Models S2.0-3.5FT

Table 4. Weight of Counterweights, Lift Truck Models S30FT, S35F

Table 5. Weight of Counterweights, Lift Truck Models H1.6FT, H1

Table 6. Weight of Counterweights, Lift Truck Models H2.0-3.5FT

Show all 181 sections

GM Engine Repair

Engine Serial Number

Engine Removal and Installation

Intake Manifold

Exhaust Manifold

Camshaft and Cylinder Head Repair3 topics

Rocker Arm Cover
Camshaft Timing Pulley and/or Front Seal
Camshaft Carrier and Cylinder Head

Timing Belt3 topics

Timing Belt Front Cover
Timing Belt and Timing Belt Tensioner
Timing Belt Rear Cover

Lubrication System Repair2 topics

Oil Pan
Oil Pump

Piston and Piston Rod Assemblies Repair2 topics

Piston Rod Bearings, Replace
Piston and Piston Rod Assemblies

Crankshaft and Main Bearings5 topics

Crankshaft Timing Pulley and/or Front Seal
Crankshaft Rear Main Oil Seal
Crankshaft/RPM Sensor
Crankshaft Reluctor Wheel
Crankshaft and Main Bearings

Flywheel and Flywheel Housing

Cooling System Repair4 topics

Serpentine Belt
Water Pump
Thermostat
Thermostat Housing

Sensors and Switches3 topics

Crankshaft Position (CKP) Sensor
Camshaft Position (CMP) Sensor
Oil Pressure Sensor

Ignition System5 topics

Spark Plug Wire Inspection
Spark Plug Wire Replacement
Spark Plug Replacement
Spark Plug Inspection
Coil Pack

Alternator Repair2 topics

Alternator
Alternator Fuse, Replace

Starter Repair

Engine Specifications12 topics

Engine Data
Cylinder Bore
Piston
Piston Rings
Wrist Pin
Crankshaft
Piston Rod
Camshaft and Camshaft Carrier
Valve System
Cylinder Head Warpage
Lubrication System
Cooling System

Torque Specifications

Special Tools

Mazda Engine1 topic

Serial Number

Cylinder Head, Camshaft, and Valve Mechanism Repair1 topic

Inspect and Repair

Crankshaft and Main Bearings Repair

Pistons and Connecting Rods Repair2 topics

Remove and Disassemble
Assemble and Install

Cylinder Block Repair

Oil Pump Repair3 topics

Disassemble
Assemble
Fan Assembly

Flywheel and Ring Gear Repair

Valve Adjustment

Compression Pressure Check

Engine Timing Adjustment7 topics

Engine Speeds
Cylinder Head
Valve Mechanism
Camshaft
Connecting Rods
Cylinder Block
Pistons

Table 1. Pressure Specifications

Cooling System Checks3 topics

Exhaust Leaks Into Cooling System
Water Flow Restrictions in Radiator
Radiator Hoses

Flushing the Cooling System1 topic

Cooling System, Clean

Radiator Replacement6 topics

Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0
Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S
Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0
Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT
Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT

Fan Assembly Replacement2 topics

Fan Removal
Fan Installation

LPG Fuel System

Hoses Replacement

LPG Tank and Bracket Replacement6 topics

Remove LPG Tank
Install LPG Tank
Remove LPG Bracket
Install LPG Bracket
Remove LPG Tank Bracket Alignment Pin
Install LPG Tank Bracket Alignment Pin

Fuel Filter Unit Repair2 topics

Fuel Filter Element
Fuel Filter Housing

Electronic Throttle Body Repair2 topics

Electronic Throttle Body
Electronic Throttle Body Adapter Plate

Fuel Injector Repair4 topics

Fuel Rail
Fuel Injector for Lift Trucks Built Before January, 2010
Fuel Injector Adapters for Lift Trucks Built Before January, 201
Fuel Injectors and Adapters for Lift Trucks Built After January

LPG Regulator Repair3 topics

LPG Regulator
LPG Regulator Fuel Filter
Lock-Off Solenoid and Cartridge

Control System7 topics

Electronic Control Unit (ECU)
Fuel Pump Relay
Injector Driver Module
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT)
Engine Coolant Temperature (ECT) Sensor
Oxygen Sensor
Low LPG Pressure Switch

LPG Tank Replacement

Fuel Filter

Relief Valve Replacement

Carburetor Repair

Governor Repair

Regulator Repair4 topics

Engine Control Unit (ECU)
Intake Air Temperature (IAT) Sensor
Manifold Absolute Pressure (MAP) Sensor
Throttle Position (TP) Sensor

Gasoline Fuel System

Fuel System Repair6 topics

Before Repair Procedure
After Repair Procedure
Fuel Line Pressure Check
Fuel Injectors
Pressure Regulator
Power Latch Relay

Abbreviations

Engine Tune-up3 topics

Engine Tune-Up Preparation
Idle Speed Adjustment
Idle-Up Speed Check

Intake-Air System5 topics

Intake-Air System Manifold Vacuum Check
Throttle Body
Electronic Governor
Intake-Air Control (IAC) Valve
Intake Manifold

Fuel System1 topic

Fuel Injector

Exhaust System6 topics

Exhaust System, Inspect
Three-Way Catalytic (TWC) Converter
Exhaust Manifold
Positive Crankcase Ventilation (PCV) Valve
Mass Air Flow (MAF) Sensor
Manifold Absolute Pressure (MAP)/Boost Sensor

Technical Data

Table 1. PCV Valve Specifications

Table 2. Closed Throttle Position Specifications

Table 3. Gasoline Fuel Systems Technical Data

Powershift Transmission

Charge Pump Repair

Torque Converter Replace

Front Cover Housing and Chain Drive Repair

Clutch Packs Repair

Control Valve Repair

MONOTROL® Pedal Repair

Direction Control Lever

Steering Axle

Steering Axle Assembly Repair

Spindles, Bearings, and Tie Rods Repair2 topics

Spindles and Bearings
Tie Rods

Steering Cylinder Repair

Brake System2 topics

Dry Brake System
Wet Brake System

Service Brakes Repair (Dry Brake)2 topics

Adjust
Inching Overlap Adjustment

Parking Brake Repair

Master Cylinder Repair11 topics

Remove (Dry Brake)
Disassemble (Dry Brake)
Clean and Inspect (Dry Brake)
Assemble (Dry Brake)
Bench Bleed Master Cylinder (Dry Brake)
Install and Adjust (Dry Brake)
Remove (Wet Brake)
Disassemble (Wet Brake)
Clean and Inspect (Wet Brake)
Assemble (Wet Brake)
Install and Adjust (Wet Brake)

Service Brakes Adjustment (Dry Brake)

Brake System Air Removal2 topics

Using Pressure Bleed System
Using Brake Pedal Pressure

Brake Pedal Adjustment

Free Pedal Adjustment

Electrical System4 topics

General
Ignition Timing Adjustment, Gasoline and LPG
Spark Plugs Check
Spark Plug Wires Check

Distributor Repair1 topic

Igniter

Ignition Coil Check7 topics

Primary Coil Winding
Secondary Coil Winding
No-Load Test
Magnetic Switch Test
Charging System Inspection
Output Current Check
No-Load Adjusted Voltage Check

Table 1. Spark Plug Wire

Table 2. Starter Specifications

Table 3. Problem Diagnosis Chart

Table 4. Specifications

Table 5. Rectifier Check Table

Periodic Maintenance4 topics

Serial Number Data
How to Move Disabled Lift Truck
How to Put Lift Truck on Blocks
How to Clean a Lift Truck

Maintenance Schedule

Maintenance Procedures Every 8 Hours or Daily2 topics

How to Make Checks With Engine Stopped
How to Make Checks With Engine Running

First Service After First 100 Hours of Operation2 topics

Mazda and GM Engine Oil and Oil Filter
Yanmar Engine Oil and Oil Filter

Maintenance Procedures Every 250 Hours or 6 Months3 topics

Drive Belt
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Complia
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engi

Maintenance Procedures Every 500 Hours or 6 Months17 topics

Hydraulic System Oil
Hydraulic Tank Breather
Battery
PCV Valve
Clean Debris From Radiator Core
Transmission Oil Level
Wet Brake Planetary Housing Oil Level Check
Forks
Mast Lubrication
Header Hose Checks
Lift Chain Lubrication
Tilt Cylinder Lubrication
Master Brake Cylinder Rod End Pin Lubrication
Manual Hydraulic Levers Lubrication
Brake Fluid
Tie Rod Lubrication (H40-70FT)
Differential and Drive Axle Oil (Dry Brake)

Maintenance Procedures Every 1000 Hours or 6 Months13 topics

Valve Clearance, Check and Adjust
Ignition System
LPG Fuel Filter Element Replace, GM 2.4L Engine
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines O
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant
Fuel Filter Replacement, Yanmar Engine
Priming the Fuel System (Yanmar)
Lift Chains Wear Check
Integral Sideshift Carriage, Check Bearings
Integral Sideshift Carriage, Check Lower Mounting Hooks
Steering Axle
Control Levers and Pedals

Maintenance Procedures Every 2000 Hours or Annually19 topics

Hydraulic System
Air Filter
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emis
LPG Regulator Fuel Filter, GM Engines
Gasoline Fuel Filter
Timing Belt
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Com
Gasoline Fuel Injector, Mazda Engines
LPG Fuel Injector, GM Engines
Gasoline Fuel Injector, GM Engines
Fuel Injector, Yanmar Engines
Integral Sideshift Carriage
Transmission Oil and Filter (Dry Brake), Replace
Transmission Oil Change, Wet Brake Drive Axle
Wet Brake Axle Center Section and Planetary Housing, Oil Change
Brake Fluid (Master Cylinder), Change
Brake Fluid (Dry Brake), Remove
Service Brakes (Dry Brake)
Differential (Dry Brake)

Maintenance Procedures Every 4000 Hours or 2 Years1 topic

Hydraulic Oil, Replace

Safety Procedures When Working Near Mast

Hood Latch Check

Lift Chain Adjustments

Jump-Starting the Lift Truck2 topics

Jump-Starting Using a Battery Charger
Jump-Starting a Lift Truck Using Another Lift Truck

Welding Repairs

Overhead Guard Changes

Wheel and Tire Replacement5 topics

Solid Rubber Tire, Change ( S Series)
Pneumatic Tire With Tube, Repair
Add Air to Pneumatic Tires With Tube
Pneumatic Tubeless Tire, Repair
Solid Rubber Tires on Pneumatic Wheels, Change

Adhesives and Sealants

Table 1. Maintenance Schedule

Table 2. V-Belt Deflection Table

Table 3. Carriage Chain Adjustment, Forks Not Installed

Capacities and Specifications

Lift Truck Lifting Capacity

Counterweight Weights

Tire Sizes

Capacities

Transmission Oil Pressures

Hydraulic System Relief Pressures

Steering System

Stall Speeds (in RPM ±100 rpm)6 topics

Mazda 2.0L (Except 2007 Emission Compliant Engines)
Mazda 2.0L (2007 Emission Compliant Engines Only)
Mazda 2.2L (Except 2007 Emission Compliant Engines)
Mazda 2.2L (2007 Emission Compliant Engines Only)
Yanmar 2.6L
Yanmar 3.3L

Mast Speeds

Tilt Angles

Front End Equipment - Mast Creep12 topics

Mast Creep
Frame
Mast
Steering System, Cushioned Tire Trucks
Steering System, Pneumatic Tire Trucks
Drive Axle (Dry Brake)
Drive Axle (Wet Brake)
Transmission - Iron Housing
Transmission - Aluminum Housing
Engine - Mazda 2.0L and 2.2L
Engine - GM 2.4L
Engine - Yanmar 2.6L and 3.3L Diesel

Table 1. Hydraulic Systems With Hydraulic Gear Pump

Table 2. Hydraulic Systems With Variable Displacement Pump

Drive Axle Repair1 topic

Identification Plate

Drive Axle Removal

Reduction Gear Assembly1 topic

Reduction Gear Assembly Repair

Brake Repair2 topics

Wet Disc Brake
Parking Brake Control Lever

Differential Repair

Drive Axle Installation

Table 1. Bevel Gear and Bevel Pinion Tooth Contact Adjustment

Table 2. Correct Tooth Contact

Table 3. Incorrect Tooth Contact

Drive Axle and Differential Assembly Repair

Table 1. Pinion Variation Numbers Examples

Table 2. Ring and Pinion Tooth Contact Adjustment

Table 3. Correct Tooth Contact

Table 4. Incorrect Tooth Contact3 topics

Counterweight Exhaust System
Overhead Exhaust System
Fuel Level Sensor

Table 2. Gasoline Fuel Systems Technical Data10 topics

Remove LPG Tank for Lift Truck Models S30FT, S35FT, S40FTS (E010
Install LPG Tank for Lift Truck Models S30FT, S35FT, S40FTS (E01
Remove LPG Tank for Lift Truck Models S50CT (A267) and H2.0-2.5C
LPG Tank Install for Lift Truck Models S50CT (A267) and H2.0-2.5
Remove LPG Bracket for Lift Truck Models S30FT, S35FT, S40FTS (E
Install LPG Bracket for Lift Truck Models S30FT, S35FT, S40FTS (
Remove LPG Tank Bracket Alignment Pin, Lift Truck Models S30FT
Install LPG Tank Bracket Alignment Pin, Lift Truck Models S30FT
Remove LPG Bracket for Lift Truck Models S50CT (A267) and H2.0-2
Install LPG Bracket for Lift Truck Models S50CT (A267) and H2.0

Electronic Pressure Regulator (EPR) Repair

LPG Shutoff Valve Assembly

Fuel Mixer Repair1 topic

LPG Low Level Sensor

Coil Replacement

Engine Sensors and Switches7 topics

Oil Pressure Sensor, Gas and LPG Engines
Air Filter Restriction Switch, Gas and LPG Engines
Cam Angle Sensor, Gas and LPG Engines
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines
Intake Air Temperature (IAT) Sensor, LPG Engines
Intake Air Temperature (IAT) Sensor, Gas Engines
Fuel Temperature Sensor, LPG Engines

Table 1. Spark Plug Wires

Table 2. Coil Inspection

Table 3. Starter Specifications

Table 4. Problem Diagnosis Chart

Table 5. Specifications - 2007 Emissions Compliant Engines

Table 6. Specifications - Lift Trucks Built After January, 2010

Table 7. Rectifier Check Table - 2007 Emissions Compliant Engine

Table 8. Rectifier Check Table - Lift Trucks Built After January

Single Speed PowerShift

Hydraulic Gear Pump2 topics

Original Charge Pump
New Charge Pump, Manufactured After July, 2013

Torque Converter Replacement

Stator Support Assembly Repair

Proportional and Enable Solenoid Valves3 topics

Proportional Valves
Enable Solenoid Valve
Remove and Disassembly

Housing Fittings Replacement2 topics

Lift Trucks Manufactured Before July, 2013
Lift Trucks Manufactured After July, 2013

Drive Chains and Sprockets

Housings and Chain Drive Repair

Inside this manual

Real pages from this service manual (4,669 pages). Open the sample pages (PDF, 354 KB)

Sample pages from the Hyster F001 (H30-35FT, H40FTS) Fortis Forklift Service Manual: Troubleshooting, Specifications, Diagram, Color page, Color page

Troubleshooting, page 837: Oxygen (O2) Sensor Signal Troubleshooting
Specifications, page 3,789: LPG Tank and Bracket Replacement
Diagram, page 4,437: S155FT) (F024, G024) and H6.0FT, H7.0FT (H135FT, H155FT) (K006)
Color page, page 1,429: STEERING CONTROL UNIT (SCU)
Color page, page 1,680: Figure 9060-10-25. Cab Component Locations

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 4,669 pages

Quantity one is the manual described above.

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Other editions and similar models

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