Forklift repair manual cd forklifts fork lift mechanic

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FORKLIFT Repair Manuals and Reference Guides
The CD contains searchable adobe acrobat reader File (PDF)
with the following information in Hundreds of easy to read pages
Actual models covered in specifically in the manuals are:
BAKER MODEL FTD-020-EE 2,000-POUND CAPACITY
BAKER MODEL FTD-020-EE-SS 2,000-POUND CAPACITY
BAKER MODEL FTD-020-EE 2,000-POUND CAPACITY
Allis Chalmers Model ACP40PS and ACC40OPS 4,000 LB CAPACITY
HYSTER MODEL H40XL-MIL 4,000 LB CAPACITY
BAKER MODEL FTD-040-EE 4,000 LB CAPACITY
BAKER MODEL FJF-040 4,000 LB CAPACITY
HYSTER MODEL S40CP 4,000 LB CAPACITY
ALLIS-CHALMERS MODEL FE-60-EE 6000 LB CAPACITY
ANTHONY MODEL MLT 6-2 6,000 LB CAPACITY
ALLIS-CHALMERS MODEL FE-60-EE 6000 LB CAPACITY
Here is an example table of contents and some diagrams.
TABLE OF CONTENTS from GASOLINE ENGINE DRIVEN, 4,000 LB.CAPACITY (716 pages)
CHAPTER I OPERATING INSTRUCTIONS ................................1-1
CHAPTER I INDEX....................................................................1-1C
GENERAL DESCRIPTION.........................................................1-1E
PREPARING A NEW TRUCK FOR SERVICE ............................1-3
OPERATING CONTROLS..........................................................1-4
OPERATION OF LIFT TRUCK ...................................................1-7
BATTERY .................................................................................1-14
LUBRICANT SPECIFICATIONS ................................................1-15
LUBRICANT AND SERVICE .....................................................1-17
CHAPTER II MAINTENANCE INSTRUCTIONS ..........................2-1
MAINTENANCE INDEX.............................................................2-1A
DESCRIPTION AND SPECIFICATIONS .....................................2-1B
VALVE ADJUSTMENT...............................................................2-4
OIL FILTER................................................................................2-5
OIL PRESSURE RELIEF VALVE ..............................................2-5
ENGINE TUNE- UP ....................................................................2-6
TROUBLESHOOTING CHART.....................................................2-11
FUEL SYSTEM (PRT) ................................................................2-16
AIR CLEANER (PRT) .................................................................2-18
AIR CLEANER (SRT) .................................................................2-18A
FUEL TANK ...............................................................................2-19
FUEL PUMP AND FILTER..........................................................2-19
CARBURETOR..........................................................................2-20
ACCELERATOR LINKAGE.........................................................2-21
GOVERNOR..............................................................................2-22
ELECTRICAL SYSTEM ..............................................................2-23
BATTERY..................................................................................2-24
ALTERNATOR AND REGULATOR .............................................2-25
STARTER MOTOR ....................................................................2-27
ELECTRICAL WIRING ...............................................................2-28
HORN AND HORN RELAY.........................................................2-29
IGNITION COIL..........................................................................2-30
DISTRIBUTOR...........................................................................2-32
INSTRUMENT PANEL................................................................2-35
COOLING SYSTEM ...................................................................2-39
RADIATOR................................................................................2-41
WATER PUMP...........................................................................2-43
THERMOSTAT..........................................................................2-45
FAN AND FAN BELT..................................................................2-47
TRANSMISSION .......................................................................2-49
POWER SHIFT TRANSMISSION CHECKOUT PROCEDURES....2-53
SHIFTING MECHANISM.............................................................2-56
OIL COOLER ............................................................................2-58
OIL FILTER................................................................................2-59
UNIVERSAL JOINT....................................................................2-61
DRIVE AXLE..............................................................................2-63
HYDRAULIC BRAKES ...............................................................2-69
DIFFERENTIAL .........................................................................2-69
DRIVE WHEEL PNEUMATIC TIRES (PRT ONLY) ......................2-73
BRAKES..............................................................................2-75
MASTER CYLINDER............................................................2-76
DRIVE WHEEL BRAKES......................................................2-77
PARKING BRAKE ................................................................2-78
STEERING ..........................................................................2-79
STEER AXLE.......................................................................2-80
STEERING WHEEL AND COLUMN......................................2-82
DRAG LINK .........................................................................2-82
TIE ROD..............................................................................2-83
POWER STEER CYLINDER.................................................2-83
WHEELS AND TIRES...........................................................2-83A
HYDRAULIC SYSTEM SERVICE ..........................................2-85
COUNTERWEIGHT AND FRAME .............................................2-91
COUNTERWEIGHT AND FRAME.........................................2-91
COUNTERWEIGHT..............................................................2-91
BODY COMPONENTS .........................................................2-94
OVERHEAD GUARD............................................................2-96
GENERAL...........................................................................2-97
MAST ASSEMBLY ...............................................................2-98
LIFT CYLINDERS ................................................................2-99
CARRIAGES, SIDESHIFTER AND FORKS
CARRIAGE..........................................................................2-101
SIDESHIFTER (PRT ONLY) ................................................2-103
FORKS................................................................................2-104
FUEL SYSTEM ....................................................................2-105
COOLING SYSTEM .............................................................2-107
HYDRAULIC SYSTEM .........................................................2-108
DRIVE UNIT.........................................................................2-109
HYDRAULIC BRAKE SYSTEM .............................................2-110
POWER STEERING SYSTEM ..............................................2-111
MAST HYDRAULIC SYSTEM ...............................................2-112
POWER SHIFT TRANSMISSION..........................................2-113
ELECTRICAL SYSTEM ........................................................2-114
LUBRICANT AND FUEL SPECIFICATIONS
LUBRICANT SPECIFICATIONS............................................2-116
FUEL SPECIFICATIONS .....................................................2-117
LUBRICATION CHART...............................................................2-119
CHAPTER III REPAIR INSTRUCTIONS ..........................................3-1
REPAIR INDEX..........................................................................3-1A
FITS AND TOLERANCES...........................................................3-1B
ENGINE SERVICE AND MAINTENANCE ....................................3-4
MANIFOLD................................................................................3-5
VALVES, INTAKE AND EXHAUST..............................................3-7
CYLINDER HEAD ......................................................................3-13
CRANKSHAFT AND CRANKSHAFT COMPONENTS ..................3-15
FLYWHEEL AND HOUSING.......................................................3-23
PISTON AND CONNECTING RODS ...........................................3-27
CAMSHAFT, CAMSHAFT BEARINGS, AND VALVE TAPPETS ....3-33
GEAR TRAIN.............................................................................3-35
CYLINDER BLOCK ....................................................................3-39
OIL PUMP .................................................................................3-43
OIL PRESSURE RELIEF VALVE ................................................3-45
FILLER BLOCKS AND OIL GUARD ............................................3-46
OIL PAN....................................................................................3-48
ENGINE RUN-IN SCHEDULE .....................................................3-49
ENGINE REMOVAL/INSTALLATION...........................................3-50
FUEL SYSTEM ..........................................................................3-53
FUEL TANK ...............................................................................3-55
FUEL PUMP AND FUEL FILTER ...............................................3-57
CARBURETOR (TYPE II) (PRT) .................................................3-59
CARBURETOR (SRT) ................................................................3-66
ACCELERATOR LINKAGE.........................................................3-67
GOVERNOR..............................................................................3-69
AIR CLEANER (PRT) ................................................................3-70
BATTERY..................................................................................3-71
ALTERNATOR...........................................................................3-81
STARTER MOTOR ....................................................................3-91
DISTRIBUTOR (TYPE II) ............................................................3-98
COOLING SYSTEM DESCRIPTION............................................3-103
WATER PUMP...........................................................................3-105
RADIATOR................................................................................3-109
EXHAUST SYSTEM .......................................................................3-113
TRANSMISSION........................................................................3-115
TORQUE CONVERTER A ND PUMP ...............................................3-125
DRUM ASSEMBLY ..........................................................................3-127
CONTROL VALVE ...........................................................................3-129
UNIVERSAL JOINT .............................................................................3-131
DRIVE AXLE....................................................................................3-135
DIFFERENTIAL................................................................................3-142
DRIVE WHEEL PNEUMATIC TIRES (PRT) .......................................3-146
DRIVE WHEEL BRAKES..................................................................3-147
MASTER CYLINDER........................................................................3-151
WHEEL CYLINDERS .......................................................................3-153
PARKING BRAKE ............................................................................3-153
BLEEDING THE BRAKE SYSTEM ....................................................3-155
GENERAL DESCRIPTION................................................................3-157
STEER AXLE...................................................................................3-157
STEERING VALVE UNIT..................................................................3-163
STEERING CYLINDER AND DRAG LINK..........................................3-171
TIE RODS .......................................................................................3-175
STEER WHEELS (PRT) ..................................................................3-176
STEER WHEELS (SRT) ...................................................................3-178a
HYDRAULIC PUMP .........................................................................3-179
CONTROL VALVE ...........................................................................3-182
TILT CYLINDER ..............................................................................3-185
MASTS ...........................................................................................3-189
LIFT CYLINDERS ...........................................................................3-192
CARRIAGES ...................................................................................3-195
FORK ..............................................................................................3-197
WELDING REPAIR PROCEDURE ....................................................3-199
SIDE SHIFTERS .............................................................................3-201
HOSE REEL ...................................................................................3-204
SUPPLEMENTAL OPERATING, MAINTENANCE
GENERAL............................................................................................1
MAINTENANCE....................................................................................3
REPAIR PARTS SUPPLY .....................................................................5
APPENDIX A-L.....................................................................................8
WARRANTY ....................................................................................8
ASL/PLL ..........................................................................................9
MAC................................................................................................10
MEL CHART....................................................................................25
MAOSL............................................................................................26
MAINTENANCE OF NEW VEHICLE..................................................28
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
(PMCS)............................................................................................30
BASIC ISSUE ITEMS LIST...............................................................42
DISTRIBUTION CODES ...................................................................44
FLOW OF REQUISITIONS AND MATERIEL PARTS, NSN.................47
FLOW OF REQUISITIONS AND MATERIEL PARTS, NONNSN................................................................................................
SAMPLE REQUISITIONING FORMATS ............................................49
PARTS LIST ........................................................................................i
BASE UNIT INDEX...........................................................................ii
FSCN INDEX...................................................................................iii
PART NUMBER LIST.......................................................................A
ILLUSTRATIONS..................................................................................1A
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