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Hyster A177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster A177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster A177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
THE TILT CYLINDERS ............................................................................................... 1 INTRODUCTION.................................................................................................. 4 GENERAL................................................................................................... 4 DESCRIPTION............................................................................................... 4 REPAIRS....................................................................................................... 4 REMOVAL................................................................................................... 4 DISASSEMBLY............................................................................................... 4 CLEANING.................................................................................................. 4 ASSEMBLY.................................................................................................. 4 Tilt Cylinders for the XM and XMS Models.............................................................. 4 Tilt Cylinders with O-Ring or Single Lip Seals........................................................ 6 Tilt Cylinders for H700-800A and Early Model H700-920B................................................ 6 INSTALLATION.............................................................................................. 6 Tilt Cylinders with Chevron Packing................................................................... 6 CHECKS AND ADJUSTMENTS........................................................................................ 10 CHECK THE TILT CYLINDERS FOR LEAKS........................................................................ 10 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE................................................... 10 TROUBLESHOOTING............................................................................................... 13 CAPACITIES AND SPECIFICATIONS .................................................................................... 16 LIFT TRUCK WEIGHTS*........................................................................................... 16 ENGINE SPECIFICATIONS......................................................................................... 16 ENGINE ELECTRICAL SPECIFICATIONS.............................................................................. 17 HYDRAULIC SPECIFICATIONS...................................................................................... 17 CAPACITIES.................................................................................................... 18 LIFT TRUCK TRAVEL SPEEDS...................................................................................... 18 TIRE SPECIFICATIONS........................................................................................... 18 MAST SPEEDS (Early A177* Units)............................................................................... 19 MAST SPEEDS (Later A177* Units)............................................................................... 19 MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)......................................... 20 MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)....................................................... 20 TORQUE SPECIFICATIONS......................................................................................... 22 TORQUE SPECIFICATIONS......................................................................................... 23 DIAGRAMS ......................................................................................................... 25 HYDRAULIC SCHEMATIC SYMBOLS................................................................................... 25 HYDRAULIC SYSTEM SCHEMATIC - FOR UNITS WITH WARNER TRANSMISSION............................................... 27 HYDRAULIC SYSTEM SCHEMATIC - FOR UNITS WITH HYSTER T41, T42, T43 TRANSMISSIONS................................ 29 TRANSMISSION HYDRAULIC SCHEMATIC - FOR UNITS WITH WARNER TRANSMISSION......................................... 30 TRANSMISSION HYDRAULIC SCHEMATIC - FOR UNITS WITH HYSTER T41, T42, T43 TRANSMISSION........................... 31 GASOLINE/LPG ENGINE WIRING DIAGRAM (G and LPG Rating)......................................................... 33 GASOLINE/LPG (SAFETY) ENGINE WIRING DIAGRAM (GS and LPS Rating)............................................... 35 GASOLINE/LPG ENGINE CABLE DIAGRAM (G and LPG Rating).......................................................... 37 DIESEL ENGINE WIRING DIAGRAM (D Rating)....................................................................... 39 DIESEL (SAFETY) ENGINE WIRING DIAGRAM (DS Rating)............................................................. 41 DIESEL ENGINE CABLE DIAGRAM (D Rating)........................................................................ 43 ELECTRICAL DIAGRAM, INSTRUMENT PANEL.......................................................................... 44 ELECTRICAL WARNING DEVICES ....................................................................................... 45 ELECTRICAL WARNING DEVICES.................................................................................... 45 GENERAL................................................................................................... 45 DESCRIPTION............................................................................................... 45 Operator Controlled Horns............................................................................. 45 System Warning Lights, Buzzers and Bells.............................................................. 45 Reverse Warning Horns................................................................................. 46 Warning Lights........................................................................................ 46 REPLACEMENT............................................................................................... 47 General............................................................................................... 47 Replacing Horns or Bells.............................................................................. 47 Replacing Horn Relay or Buzzer........................................................................ 47 Replacing Warning Lights.............................................................................. 47 Light Assemblies...................................................................................... 48 Replacing Flashing Units.............................................................................. 48 INCH (SAE) AND METRIC FASTENERS .................................................................................. 49 INTRODUCTION.................................................................................................. 49 NOMENCLATURE, THREADS..................................................................................... 49 STRENGTH IDENTIFICATION................................................................................... 50 TABLE 1. BOLTS AND SCREWS..................................................................................... 50 TABLE 2. STUDS AND NUTS....................................................................................... 51 TABLE 3. TORQUE NUTS.......................................................................................... 52 TABLE 4. TORQUE NUTS WITH NYLON INSERT........................................................................ 53 TABLE 5. TORQUE VALUES FOR INCH FASTENERS..................................................................... 54 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS................................................................... 55 INSTRUMENT PANEL INDICATORS AND SENDERS .......................................................................... 58 INTRODUCTION.................................................................................................. 58 GENERAL................................................................................................... 58 DESCRIPTION................................................................................................... 58 GENERAL................................................................................................... 58 STEERING COLUMN GAUGES, METERS AND INDICATORS............................................................. 61 LED DISPLAY PANEL......................................................................................... 61 Battery Discharge Indicators ......................................................................... 61 Brush Wear Indicators................................................................................. 62 Motor Temperature Indicators.......................................................................... 63 "LX" SERIES INSTRUMENT PANEL DISPLAY...................................................................... 64 Hourmeter Functions................................................................................... 65 Battery Indicator Function............................................................................ 65 Status Code Function.................................................................................. 65 CHECKS AND ADJUSTMENTS........................................................................................ 65 GENERAL................................................................................................... 65 REPLACEMENT................................................................................................... 66 GENERAL................................................................................................... 66 METER REPLACEMENT......................................................................................... 66 SENDER REPLACEMENT........................................................................................ 67 Fuel Level Sender..................................................................................... 67 Pressure And Temperature Sender....................................................................... 68 I.T.W. DISPLAY PANEL...................................................................................... 68 Removal............................................................................................... 68 SPECIFICATIONS................................................................................................ 69 TROUBLESHOOTING............................................................................................... 70 LIFT CYLINDERS ................................................................................................... 71 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.................................................................. 71 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................. 71 LIFT CYLINDERS................................................................................................ 74 GENERAL................................................................................................... 74 DESCRIPTION............................................................................................... 74 Lowering Control Valve................................................................................ 74 Cylinders (General)................................................................................... 77 Cylinders (H520-620B,H700-800A)....................................................................... 79 Cylinders (H360-460B)................................................................................. 80 Cylinders (Two-Speed)................................................................................. 80 REPAIRS....................................................................................................... 81 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST.................................................... 81 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.............. 81 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead............................... 85 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder......................... 83 DISASSEMBLY............................................................................................... 83 ASSEMBLY.................................................................................................. 85 INSTALLATION OF THE LIFT CYLINDER IN THE MAST............................................................. 85 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.............. 85 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead...................... 85 CHEVRON PACKING........................................................................................... 86 LIFT CYLINDERS FOR VISTA MASTS................................................................................ 89 DESCRIPTION............................................................................................... 89 Lowering Control Valve................................................................................ 91 REMOVAL................................................................................................... 92 DISASSEMBLY............................................................................................... 92 ASSEMBLY.................................................................................................. 92 INSTALLATION.............................................................................................. 93 Main Lift Cylinders................................................................................... 93 Free-Lift Cylinders................................................................................... 93 CHECKS AND ADJUSTMENTS........................................................................................ 94 CHECK FOR LEAKS IN LIFT SYSTEM............................................................................ 94 TROUBLESHOOTING............................................................................................... 95 SPECIFICATIONS................................................................................................ 96 LIFT CYLINDERS_ .................................................................................................. 97 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.................................................................. 97 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................. 97 LIFT CYLINDERS................................................................................................100 GENERAL...................................................................................................100 DESCRIPTION...............................................................................................100 Lowering Control Valve................................................................................100 Cylinders (General)...................................................................................103 Cylinders (H520-620B,H700-800A).......................................................................105 Cylinders (H360-460B).................................................................................106 Cylinders (Two-Speed).................................................................................106 REPAIRS.......................................................................................................107 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST....................................................107 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............107 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...............................111 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.........................109 DISASSEMBLY...............................................................................................109 ASSEMBLY..................................................................................................111 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.............................................................111 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............111 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead......................111 CHEVRON PACKING...........................................................................................112 LIFT CYLINDERS FOR VISTA MASTS................................................................................115 DESCRIPTION...............................................................................................115 Lowering Control Valve................................................................................117 REMOVAL...................................................................................................118 DISASSEMBLY...............................................................................................118 ASSEMBLY..................................................................................................118 INSTALLATION..............................................................................................119 Main Lift Cylinders...................................................................................119 Free-Lift Cylinders...................................................................................119 CHECKS AND ADJUSTMENTS........................................................................................120 CHECK FOR LEAKS IN LIFT SYSTEM............................................................................120 TROUBLESHOOTING...............................................................................................121 SPECIFICATIONS................................................................................................122 PERIODIC MAINTENANCE .............................................................................................123 PERIODIC MAINTENANCE..........................................................................................123 GENERAL...................................................................................................123 Serial Number Data....................................................................................123 HOW TO MOVE A DISABLED LIFT TRUCK.........................................................................124 How To Tow the Lift Truck.............................................................................124 HOW TO PUT A LIFT TRUCK ON BLOCKS.........................................................................124 How To Raise the Drive Tires..........................................................................124 How To Raise the Steering Tires.......................................................................125 MAINTENANCE PROCEDURES........................................................................................129 EVERY 8 HOURS OR DAILY........................................................................................129 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED................................................................129 Engine Oil............................................................................................129 Drive Belts...........................................................................................129 Cooling System........................................................................................129 Battery...............................................................................................130 Fuel System...........................................................................................132 Air Filter............................................................................................132 Hydraulic System Oil..................................................................................132 Tires and Wheels......................................................................................133 Forks.................................................................................................133 Forks, Adjustment.....................................................................................134 Forks, Removal And Installation.......................................................................134 Inspection Of Forks, Mast, and Lift Chains............................................................135 Safety Labels.........................................................................................136 Operator Restraint System.............................................................................136 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING................................................................137 Gauges, Lights, Horn, and Fuses.......................................................................137 Fuel Filter, Diesel Engine............................................................................138 How To Drain The Water From The Fuel Filter...........................................................138 Oil Level, Powershift Transmission....................................................................138 Control Levers and Pedals.............................................................................138 Lift System Operation.................................................................................138 Inching/Brake Pedal...................................................................................139 Service Brakes........................................................................................139 Parking Brake.........................................................................................139 Steering System.......................................................................................139 EVERY 250 HOURS OR TWO MONTHS.................................................................................140 ENGINE OIL AND FILTER.....................................................................................140 Mazda, GM, And Later Production Isuzu Engines.........................................................140 Earlier Production Isuzu C240 Engines.................................................................140 GOVERNOR, MAZDA ENGINE....................................................................................141 DRIVE BELTS...............................................................................................141 Mazda Engine..........................................................................................141 Isuzu, GM 4-181, And GM 4-153 Engines.................................................................141 BRAKE FLUID...............................................................................................142 HYDRAULIC TANK BREATHER, CLEAN AND CHECK..................................................................142 FORKS, CHECK FOR WEAR AND DAMAGE..........................................................................142 LIFT CHAINS...............................................................................................142 Lubrication...........................................................................................142 Check For Wear........................................................................................142 MAST, LUBRICATION.........................................................................................143 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...............................................................143 CONTROL LEVERS AND PEDALS, LUBRICATION....................................................................144 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.......................................................................144 Idle Speed, Diesel....................................................................................144 LPG Carburetor........................................................................................145 Gasoline Carburetor...................................................................................145 EVERY 1000 HOURS OR SIX MONTHS................................................................................146 DIESEL FUEL FILTER........................................................................................146 Filter Replacement, Models Without A Water Separator..................................................147 Filter Replacement, Models With A Water Separator.....................................................147 Remove Air from the Diesel Fuel System................................................................147 DIFFERENTIAL..............................................................................................148 VALVE CLEARANCE ADJUSTMENT................................................................................148 IGNITION SYSTEM, MAZDA AND GM ENGINES.....................................................................148 PCV VALVE AND FILTER......................................................................................150 EVERY 2000 HOURS OR YEARLY....................................................................................150 HYDRAULIC SYSTEM..........................................................................................150 Replace the Hydraulic Oil and Filter..................................................................150 POWERSHIFT TRANSMISSION...................................................................................150 COOLING SYSTEM............................................................................................151 SERVICE BRAKES............................................................................................151 DIFFERENTIAL..............................................................................................151 WHEEL BEARINGS............................................................................................152 Steering Wheels, lubrication..........................................................................152 Drive Wheels, Lubrication.............................................................................152 GASOLINE FUEL FILTER, REPLACEMENT.........................................................................152 PCV VALVE, GM ENGINES.....................................................................................152 LPG FILTER, REPLACEMENT...................................................................................152 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A............................................................152 GENERAL PROCEDURES............................................................................................153 CHECK THE HOOD LATCH......................................................................................153 LIFT CHAIN ADJUSTMENTS....................................................................................153 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................155 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................156 Check the Lift Cylinders for Leaks....................................................................156 Check the Tilt Cylinders for Leaks....................................................................156 FUEL INJECTORS............................................................................................157 WELDING REPAIRS...........................................................................................157 CHANGES TO THE OVERHEAD GUARD.............................................................................157 WHEELS AND TIRES..........................................................................................157 Solid Rubber Tires (Press-on).........................................................................157 Install The Wheels....................................................................................158 Pneumatic Tires, Remove The Wheels From The Lift Truck................................................159 Pneumatic Tires, Remove the Tire From The Wheel.......................................................159 Pneumatic Tires, Install The Wheel In The Tire........................................................160 Pneumatic Tires, Add Air To The Tires.................................................................161 Pneumatic Tires, Install the Wheels...................................................................162 Pneumatic Tires, Installation Procedures, Dual Drive Wheels...........................................162 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.........................................................163 Remove The Wheels From The Lift Truck.................................................................163 Remove The Tire From The Wheel........................................................................163 Install The Tire On The Wheel.........................................................................164 REFERENCE TABLE...............................................................................................165 THE BRAKE SYSTEM .................................................................................................166 INTRODUCTION..................................................................................................166 GENERAL...................................................................................................166 DESCRIPTION AND OPERATION.................................................................................166 Service and Parking Brakes............................................................................168 REPAIRS.......................................................................................................168 REMOVAL AND DISASSEMBLY...................................................................................168 Service and Parking Brakes............................................................................168 Master Cylinder.......................................................................................169 CLEANING AND INSPECTION...................................................................................170 ASSEMBLY AND INSTALLATION.................................................................................170 Service and Parking Brakes............................................................................170 Master Cylinder.......................................................................................175 CHECKS AND ADJUSTMENTS........................................................................................175 ADJUST THE SERVICE BRAKES.................................................................................175 ADJUST THE PARKING BRAKE..................................................................................176 Units with Monotrol Pedal.............................................................................176 REMOVE THE AIR FROM THE BRAKE SYSTEM......................................................................177 ADJUST THE BRAKE PEDAL AND INCHING PEDAL..................................................................177 CHECK AND ADJUST THE NEUTRAL START SWITCH (Monotrol Control Only).........................................181 TROUBLESHOOTING...............................................................................................183 SPECIFICATIONS................................................................................................184 THE CARBURETOR ...................................................................................................185 THE CARBURETOR, (MAZDA M4-121G ENGINE)........................................................................185 DESCRIPTION...............................................................................................185 REPAIRS, CARBURETOR.......................................................................................186 Removal...............................................................................................186 Cleaning..............................................................................................189 Inspection............................................................................................189 Assembly..............................................................................................189 Installation..........................................................................................191 CHECKS AND ADJUSTMENTS....................................................................................191 Carburetor, Idle Speed And Mixture Adjustment.........................................................191 Adjust The Governor...................................................................................192 ADJUST THE THROTTLE LINKAGE...............................................................................193 SPECIFICATIONS................................................................................................193 TROUBLESHOOTING...............................................................................................194 THE COOLING SYSTEM ...............................................................................................196 COOLING SYSTEM................................................................................................196 INTRODUCTION..............................................................................................196 DESCRIPTION...............................................................................................196 RADIATOR..................................................................................................196 RADIATOR CAP..............................................................................................196 THERMOSTAT................................................................................................196 WATER PUMP................................................................................................197 FAN AND FAN SHROUD .......................................................................................197 REPAIRS.......................................................................................................197 COOLING SYSTEM CHECKS.....................................................................................197 Exhaust Leaks.........................................................................................197 RADIATOR..................................................................................................197 Checks................................................................................................197 Cleaning The Radiator.................................................................................197 Drain The Cooling System..............................................................................199 Fill The Cooling System...............................................................................199 WATER PUMP................................................................................................199 Checks................................................................................................199 THERMOSTAT................................................................................................200 Checks................................................................................................200 FAN AND FAN SHROUD .......................................................................................200 TROUBLESHOOTING...............................................................................................201 THE DRIVE AXLE ...................................................................................................202 INTRODUCTION..................................................................................................202 GENERAL...................................................................................................202 DESCRIPTION...............................................................................................202 REPAIRS.......................................................................................................203 REMOVAL...................................................................................................203 CLEANING..................................................................................................203 INSPECTION................................................................................................203 ASSEMBLY..................................................................................................203 TROUBLESHOOTING...............................................................................................206 SPECIFICATIONS................................................................................................206 THE DRIVE AXLE_ ..................................................................................................207 INTRODUCTION..................................................................................................207 DESCRIPTION...............................................................................................207 GENERAL...................................................................................................207 REPAIRS.......................................................................................................208 STEERING AXLE.............................................................................................208 Removal...................................................................................................208 Installation..............................................................................................209 STEERING CYLINDER.........................................................................................209 Removal...................................................................................................209 Service...................................................................................................210 Installation..............................................................................................210 HUBS......................................................................................................210 Removal...................................................................................................210 Installation..............................................................................................211 SPINDLES..................................................................................................211 Removal...................................................................................................211 Installation..............................................................................................212 CHECKS AND ADJUSTMENTS........................................................................................212 REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................212 SET THE PRESSURE RELIEF VALVE.............................................................................212 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...................................................212 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION........................................................212 H2.00-3.00J (H40-60J) With Powershift Transmission........................................................212 TROUBLESHOOTING...............................................................................................214 THE ELECTRICAL SYSTEM (ISUZU) ....................................................................................215 INTRODUCTION..................................................................................................215 GENERAL...................................................................................................215 DESCRIPTION...............................................................................................215 Starting System.......................................................................................215 Charging System.......................................................................................215 Vacuum Pump On Alternator (On Units With Brake Booster)...............................................217 REPAIRS.......................................................................................................218 STARTER...................................................................................................218 Removal And Disassembly...............................................................................218 Assembly And Installation.............................................................................218 REPLACING GLOW PLUGS......................................................................................220 ALTERNATOR (With Vaccum Pump).............................................................................220 Removal And Disassembly...............................................................................220 Cleaning..............................................................................................222 Assembly And Installation.............................................................................222 ALTERNATOR (Without Vacuum Pump)..........................................................................223 Removal And Disassembly...............................................................................223 Cleaning..............................................................................................225 Assembly And Installation.............................................................................225 REGULATOR REPLACEMENT.....................................................................................226 CHECKS........................................................................................................226 GENERAL...................................................................................................226 STARTER...................................................................................................226 Starter Operation.....................................................................................226 Solenoid Coil Checks..................................................................................227 Brush Length..........................................................................................227 Brush Holder..........................................................................................227 Armature..............................................................................................227 Field Windings........................................................................................228 Clutch And Bearings...................................................................................228 COLD START AID............................................................................................228 Glow Plugs............................................................................................228 Resistor..............................................................................................228 CHARGING CIRCUIT..........................................................................................228 Check For Low Output..................................................................................228 Check Ford High Output................................................................................230 ALTERNATOR................................................................................................230 Rotor Resistance......................................................................................230 Diodes Circuit........................................................................................230 Rotor Coil............................................................................................231 Stator Coil...........................................................................................231 Diode Assembly........................................................................................231 Brushes And Bearings..................................................................................232 REGULATOR (At Hydraulic Tank).............................................................................232 TROUBLESHOOTING...............................................................................................233 THE ELECTRICAL SYSTEM (MAZDA) ....................................................................................236 INTRODUCTION..................................................................................................236 GENERAL...................................................................................................236 DESCRIPTION...............................................................................................236 Starting System.......................................................................................236 Ignition System.......................................................................................236 Charging System.......................................................................................237 REPAIR........................................................................................................239 STARTER...................................................................................................239 Removal And Disassembly...............................................................................239 Assembly And Installation.............................................................................239 BALLAST RESISTOR RELAY (Earlier Production)...............................................................241 DISTRIBUTOR (Earlier Production With Contact Points)......................................................241 Removal And Disassembly...............................................................................241 Assembly And Installation.............................................................................243 COIL REPLACEMENT..........................................................................................243 DISTRIBUTOR (Later Production with Electronic Ignition System)............................................243 Removal And Disassembly...............................................................................243 Assembly And Installation.............................................................................245 ALTERNATOR (All Models)...................................................................................245 Removal And Disassembly...............................................................................245 Assembly And Installation.............................................................................246 REGULATOR REPLACEMENT (Earlier Production)................................................................247 CHECKS AND ADJUSTMENTS........................................................................................248 GENERAL...................................................................................................248 STARTER...................................................................................................248 Check Operation.......................................................................................248 Check Brush Length....................................................................................249 Check Brush Holder....................................................................................249 Armature..............................................................................................249 Field Windings........................................................................................249 Clutch And Bearing....................................................................................249 BALLAST RESISTOR RELAY (Earlier Production)...............................................................249 DISTRIBUTOR...............................................................................................250 Distributor Contact Clearance.........................................................................250 SPARK PLUGS...............................................................................................251 COIL AND BALLAST RESISTOR (Earlier Production)............................................................251 ALTERNATOR................................................................................................251 Check For Low Output (Alternator With Separate Regulator).............................................251 Check For Low Output (Alternator With Integral Regulator).............................................253 Check For High Output (Alternator With Separate Regulator)............................................254 Check For High Output (Alternator With Integral Regulator)............................................254 Rotor Resistance (Alternator with Separate Regulator).................................................254 Diodes Circuit (Alternator with Separate Regulator)...................................................255 Diode Assembly (Alternator With Separate Regulator)...................................................255 Check The Diodes, Diode Trio (Alternator with Integral Regulator).....................................255 Check The Rectifier Bridge (Alternator with Integral Regulator).......................................256 Check Field Winding For The Rotor (All Alternators)...................................................256 Check Windings In The Stator (All Alternators)........................................................257 Brushes And Bearings..................................................................................257 Check The Voltage Regulator (Alternator with Separate Regulator)......................................257 Check The Voltage Regulator (Alternator with Integral Regulator)......................................258 ADJUSTMENTS...............................................................................................258 TROBLESHOOTING................................................................................................259 THE FRAME.........................................................................................................261 INTRODUCTION..................................................................................................261 GENERAL...................................................................................................261 DESCRIPTION...............................................................................................261 REPAIRS.......................................................................................................261 COUNTERWEIGHT.............................................................................................262 Removal...............................................................................................262 Installation..........................................................................................262 MUFFLER...................................................................................................263 HOOD......................................................................................................263 Removal...............................................................................................263 Installation..........................................................................................263 RADIATOR AND COOLANT SYSTEM...............................................................................263 Removal...............................................................................................263 Installation..........................................................................................263 OVERHEAD GUARD............................................................................................264 Removal And Installation..............................................................................264 OPERATOR RESTRAINT SYSTEM.................................................................................264 ENGINE REMOVAL AND INSTALLATION...........................................................................265 Removal of the Engine and Transmission................................................................265 Installation of the Engine and Transmission...........................................................269 FUEL AND HYDRAULIC TANKS..................................................................................271 Inspection............................................................................................271 Repairs, Small Leaks..................................................................................271 Repairs, Large Leaks..................................................................................271 Cleaning..............................................................................................271 Steam Method Of Cleaning..............................................................................271 Chemical Solution Method of Cleaning..................................................................272 Additional Preparations For Repair....................................................................272 SAFETY LABELS.............................................................................................272 CAB.......................................................................................................274 Cab Replacement.......................................................................................274 Window Replacement....................................................................................274 Windshield Wipers and Heater..........................................................................276 THE HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY .........................................................................277 INTRODUCTION..................................................................................................277 GENERAL...................................................................................................277 DESCRIPTION...............................................................................................279 Hydraulic System......................................................................................279 Gear Pump Assembly....................................................................................279 Flow Control Valve....................................................................................280 Relief Valve (Early Model)............................................................................280 Relief Valve (Later Model)............................................................................280 OPERATION.................................................................................................282 Hydraulic System......................................................................................282 Gear Pump.............................................................................................282 Flow Control Valve....................................................................................282 Relief Valve (Early Model)............................................................................282 Relief Valve (Later Model)............................................................................282 REPAIR........................................................................................................284 GEAR PUMP ASSEMBLY........................................................................................284 Removal and Disassembly...............................................................................284 Assembly and Installation.............................................................................285 CHECKS AND ADJUSTMENTS........................................................................................285 CHECK AND ADJUST STEERING RELIEF PRESSURE.................................................................285 CHECK GEAR PUMP FOR CORRECT FLOW..........................................................................286 TROUBLESHOOTING...............................................................................................286 THE ISUZU C240 ENGINE ............................................................................................288 INTRODUCTION .................................................................................................288 GENERAL ..................................................................................................288 DESCRIPTION ..............................................................................................288 FUEL SYSTEM ..............................................................................................289 Description ..........................................................................................289 Operation, Fuel Injection Pump, Model VE .............................................................291 Operation, Fuel Injection Pump, Model PE4A ...........................................................292 Pneumatic Governor For Fuel Injection Pump, Model PE4A ...............................................293 Inlet Manifold For Fuel Injection Pump, Model PE4A ...................................................294 REPAIRS ......................................................................................................295 FUEL INJECTION PUMP (ALL MODELS) .........................................................................295 Removal ..............................................................................................295 Installation .........................................................................................295 REMOVAL AND INSTALLATION OF THE ENGINE ...................................................................295 CYLINDER HEAD AND VALVE MECHANISM ........................................................................295 Cylinder Head, Removal ...............................................................................295 Valve Guides, Replacement ............................................................................296 Cylinder Head, Inspection And Repair .................................................................297 Combustion Chamber Plugs, Inspection And Repair ......................................................297 Combustion Chamber Plugs, Installation ...............................................................297 Valves, Inspection And Repair ........................................................................298 Valve Seat, Inspection ...............................................................................298 Valve Seat, Removal ..................................................................................299 Valve Seat, Installation .............................................................................299 Valve Spring, Inspection .............................................................................299 Rocker Arms, Inspection And Assembly .................................................................299 Installation Of The Cylinder Head ....................................................................300 TIMING GEAR CASE .........................................................................................301 Removal ..............................................................................................301 Installation .........................................................................................301 CAMSHAFT .................................................................................................303 Removal ..............................................................................................303 Inspection ...........................................................................................303 Camshaft Bearings ....................................................................................304 Cam Followers ........................................................................................304 CAMSHAFT, INSTALLATION ...................................................................................304 CRANKSHAFT AND MAIN BEARINGS .............................................................................305 Crankshaft, Removal ..................................................................................305 Crankshaft, Inspection And Repair ....................................................................305 Main Bearings ........................................................................................305 Pilot Bearing ........................................................................................306 Crankshaft, Installation .............................................................................306 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) ..........................................................308 Flywheel, Removal ....................................................................................308 Ring Gear, Replacement ...............................................................................308 Flywheel, Installation ...............................................................................308 PISTONS AND CONNECTING RODS ..............................................................................309 Pistons And Connecting Rods, Removal .................................................................309 Disassembly ..........................................................................................309 Pistons, Inspection And Repair .......................................................................310 Piston Rings, Inspection And Repair ..................................................................310 Piston Pins, Inspection And Repair ...................................................................311 Connecting Rods, Inspection And Repair ...............................................................312 Pistons And Connecting Rods, Assembly And Installation ...............................................312 CYLINDER BLOCK AND CYLINDER LINERS .......................................................................312 Cylinder Liners, Inspection ..........................................................................312 Replacement Of A Cylinder Liner ......................................................................313 LUBRICATION SYSTEM .......................................................................................314 Oil Pump, Removal And Disassembly ....................................................................314 Oil Pump, Inspection .................................................................................314 Oil Pump, Assembly And Installation ..................................................................315 Oil Filter ...........................................................................................315 COOLING SYSTEM ...........................................................................................316 Coolant Pump, Removal ................................................................................316 Coolant Pump, Disassembly ............................................................................316 Coolant Pump, Assembly And Installation ..............................................................316 Thermostat, Replacement ..............................................................................317 CHECKS AND ADJUSTMENTS .......................................................................................317 VALVE CLEARANCE ADJUSTMENT ...............................................................................317 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ....................................................318 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A ..................................................319 FUEL INJECTORS ...........................................................................................319 Fuel Injectors, Removal ..............................................................................320 Fuel Injectors, Inspection ...........................................................................320 Fuel Injectors, Installation .........................................................................321 DIESEL FUEL FILTERS ......................................................................................321 Filter Replacement, Models With A Water Separator ....................................................321 Filter Replacement, Models Without A Water Separator .................................................322 Filter For The Fuel Injection Pump, Model PE4A .......................................................322 REMOVE AIR FROM THE FUEL SYSTEM ..........................................................................322 Throttle Linkage, Adjustment .........................................................................323 Idle Speed, Adjustment ...............................................................................323 Check The Elements For The Cold Start Aid System .....................................................323 ENGINE SPECIFICATIONS ........................................................................................323 TORQUE SPECIFICATIONS ........................................................................................325 THE LPG FUEL SYSTEM...............................................................................................326 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100).....................................................................326 GENERAL...................................................................................................326 DESCRIPTION...............................................................................................326 Fuel Tank.............................................................................................327 Fuel Filter And Fuel Valve Unit.......................................................................328 Vaporizer.............................................................................................328 The IMPCO CA 100 Carbureto............................................................................330 IMPCO CA 50 Carburetor................................................................................332 The Governor (GM Engines Only)........................................................................333 Governor With Electronic Controller...................................................................334 REPAIRS.......................................................................................................335 LPG TANK..................................................................................................335 Removal...............................................................................................335 Installation..........................................................................................336 REPLACE THE HOSES.........................................................................................336 HYDROSTATIC RELIEF VALVE..................................................................................336 Removal and Installation..............................................................................336 FILTER UNIT...............................................................................................337 Replacement Of the Fuel Filter Element................................................................337 Replacement of the Diaphragm and Fuel Valve...........................................................338 VAPORIZER.................................................................................................338 Removal...............................................................................................338 Disassembly...........................................................................................338 Cleaning..............................................................................................338 Inspection............................................................................................338 Assembly..............................................................................................340 Installation..........................................................................................340 CARBURETOR (IMPCO CA 100).................................................................................342 Removal...............................................................................................342 Disassembly...........................................................................................342 Cleaning..............................................................................................342 Assembly..............................................................................................342 Installation..........................................................................................345 CARBURETER (IMPCO CA 50)..................................................................................344 Removal...............................................................................................344 Disassembly...........................................................................................344 Cleaning..............................................................................................345 Inspection............................................................................................345 Assembly (See FIGURE 26.).............................................................................345 Installation..........................................................................................345 CHECKS AND ADJUSTMENTS........................................................................................346 CHECK THE FILTER UNIT.....................................................................................346 CHECK THE VAPORIZER.......................................................................................346 Pressure Reducer Valve................................................................................346 Vapor Valve...........................................................................................346 ADJUST THE CARBURETOR.....................................................................................346 Idle Mixture..........................................................................................346 Idle Speed............................................................................................346 Power Mixture.........................................................................................346 ADJUST THE GOVERNOR (GM Engines Only).....................................................................347 Checks................................................................................................347 Main Adjusting Screw..................................................................................347 Secondary Adjusting Screw.............................................................................347 AISAN Governor........................................................................................348 Adjustment, AISAN Governor............................................................................348 TROUBLESHOOTING...............................................................................................349 THE MAIN CONTROL VALVE ...........................................................................................353 INTRODUCTION..................................................................................................353 GENERAL...................................................................................................353 DESCRIPTION...............................................................................................353 OPERATION.................................................................................................354 Lift Section..........................................................................................355 Tilt Section..........................................................................................355 Relief Valve..........................................................................................357 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................358 Operation.............................................................................................358 REPAIRS.......................................................................................................358 MAIN CONTROL VALVE........................................................................................358 Removal and Disassembly...............................................................................358 Cleaning and Inspection...............................................................................359 Assembly..............................................................................................359 Installation..........................................................................................359 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................359 Removal and Disassembly...............................................................................359 Assembly and Installation.............................................................................361 CHECKS AND ADJUSTMENTS........................................................................................361 PRESSURE RELIEF VALVES....................................................................................361 Primary Relief Valve..................................................................................361 Seconday Relief Valve.................................................................................362 CONTROL LEVER ARRANGEMENT.................................................................................362 TROUBLESHOOTING...............................................................................................365 SPECIFICATIONS................................................................................................367 THE MAZDA M4-121G ENGINE .........................................................................................368 MAZDA M4-121G ENGINE..........................................................................................368 GENERAL...................................................................................................368 DESCRIPTION...............................................................................................369 REMOVAL AND INSTALLATION OF THE ENGINE....................................................................369 CYLINDER HEAD AND VALVE MECHANISM.........................................................................369 Cylinder Head, Removal................................................................................369 Cylinder Head, Inspection and Repairs.................................................................370 Rocker Arm Assembly...................................................................................370 Valve Guides..........................................................................................370 Valve Seats...........................................................................................371 Valves................................................................................................371 Valve Springs.........................................................................................371 Cylinder Head, Installation...........................................................................371 TIMING GEAR CASE, REMOVAL.................................................................................372 TIMING GEAR CASE, INSTALLATION............................................................................373 CAMSHAFT..................................................................................................373 Removal...............................................................................................373 Inspection............................................................................................374 Cam Followers, Inspection.............................................................................374 Installation..........................................................................................374 CRANKSHAFT AND MAIN BEARINGS..............................................................................374 Crankshaft, Removal...................................................................................374 Crankshaft, Inspection And Repair.....................................................................375 Main Bearings.........................................................................................376 Crankshaft, Installation..............................................................................376 PISTONS AND CONNECTING RODS...............................................................................377 Removal...............................................................................................377 Disassembly...........................................................................................377 Pistons, Inspection And Repair........................................................................377 Piston Rings..........................................................................................378 Piston Pin and Bushing................................................................................378 Connecting Rods and Bearings, Inspection..............................................................378 Pistons and Connecting Rods, Assembly.................................................................378 Pistons and Connecting Rods, Installation.............................................................379 CYLINDER BLOCK AND CYLINDER LINERS........................................................................379 Cylinder Block, Repairs...............................................................................379 Cylinder Liners.......................................................................................379 DISTRIBUTOR...............................................................................................380 Removal...............................................................................................380 Installation..........................................................................................380 OIL PUMP..................................................................................................382 Removal...............................................................................................382 Repairs...............................................................................................382 Installation..........................................................................................383 GOVERNOR..................................................................................................383 Description...........................................................................................383 Removal...............................................................................................383 Disassembly...........................................................................................384 Assembly..............................................................................................385 Installation..........................................................................................386 COOLANT PUMP..............................................................................................386 Removal...............................................................................................386 Disassembly and Repair................................................................................387 Assembly..............................................................................................387 Installation..........................................................................................388 FLYWHEEL..................................................................................................388 Repairs...............................................................................................388 Installation..........................................................................................388 CHECKS AND ADJUSTMENTS........................................................................................388 ADJUST THE VALVES.........................................................................................388 ADJUST THE THROTTLE LINKAGE...............................................................................389 ENGINE SPECIFICATIONS.........................................................................................389 ENGINE SPECIFICATIONS.....................................................................................389 Engine Data...........................................................................................389 Cooling System........................................................................................389 Cylinder Head and Valve Mechanism.....................................................................389 Camshaft..............................................................................................391 Timing Gear...........................................................................................392 Camshaft..............................................................................................392 Connecting Rods.......................................................................................392 Cylinder Liners.......................................................................................392 Pistons...............................................................................................392 Lubrication System....................................................................................393 Fuel Pump.............................................................................................393 TORQUE SPECIFICATIONS.....................................................................................394 TROUBLESHOOTING...............................................................................................395 THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS ...............................................................399 INTRODUCTION..................................................................................................399 General...................................................................................................399 DESCRIPTION AND OPERATION.....................................................................................399 General...................................................................................................399 Torque Converter..........................................................................................400 Description...........................................................................................400 Operation.............................................................................................400 Clutch Assemblies.........................................................................................402 Description...........................................................................................402 Operation.............................................................................................403 Hydraulic System..........................................................................................403 General...............................................................................................403 Oil Pump and Front Cover..................................................................................404 Torque Converter Regulator............................................................................404 Oil Cooler By-Pass....................................................................................404 Control Valve.............................................................................................404 General...............................................................................................404 Differential..............................................................................................409 Oil Flow Diagrams.........................................................................................410 Neutral...............................................................................................410 Forward...............................................................................................412 Forward-Inching.......................................................................................414 Reverse...............................................................................................416 THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS _..............................................................418 INTRODUCTION..................................................................................................418 GENERAL...................................................................................................418 DESCRIPTION AND OPERATION.....................................................................................419 GENERAL...................................................................................................419 TORQE CONVERTER...........................................................................................419 Description...........................................................................................419 Operation.............................................................................................419 CLUTCH ASSEMBLIES.........................................................................................422 Description...........................................................................................422 Operation.............................................................................................424 HYDRAULIC SYSTEM..........................................................................................424 General...............................................................................................424 CONTROL VALVE.............................................................................................424 Regulator for Clutch Pressure.........................................................................427 Inching Spool Assembly................................................................................427 Direction Spool.......................................................................................427 MONOTROL Control Valve................................................................................427 Neutral Start Switch, MONOTROL Pedal Only.............................................................428 Neutral Start Switch, Direction Control Lever Only....................................................428 Modulator Circuit.....................................................................................428 Regulator for the Toruqe Converter....................................................................429 By-Pass Valve for the Oil Cooler......................................................................429 DIFFERENTIAL..............................................................................................430 OIL FLOW DIAGRAMS.........................................................................................430 THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS................................................................439 INTRODUCTION..................................................................................................439 GENERAL...................................................................................................439 REPAIRS.......................................................................................................441 REPAIRS...................................................................................................441 Torque Converter, Removal.............................................................................441 Torque Converter, Installation........................................................................441 Front Cover And Transmission Pump, Removal and Disassembly............................................442 Front Cover And Transmission Pump, Assembly and Installation..........................................442 Clutch Assemblies, Removal and Disassembly............................................................443 Clutch Assemblies, Inspection.........................................................................446 Clutch Assemblies, Assembly and Installation..........................................................447 Differential, Removal and Disassembly.................................................................450 Differential, Inspection..............................................................................452 Differential, Assembly And Installation...............................................................452 CONTROL VALVE.............................................................................................462 Control Valve, Removal and Disassembly................................................................462 Control Valve, Inspection.............................................................................462 Control Valve, Assembly and Installation..............................................................464 MONOTROL Pedal, Removal and Disassembly...............................................................466 MONOTROL Pedal, Assembly and Installation.............................................................466 CHECKS AND ADJUSTMENTS........................................................................................468 Stall Test................................................................................................468 Adjustment Of The Direction Control Linkage...............................................................469 Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1).............470 Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)..............473 Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187).......................474 Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)....................475 Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)....479 Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)............480 Check The Oil Pressures...................................................................................480 Check The Relief Valve for the Transmission Pump..........................................................480 Check The Clutch Pressure.................................................................................480 Check The Torque Converter Regulator......................................................................481 Check The Oil Pressure from the Oil Cooler................................................................481 Check The Modulator Pressure..............................................................................482 TROUBLESHOOTING...............................................................................................482 TROUBLESHOOTING, PRESSURE TESTS...............................................................................484 THE STEERING AXLE ................................................................................................487 INTRODUCTION..................................................................................................487 DESCRIPTION...............................................................................................487 GENERAL...................................................................................................487 REPAIRS.......................................................................................................488 STEERING AXLE.............................................................................................488 Removal...................................................................................................488 Installation..............................................................................................489 STEERING CYLINDER.........................................................................................489 Removal...................................................................................................489 Service...................................................................................................490 Installation..............................................................................................490 HUBS......................................................................................................490 Removal...................................................................................................490 Installation..............................................................................................491 SPINDLES..................................................................................................491 Removal...................................................................................................491 Installation..............................................................................................492 CHECKS AND ADJUSTMENTS........................................................................................492 REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................492 SET THE PRESSURE RELIEF VALVE.............................................................................492 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...................................................492 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION........................................................492 H2.00-3.00J (H40-60J) With Powershift Transmission........................................................492 TROUBLESHOOTING...............................................................................................494 THE STEERING CONTROL UNIT ........................................................................................495 INTRODUCTION..................................................................................................495 GENERAL...................................................................................................495 DESCRIPTION...............................................................................................495 OPERATION.................................................................................................495 REPAIRS.......................................................................................................495 STEERING WHEEL AND COLUMN ASSEMBLY........................................................................495 TYPE "A" STEERING COLUMN ASSEMBLY.........................................................................497 Removal And Disassembly...............................................................................497 Assembly And Installation.............................................................................497 TYPE "A" STEERING COLUMN..................................................................................498 TYPE "A" STEERING COLUMN..................................................................................499 TYPE "B" STEERING COLUMN..................................................................................500 Removal And Disassembly...............................................................................500 Assembly And Installation.............................................................................500 TYPE "B" STEERING COLUMN..................................................................................501 Disassembly of Steering Control Unit..................................................................502 Cleaning of Steering Control Unit.....................................................................502 Assembly of Steering Control Unit.....................................................................504 CHECKS AND ADJUSTMENTS........................................................................................507 REMOVE AIR FROM THE SYSTEM................................................................................507 TROUBLESHOOTING...............................................................................................508 THE STEERING CONTROL UNIT_ .......................................................................................509 INTRODUCTION..................................................................................................509 General...................................................................................................509 Description and Operation.................................................................................509 REPAIRS.......................................................................................................512 Removal...................................................................................................512 Disassembly...............................................................................................513 Inspection................................................................................................517 Assembly..................................................................................................520 Installation..............................................................................................529 CHECKS AND ADJUSTMENTS........................................................................................529 Adjusting the Rotary Spool................................................................................529 Removing the Air from the System..........................................................................530 Checking the Steering Hydraulic System....................................................................531 TROUBLESHOOTING...............................................................................................539 UPRIGHTS - DESCRIPTION ...........................................................................................542 INTRODUCTION..................................................................................................542 GENERAL...................................................................................................542 DESCRIPTION...............................................................................................542 Upright Assembly......................................................................................542 Upright Mounts........................................................................................543 Carriage..............................................................................................544 OPERATION.................................................................................................544 Standard Upright......................................................................................544 Three Stage Uprights..................................................................................544 UPRIGHTS - REPAIRS ...............................................................................................547 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................547 INTRODUCTION..................................................................................................548 GENERAL...................................................................................................548 REPAIR....................................................................................................548 Forks.................................................................................................548 Forks, Adjustment.....................................................................................548 Forks, Removal And Installation.......................................................................549 Hook Fork, Removal....................................................................................549 Hook Fork, Installation...............................................................................549 CARRIAGE..................................................................................................549 Removal...............................................................................................549 Installation..........................................................................................550 MAST......................................................................................................550 Removal...............................................................................................550 Disassembly, Standard Mast............................................................................551 Disassembly, Three-Stage Mast.........................................................................551 Cleaning And Inspection...............................................................................555 Assembly..............................................................................................556 Installation..........................................................................................556 SIDE-SHIFT CARRIAGE.......................................................................................556 Removal...............................................................................................556 Repairs...............................................................................................558 Installation..........................................................................................558 CHECKS AND ADJUSTMENTS....................................................................................558 Check For Leaks In The Lift Sytem.....................................................................558 Leakage Outside the Hydraulic Lift System.............................................................558 Leakage Inside the Hydraulic Lift System..............................................................558 Check the lift cylinder for inside leakage............................................................558 Check For Leaks In The Tilt System....................................................................558 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...............................................558 LIFT CHAIN ADJUSTMENTS....................................................................................559 MAST ADJUSTMENTS..........................................................................................560 CARRIAGE ADJUSTMENT.......................................................................................561 HEADER HOSE ARRANGEMENT...................................................................................561 Three-Stage Header Hoses..............................................................................561 TROUBLESHOOTING...............................................................................................563 VISTA UPRIGHTS - DESCRIPTION .....................................................................................564 INTRODUCTION..................................................................................................564 GENERAL...................................................................................................564 VISTA TWO-STAGE MASTS.........................................................................................566 DESCRIPTION...............................................................................................566 OPERATION.................................................................................................569 VISTA THREE-STAGE MASTS.......................................................................................569 DESCRIPTION...............................................................................................569 OPERATION.................................................................................................571 SEQUENCE VALVE............................................................................................573 VISTA UPRIGHTS - REPAIR ..........................................................................................576 INTRODUCTION..................................................................................................576 GENERAL...................................................................................................576 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................576 REPAIRS.......................................................................................................577 FORKS.....................................................................................................577 Removal...............................................................................................577 CARRIAGE..................................................................................................577 Removal (Two-Stage and Later Production Three-Stage Carriages)........................................577 Removal (Carriages with Removable Stop Block).........................................................578 Installation (Two-Stage and Later Production Three-Stage Carriages)...................................579 Installation (Carriages With Removable Stop Block)....................................................579 TWO-STAGE MASTS...............................................................................................581 REMOVAL...................................................................................................581 DISASSEMBLY...............................................................................................582 CLEANING AND INSPECTION...................................................................................583 ASSEMBLY..................................................................................................584 INSTALLATION..............................................................................................585 THREE-STAGE MASTS.............................................................................................585 REMOVAL...................................................................................................585 DISASSEMBLY...............................................................................................585 CLEANING AND INSPECTION...................................................................................587 ASSEMBLY..................................................................................................587 INSTALLATION..............................................................................................588 LIFT AND TILT CYLINDERS...................................................................................589 SIDE SHIFT CARRIAGE.......................................................................................589 Removal...............................................................................................589 Repairs...............................................................................................589 Installation..........................................................................................589 SEQUENCE VALVE............................................................................................590 Removal and Disassembly...............................................................................593 Cleaning..............................................................................................593 Assembly and Installation.............................................................................593 CHECKS AND ADJUSTMENTS........................................................................................594 CHECKING FOR LEAKS IN THE LIFT SYSTEM.....................................................................594 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE............................................594 LIFTING CHAIN ADJUSTMENTS.................................................................................595 MAST ADJUSTMENTS..........................................................................................596 CARRIAGE ADJUSTMENT.......................................................................................597 HEADER HOSE ROLLER ADJUSTMENT, 2-STAGE....................................................................598 TROUBLESHOOTING...............................................................................................599 TORQUE SPECIFICATIONS.........................................................................................600 VISTA MASTS...................................................................................................601
HYSTER A177 (H2.00-3.00XL EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
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