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Hyster B177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster B177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster B177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 533
Downloadable : Yes
File Type : PDF
Size: 15.9 MB
TABLE OF CONTENTS:
Hyster B177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
22002............................................................................................................. 1 INTRODUCTION.................................................................................................. 1 GENERAL................................................................................................... 1 DESCRIPTION............................................................................................... 1 REPAIRS....................................................................................................... 3 GENERAL................................................................................................... 3 REMOVAL AND DISASSEMBLY (Type A).......................................................................... 3 CLEANING.................................................................................................. 3 ASSEMBLY (Type A)......................................................................................... 4 REMOVAL AND DISAASSEMBLY (Type B)......................................................................... 6 CLEANING.................................................................................................. 8 ASSEMBLY (Type B)......................................................................................... 8 INSTALLATION (Type A and Type B).......................................................................... 9 CHECKS AND ADJUSTMENTS........................................................................................ 9 GENERAL................................................................................................... 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B).................................................... 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)................................................... 11 CHECK THE CIRCUIT FOR THE BRUSHES......................................................................... 13 Delco Alternators..................................................................................... 13 Motorola Alternators.................................................................................. 13 CHECK THE DIODES.......................................................................................... 13 CHECK THE DIODE BRIDGE.................................................................................... 13 Delco and Leece–Neville Alternators................................................................... 13 Motorola Alternators.................................................................................. 13 CHECK THE FIELD WINDING FOR THE ROTOR..................................................................... 14 CHECK THE WINDINGS IN THE STATOR.......................................................................... 14 CHECK THE VOLTAGE REGULATOR............................................................................... 15 TROUBLESHOOTING............................................................................................... 15 60066............................................................................................................. 16 MAZDA M4-121G ENGINE.......................................................................................... 16 GENERAL................................................................................................... 16 DESCRIPTION............................................................................................... 17 REMOVAL AND INSTALLATION OF THE ENGINE.................................................................... 17 CYLINDER HEAD AND VALVE MECHANISM......................................................................... 17 Cylinder Head, Removal................................................................................ 17 Cylinder Head, Inspection and Repairs................................................................. 18 Rocker Arm Assembly................................................................................... 18 Valve Guides.......................................................................................... 18 Valve Seats........................................................................................... 19 Valves................................................................................................ 19 Valve Springs......................................................................................... 19 Cylinder Head, Installation........................................................................... 19 TIMING GEAR CASE, REMOVAL................................................................................. 20 TIMING GEAR CASE, INSTALLATION............................................................................ 21 CAMSHAFT.................................................................................................. 21 Removal............................................................................................... 21 Inspection............................................................................................ 22 Cam Followers, Inspection............................................................................. 22 Installation.......................................................................................... 22 CRANKSHAFT AND MAIN BEARINGS.............................................................................. 22 Crankshaft, Removal................................................................................... 22 Crankshaft, Inspection And Repair..................................................................... 23 Main Bearings......................................................................................... 24 Crankshaft, Installation.............................................................................. 24 PISTONS AND CONNECTING RODS............................................................................... 25 Removal............................................................................................... 25 Disassembly........................................................................................... 25 Pistons, Inspection And Repair........................................................................ 25 Piston Rings.......................................................................................... 26 Piston Pin and Bushing................................................................................ 26 Connecting Rods and Bearings, Inspection.............................................................. 26 Pistons and Connecting Rods, Assembly................................................................. 26 Pistons and Connecting Rods, Installation............................................................. 27 CYLINDER BLOCK AND CYLINDER LINERS........................................................................ 27 Cylinder Block, Repairs............................................................................... 27 Cylinder Liners....................................................................................... 27 DISTRIBUTOR............................................................................................... 28 Removal............................................................................................... 28 Installation.......................................................................................... 28 OIL PUMP.................................................................................................. 30 Removal............................................................................................... 30 Repairs............................................................................................... 30 Installation.......................................................................................... 31 GOVERNOR.................................................................................................. 31 Description........................................................................................... 31 Removal............................................................................................... 31 Disassembly........................................................................................... 32 Assembly.............................................................................................. 33 Installation.......................................................................................... 34 COOLANT PUMP.............................................................................................. 34 Removal............................................................................................... 34 Disassembly and Repair................................................................................ 35 Assembly.............................................................................................. 35 Installation.......................................................................................... 36 FLYWHEEL.................................................................................................. 36 Repairs............................................................................................... 36 Installation.......................................................................................... 36 CHECKS AND ADJUSTMENTS........................................................................................ 36 ADJUST THE VALVES......................................................................................... 36 ADJUST THE THROTTLE LINKAGE............................................................................... 37 ENGINE SPECIFICATIONS......................................................................................... 37 ENGINE SPECIFICATIONS..................................................................................... 37 Engine Data........................................................................................... 37 Cooling System........................................................................................ 37 Cylinder Head and Valve Mechanism..................................................................... 37 Camshaft.............................................................................................. 39 Timing Gear........................................................................................... 40 Camshaft.............................................................................................. 40 Connecting Rods....................................................................................... 40 Cylinder Liners....................................................................................... 40 Pistons............................................................................................... 40 Lubrication System.................................................................................... 41 Fuel Pump............................................................................................. 41 TORQUE SPECIFICATIONS..................................................................................... 42 TROUBLESHOOTING............................................................................................... 43 60070............................................................................................................. 47 INTRODUCTION ................................................................................................. 47 GENERAL .................................................................................................. 47 DESCRIPTION .............................................................................................. 47 FUEL SYSTEM .............................................................................................. 48 Description .......................................................................................... 48 Operation, Fuel Injection Pump, Model VE ............................................................. 50 Operation, Fuel Injection Pump, Model PE4A ........................................................... 51 Pneumatic Governor For Fuel Injection Pump, Model PE4A ............................................... 52 Inlet Manifold For Fuel Injection Pump, Model PE4A ................................................... 53 REPAIRS ...................................................................................................... 54 FUEL INJECTION PUMP (ALL MODELS) ......................................................................... 54 Removal .............................................................................................. 54 Installation ......................................................................................... 54 REMOVAL AND INSTALLATION OF THE ENGINE ................................................................... 54 CYLINDER HEAD AND VALVE MECHANISM ........................................................................ 54 Cylinder Head, Removal ............................................................................... 54 Valve Guides, Replacement ............................................................................ 55 Cylinder Head, Inspection And Repair ................................................................. 56 Combustion Chamber Plugs, Inspection And Repair ...................................................... 56 Combustion Chamber Plugs, Installation ............................................................... 56 Valves, Inspection And Repair ........................................................................ 57 Valve Seat, Inspection ............................................................................... 57 Valve Seat, Removal .................................................................................. 58 Valve Seat, Installation ............................................................................. 58 Valve Spring, Inspection ............................................................................. 58 Rocker Arms, Inspection And Assembly ................................................................. 58 Installation Of The Cylinder Head .................................................................... 59 TIMING GEAR CASE ......................................................................................... 60 Removal .............................................................................................. 60 Installation ......................................................................................... 60 CAMSHAFT ................................................................................................. 62 Removal .............................................................................................. 62 Inspection ........................................................................................... 62 Camshaft Bearings .................................................................................... 63 Cam Followers ........................................................................................ 63 CAMSHAFT, INSTALLATION ................................................................................... 63 CRANKSHAFT AND MAIN BEARINGS ............................................................................. 64 Crankshaft, Removal .................................................................................. 64 Crankshaft, Inspection And Repair .................................................................... 64 Main Bearings ........................................................................................ 64 Pilot Bearing ........................................................................................ 65 Crankshaft, Installation ............................................................................. 65 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) .......................................................... 67 Flywheel, Removal .................................................................................... 67 Ring Gear, Replacement ............................................................................... 67 Flywheel, Installation ............................................................................... 67 PISTONS AND CONNECTING RODS .............................................................................. 68 Pistons And Connecting Rods, Removal ................................................................. 68 Disassembly .......................................................................................... 68 Pistons, Inspection And Repair ....................................................................... 69 Piston Rings, Inspection And Repair .................................................................. 69 Piston Pins, Inspection And Repair ................................................................... 70 Connecting Rods, Inspection And Repair ............................................................... 71 Pistons And Connecting Rods, Assembly And Installation ............................................... 71 CYLINDER BLOCK AND CYLINDER LINERS ....................................................................... 71 Cylinder Liners, Inspection .......................................................................... 71 Replacement Of A Cylinder Liner ...................................................................... 72 LUBRICATION SYSTEM ....................................................................................... 73 Oil Pump, Removal And Disassembly .................................................................... 73 Oil Pump, Inspection ................................................................................. 73 Oil Pump, Assembly And Installation .................................................................. 74 Oil Filter ........................................................................................... 74 COOLING SYSTEM ........................................................................................... 75 Coolant Pump, Removal ................................................................................ 75 Coolant Pump, Disassembly ............................................................................ 75 Coolant Pump, Assembly And Installation .............................................................. 75 Thermostat, Replacement .............................................................................. 76 CHECKS AND ADJUSTMENTS ....................................................................................... 76 VALVE CLEARANCE ADJUSTMENT ............................................................................... 76 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE .................................................... 77 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A .................................................. 78 FUEL INJECTORS ........................................................................................... 78 Fuel Injectors, Removal .............................................................................. 79 Fuel Injectors, Inspection ........................................................................... 79 Fuel Injectors, Installation ......................................................................... 80 DIESEL FUEL FILTERS ...................................................................................... 80 Filter Replacement, Models With A Water Separator .................................................... 80 Filter Replacement, Models Without A Water Separator ................................................. 81 Filter For The Fuel Injection Pump, Model PE4A ....................................................... 81 REMOVE AIR FROM THE FUEL SYSTEM .......................................................................... 81 Throttle Linkage, Adjustment ......................................................................... 82 Idle Speed, Adjustment ............................................................................... 82 Check The Elements For The Cold Start Aid System ..................................................... 82 ENGINE SPECIFICATIONS ........................................................................................ 82 TORQUE SPECIFICATIONS ........................................................................................ 84 90015............................................................................................................. 85 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)..................................................................... 85 GENERAL................................................................................................... 85 DESCRIPTION............................................................................................... 85 Fuel Tank............................................................................................. 86 Fuel Filter And Fuel Valve Unit....................................................................... 87 Vaporizer............................................................................................. 87 The IMPCO CA 100 Carbureto............................................................................ 89 IMPCO CA 50 Carburetor................................................................................ 91 The Governor (GM Engines Only)........................................................................ 92 Governor With Electronic Controller................................................................... 93 REPAIRS....................................................................................................... 94 LPG TANK.................................................................................................. 94 Removal............................................................................................... 94 Installation.......................................................................................... 95 REPLACE THE HOSES......................................................................................... 95 HYDROSTATIC RELIEF VALVE.................................................................................. 95 Removal and Installation.............................................................................. 95 FILTER UNIT............................................................................................... 96 Replacement Of the Fuel Filter Element................................................................ 96 Replacement of the Diaphragm and Fuel Valve........................................................... 97 VAPORIZER................................................................................................. 97 Removal............................................................................................... 97 Disassembly........................................................................................... 97 Cleaning.............................................................................................. 97 Inspection............................................................................................ 97 Assembly.............................................................................................. 99 Installation.......................................................................................... 99 CARBURETOR (IMPCO CA 100).................................................................................101 Removal...............................................................................................101 Disassembly...........................................................................................101 Cleaning..............................................................................................101 Assembly..............................................................................................101 Installation..........................................................................................104 CARBURETER (IMPCO CA 50)..................................................................................103 Removal...............................................................................................103 Disassembly...........................................................................................103 Cleaning..............................................................................................104 Inspection............................................................................................104 Assembly (See FIGURE 26.).............................................................................104 Installation..........................................................................................104 CHECKS AND ADJUSTMENTS........................................................................................105 CHECK THE FILTER UNIT.....................................................................................105 CHECK THE VAPORIZER.......................................................................................105 Pressure Reducer Valve................................................................................105 Vapor Valve...........................................................................................105 ADJUST THE CARBURETOR.....................................................................................105 Idle Mixture..........................................................................................105 Idle Speed............................................................................................105 Power Mixture.........................................................................................105 ADJUST THE GOVERNOR (GM Engines Only).....................................................................106 Checks................................................................................................106 Main Adjusting Screw..................................................................................106 Secondary Adjusting Screw.............................................................................106 AISAN Governor........................................................................................107 Adjustment, AISAN Governor............................................................................107 TROUBLESHOOTING...............................................................................................108 100137............................................................................................................112 INTRODUCTION..................................................................................................112 GENERAL...................................................................................................112 DESCRIPTION...............................................................................................112 REPAIRS.......................................................................................................112 COUNTERWEIGHT.............................................................................................113 Removal...............................................................................................113 Installation..........................................................................................113 MUFFLER...................................................................................................114 HOOD......................................................................................................114 Removal...............................................................................................114 Installation..........................................................................................114 RADIATOR AND COOLANT SYSTEM...............................................................................114 Removal...............................................................................................114 Installation..........................................................................................114 OVERHEAD GUARD............................................................................................115 Removal And Installation..............................................................................115 OPERATOR RESTRAINT SYSTEM.................................................................................115 ENGINE REMOVAL AND INSTALLATION...........................................................................116 Removal of the Engine and Transmission................................................................116 Installation of the Engine and Transmission...........................................................120 FUEL AND HYDRAULIC TANKS..................................................................................122 Inspection............................................................................................122 Repairs, Small Leaks..................................................................................122 Repairs, Large Leaks..................................................................................122 Cleaning..............................................................................................122 Steam Method Of Cleaning..............................................................................122 Chemical Solution Method of Cleaning..................................................................123 Additional Preparations For Repair....................................................................123 SAFETY LABELS.............................................................................................123 CAB.......................................................................................................125 Cab Replacement.......................................................................................125 Window Replacement....................................................................................125 Windshield Wipers and Heater..........................................................................127 140085............................................................................................................128 INTRODUCTION..................................................................................................128 GENERAL...................................................................................................128 DESCRIPTION...............................................................................................128 REPAIRS.......................................................................................................129 REMOVAL...................................................................................................129 CLEANING..................................................................................................129 INSPECTION................................................................................................129 ASSEMBLY..................................................................................................129 TROUBLESHOOTING...............................................................................................132 SPECIFICATIONS................................................................................................132 160010............................................................................................................133 INTRODUCTION..................................................................................................133 DESCRIPTION...............................................................................................133 GENERAL...................................................................................................133 REPAIRS.......................................................................................................134 STEERING AXLE.............................................................................................134 Removal...................................................................................................134 Installation..............................................................................................135 STEERING CYLINDER.........................................................................................135 Removal...................................................................................................135 Service...................................................................................................136 Installation..............................................................................................136 HUBS......................................................................................................136 Removal...................................................................................................136 Installation..............................................................................................137 SPINDLES..................................................................................................137 Removal...................................................................................................137 Installation..............................................................................................138 CHECKS AND ADJUSTMENTS........................................................................................138 REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................138 SET THE PRESSURE RELIEF VALVE.............................................................................138 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...................................................138 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION........................................................138 H2.00-3.00J (H40-60J) With Powershift Transmission........................................................138 TROUBLESHOOTING...............................................................................................140 200077............................................................................................................141 INTRODUCTION..................................................................................................141 GENERAL...................................................................................................141 DESCRIPTION...............................................................................................141 OPERATION.................................................................................................142 Lift Section..........................................................................................143 Tilt Section..........................................................................................143 Relief Valve..........................................................................................145 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................146 Operation.............................................................................................146 REPAIRS.......................................................................................................146 MAIN CONTROL VALVE........................................................................................146 Removal and Disassembly...............................................................................146 Cleaning and Inspection...............................................................................147 Assembly..............................................................................................147 Installation..........................................................................................147 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................147 Removal and Disassembly...............................................................................147 Assembly and Installation.............................................................................149 CHECKS AND ADJUSTMENTS........................................................................................149 PRESSURE RELIEF VALVES....................................................................................149 Primary Relief Valve..................................................................................149 Seconday Relief Valve.................................................................................150 CONTROL LEVER ARRANGEMENT.................................................................................150 TROUBLESHOOTING...............................................................................................153 SPECIFICATIONS................................................................................................155 700626............................................................................................................156 COOLING SYSTEM................................................................................................156 INTRODUCTION..............................................................................................156 DESCRIPTION...............................................................................................156 RADIATOR..................................................................................................156 RADIATOR CAP..............................................................................................156 THERMOSTAT................................................................................................156 WATER PUMP................................................................................................157 FAN AND FAN SHROUD .......................................................................................157 REPAIRS.......................................................................................................157 COOLING SYSTEM CHECKS.....................................................................................157 Exhaust Leaks.........................................................................................157 RADIATOR..................................................................................................157 Checks................................................................................................157 Cleaning The Radiator.................................................................................157 Drain The Cooling System..............................................................................159 Fill The Cooling System...............................................................................159 WATER PUMP................................................................................................159 Checks................................................................................................159 THERMOSTAT................................................................................................160 Checks................................................................................................160 FAN AND FAN SHROUD .......................................................................................160 TROUBLESHOOTING...............................................................................................161 800048............................................................................................................162 LIFT TRUCK WEIGHTS*...........................................................................................162 ENGINE SPECIFICATIONS.........................................................................................162 ENGINE ELECTRICAL SPECIFICATIONS..............................................................................163 HYDRAULIC SPECIFICATIONS......................................................................................163 CAPACITIES....................................................................................................164 LIFT TRUCK TRAVEL SPEEDS......................................................................................164 TIRE SPECIFICATIONS...........................................................................................164 MAST SPEEDS (Early A177* Units)...............................................................................165 MAST SPEEDS (Later A177* Units)...............................................................................165 MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines).........................................166 MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines).......................................................166 TORQUE SPECIFICATIONS.........................................................................................168 TORQUE SPECIFICATIONS.........................................................................................169 900129............................................................................................................171 THE CARBURETOR, (MAZDA M4-121G ENGINE)........................................................................171 DESCRIPTION...............................................................................................171 REPAIRS, CARBURETOR.......................................................................................172 Removal...............................................................................................172 Cleaning..............................................................................................175 Inspection............................................................................................175 Assembly..............................................................................................175 Installation..........................................................................................177 CHECKS AND ADJUSTMENTS....................................................................................177 Carburetor, Idle Speed And Mixture Adjustment.........................................................177 Adjust The Governor...................................................................................178 ADJUST THE THROTTLE LINKAGE...............................................................................179 SPECIFICATIONS................................................................................................179 TROUBLESHOOTING...............................................................................................180 1300255...........................................................................................................182 INTRODUCTION..................................................................................................182 GENERAL...................................................................................................182 DESCRIPTION AND OPERATION.....................................................................................183 GENERAL...................................................................................................183 TORQE CONVERTER...........................................................................................183 Description...........................................................................................183 Operation.............................................................................................183 CLUTCH ASSEMBLIES.........................................................................................186 Description...........................................................................................186 Operation.............................................................................................188 HYDRAULIC SYSTEM..........................................................................................188 General...............................................................................................188 CONTROL VALVE.............................................................................................188 Regulator for Clutch Pressure.........................................................................191 Inching Spool Assembly................................................................................191 Direction Spool.......................................................................................191 MONOTROL Control Valve................................................................................191 Neutral Start Switch, MONOTROL Pedal Only.............................................................192 Neutral Start Switch, Direction Control Lever Only....................................................192 Modulator Circuit.....................................................................................192 Regulator for the Toruqe Converter....................................................................193 By-Pass Valve for the Oil Cooler......................................................................193 DIFFERENTIAL..............................................................................................194 OIL FLOW DIAGRAMS.........................................................................................194 1300256...........................................................................................................203 INTRODUCTION..................................................................................................203 GENERAL...................................................................................................203 REPAIRS.......................................................................................................205 REPAIRS...................................................................................................205 Torque Converter, Removal.............................................................................205 Torque Converter, Installation........................................................................205 Front Cover And Transmission Pump, Removal and Disassembly............................................206 Front Cover And Transmission Pump, Assembly and Installation..........................................206 Clutch Assemblies, Removal and Disassembly............................................................207 Clutch Assemblies, Inspection.........................................................................210 Clutch Assemblies, Assembly and Installation..........................................................211 Differential, Removal and Disassembly.................................................................214 Differential, Inspection..............................................................................216 Differential, Assembly And Installation...............................................................216 CONTROL VALVE.............................................................................................226 Control Valve, Removal and Disassembly................................................................226 Control Valve, Inspection.............................................................................226 Control Valve, Assembly and Installation..............................................................228 MONOTROL Pedal, Removal and Disassembly...............................................................230 MONOTROL Pedal, Assembly and Installation.............................................................230 CHECKS AND ADJUSTMENTS........................................................................................232 Stall Test................................................................................................232 Adjustment Of The Direction Control Linkage...............................................................233 Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1).............234 Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)..............237 Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187).......................238 Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)....................239 Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)....243 Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)............244 Check The Oil Pressures...................................................................................244 Check The Relief Valve for the Transmission Pump..........................................................244 Check The Clutch Pressure.................................................................................244 Check The Torque Converter Regulator......................................................................245 Check The Oil Pressure from the Oil Cooler................................................................245 Check The Modulator Pressure..............................................................................246 TROUBLESHOOTING...............................................................................................246 TROUBLESHOOTING, PRESSURE TESTS...............................................................................248 1600459...........................................................................................................251 THE STEERING SYSTEM...........................................................................................251 GENERAL...................................................................................................251 DESCRIPTION...............................................................................................251 Hydraulic Pump Assembly...............................................................................252 Flow Control Valve....................................................................................253 Relief Valve..........................................................................................253 OPERATION.................................................................................................253 Steering System.......................................................................................253 Hydraulic Pump........................................................................................254 Flow Control Valve....................................................................................254 Relief Valve..........................................................................................254 STEERING WHEEL AND COLUMN ASSEMBLY........................................................................255 Removal (Serial Code C177 And C187)...................................................................255 Installation (Serial Code C177 And C187)..............................................................255 Removal (Serial Code B177 And B187)...................................................................258 Installation (Serial Code B177 And B187)..............................................................258 STEERING CONTROL UNIT.....................................................................................259 Description...........................................................................................259 Operation, Control Valve Section......................................................................259 Operation, Metering Section...........................................................................260 CHECKS AND ADJUSTMENTS....................................................................................260 Remove Air From The Steering System...................................................................260 Check And Adjust Steering Relief Pressure.............................................................260 Check Hydraulic Pump For Correct Flow.................................................................260 TROUBLESHOOTING...............................................................................................261 1800458...........................................................................................................262 INTRODUCTION..................................................................................................262 GENERAL...................................................................................................262 SERVICE BRAKES AND PARKING BRAKE..............................................................................262 DESCRIPTION AND OPERATION.................................................................................262 Service Brakes........................................................................................262 Parking Brake.........................................................................................263 REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES...........................................263 Parking Brake.........................................................................................265 CLEANING..................................................................................................266 INSPECTION................................................................................................266 ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES.........................................266 Adjustments...........................................................................................269 Parking Brake Installation............................................................................270 Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes........................270 REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES...........................................272 Parking Brake.........................................................................................274 CLEANING..................................................................................................275 INSPECTION................................................................................................275 ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES.........................................275 Adjustments...........................................................................................277 Parking brake.........................................................................................278 Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes........................278 MASTER CYLINDER...........................................................................................279 Removal...............................................................................................279 Repair................................................................................................279 Installation..........................................................................................279 Cleaning And Inspection...............................................................................281 MASTER CYLINDER WITH BRAKE BOOSTER........................................................................283 Operation.............................................................................................283 Repair................................................................................................283 CHECKS AND ADJUSTMENTS........................................................................................285 ADJUST THE SERVICE BRAKES.................................................................................285 TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY).......................................................285 REMOVE THE AIR FROM THE BRAKE SYSTEM......................................................................286 ADJUST THE INCHING/BRAKE PEDAL............................................................................286 ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL)..................................291 TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)............................................................291 Test 1................................................................................................291 Test 2................................................................................................292 TORQUE SPECIFICATIONS.........................................................................................292 TROUBLESHOOTING...............................................................................................292 1900130...........................................................................................................295 INTRODUCTION..................................................................................................295 GENERAL...................................................................................................295 DESCRIPTION...............................................................................................297 Hydraulic System......................................................................................297 Gear Pump Assembly....................................................................................297 Flow Control Valve....................................................................................298 Relief Valve (Early Model)............................................................................298 Relief Valve (Later Model)............................................................................298 OPERATION.................................................................................................300 Hydraulic System......................................................................................300 Gear Pump.............................................................................................300 Flow Control Valve....................................................................................300 Relief Valve (Early Model)............................................................................300 Relief Valve (Later Model)............................................................................300 REPAIR........................................................................................................302 GEAR PUMP ASSEMBLY........................................................................................302 Removal and Disassembly...............................................................................302 Assembly and Installation.............................................................................303 CHECKS AND ADJUSTMENTS........................................................................................303 CHECK AND ADJUST STEERING RELIEF PRESSURE.................................................................303 CHECK GEAR PUMP FOR CORRECT FLOW..........................................................................304 TROUBLESHOOTING...............................................................................................304 2100103...........................................................................................................306 INTRODUCTION..................................................................................................309 GENERAL...................................................................................................309 DESCRIPTION...............................................................................................309 REPAIRS.......................................................................................................309 REMOVAL...................................................................................................309 DISASSEMBLY...............................................................................................309 CLEANING..................................................................................................309 ASSEMBLY..................................................................................................309 Tilt Cylinders for the XM and XMS Models..............................................................309 Tilt Cylinders with O-Ring or Single Lip Seals........................................................311 Tilt Cylinders for H700-800A and Early Model H700-920B................................................311 INSTALLATION..............................................................................................311 Tilt Cylinders with Chevron Packing...................................................................311 CHECKS AND ADJUSTMENTS........................................................................................315 CHECK THE TILT CYLINDERS FOR LEAKS........................................................................315 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...................................................315 TROUBLESHOOTING...............................................................................................318 2200106...........................................................................................................321 INTRODUCTION..................................................................................................321 GENERAL...................................................................................................321 DESCRIPTION AND OPERATION.................................................................................321 REPAIRS.......................................................................................................323 REMOVAL...................................................................................................323 DISSASEMBLY...............................................................................................323 CLEANING..................................................................................................324 ASSEMBLY..................................................................................................324 INSTALLATION..............................................................................................324 CHECKS AND ADJUSTMENTS........................................................................................325 GENERAL...................................................................................................325 TROUBLESHOOTING...............................................................................................327 2200132...........................................................................................................329 INTRODUCTION..................................................................................................329 GENERAL...................................................................................................329 DESCRIPTION...............................................................................................329 Starting System.......................................................................................329 Ignition System.......................................................................................329 Charging System.......................................................................................330 REPAIR........................................................................................................332 STARTER...................................................................................................332 Removal And Disassembly...............................................................................332 Assembly And Installation.............................................................................332 BALLAST RESISTOR RELAY (Earlier Production)...............................................................334 DISTRIBUTOR (Earlier Production With Contact Points)......................................................334 Removal And Disassembly...............................................................................334 Assembly And Installation.............................................................................336 COIL REPLACEMENT..........................................................................................336 DISTRIBUTOR (Later Production with Electronic Ignition System)............................................336 Removal And Disassembly...............................................................................336 Assembly And Installation.............................................................................338 ALTERNATOR (All Models)...................................................................................338 Removal And Disassembly...............................................................................338 Assembly And Installation.............................................................................339 REGULATOR REPLACEMENT (Earlier Production)................................................................340 CHECKS AND ADJUSTMENTS........................................................................................341 GENERAL...................................................................................................341 STARTER...................................................................................................341 Check Operation.......................................................................................341 Check Brush Length....................................................................................342 Check Brush Holder....................................................................................342 Armature..............................................................................................342 Field Windings........................................................................................342 Clutch And Bearing....................................................................................342 BALLAST RESISTOR RELAY (Earlier Production)...............................................................342 DISTRIBUTOR...............................................................................................343 Distributor Contact Clearance.........................................................................343 SPARK PLUGS...............................................................................................344 COIL AND BALLAST RESISTOR (Earlier Production)............................................................344 ALTERNATOR................................................................................................344 Check For Low Output (Alternator With Separate Regulator).............................................344 Check For Low Output (Alternator With Integral Regulator).............................................346 Check For High Output (Alternator With Separate Regulator)............................................347 Check For High Output (Alternator With Integral Regulator)............................................347 Rotor Resistance (Alternator with Separate Regulator).................................................347 Diodes Circuit (Alternator with Separate Regulator)...................................................348 Diode Assembly (Alternator With Separate Regulator)...................................................348 Check The Diodes, Diode Trio (Alternator with Integral Regulator).....................................348 Check The Rectifier Bridge (Alternator with Integral Regulator).......................................349 Check Field Winding For The Rotor (All Alternators)...................................................349 Check Windings In The Stator (All Alternators)........................................................350 Brushes And Bearings..................................................................................350 Check The Voltage Regulator (Alternator with Separate Regulator)......................................350 Check The Voltage Regulator (Alternator with Integral Regulator)......................................351 ADJUSTMENTS...............................................................................................351 TROBLESHOOTING................................................................................................352 2200134...........................................................................................................354 INTRODUCTION..................................................................................................354 GENERAL...................................................................................................354 DESCRIPTION...............................................................................................354 Starting System.......................................................................................354 Charging System.......................................................................................354 Vacuum Pump On Alternator (On Units With Brake Booster)...............................................356 REPAIRS.......................................................................................................357 STARTER...................................................................................................357 Removal And Disassembly...............................................................................357 Assembly And Installation.............................................................................357 REPLACING GLOW PLUGS......................................................................................359 ALTERNATOR (With Vaccum Pump).............................................................................359 Removal And Disassembly...............................................................................359 Cleaning..............................................................................................361 Assembly And Installation.............................................................................361 ALTERNATOR (Without Vacuum Pump)..........................................................................362 Removal And Disassembly...............................................................................362 Cleaning..............................................................................................364 Assembly And Installation.............................................................................364 REGULATOR REPLACEMENT.....................................................................................365 CHECKS........................................................................................................365 GENERAL...................................................................................................365 STARTER...................................................................................................365 Starter Operation.....................................................................................365 Solenoid Coil Checks..................................................................................366 Brush Length..........................................................................................366 Brush Holder..........................................................................................366 Armature..............................................................................................366 Field Windings........................................................................................367 Clutch And Bearings...................................................................................367 COLD START AID............................................................................................367 Glow Plugs............................................................................................367 Resistor..............................................................................................367 CHARGING CIRCUIT..........................................................................................367 Check For Low Output..................................................................................367 Check Ford High Output................................................................................369 ALTERNATOR................................................................................................369 Rotor Resistance......................................................................................369 Diodes Circuit........................................................................................369 Rotor Coil............................................................................................370 Stator Coil...........................................................................................370 Diode Assembly........................................................................................370 Brushes And Bearings..................................................................................371 REGULATOR (At Hydraulic Tank).............................................................................371 TROUBLESHOOTING...............................................................................................372 2200143...........................................................................................................375 INTRODUCTION..................................................................................................375 GENERAL...................................................................................................375 DESCRIPTION...................................................................................................375 GENERAL...................................................................................................375 STEERING COLUMN GAUGES, METERS AND INDICATORS.............................................................378 LED DISPLAY PANEL.........................................................................................378 Battery Discharge Indicators .........................................................................378 Brush Wear Indicators.................................................................................379 Motor Temperature Indicators..........................................................................380 "LX" SERIES INSTRUMENT PANEL DISPLAY......................................................................381 Hourmeter Functions...................................................................................382 Battery Indicator Function............................................................................382 Status Code Function..................................................................................382 CHECKS AND ADJUSTMENTS........................................................................................382 GENERAL...................................................................................................382 REPLACEMENT...................................................................................................383 GENERAL...................................................................................................383 METER REPLACEMENT.........................................................................................383 SENDER REPLACEMENT........................................................................................384 Fuel Level Sender.....................................................................................384 Pressure And Temperature Sender.......................................................................385 I.T.W. DISPLAY PANEL......................................................................................385 Removal...............................................................................................385 SPECIFICATIONS................................................................................................386 TROUBLESHOOTING...............................................................................................387 2200144...........................................................................................................388 ELECTRICAL WARNING DEVICES....................................................................................388 GENERAL...................................................................................................388 DESCRIPTION...............................................................................................388 Operator Controlled Horns.............................................................................388 System Warning Lights, Buzzers and Bells..............................................................388 Reverse Warning Horns.................................................................................389 Warning Lights........................................................................................389 REPLACEMENT...............................................................................................390 General...............................................................................................390 Replacing Horns or Bells..............................................................................390 Replacing Horn Relay or Buzzer........................................................................390 Replacing Warning Lights..............................................................................390 Light Assemblies......................................................................................391 Replacing Flashing Units..............................................................................391 4000135...........................................................................................................392 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................392 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................392 LIFT CYLINDERS................................................................................................395 GENERAL...................................................................................................395 DESCRIPTION...............................................................................................395 Lowering Control Valve................................................................................395 Cylinders (General)...................................................................................398 Cylinders (H520-620B,H700-800A).......................................................................400 Cylinders (H360-460B).................................................................................401 Cylinders (Two-Speed).................................................................................401 REPAIRS.......................................................................................................402 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST....................................................402 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............402 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...............................406 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.........................404 DISASSEMBLY...............................................................................................404 ASSEMBLY..................................................................................................406 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.............................................................406 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............406 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead......................406 CHEVRON PACKING...........................................................................................407 LIFT CYLINDERS FOR VISTA MASTS................................................................................410 DESCRIPTION...............................................................................................410 Lowering Control Valve................................................................................412 REMOVAL...................................................................................................413 DISASSEMBLY...............................................................................................413 ASSEMBLY..................................................................................................413 INSTALLATION..............................................................................................414 Main Lift Cylinders...................................................................................414 Free-Lift Cylinders...................................................................................414 CHECKS AND ADJUSTMENTS........................................................................................415 CHECK FOR LEAKS IN LIFT SYSTEM............................................................................415 TROUBLESHOOTING...............................................................................................416 SPECIFICATIONS................................................................................................417 4000222...........................................................................................................418 INTRODUCTION..................................................................................................418 GENERAL...................................................................................................418 MAST WELDMENTS............................................................................................418 CARRIAGE..................................................................................................418 MAST MOUNTS...............................................................................................419 VISTA® TWO-STAGE MAST.........................................................................................420 DESCRIPTION AND OPERATION.................................................................................420 VISTA® FREE-LIFT MAST.........................................................................................422 DESCRIPTION...............................................................................................422 OPERATION.................................................................................................422 VISTA® THREE-STAGE MAST.......................................................................................424 DESCRIPTION...............................................................................................424 OPERATION.................................................................................................424 VISTA® FOUR-STAGE MAST........................................................................................425 DESCRIPTION...............................................................................................425 OPERATION.................................................................................................426 4000223...........................................................................................................428 VISTA MAST, REPAIR............................................................................................428 GENERAL...................................................................................................428 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................428 FORKS.....................................................................................................429 Forks, Removal And Installation.......................................................................429 CARRIAGE..................................................................................................430 Removal...............................................................................................430 Installation..........................................................................................431 MASTS.....................................................................................................431 Removal...............................................................................................431 Disassembly...........................................................................................432 Cleaning and Inspection...............................................................................437 Assembly..............................................................................................437 Installation..........................................................................................441 SIDE-SHIFT CARRIAGE (EARLIER DESIGN)......................................................................442 Removal...............................................................................................442 Repairs...............................................................................................442 Installation..........................................................................................442 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)...............................................................443 Removal...............................................................................................443 Repairs...............................................................................................443 Installation..........................................................................................444 CHECKS AND ADJUSTMENTS........................................................................................445 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................445 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...............................................446 LIFT CHAIN ADJUSTMENTS....................................................................................447 MAST ADJUSTMENTS..........................................................................................447 CARRIAGE ADJUSTMENT.......................................................................................449 HEADER HOSE ARRANGEMENTS..................................................................................449 Two-Stage Header Hose.................................................................................450 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts.........................................450 TROUBLESHOOTING...............................................................................................455 8000231...........................................................................................................456 INTRODUCTION..................................................................................................456 NOMENCLATURE, THREADS.....................................................................................456 STRENGTH IDENTIFICATION...................................................................................457 TABLE 1. BOLTS AND SCREWS.....................................................................................457 TABLE 2. STUDS AND NUTS.......................................................................................458 TABLE 3. TORQUE NUTS..........................................................................................459 TABLE 4. TORQUE NUTS WITH NYLON INSERT........................................................................460 TABLE 5. TORQUE VALUES FOR INCH FASTENERS.....................................................................461 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...................................................................462 8000259...........................................................................................................465 PERIODIC MAINTENANCE..........................................................................................465 GENERAL...................................................................................................465 Serial Number Data....................................................................................465 HOW TO MOVE A DISABLED LIFT TRUCK.........................................................................466 How To Tow the Lift Truck.............................................................................466 HOW TO PUT A LIFT TRUCK ON BLOCKS.........................................................................466 How To Raise the Drive Tires..........................................................................466 How To Raise the Steering Tires.......................................................................467 MAINTENANCE PROCEDURES........................................................................................471 EVERY 8 HOURS OR DAILY........................................................................................471 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED................................................................471 Engine Oil............................................................................................471 Drive Belts...........................................................................................471 Cooling System........................................................................................471 Battery...............................................................................................472 Fuel System...........................................................................................474 Air Filter............................................................................................474 Hydraulic System Oil..................................................................................474 Tires and Wheels......................................................................................475 Forks.................................................................................................475 Forks, Adjustment.....................................................................................476 Forks, Removal And Installation.......................................................................476 Inspection Of Forks, Mast, and Lift Chains............................................................477 Safety Labels.........................................................................................478 Operator Restraint System.............................................................................478 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING................................................................479 Gauges, Lights, Horn, and Fuses.......................................................................479 Fuel Filter, Diesel Engine............................................................................480 How To Drain The Water From The Fuel Filter...........................................................480 Oil Level, Powershift Transmission....................................................................480 Control Levers and Pedals.............................................................................480 Lift System Operation.................................................................................480 Inching/Brake Pedal...................................................................................481 Service Brakes........................................................................................481 Parking Brake.........................................................................................481 Steering System.......................................................................................481 EVERY 250 HOURS OR TWO MONTHS.................................................................................482 ENGINE OIL AND FILTER.....................................................................................482 Mazda, GM, And Later Production Isuzu Engines.........................................................482 Earlier Production Isuzu C240 Engines.................................................................482 GOVERNOR, MAZDA ENGINE....................................................................................483 DRIVE BELTS...............................................................................................483 Mazda Engine..........................................................................................483 Isuzu, GM 4-181, And GM 4-153 Engines.................................................................483 BRAKE FLUID...............................................................................................484 HYDRAULIC TANK BREATHER, CLEAN AND CHECK..................................................................484 FORKS, CHECK FOR WEAR AND DAMAGE..........................................................................484 LIFT CHAINS...............................................................................................484 Lubrication...........................................................................................484 Check For Wear........................................................................................484 MAST, LUBRICATION.........................................................................................485 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...............................................................485 CONTROL LEVERS AND PEDALS, LUBRICATION....................................................................486 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.......................................................................486 Idle Speed, Diesel....................................................................................486 LPG Carburetor........................................................................................487 Gasoline Carburetor...................................................................................487 EVERY 1000 HOURS OR SIX MONTHS................................................................................488 DIESEL FUEL FILTER........................................................................................488 Filter Replacement, Models Without A Water Separator..................................................489 Filter Replacement, Models With A Water Separator.....................................................489 Remove Air from the Diesel Fuel System................................................................489 DIFFERENTIAL..............................................................................................490 VALVE CLEARANCE ADJUSTMENT................................................................................490 IGNITION SYSTEM, MAZDA AND GM ENGINES.....................................................................490 PCV VALVE AND FILTER......................................................................................492 EVERY 2000 HOURS OR YEARLY....................................................................................492 HYDRAULIC SYSTEM..........................................................................................492 Replace the Hydraulic Oil and Filter..................................................................492 POWERSHIFT TRANSMISSION...................................................................................492 COOLING SYSTEM............................................................................................493 SERVICE BRAKES............................................................................................493 DIFFERENTIAL..............................................................................................493 WHEEL BEARINGS............................................................................................494 Steering Wheels, lubrication..........................................................................494 Drive Wheels, Lubrication.............................................................................494 GASOLINE FUEL FILTER, REPLACEMENT.........................................................................494 PCV VALVE, GM ENGINES.....................................................................................494 LPG FILTER, REPLACEMENT...................................................................................494 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A............................................................494 GENERAL PROCEDURES............................................................................................495 CHECK THE HOOD LATCH......................................................................................495 LIFT CHAIN ADJUSTMENTS....................................................................................495 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................497 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................498 Check the Lift Cylinders for Leaks....................................................................498 Check the Tilt Cylinders for Leaks....................................................................498 FUEL INJECTORS............................................................................................499 WELDING REPAIRS...........................................................................................499 CHANGES TO THE OVERHEAD GUARD.............................................................................499 WHEELS AND TIRES..........................................................................................499 Solid Rubber Tires (Press-on).........................................................................499 Install The Wheels....................................................................................500 Pneumatic Tires, Remove The Wheels From The Lift Truck................................................501 Pneumatic Tires, Remove the Tire From The Wheel.......................................................501 Pneumatic Tires, Install The Wheel In The Tire........................................................502 Pneumatic Tires, Add Air To The Tires.................................................................503 Pneumatic Tires, Install the Wheels...................................................................504 Pneumatic Tires, Installation Procedures, Dual Drive Wheels...........................................504 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.........................................................505 Remove The Wheels From The Lift Truck.................................................................505 Remove The Tire From The Wheel........................................................................505 Install The Tire On The Wheel.........................................................................506 REFERENCE TABLE...............................................................................................507 8000461...........................................................................................................508 FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC..........................................................................509 FIGURE 2. TRANSMISSION SCHEMATIC..............................................................................510 FIGURE 3. INSTRUMENT PANEL ELECTRICAL DIAGRAM.................................................................511 FIGURE 4. MAZDA ENGINE, GASOLINE/LPG WIRING SCHEMATIC.........................................................513 FIGURE 5. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating).........................................515 FIGURE 6. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)........................................517 FIGURE 7. DIESEL ENGINE WIRING SCHEMATIC......................................................................519 FIGURE 8. DIESEL ENGINE CABLE DIAGRAM (D Rating)..............................................................521 FIGURE 9. DIESEL (SAFETY) ENGINE CABLE DIAGRAM (DS RATING)....................................................523 FIGURE 10. GM ENGINE, GASOLINE/LPG WIRING DIAGRAM (GS and LPS Rating).........................................525 FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)...........................................527 FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)..........................................529
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