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Hyster B177 (H40-60XL) Service Manual – PDF DOWNLOAD
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Description
Hyster B177 (H40-60XL) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster B177 (H40-60XL) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR :
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid PetroleumGas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster B177 (H40-60XL) Service Manual – PDF DOWNLOAD
22002............................................................................................................. 1 General....................................................................................................... 3 Description................................................................................................... 3 Alternator Repair............................................................................................. 5 Alternator Type A......................................................................................... 5 Remove and Disassemble................................................................................ 5 Clean................................................................................................. 6 Assemble.............................................................................................. 6 Install............................................................................................... 7 Alternator Type B......................................................................................... 10 Remove and Disassemble................................................................................ 10 Clean................................................................................................. 10 Assemble.............................................................................................. 11 Install............................................................................................... 12 General Check and Adjustment.................................................................................. 13 Low Output Check (Type A or Type B)........................................................................... 13 High Output Check (Type A or Type B).......................................................................... 15 Brushes Circuit Check......................................................................................... 16 Delco Alternators......................................................................................... 16 Motorola Alternators...................................................................................... 17 Diodes Check.................................................................................................. 18 Diodes Bridge Check........................................................................................... 18 Delco and Leece-Neville Alternators....................................................................... 18 Motorola Alternators...................................................................................... 18 Rotor Field Winding Check..................................................................................... 19 Stator Windings Check......................................................................................... 20 Voltage Regulator Check....................................................................................... 20 Troubleshooting............................................................................................... 21 60066............................................................................................................. 23 MAZDA M4-121G ENGINE.......................................................................................... 23 GENERAL................................................................................................... 23 DESCRIPTION............................................................................................... 24 REMOVAL AND INSTALLATION OF THE ENGINE.................................................................... 24 CYLINDER HEAD AND VALVE MECHANISM......................................................................... 24 Cylinder Head, Removal................................................................................ 24 Cylinder Head, Inspection and Repairs................................................................. 25 Rocker Arm Assembly................................................................................... 25 Valve Guides.......................................................................................... 25 Valve Seats........................................................................................... 26 Valves................................................................................................ 26 Valve Springs......................................................................................... 26 Cylinder Head, Installation........................................................................... 26 TIMING GEAR CASE, REMOVAL................................................................................. 27 TIMING GEAR CASE, INSTALLATION............................................................................ 28 CAMSHAFT.................................................................................................. 28 Removal............................................................................................... 28 Inspection............................................................................................ 29 Cam Followers, Inspection............................................................................. 29 Installation.......................................................................................... 29 CRANKSHAFT AND MAIN BEARINGS.............................................................................. 29 Crankshaft, Removal................................................................................... 29 Crankshaft, Inspection And Repair..................................................................... 30 Main Bearings......................................................................................... 31 Crankshaft, Installation.............................................................................. 31 PISTONS AND CONNECTING RODS............................................................................... 32 Removal............................................................................................... 32 Disassembly........................................................................................... 32 Pistons, Inspection And Repair........................................................................ 32 Piston Rings.......................................................................................... 33 Piston Pin and Bushing................................................................................ 33 Connecting Rods and Bearings, Inspection.............................................................. 33 Pistons and Connecting Rods, Assembly................................................................. 33 Pistons and Connecting Rods, Installation............................................................. 34 CYLINDER BLOCK AND CYLINDER LINERS........................................................................ 34 Cylinder Block, Repairs............................................................................... 34 Cylinder Liners....................................................................................... 34 DISTRIBUTOR............................................................................................... 35 Removal............................................................................................... 35 Installation.......................................................................................... 35 OIL PUMP.................................................................................................. 37 Removal............................................................................................... 37 Repairs............................................................................................... 37 Installation.......................................................................................... 38 GOVERNOR.................................................................................................. 38 Description........................................................................................... 38 Removal............................................................................................... 38 Disassembly........................................................................................... 39 Assembly.............................................................................................. 40 Installation.......................................................................................... 41 COOLANT PUMP.............................................................................................. 41 Removal............................................................................................... 41 Disassembly and Repair................................................................................ 42 Assembly.............................................................................................. 42 Installation.......................................................................................... 43 FLYWHEEL.................................................................................................. 43 Repairs............................................................................................... 43 Installation.......................................................................................... 43 CHECKS AND ADJUSTMENTS........................................................................................ 43 ADJUST THE VALVES......................................................................................... 43 ADJUST THE THROTTLE LINKAGE............................................................................... 44 ENGINE SPECIFICATIONS......................................................................................... 44 ENGINE SPECIFICATIONS..................................................................................... 44 Engine Data........................................................................................... 44 Cooling System........................................................................................ 44 Cylinder Head and Valve Mechanism..................................................................... 44 Camshaft.............................................................................................. 46 Timing Gear........................................................................................... 47 Camshaft.............................................................................................. 47 Connecting Rods....................................................................................... 47 Cylinder Liners....................................................................................... 47 Pistons............................................................................................... 47 Lubrication System.................................................................................... 48 Fuel Pump............................................................................................. 48 TORQUE SPECIFICATIONS..................................................................................... 49 TROUBLESHOOTING............................................................................................... 50 60070............................................................................................................. 54 INTRODUCTION ................................................................................................. 54 GENERAL .................................................................................................. 54 DESCRIPTION .............................................................................................. 54 FUEL SYSTEM .............................................................................................. 55 Description .......................................................................................... 55 Operation, Fuel Injection Pump, Model VE ............................................................. 57 Operation, Fuel Injection Pump, Model PE4A ........................................................... 58 Pneumatic Governor For Fuel Injection Pump, Model PE4A ............................................... 59 Inlet Manifold For Fuel Injection Pump, Model PE4A ................................................... 60 REPAIRS ...................................................................................................... 61 FUEL INJECTION PUMP (ALL MODELS) ......................................................................... 61 Removal .............................................................................................. 61 Installation ......................................................................................... 61 REMOVAL AND INSTALLATION OF THE ENGINE ................................................................... 61 CYLINDER HEAD AND VALVE MECHANISM ........................................................................ 61 Cylinder Head, Removal ............................................................................... 61 Valve Guides, Replacement ............................................................................ 62 Cylinder Head, Inspection And Repair ................................................................. 63 Combustion Chamber Plugs, Inspection And Repair ...................................................... 63 Combustion Chamber Plugs, Installation ............................................................... 63 Valves, Inspection And Repair ........................................................................ 64 Valve Seat, Inspection ............................................................................... 64 Valve Seat, Removal .................................................................................. 65 Valve Seat, Installation ............................................................................. 65 Valve Spring, Inspection ............................................................................. 65 Rocker Arms, Inspection And Assembly ................................................................. 65 Installation Of The Cylinder Head .................................................................... 66 TIMING GEAR CASE ......................................................................................... 67 Removal .............................................................................................. 67 Installation ......................................................................................... 67 CAMSHAFT ................................................................................................. 69 Removal .............................................................................................. 69 Inspection ........................................................................................... 69 Camshaft Bearings .................................................................................... 70 Cam Followers ........................................................................................ 70 CAMSHAFT, INSTALLATION ................................................................................... 70 CRANKSHAFT AND MAIN BEARINGS ............................................................................. 71 Crankshaft, Removal .................................................................................. 71 Crankshaft, Inspection And Repair .................................................................... 71 Main Bearings ........................................................................................ 71 Pilot Bearing ........................................................................................ 72 Crankshaft, Installation ............................................................................. 72 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) .......................................................... 74 Flywheel, Removal .................................................................................... 74 Ring Gear, Replacement ............................................................................... 74 Flywheel, Installation ............................................................................... 74 PISTONS AND CONNECTING RODS .............................................................................. 75 Pistons And Connecting Rods, Removal ................................................................. 75 Disassembly .......................................................................................... 75 Pistons, Inspection And Repair ....................................................................... 76 Piston Rings, Inspection And Repair .................................................................. 76 Piston Pins, Inspection And Repair ................................................................... 77 Connecting Rods, Inspection And Repair ............................................................... 78 Pistons And Connecting Rods, Assembly And Installation ............................................... 78 CYLINDER BLOCK AND CYLINDER LINERS ....................................................................... 78 Cylinder Liners, Inspection .......................................................................... 78 Replacement Of A Cylinder Liner ...................................................................... 79 LUBRICATION SYSTEM ....................................................................................... 80 Oil Pump, Removal And Disassembly .................................................................... 80 Oil Pump, Inspection ................................................................................. 80 Oil Pump, Assembly And Installation .................................................................. 81 Oil Filter ........................................................................................... 81 COOLING SYSTEM ........................................................................................... 82 Coolant Pump, Removal ................................................................................ 82 Coolant Pump, Disassembly ............................................................................ 82 Coolant Pump, Assembly And Installation .............................................................. 82 Thermostat, Replacement .............................................................................. 83 CHECKS AND ADJUSTMENTS ....................................................................................... 83 VALVE CLEARANCE ADJUSTMENT ............................................................................... 83 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE .................................................... 84 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A .................................................. 85 FUEL INJECTORS ........................................................................................... 85 Fuel Injectors, Removal .............................................................................. 86 Fuel Injectors, Inspection ........................................................................... 86 Fuel Injectors, Installation ......................................................................... 87 DIESEL FUEL FILTERS ...................................................................................... 87 Filter Replacement, Models With A Water Separator .................................................... 87 Filter Replacement, Models Without A Water Separator ................................................. 88 Filter For The Fuel Injection Pump, Model PE4A ....................................................... 88 REMOVE AIR FROM THE FUEL SYSTEM .......................................................................... 88 Throttle Linkage, Adjustment ......................................................................... 89 Idle Speed, Adjustment ............................................................................... 89 Check The Elements For The Cold Start Aid System ..................................................... 89 ENGINE SPECIFICATIONS ........................................................................................ 89 TORQUE SPECIFICATIONS ........................................................................................ 91 90015............................................................................................................. 92 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)..................................................................... 92 GENERAL................................................................................................... 92 DESCRIPTION............................................................................................... 92 Fuel Tank............................................................................................. 93 Fuel Filter And Fuel Valve Unit....................................................................... 94 Vaporizer............................................................................................. 94 The IMPCO CA 100 Carbureto............................................................................ 96 IMPCO CA 50 Carburetor................................................................................ 98 The Governor (GM Engines Only)........................................................................ 99 Governor With Electronic Controller................................................................... 100 REPAIRS....................................................................................................... 101 LPG TANK.................................................................................................. 101 Removal............................................................................................... 101 Installation.......................................................................................... 102 REPLACE THE HOSES......................................................................................... 102 HYDROSTATIC RELIEF VALVE.................................................................................. 102 Removal and Installation.............................................................................. 102 FILTER UNIT............................................................................................... 103 Replacement Of the Fuel Filter Element................................................................ 103 Replacement of the Diaphragm and Fuel Valve........................................................... 104 VAPORIZER................................................................................................. 104 Removal............................................................................................... 104 Disassembly........................................................................................... 104 Cleaning.............................................................................................. 104 Inspection............................................................................................ 104 Assembly.............................................................................................. 106 Installation.......................................................................................... 106 CARBURETOR (IMPCO CA 100)................................................................................. 108 Removal............................................................................................... 108 Disassembly........................................................................................... 108 Cleaning.............................................................................................. 108 Assembly.............................................................................................. 108 Installation.......................................................................................... 111 CARBURETER (IMPCO CA 50).................................................................................. 110 Removal............................................................................................... 110 Disassembly........................................................................................... 110 Cleaning.............................................................................................. 111 Inspection............................................................................................ 111 Assembly (See FIGURE 26.)............................................................................. 111 Installation.......................................................................................... 111 CHECKS AND ADJUSTMENTS........................................................................................ 112 CHECK THE FILTER UNIT..................................................................................... 112 CHECK THE VAPORIZER....................................................................................... 112 Pressure Reducer Valve................................................................................ 112 Vapor Valve........................................................................................... 112 ADJUST THE CARBURETOR..................................................................................... 112 Idle Mixture.......................................................................................... 112 Idle Speed............................................................................................ 112 Power Mixture......................................................................................... 112 ADJUST THE GOVERNOR (GM Engines Only)..................................................................... 113 Checks................................................................................................ 113 Main Adjusting Screw.................................................................................. 113 Secondary Adjusting Screw............................................................................. 113 AISAN Governor........................................................................................ 114 Adjustment, AISAN Governor............................................................................ 114 TROUBLESHOOTING............................................................................................... 115 100137............................................................................................................ 119 INTRODUCTION.................................................................................................. 119 GENERAL................................................................................................... 119 DESCRIPTION............................................................................................... 119 REPAIRS....................................................................................................... 119 COUNTERWEIGHT............................................................................................. 120 Removal............................................................................................... 120 Installation.......................................................................................... 120 MUFFLER................................................................................................... 121 HOOD...................................................................................................... 121 Removal............................................................................................... 121 Installation.......................................................................................... 121 RADIATOR AND COOLANT SYSTEM............................................................................... 121 Removal............................................................................................... 121 Installation.......................................................................................... 121 OVERHEAD GUARD............................................................................................ 122 Removal And Installation.............................................................................. 122 OPERATOR RESTRAINT SYSTEM................................................................................. 122 ENGINE REMOVAL AND INSTALLATION........................................................................... 123 Removal of the Engine and Transmission................................................................ 123 Installation of the Engine and Transmission........................................................... 127 FUEL AND HYDRAULIC TANKS.................................................................................. 129 Inspection............................................................................................ 129 Repairs, Small Leaks.................................................................................. 129 Repairs, Large Leaks.................................................................................. 129 Cleaning.............................................................................................. 129 Steam Method Of Cleaning.............................................................................. 129 Chemical Solution Method of Cleaning.................................................................. 130 Additional Preparations For Repair.................................................................... 130 SAFETY LABELS............................................................................................. 130 CAB....................................................................................................... 132 Cab Replacement....................................................................................... 132 Window Replacement.................................................................................... 132 Windshield Wipers and Heater.......................................................................... 134 140085............................................................................................................ 135 INTRODUCTION.................................................................................................. 135 GENERAL................................................................................................... 135 DESCRIPTION............................................................................................... 135 REPAIRS....................................................................................................... 136 REMOVAL................................................................................................... 136 CLEANING.................................................................................................. 136 INSPECTION................................................................................................ 136 ASSEMBLY.................................................................................................. 136 TROUBLESHOOTING............................................................................................... 139 SPECIFICATIONS................................................................................................ 139 160010............................................................................................................ 140 INTRODUCTION.................................................................................................. 140 DESCRIPTION............................................................................................... 140 GENERAL................................................................................................... 140 REPAIRS....................................................................................................... 141 STEERING AXLE............................................................................................. 141 Removal................................................................................................... 141 Installation.............................................................................................. 142 STEERING CYLINDER......................................................................................... 142 Removal................................................................................................... 142 Service................................................................................................... 143 Installation.............................................................................................. 143 HUBS...................................................................................................... 143 Removal................................................................................................... 143 Installation.............................................................................................. 144 SPINDLES.................................................................................................. 144 Removal................................................................................................... 144 Installation.............................................................................................. 145 CHECKS AND ADJUSTMENTS........................................................................................ 145 REMOVE THE AIR FROM THE STEERING SYSTEM................................................................... 145 SET THE PRESSURE RELIEF VALVE............................................................................. 145 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)................................................... 145 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION........................................................ 145 H2.00-3.00J (H40-60J) With Powershift Transmission........................................................ 145 TROUBLESHOOTING............................................................................................... 147 200077............................................................................................................ 148 INTRODUCTION.................................................................................................. 148 GENERAL................................................................................................... 148 DESCRIPTION............................................................................................... 148 OPERATION................................................................................................. 149 Lift Section.......................................................................................... 150 Tilt Section.......................................................................................... 150 Relief Valve.......................................................................................... 152 SOLENOID VALVE FOR AUXILIARY FUNCTION..................................................................... 153 Operation............................................................................................. 153 REPAIRS....................................................................................................... 153 MAIN CONTROL VALVE........................................................................................ 153 Removal and Disassembly............................................................................... 153 Cleaning and Inspection............................................................................... 154 Assembly.............................................................................................. 154 Installation.......................................................................................... 154 SOLENOID VALVE FOR AUXILIARY FUNCTION..................................................................... 154 Removal and Disassembly............................................................................... 154 Assembly and Installation............................................................................. 156 CHECKS AND ADJUSTMENTS........................................................................................ 156 PRESSURE RELIEF VALVES.................................................................................... 156 Primary Relief Valve.................................................................................. 156 Seconday Relief Valve................................................................................. 157 CONTROL LEVER ARRANGEMENT................................................................................. 157 TROUBLESHOOTING............................................................................................... 160 SPECIFICATIONS................................................................................................ 162 700626............................................................................................................ 163 General....................................................................................................... 165 Description................................................................................................... 166 Radiator.................................................................................................. 166 Radiator Cap.............................................................................................. 166 Thermostat................................................................................................ 166 Water Pump................................................................................................ 167 Fan and Fan Shroud........................................................................................ 167 Cooling System Checks......................................................................................... 167 Radiator.................................................................................................. 167 Thermostat................................................................................................ 167 Water Pump................................................................................................ 168 Exhaust Leaks............................................................................................. 168 Fan and Fan Shroud........................................................................................ 168 Radiator Cleaning............................................................................................. 168 Drain..................................................................................................... 168 Clean..................................................................................................... 168 Fill...................................................................................................... 169 Troubleshooting............................................................................................... 170 800048............................................................................................................ 172 LIFT TRUCK WEIGHTS*........................................................................................... 172 ENGINE SPECIFICATIONS......................................................................................... 172 ENGINE ELECTRICAL SPECIFICATIONS.............................................................................. 173 HYDRAULIC SPECIFICATIONS...................................................................................... 173 CAPACITIES.................................................................................................... 174 LIFT TRUCK TRAVEL SPEEDS...................................................................................... 174 TIRE SPECIFICATIONS........................................................................................... 174 MAST SPEEDS (Early A177* Units)............................................................................... 175 MAST SPEEDS (Later A177* Units)............................................................................... 175 MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)......................................... 176 MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)....................................................... 176 TORQUE SPECIFICATIONS......................................................................................... 178 TORQUE SPECIFICATIONS......................................................................................... 179 900129............................................................................................................ 181 THE CARBURETOR, (MAZDA M4-121G ENGINE)........................................................................ 181 DESCRIPTION............................................................................................... 181 REPAIRS, CARBURETOR....................................................................................... 182 Removal............................................................................................... 182 Cleaning.............................................................................................. 185 Inspection............................................................................................ 185 Assembly.............................................................................................. 185 Installation.......................................................................................... 187 CHECKS AND ADJUSTMENTS.................................................................................... 187 Carburetor, Idle Speed And Mixture Adjustment......................................................... 187 Adjust The Governor................................................................................... 188 ADJUST THE THROTTLE LINKAGE............................................................................... 189 SPECIFICATIONS................................................................................................ 189 TROUBLESHOOTING............................................................................................... 190 1300255........................................................................................................... 192 .............................................................................................................. 192 .............................................................................................................. 193 .............................................................................................................. 194 .............................................................................................................. 195 .............................................................................................................. 196 .............................................................................................................. 197 .............................................................................................................. 198 .............................................................................................................. 199 .............................................................................................................. 200 .............................................................................................................. 201 .............................................................................................................. 202 .............................................................................................................. 203 .............................................................................................................. 204 .............................................................................................................. 205 .............................................................................................................. 206 .............................................................................................................. 207 .............................................................................................................. 208 .............................................................................................................. 209 .............................................................................................................. 210 .............................................................................................................. 211 .............................................................................................................. 212 .............................................................................................................. 213 .............................................................................................................. 214 .............................................................................................................. 215 .............................................................................................................. 216 .............................................................................................................. 217 .............................................................................................................. 218 .............................................................................................................. 219 1300256........................................................................................................... 220 .............................................................................................................. 220 .............................................................................................................. 221 .............................................................................................................. 222 .............................................................................................................. 223 .............................................................................................................. 224 .............................................................................................................. 225 .............................................................................................................. 226 .............................................................................................................. 227 .............................................................................................................. 228 .............................................................................................................. 229 .............................................................................................................. 230 .............................................................................................................. 231 .............................................................................................................. 232 .............................................................................................................. 233 .............................................................................................................. 234 .............................................................................................................. 235 .............................................................................................................. 236 .............................................................................................................. 237 .............................................................................................................. 238 .............................................................................................................. 239 .............................................................................................................. 240 .............................................................................................................. 241 .............................................................................................................. 242 .............................................................................................................. 243 .............................................................................................................. 244 .............................................................................................................. 245 .............................................................................................................. 246 .............................................................................................................. 247 .............................................................................................................. 248 .............................................................................................................. 249 .............................................................................................................. 250 .............................................................................................................. 251 .............................................................................................................. 252 .............................................................................................................. 253 .............................................................................................................. 254 .............................................................................................................. 255 .............................................................................................................. 256 .............................................................................................................. 257 .............................................................................................................. 258 .............................................................................................................. 259 .............................................................................................................. 260 .............................................................................................................. 261 .............................................................................................................. 262 .............................................................................................................. 263 .............................................................................................................. 264 .............................................................................................................. 265 .............................................................................................................. 266 .............................................................................................................. 267 .............................................................................................................. 268 .............................................................................................................. 269 .............................................................................................................. 270 .............................................................................................................. 271 1600459........................................................................................................... 272 THE STEERING SYSTEM........................................................................................... 272 GENERAL................................................................................................... 272 DESCRIPTION............................................................................................... 272 Hydraulic Pump Assembly............................................................................... 273 Flow Control Valve.................................................................................... 274 Relief Valve.......................................................................................... 274 OPERATION................................................................................................. 274 Steering System....................................................................................... 274 Hydraulic Pump........................................................................................ 275 Flow Control Valve.................................................................................... 275 Relief Valve.......................................................................................... 275 STEERING WHEEL AND COLUMN ASSEMBLY........................................................................ 276 Removal (Serial Code C177 And C187)................................................................... 276 Installation (Serial Code C177 And C187).............................................................. 276 Removal (Serial Code B177 And B187)................................................................... 279 Installation (Serial Code B177 And B187).............................................................. 279 STEERING CONTROL UNIT..................................................................................... 280 Description........................................................................................... 280 Operation, Control Valve Section...................................................................... 280 Operation, Metering Section........................................................................... 281 CHECKS AND ADJUSTMENTS.................................................................................... 281 Remove Air From The Steering System................................................................... 281 Check And Adjust Steering Relief Pressure............................................................. 281 Check Hydraulic Pump For Correct Flow................................................................. 281 TROUBLESHOOTING............................................................................................... 282 1800458........................................................................................................... 283 INTRODUCTION.................................................................................................. 283 GENERAL................................................................................................... 283 SERVICE BRAKES AND PARKING BRAKE.............................................................................. 283 DESCRIPTION AND OPERATION................................................................................. 283 Service Brakes........................................................................................ 283 Parking Brake......................................................................................... 284 REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES........................................... 284 Parking Brake......................................................................................... 286 CLEANING.................................................................................................. 287 INSPECTION................................................................................................ 287 ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES......................................... 287 Adjustments........................................................................................... 290 Parking Brake Installation............................................................................ 291 Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes........................ 291 REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES........................................... 293 Parking Brake......................................................................................... 295 CLEANING.................................................................................................. 296 INSPECTION................................................................................................ 296 ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES......................................... 296 Adjustments........................................................................................... 298 Parking brake......................................................................................... 299 Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes........................ 299 MASTER CYLINDER........................................................................................... 300 Removal............................................................................................... 300 Repair................................................................................................ 300 Installation.......................................................................................... 300 Cleaning And Inspection............................................................................... 302 MASTER CYLINDER WITH BRAKE BOOSTER........................................................................ 304 Operation............................................................................................. 304 Repair................................................................................................ 304 CHECKS AND ADJUSTMENTS........................................................................................ 306 ADJUST THE SERVICE BRAKES................................................................................. 306 TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)....................................................... 306 REMOVE THE AIR FROM THE BRAKE SYSTEM...................................................................... 307 ADJUST THE INCHING/BRAKE PEDAL............................................................................ 307 ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL).................................. 312 TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)............................................................ 312 Test 1................................................................................................ 312 Test 2................................................................................................ 313 TORQUE SPECIFICATIONS......................................................................................... 313 TROUBLESHOOTING............................................................................................... 313 1900130........................................................................................................... 316 INTRODUCTION.................................................................................................. 316 GENERAL................................................................................................... 316 DESCRIPTION............................................................................................... 318 Hydraulic System...................................................................................... 318 Gear Pump Assembly.................................................................................... 318 Flow Control Valve.................................................................................... 319 Relief Valve (Early Model)............................................................................ 319 Relief Valve (Later Model)............................................................................ 319 OPERATION................................................................................................. 321 Hydraulic System...................................................................................... 321 Gear Pump............................................................................................. 321 Flow Control Valve.................................................................................... 321 Relief Valve (Early Model)............................................................................ 321 Relief Valve (Later Model)............................................................................ 321 REPAIR........................................................................................................ 323 GEAR PUMP ASSEMBLY........................................................................................ 323 Removal and Disassembly............................................................................... 323 Assembly and Installation............................................................................. 324 CHECKS AND ADJUSTMENTS........................................................................................ 324 CHECK AND ADJUST STEERING RELIEF PRESSURE................................................................. 324 CHECK GEAR PUMP FOR CORRECT FLOW.......................................................................... 325 TROUBLESHOOTING............................................................................................... 325 2100103........................................................................................................... 327 General....................................................................................................... 329 Description................................................................................................... 329 Tilt Cylinder................................................................................................. 329 Remove.................................................................................................... 329 Disassemble............................................................................................... 329 Clean..................................................................................................... 329 Assemble.................................................................................................. 329 Tilt Cylinders with O-Ring or Single-Lip Seals........................................................ 329 Tilt Cylinders for XM and XMS Models.................................................................. 331 Tilt Cylinders for H700-800A and Early Model H700-920B................................................ 332 Install................................................................................................... 333 Tilt Cylinders Using Chevron Packing.................................................................. 334 Install........................................................................................... 335 Tilt Cylinder Leak Check...................................................................................... 337 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment........................................................... 338 Torque Specifications......................................................................................... 338 Piston Rod Nut............................................................................................ 338 Retainer.................................................................................................. 340 Troubleshooting............................................................................................... 341 2200106........................................................................................................... 344 General....................................................................................................... 346 Description and Operation..................................................................................... 346 Starter Repair................................................................................................ 348 Remove.................................................................................................... 348 Disassemble............................................................................................... 348 Clean..................................................................................................... 349 Assemble.................................................................................................. 349 Install................................................................................................... 350 General Checks and Adjustments................................................................................ 350 Troubleshooting............................................................................................... 353 2200132........................................................................................................... 357 INTRODUCTION.................................................................................................. 357 GENERAL................................................................................................... 357 DESCRIPTION............................................................................................... 357 Starting System....................................................................................... 357 Ignition System....................................................................................... 357 Charging System....................................................................................... 358 REPAIR........................................................................................................ 360 STARTER................................................................................................... 360 Removal And Disassembly............................................................................... 360 Assembly And Installation............................................................................. 360 BALLAST RESISTOR RELAY (Earlier Production)............................................................... 362 DISTRIBUTOR (Earlier Production With Contact Points)...................................................... 362 Removal And Disassembly............................................................................... 362 Assembly And Installation............................................................................. 364 COIL REPLACEMENT.......................................................................................... 364 DISTRIBUTOR (Later Production with Electronic Ignition System)............................................ 364 Removal And Disassembly............................................................................... 364 Assembly And Installation............................................................................. 366 ALTERNATOR (All Models)................................................................................... 366 Removal And Disassembly............................................................................... 366 Assembly And Installation............................................................................. 367 REGULATOR REPLACEMENT (Earlier Production)................................................................ 368 CHECKS AND ADJUSTMENTS........................................................................................ 369 GENERAL................................................................................................... 369 STARTER................................................................................................... 369 Check Operation....................................................................................... 369 Check Brush Length.................................................................................... 370 Check Brush Holder.................................................................................... 370 Armature.............................................................................................. 370 Field Windings........................................................................................ 370 Clutch And Bearing.................................................................................... 370 BALLAST RESISTOR RELAY (Earlier Production)............................................................... 370 DISTRIBUTOR............................................................................................... 371 Distributor Contact Clearance......................................................................... 371 SPARK PLUGS............................................................................................... 372 COIL AND BALLAST RESISTOR (Earlier Production)............................................................ 372 ALTERNATOR................................................................................................ 372 Check For Low Output (Alternator With Separate Regulator)............................................. 372 Check For Low Output (Alternator With Integral Regulator)............................................. 374 Check For High Output (Alternator With Separate Regulator)............................................ 375 Check For High Output (Alternator With Integral Regulator)............................................ 375 Rotor Resistance (Alternator with Separate Regulator)................................................. 375 Diodes Circuit (Alternator with Separate Regulator)................................................... 376 Diode Assembly (Alternator With Separate Regulator)................................................... 376 Check The Diodes, Diode Trio (Alternator with Integral Regulator)..................................... 376 Check The Rectifier Bridge (Alternator with Integral Regulator)....................................... 377 Check Field Winding For The Rotor (All Alternators)................................................... 377 Check Windings In The Stator (All Alternators)........................................................ 378 Brushes And Bearings.................................................................................. 378 Check The Voltage Regulator (Alternator with Separate Regulator)...................................... 378 Check The Voltage Regulator (Alternator with Integral Regulator)...................................... 379 ADJUSTMENTS............................................................................................... 379 TROBLESHOOTING................................................................................................ 380 2200134........................................................................................................... 382 INTRODUCTION.................................................................................................. 382 GENERAL................................................................................................... 382 DESCRIPTION............................................................................................... 382 Starting System....................................................................................... 382 Charging System....................................................................................... 382 Vacuum Pump On Alternator (On Units With Brake Booster)............................................... 384 REPAIRS....................................................................................................... 385 STARTER................................................................................................... 385 Removal And Disassembly............................................................................... 385 Assembly And Installation............................................................................. 385 REPLACING GLOW PLUGS...................................................................................... 387 ALTERNATOR (With Vaccum Pump)............................................................................. 387 Removal And Disassembly............................................................................... 387 Cleaning.............................................................................................. 389 Assembly And Installation............................................................................. 389 ALTERNATOR (Without Vacuum Pump).......................................................................... 390 Removal And Disassembly............................................................................... 390 Cleaning.............................................................................................. 392 Assembly And Installation............................................................................. 392 REGULATOR REPLACEMENT..................................................................................... 393 CHECKS........................................................................................................ 393 GENERAL................................................................................................... 393 STARTER................................................................................................... 393 Starter Operation..................................................................................... 393 Solenoid Coil Checks.................................................................................. 394 Brush Length.......................................................................................... 394 Brush Holder.......................................................................................... 394 Armature.............................................................................................. 394 Field Windings........................................................................................ 395 Clutch And Bearings................................................................................... 395 COLD START AID............................................................................................ 395 Glow Plugs............................................................................................ 395 Resistor.............................................................................................. 395 CHARGING CIRCUIT.......................................................................................... 395 Check For Low Output.................................................................................. 395 Check Ford High Output................................................................................ 397 ALTERNATOR................................................................................................ 397 Rotor Resistance...................................................................................... 397 Diodes Circuit........................................................................................ 397 Rotor Coil............................................................................................ 398 Stator Coil........................................................................................... 398 Diode Assembly........................................................................................ 398 Brushes And Bearings.................................................................................. 399 REGULATOR (At Hydraulic Tank)............................................................................. 399 TROUBLESHOOTING............................................................................................... 400 2200143........................................................................................................... 403 INTRODUCTION.................................................................................................. 403 GENERAL................................................................................................... 403 DESCRIPTION................................................................................................... 403 GENERAL................................................................................................... 403 STEERING COLUMN GAUGES, METERS AND INDICATORS............................................................. 406 LED DISPLAY PANEL......................................................................................... 406 Battery Discharge Indicators.......................................................................... 406 Brush Wear Indicators................................................................................. 407 Motor Temperature Indicators.......................................................................... 408 "LX" SERIES DISPLAY PANEL................................................................................. 409 Hourmeter Functions................................................................................... 410 Battery Indicator Function............................................................................ 410 Status Code Function.................................................................................. 410 "ZX" SERIES DISPLAY PANELS................................................................................ 410 Display Panel......................................................................................... 411 Basic Display Panels.................................................................................. 411 Performance Display................................................................................... 413 Brush Wear Indicators................................................................................. 416 CHECKS AND ADJUSTMENTS........................................................................................ 416 GENERAL................................................................................................... 416 REPLACEMENT................................................................................................... 417 GENERAL................................................................................................... 417 METER REPLACEMENT......................................................................................... 417 SENDER REPLACEMENT........................................................................................ 418 Fuel Level Sender..................................................................................... 418 Pressure And Temperature Sender....................................................................... 418 I.T.W. DISPLAY PANEL...................................................................................... 419 Removal............................................................................................... 419 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT..................................... 420 Removal............................................................................................... 420 Replacing Display Panel Assembly...................................................................... 420 Indicator LEDs........................................................................................ 420 Battery Indicators.................................................................................... 420 Digital Display (Performance Disply Panel Only)....................................................... 420 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)......... 420 Replacing Parts Of The Basic Display Panel............................................................ 421 Replacing Parts Of The Performance Display Panel...................................................... 423 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT......................................... 423 Removal And Replacement............................................................................... 423 SPECIFICATIONS................................................................................................ 424 TROUBLESHOOTING............................................................................................... 425 2200144........................................................................................................... 426 ELECTRICAL WARNING DEVICES.................................................................................... 426 GENERAL................................................................................................... 426 DESCRIPTION............................................................................................... 426 Operator Controlled Horns............................................................................. 426 System Warning Lights, Buzzers and Bells.............................................................. 426 Reverse Warning Horns................................................................................. 427 Warning Lights........................................................................................ 427 REPLACEMENT............................................................................................... 428 General............................................................................................... 428 Replacing Horns or Bells.............................................................................. 428 Replacing Horn Relay or Buzzer........................................................................ 428 Replacing Warning Lights.............................................................................. 428 Light Assemblies...................................................................................... 429 Replacing Flashing Units.............................................................................. 429 4000135........................................................................................................... 430 Safety Procedures When Working Near Mast...................................................................... 432 General....................................................................................................... 437 Description................................................................................................... 437 Lowering Control Valve.................................................................................... 437 Cylinders (General)....................................................................................... 440 Cylinders (H520-620B, H700-800A).......................................................................... 440 Retainer, Install..................................................................................... 440 Cylinders (H360-460B)..................................................................................... 442 Cylinders (Two-Speed)..................................................................................... 445 Lift Cylinder Repair.......................................................................................... 446 Lift Cylinder Removal Without Removing Mast............................................................... 446 Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast......................... 446 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead............................ 447 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder.............................. 448 Disasemble................................................................................................ 448 Assemble.................................................................................................. 448 Lift Cylinder Installation in Mast........................................................................ 450 Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast.......................... 450 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead............................ 450 Chevron-Style Packing..................................................................................... 450 Chevron-Style Packing Installation on Piston.......................................................... 451 Chevron-Style Packing Installation in Packing Gland................................................... 453 Lift Cylinders for Vista Masts................................................................................ 454 Description............................................................................................... 454 Lowering Control Valve................................................................................ 454 Remove.................................................................................................... 456 Disassemble............................................................................................... 457 Assemble.................................................................................................. 458 Install................................................................................................... 459 Main Lift Cylinders................................................................................... 459 Free-Lift Cylinder.................................................................................... 459 Lift System Leak Check........................................................................................ 459 Specifications................................................................................................ 460 Troubleshooting............................................................................................... 461 4000222........................................................................................................... 464 INTRODUCTION.................................................................................................. 464 GENERAL................................................................................................... 464 MAST WELDMENTS............................................................................................ 464 CARRIAGE.................................................................................................. 464 MAST MOUNTS............................................................................................... 465 VISTA® TWO-STAGE MAST......................................................................................... 466 DESCRIPTION AND OPERATION................................................................................. 466 VISTA® FREE-LIFT MAST......................................................................................... 468 DESCRIPTION............................................................................................... 468 OPERATION................................................................................................. 468 VISTA® THREE-STAGE MAST....................................................................................... 470 DESCRIPTION............................................................................................... 470 OPERATION................................................................................................. 470 VISTA® FOUR-STAGE MAST........................................................................................ 471 DESCRIPTION............................................................................................... 471 OPERATION................................................................................................. 472 4000223........................................................................................................... 474 VISTA MAST, REPAIR............................................................................................ 474 GENERAL................................................................................................... 474 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................. 474 FORKS..................................................................................................... 475 Forks, Removal And Installation....................................................................... 475 CARRIAGE.................................................................................................. 476 Removal............................................................................................... 476 Installation.......................................................................................... 477 MASTS..................................................................................................... 477 Removal............................................................................................... 477 Disassembly........................................................................................... 478 Cleaning and Inspection............................................................................... 483 Assembly.............................................................................................. 483 Installation.......................................................................................... 487 SIDE-SHIFT CARRIAGE (EARLIER DESIGN)...................................................................... 488 Removal............................................................................................... 488 Repairs............................................................................................... 488 Installation.......................................................................................... 488 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)............................................................... 489 Removal............................................................................................... 489 Repairs............................................................................................... 489 Installation.......................................................................................... 490 CHECKS AND ADJUSTMENTS........................................................................................ 491 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM............................................................... 491 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE............................................... 492 LIFT CHAIN ADJUSTMENTS.................................................................................... 493 MAST ADJUSTMENTS.......................................................................................... 493 CARRIAGE ADJUSTMENT....................................................................................... 495 HEADER HOSE ARRANGEMENTS.................................................................................. 495 Two-Stage Header Hose................................................................................. 496 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts......................................... 496 TROUBLESHOOTING............................................................................................... 501 8000231........................................................................................................... 502 General....................................................................................................... 504 Nomenclature, Threads..................................................................................... 504 Strength Identification................................................................................... 505 Fastener Torque Tables.................................................................................... 509 Conversion Table.......................................................................................... 511 8000259........................................................................................................... 513 PERIODIC MAINTENANCE.......................................................................................... 513 GENERAL................................................................................................... 513 Serial Number Data.................................................................................... 513 HOW TO MOVE A DISABLED LIFT TRUCK......................................................................... 514 How To Tow the Lift Truck............................................................................. 514 HOW TO PUT A LIFT TRUCK ON BLOCKS......................................................................... 514 How To Raise the Drive Tires.......................................................................... 514 How To Raise the Steering Tires....................................................................... 515 MAINTENANCE PROCEDURES........................................................................................ 519 EVERY 8 HOURS OR DAILY........................................................................................ 519 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED................................................................ 519 Engine Oil............................................................................................ 519 Drive Belts........................................................................................... 519 Cooling System........................................................................................ 519 Battery............................................................................................... 520 Fuel System........................................................................................... 522 Air Filter............................................................................................ 522 Hydraulic System Oil.................................................................................. 522 Tires and Wheels...................................................................................... 523 Forks................................................................................................. 523 Forks, Adjustment..................................................................................... 524 Forks, Removal And Installation....................................................................... 524 Inspection Of Forks, Mast, and Lift Chains............................................................ 525 Safety Labels......................................................................................... 526 Operator Restraint System............................................................................. 526 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING................................................................ 527 Gauges, Lights, Horn, and Fuses....................................................................... 527 Fuel Filter, Diesel Engine............................................................................ 528 How To Drain The Water From The Fuel Filter........................................................... 528 Oil Level, Powershift Transmission.................................................................... 528 Control Levers and Pedals............................................................................. 528 Lift System Operation................................................................................. 528 Inching/Brake Pedal................................................................................... 529 Service Brakes........................................................................................ 529 Parking Brake......................................................................................... 529 Steering System....................................................................................... 529 EVERY 250 HOURS OR TWO MONTHS................................................................................. 530 ENGINE OIL AND FILTER..................................................................................... 530 Mazda, GM, And Later Production Isuzu Engines......................................................... 530 Earlier Production Isuzu C240 Engines................................................................. 530 GOVERNOR, MAZDA ENGINE.................................................................................... 531 DRIVE BELTS............................................................................................... 531 Mazda Engine.......................................................................................... 531 Isuzu, GM 4-181, And GM 4-153 Engines................................................................. 531 BRAKE FLUID............................................................................................... 532 HYDRAULIC TANK BREATHER, CLEAN AND CHECK.................................................................. 532 FORKS, CHECK FOR WEAR AND DAMAGE.......................................................................... 532 LIFT CHAINS............................................................................................... 532 Lubrication........................................................................................... 532 Check For Wear........................................................................................ 532 MAST, LUBRICATION......................................................................................... 533 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE............................................................... 533 CONTROL LEVERS AND PEDALS, LUBRICATION.................................................................... 534 FUEL SYSTEM, CHECKS AND ADJUSTMENTS....................................................................... 534 Idle Speed, Diesel.................................................................................... 534 LPG Carburetor........................................................................................ 535 Gasoline Carburetor................................................................................... 535 EVERY 1000 HOURS OR SIX MONTHS................................................................................ 536 DIESEL FUEL FILTER........................................................................................ 536 Filter Replacement, Models Without A Water Separator.................................................. 537 Filter Replacement, Models With A Water Separator..................................................... 537 Remove Air from the Diesel Fuel System................................................................ 537 DIFFERENTIAL.............................................................................................. 538 VALVE CLEARANCE ADJUSTMENT................................................................................ 538 IGNITION SYSTEM, MAZDA AND GM ENGINES..................................................................... 538 PCV VALVE AND FILTER...................................................................................... 540 EVERY 2000 HOURS OR YEARLY.................................................................................... 540 HYDRAULIC SYSTEM.......................................................................................... 540 Replace the Hydraulic Oil and Filter.................................................................. 540 POWERSHIFT TRANSMISSION................................................................................... 540 COOLING SYSTEM............................................................................................ 541 SERVICE BRAKES............................................................................................ 541 DIFFERENTIAL.............................................................................................. 541 WHEEL BEARINGS............................................................................................ 542 Steering Wheels, lubrication.......................................................................... 542 Drive Wheels, Lubrication............................................................................. 542 GASOLINE FUEL FILTER, REPLACEMENT......................................................................... 542 PCV VALVE, GM ENGINES..................................................................................... 542 LPG FILTER, REPLACEMENT................................................................................... 542 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A............................................................ 542 GENERAL PROCEDURES............................................................................................ 543 CHECK THE HOOD LATCH...................................................................................... 543 LIFT CHAIN ADJUSTMENTS.................................................................................... 543 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................. 545 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM............................................................... 546 Check the Lift Cylinders for Leaks.................................................................... 546 Check the Tilt Cylinders for Leaks.................................................................... 546 FUEL INJECTORS............................................................................................ 547 WELDING REPAIRS........................................................................................... 547 CHANGES TO THE OVERHEAD GUARD............................................................................. 547 WHEELS AND TIRES.......................................................................................... 547 Solid Rubber Tires (Press-on)......................................................................... 547 Install The Wheels.................................................................................... 548 Pneumatic Tires, Remove The Wheels From The Lift Truck................................................ 549 Pneumatic Tires, Remove the Tire From The Wheel....................................................... 549 Pneumatic Tires, Install The Wheel In The Tire........................................................ 550 Pneumatic Tires, Add Air To The Tires................................................................. 551 Pneumatic Tires, Install the Wheels................................................................... 552 Pneumatic Tires, Installation Procedures, Dual Drive Wheels........................................... 552 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES......................................................... 553 Remove The Wheels From The Lift Truck................................................................. 553 Remove The Tire From The Wheel........................................................................ 553 Install The Tire On The Wheel......................................................................... 554 REFERENCE TABLE............................................................................................... 555 8000461........................................................................................................... 556 FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC.......................................................................... 557 FIGURE 2. TRANSMISSION SCHEMATIC.............................................................................. 558 FIGURE 3. INSTRUMENT PANEL ELECTRICAL DIAGRAM................................................................. 559 FIGURE 4. MAZDA ENGINE, GASOLINE/LPG WIRING SCHEMATIC......................................................... 561 FIGURE 5. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)......................................... 563 FIGURE 6. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)........................................ 565 FIGURE 7. DIESEL ENGINE WIRING SCHEMATIC...................................................................... 567 FIGURE 8. DIESEL ENGINE CABLE DIAGRAM (D Rating).............................................................. 569 FIGURE 9. DIESEL (SAFETY) ENGINE CABLE DIAGRAM (DS RATING).................................................... 571 FIGURE 10. GM ENGINE, GASOLINE/LPG WIRING DIAGRAM (GS and LPS Rating)......................................... 573 FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)........................................... 575 FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating).......................................... 577 Alternator........................................................................................................ 582 INTRODUCTION.................................................................................................. 582 GENERAL................................................................................................... 582 DESCRIPTION............................................................................................... 582 REPAIRS....................................................................................................... 584 GENERAL................................................................................................... 584 REMOVAL AND DISASSEMBLY (Type A).......................................................................... 584 CLEANING.................................................................................................. 584 ASSEMBLY (Type A)......................................................................................... 585 REMOVAL AND DISAASSEMBLY (Type B)......................................................................... 587 CLEANING.................................................................................................. 589 ASSEMBLY (Type B)......................................................................................... 589 INSTALLATION (Type A and Type B).......................................................................... 590 CHECKS AND ADJUSTMENTS........................................................................................ 590 GENERAL................................................................................................... 590 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B).................................................... 591 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)................................................... 592 CHECK THE CIRCUIT FOR THE BRUSHES......................................................................... 594 Delco Alternators..................................................................................... 594 Motorola Alternators.................................................................................. 594 CHECK THE DIODES.......................................................................................... 594 CHECK THE DIODE BRIDGE.................................................................................... 594 Delco and Leece–Neville Alternators................................................................... 594 Motorola Alternators.................................................................................. 594 CHECK THE FIELD WINDING FOR THE ROTOR..................................................................... 595 CHECK THE WINDINGS IN THE STATOR.......................................................................... 595 CHECK THE VOLTAGE REGULATOR............................................................................... 596 TROUBLESHOOTING............................................................................................... 596 Brake System...................................................................................................... 597 INTRODUCTION.................................................................................................. 597 GENERAL................................................................................................... 597 SERVICE BRAKES AND PARKING BRAKE.............................................................................. 597 DESCRIPTION AND OPERATION................................................................................. 597 Service Brakes........................................................................................ 597 Parking Brake......................................................................................... 598 REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES........................................... 598 Parking Brake......................................................................................... 600 CLEANING.................................................................................................. 601 INSPECTION................................................................................................ 601 ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES......................................... 601 Adjustments........................................................................................... 604 Parking Brake Installation............................................................................ 605 Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes........................ 605 REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES........................................... 607 Parking Brake......................................................................................... 609 CLEANING.................................................................................................. 610 INSPECTION................................................................................................ 610 ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES......................................... 610 Adjustments........................................................................................... 612 Parking brake......................................................................................... 613 Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes........................ 613 MASTER CYLINDER........................................................................................... 614 Removal............................................................................................... 614 Repair................................................................................................ 614 Installation.......................................................................................... 614 Cleaning And Inspection............................................................................... 616 MASTER CYLINDER WITH BRAKE BOOSTER........................................................................ 618 Operation............................................................................................. 618 Repair................................................................................................ 618 CHECKS AND ADJUSTMENTS........................................................................................ 620 ADJUST THE SERVICE BRAKES................................................................................. 620 TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)....................................................... 620 REMOVE THE AIR FROM THE BRAKE SYSTEM...................................................................... 621 ADJUST THE INCHING/BRAKE PEDAL............................................................................ 621 ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL).................................. 626 TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)............................................................ 626 Test 1................................................................................................ 626 Test 2................................................................................................ 627 TORQUE SPECIFICATIONS......................................................................................... 627 TROUBLESHOOTING............................................................................................... 627 Capacities & Specifications....................................................................................... 630 LIFT TRUCK WEIGHTS*........................................................................................... 630 ENGINE SPECIFICATIONS......................................................................................... 630 ENGINE ELECTRICAL SPECIFICATIONS.............................................................................. 631 HYDRAULIC SPECIFICATIONS...................................................................................... 631 CAPACITIES.................................................................................................... 632 LIFT TRUCK TRAVEL SPEEDS...................................................................................... 632 TIRE SPECIFICATIONS........................................................................................... 632 MAST SPEEDS (Early A177* Units)............................................................................... 633 MAST SPEEDS (Later A177* Units)............................................................................... 633 MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)......................................... 634 MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)....................................................... 634 TORQUE SPECIFICATIONS......................................................................................... 636 TORQUE SPECIFICATIONS......................................................................................... 637 Cooling System.................................................................................................... 639 COOLING SYSTEM................................................................................................ 639 INTRODUCTION.............................................................................................. 639 DESCRIPTION............................................................................................... 639 RADIATOR.................................................................................................. 639 RADIATOR CAP.............................................................................................. 639 THERMOSTAT................................................................................................ 639 WATER PUMP................................................................................................ 640 FAN AND FAN SHROUD........................................................................................ 640 REPAIRS....................................................................................................... 640 COOLING SYSTEM CHECKS..................................................................................... 640 Exhaust Leaks......................................................................................... 640 RADIATOR.................................................................................................. 640 Checks................................................................................................ 640 Cleaning The Radiator................................................................................. 640 Drain The Cooling System.............................................................................. 642 Fill The Cooling System............................................................................... 642 WATER PUMP................................................................................................ 642 Checks................................................................................................ 642 THERMOSTAT................................................................................................ 643 Checks................................................................................................ 643 FAN AND FAN SHROUD........................................................................................ 643 TROUBLESHOOTING............................................................................................... 644 Diagrams.......................................................................................................... 645 FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC.......................................................................... 646 FIGURE 2. TRANSMISSION SCHEMATIC.............................................................................. 647 FIGURE 3. INSTRUMENT PANEL ELECTRICAL DIAGRAM................................................................. 648 FIGURE 4. MAZDA ENGINE, GASOLINE/LPG WIRING SCHEMATIC......................................................... 650 FIGURE 5. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)......................................... 652 FIGURE 6. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)........................................ 654 FIGURE 7. DIESEL ENGINE WIRING SCHEMATIC...................................................................... 656 FIGURE 8. DIESEL ENGINE CABLE DIAGRAM (D Rating).............................................................. 658 FIGURE 9. DIESEL (SAFETY) ENGINE CABLE DIAGRAM (DS RATING).................................................... 660 FIGURE 10. GM ENGINE, GASOLINE/LPG WIRING DIAGRAM (GS and LPS Rating)......................................... 662 FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)........................................... 664 FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating).......................................... 666 Drive Axle........................................................................................................ 671 INTRODUCTION.................................................................................................. 671 GENERAL................................................................................................... 671 DESCRIPTION............................................................................................... 671 REPAIRS....................................................................................................... 672 REMOVAL................................................................................................... 672 CLEANING.................................................................................................. 672 INSPECTION................................................................................................ 672 ASSEMBLY.................................................................................................. 672 TROUBLESHOOTING............................................................................................... 675 SPECIFICATIONS................................................................................................ 675 Electrical System (Isuzu)......................................................................................... 676 INTRODUCTION.................................................................................................. 676 GENERAL................................................................................................... 676 DESCRIPTION............................................................................................... 676 Starting System....................................................................................... 676 Charging System....................................................................................... 676 Vacuum Pump On Alternator (On Units With Brake Booster)............................................... 678 REPAIRS....................................................................................................... 679 STARTER................................................................................................... 679 Removal And Disassembly............................................................................... 679 Assembly And Installation............................................................................. 679 REPLACING GLOW PLUGS...................................................................................... 681 ALTERNATOR (With Vaccum Pump)............................................................................. 681 Removal And Disassembly............................................................................... 681 Cleaning.............................................................................................. 683 Assembly And Installation............................................................................. 683 ALTERNATOR (Without Vacuum Pump).......................................................................... 684 Removal And Disassembly............................................................................... 684 Cleaning.............................................................................................. 686 Assembly And Installation............................................................................. 686 REGULATOR REPLACEMENT..................................................................................... 687 CHECKS........................................................................................................ 687 GENERAL................................................................................................... 687 STARTER................................................................................................... 687 Starter Operation..................................................................................... 687 Solenoid Coil Checks.................................................................................. 688 Brush Length.......................................................................................... 688 Brush Holder.......................................................................................... 688 Armature.............................................................................................. 688 Field Windings........................................................................................ 689 Clutch And Bearings................................................................................... 689 COLD START AID............................................................................................ 689 Glow Plugs............................................................................................ 689 Resistor.............................................................................................. 689 CHARGING CIRCUIT.......................................................................................... 689 Check For Low Output.................................................................................. 689 Check Ford High Output................................................................................ 691 ALTERNATOR................................................................................................ 691 Rotor Resistance...................................................................................... 691 Diodes Circuit........................................................................................ 691 Rotor Coil............................................................................................ 692 Stator Coil........................................................................................... 692 Diode Assembly........................................................................................ 692 Brushes And Bearings.................................................................................. 693 REGULATOR (At Hydraulic Tank)............................................................................. 693 TROUBLESHOOTING............................................................................................... 694 Electrical System (Mazdz)......................................................................................... 697 INTRODUCTION.................................................................................................. 697 GENERAL................................................................................................... 697 DESCRIPTION............................................................................................... 697 Starting System....................................................................................... 697 Ignition System....................................................................................... 697 Charging System....................................................................................... 698 REPAIR........................................................................................................ 700 STARTER................................................................................................... 700 Removal And Disassembly............................................................................... 700 Assembly And Installation............................................................................. 700 BALLAST RESISTOR RELAY (Earlier Production)............................................................... 702 DISTRIBUTOR (Earlier Production With Contact Points)...................................................... 702 Removal And Disassembly............................................................................... 702 Assembly And Installation............................................................................. 704 COIL REPLACEMENT.......................................................................................... 704 DISTRIBUTOR (Later Production with Electronic Ignition System)............................................ 704 Removal And Disassembly............................................................................... 704 Assembly And Installation............................................................................. 706 ALTERNATOR (All Models)................................................................................... 706 Removal And Disassembly............................................................................... 706 Assembly And Installation............................................................................. 707 REGULATOR REPLACEMENT (Earlier Production)................................................................ 708 CHECKS AND ADJUSTMENTS........................................................................................ 709 GENERAL................................................................................................... 709 STARTER................................................................................................... 709 Check Operation....................................................................................... 709 Check Brush Length.................................................................................... 710 Check Brush Holder.................................................................................... 710 Armature.............................................................................................. 710 Field Windings........................................................................................ 710 Clutch And Bearing.................................................................................... 710 BALLAST RESISTOR RELAY (Earlier Production)............................................................... 710 DISTRIBUTOR............................................................................................... 711 Distributor Contact Clearance......................................................................... 711 SPARK PLUGS............................................................................................... 712 COIL AND BALLAST RESISTOR (Earlier Production)............................................................ 712 ALTERNATOR................................................................................................ 712 Check For Low Output (Alternator With Separate Regulator)............................................. 712 Check For Low Output (Alternator With Integral Regulator)............................................. 714 Check For High Output (Alternator With Separate Regulator)............................................ 715 Check For High Output (Alternator With Integral Regulator)............................................ 715 Rotor Resistance (Alternator with Separate Regulator)................................................. 715 Diodes Circuit (Alternator with Separate Regulator)................................................... 716 Diode Assembly (Alternator With Separate Regulator)................................................... 716 Check The Diodes, Diode Trio (Alternator with Integral Regulator)..................................... 716 Check The Rectifier Bridge (Alternator with Integral Regulator)....................................... 717 Check Field Winding For The Rotor (All Alternators)................................................... 717 Check Windings In The Stator (All Alternators)........................................................ 718 Brushes And Bearings.................................................................................. 718 Check The Voltage Regulator (Alternator with Separate Regulator)...................................... 718 Check The Voltage Regulator (Alternator with Integral Regulator)...................................... 719 ADJUSTMENTS............................................................................................... 719 TROBLESHOOTING................................................................................................ 720 Frame............................................................................................................. 722 INTRODUCTION.................................................................................................. 722 GENERAL................................................................................................... 722 DESCRIPTION............................................................................................... 722 REPAIRS....................................................................................................... 722 COUNTERWEIGHT............................................................................................. 723 Removal............................................................................................... 723 Installation.......................................................................................... 723 MUFFLER................................................................................................... 724 HOOD...................................................................................................... 724 Removal............................................................................................... 724 Installation.......................................................................................... 724 RADIATOR AND COOLANT SYSTEM............................................................................... 724 Removal............................................................................................... 724 Installation.......................................................................................... 724 OVERHEAD GUARD............................................................................................ 725 Removal And Installation.............................................................................. 725 OPERATOR RESTRAINT SYSTEM................................................................................. 725 ENGINE REMOVAL AND INSTALLATION........................................................................... 726 Removal of the Engine and Transmission................................................................ 726 Installation of the Engine and Transmission........................................................... 730 FUEL AND HYDRAULIC TANKS.................................................................................. 732 Inspection............................................................................................ 732 Repairs, Small Leaks.................................................................................. 732 Repairs, Large Leaks.................................................................................. 732 Cleaning.............................................................................................. 732 Steam Method Of Cleaning.............................................................................. 732 Chemical Solution Method of Cleaning.................................................................. 733 Additional Preparations For Repair.................................................................... 733 SAFETY LABELS............................................................................................. 733 CAB....................................................................................................... 735 Cab Replacement....................................................................................... 735 Window Replacement.................................................................................... 735 Windshield Wipers and Heater.......................................................................... 737 Gasoline Carburetor (Mazda)....................................................................................... 738 THE CARBURETOR, (MAZDA M4-121G ENGINE)........................................................................ 738 DESCRIPTION............................................................................................... 738 REPAIRS, CARBURETOR....................................................................................... 739 Removal............................................................................................... 739 Cleaning.............................................................................................. 742 Inspection............................................................................................ 742 Assembly.............................................................................................. 742 Installation.......................................................................................... 744 CHECKS AND ADJUSTMENTS.................................................................................... 744 Carburetor, Idle Speed And Mixture Adjustment......................................................... 744 Adjust The Governor................................................................................... 745 ADJUST THE THROTTLE LINKAGE............................................................................... 746 SPECIFICATIONS................................................................................................ 746 TROUBLESHOOTING............................................................................................... 747 GM Engine......................................................................................................... 749 INTRODUCTION.................................................................................................. 749 GENERAL................................................................................................... 749 DESCRIPTION............................................................................................... 750 REMOVAL AND INSTALLATION OF THE ENGINE.................................................................... 750 CYLINDER HEAD AND MECHANISM............................................................................... 750 Cylinder Head, Removal................................................................................ 750 Cylinder Head, Disassembly............................................................................ 751 Cleaning And Inspection............................................................................... 752 Valve And Valve Seats................................................................................. 753 Studs For The Rocker Arms............................................................................. 753 Hydraulic Valve Lifters, Replacement.................................................................. 753 Hydraulic Valve Lifters, Cleaning And Inspection...................................................... 754 Cylinder Head, Assembly............................................................................... 754 Cylinder Head, Installation........................................................................... 754 Rocker Arm Cover, Installation........................................................................ 755 TIMING GEAR COVER......................................................................................... 756 Removal............................................................................................... 756 Installation.......................................................................................... 756 CAMSHAFT.................................................................................................. 757 Removal............................................................................................... 757 Inspection............................................................................................ 758 Camshaft Bearings, Removal............................................................................ 758 Camshaft Bearings, Installation....................................................................... 758 DISTRIBUTOR............................................................................................... 759 Removal............................................................................................... 759 Installation.......................................................................................... 759 LUBRICATION SYSTEM........................................................................................ 760 Oil Sump, Removal..................................................................................... 760 Oil Sump, Installation................................................................................ 760 Oil Pump, Removal..................................................................................... 760 Oil Pump, Disassembly and Repair...................................................................... 760 Oil Pump, Assembly.................................................................................... 761 Oil Pump, Installation................................................................................ 761 PISTON AND CONNECTING ROD ASSEMBLIES...................................................................... 761 Connecting Rod Bearings, Replacement.................................................................. 761 Piston And Connecting Rod Assemblies, Removal......................................................... 762 Disassembly........................................................................................... 763 Piston, Cleaning And Inspection....................................................................... 763 Cylinder Bores, Inspection And Repair................................................................. 763 Piston Rings.......................................................................................... 764 Assembly.............................................................................................. 765 Piston And Connecting Rod Assemblies, Installation.................................................... 765 CRANKSHAFT................................................................................................ 766 Main Bearings, Replacement............................................................................ 766 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).............................. 767 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).............. 767 Crankshaft, Removal................................................................................... 768 Inspection and Repair................................................................................. 769 How To Check The Clearance Between The Main Bearings And Their Journals............................... 769 Installation.......................................................................................... 770 FLYWHEEL AND FLYWHEEL HOUSING............................................................................. 771 Flywheel, Removal..................................................................................... 771 Ring Gear, Replacement................................................................................ 772 Flywheel, Installation................................................................................ 772 COOLING SYSTEM............................................................................................ 772 Coolant Pump.......................................................................................... 772 Fan Drive............................................................................................. 773 Viscous Fan Drive..................................................................................... 773 ENGINE SPECIFICATIONS......................................................................................... 774 ENGINE DATA............................................................................................... 774 CYLINDER HEAD............................................................................................. 774 HYDRAULIC VALVE LIFTER.................................................................................... 775 CAMSHAFT.................................................................................................. 775 PISTONS................................................................................................... 775 CYLINDER BORE............................................................................................. 776 CRANKSHAFT................................................................................................ 776 CONNECTING RODS........................................................................................... 776 COOLING SYSTEM............................................................................................ 777 LUBRICATION SYSTEM........................................................................................ 777 TORQUE SPECIFICATIONS......................................................................................... 777 Hydraulic Pump & Drive Assembly................................................................................... 780 INTRODUCTION.................................................................................................. 780 GENERAL................................................................................................... 780 DESCRIPTION............................................................................................... 780 REPAIRS....................................................................................................... 782 REMOVAL AND DISASSEMBLY................................................................................... 782 CLEANING.................................................................................................. 782 INSPECTION................................................................................................ 782 ASSEMBLY AND INSTALLATION................................................................................. 783 TROUBLESHOOTING............................................................................................... 784 GENERAL................................................................................................... 784 Hydraulic System & Gear Pump...................................................................................... 785 INTRODUCTION.................................................................................................. 785 GENERAL................................................................................................... 785 DESCRIPTION............................................................................................... 787 Hydraulic System...................................................................................... 787 Gear Pump Assembly.................................................................................... 787 Flow Control Valve.................................................................................... 788 Relief Valve (Early Model)............................................................................ 788 Relief Valve (Later Model)............................................................................ 788 OPERATION................................................................................................. 790 Hydraulic System...................................................................................... 790 Gear Pump............................................................................................. 790 Flow Control Valve.................................................................................... 790 Relief Valve (Early Model)............................................................................ 790 Relief Valve (Later Model)............................................................................ 790 REPAIR........................................................................................................ 792 GEAR PUMP ASSEMBLY........................................................................................ 792 Removal and Disassembly............................................................................... 792 Assembly and Installation............................................................................. 793 CHECKS AND ADJUSTMENTS........................................................................................ 793 CHECK AND ADJUST STEERING RELIEF PRESSURE................................................................. 793 CHECK GEAR PUMP FOR CORRECT FLOW.......................................................................... 794 TROUBLESHOOTING............................................................................................... 794 INCH (SAE) & Metric Fasteners..................................................................................... 796 INTRODUCTION.................................................................................................. 796 NOMENCLATURE, THREADS..................................................................................... 796 STRENGTH IDENTIFICATION................................................................................... 797 TABLE 1. BOLTS AND SCREWS..................................................................................... 797 TABLE 2. STUDS AND NUTS....................................................................................... 798 TABLE 3. TORQUE NUTS.......................................................................................... 799 TABLE 4. TORQUE NUTS WITH NYLON INSERT........................................................................ 800 TABLE 5. TORQUE VALUES FOR INCH FASTENERS..................................................................... 801 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS................................................................... 802 Instrument Panel indicators & Senders............................................................................. 805 INTRODUCTION.................................................................................................. 805 GENERAL................................................................................................... 805 DESCRIPTION................................................................................................... 805 GENERAL................................................................................................... 805 STEERING COLUMN GAUGES, METERS AND INDICATORS............................................................. 808 LED DISPLAY PANEL......................................................................................... 808 Battery Discharge Indicators.......................................................................... 808 Brush Wear Indicators................................................................................. 809 Motor Temperature Indicators.......................................................................... 810 "LX" SERIES DISPLAY PANEL................................................................................. 811 Hourmeter Functions................................................................................... 812 Battery Indicator Function............................................................................ 812 Status Code Function.................................................................................. 812 "ZX" SERIES DISPLAY PANELS................................................................................ 812 Display Panel......................................................................................... 813 Basic Display Panels.................................................................................. 813 Performance Display................................................................................... 815 Brush Wear Indicators................................................................................. 818 CHECKS AND ADJUSTMENTS........................................................................................ 818 GENERAL................................................................................................... 818 REPLACEMENT................................................................................................... 819 GENERAL................................................................................................... 819 METER REPLACEMENT......................................................................................... 819 SENDER REPLACEMENT........................................................................................ 820 Fuel Level Sender..................................................................................... 820 Pressure And Temperature Sender....................................................................... 820 I.T.W. DISPLAY PANEL...................................................................................... 821 Removal............................................................................................... 821 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT..................................... 822 Removal............................................................................................... 822 Replacing Display Panel Assembly...................................................................... 822 Indicator LEDs........................................................................................ 822 Battery Indicators.................................................................................... 822 Digital Display (Performance Disply Panel Only)....................................................... 822 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)......... 822 Replacing Parts Of The Basic Display Panel............................................................ 823 Replacing Parts Of The Performance Display Panel...................................................... 825 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT......................................... 825 Removal And Replacement............................................................................... 825 SPECIFICATIONS................................................................................................ 826 TROUBLESHOOTING............................................................................................... 827 Isuzu C240 (2.4L) Engine.......................................................................................... 828 INTRODUCTION ................................................................................................. 828 GENERAL .................................................................................................. 828 DESCRIPTION .............................................................................................. 828 FUEL SYSTEM .............................................................................................. 829 Description .......................................................................................... 829 Operation, Fuel Injection Pump, Model VE ............................................................. 831 Operation, Fuel Injection Pump, Model PE4A ........................................................... 832 Pneumatic Governor For Fuel Injection Pump, Model PE4A ............................................... 833 Inlet Manifold For Fuel Injection Pump, Model PE4A ................................................... 834 REPAIRS ...................................................................................................... 835 FUEL INJECTION PUMP (ALL MODELS) ......................................................................... 835 Removal .............................................................................................. 835 Installation ......................................................................................... 835 REMOVAL AND INSTALLATION OF THE ENGINE ................................................................... 835 CYLINDER HEAD AND VALVE MECHANISM ........................................................................ 835 Cylinder Head, Removal ............................................................................... 835 Valve Guides, Replacement ............................................................................ 836 Cylinder Head, Inspection And Repair ................................................................. 837 Combustion Chamber Plugs, Inspection And Repair ...................................................... 837 Combustion Chamber Plugs, Installation ............................................................... 837 Valves, Inspection And Repair ........................................................................ 838 Valve Seat, Inspection ............................................................................... 838 Valve Seat, Removal .................................................................................. 839 Valve Seat, Installation ............................................................................. 839 Valve Spring, Inspection ............................................................................. 839 Rocker Arms, Inspection And Assembly ................................................................. 839 Installation Of The Cylinder Head .................................................................... 840 TIMING GEAR CASE ......................................................................................... 841 Removal .............................................................................................. 841 Installation ......................................................................................... 841 CAMSHAFT ................................................................................................. 843 Removal .............................................................................................. 843 Inspection ........................................................................................... 843 Camshaft Bearings .................................................................................... 844 Cam Followers ........................................................................................ 844 CAMSHAFT, INSTALLATION ................................................................................... 844 CRANKSHAFT AND MAIN BEARINGS ............................................................................. 845 Crankshaft, Removal .................................................................................. 845 Crankshaft, Inspection And Repair .................................................................... 845 Main Bearings ........................................................................................ 845 Pilot Bearing ........................................................................................ 846 Crankshaft, Installation ............................................................................. 846 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) .......................................................... 848 Flywheel, Removal .................................................................................... 848 Ring Gear, Replacement ............................................................................... 848 Flywheel, Installation ............................................................................... 848 PISTONS AND CONNECTING RODS .............................................................................. 849 Pistons And Connecting Rods, Removal ................................................................. 849 Disassembly .......................................................................................... 849 Pistons, Inspection And Repair ....................................................................... 850 Piston Rings, Inspection And Repair .................................................................. 850 Piston Pins, Inspection And Repair ................................................................... 851 Connecting Rods, Inspection And Repair ............................................................... 852 Pistons And Connecting Rods, Assembly And Installation ............................................... 852 CYLINDER BLOCK AND CYLINDER LINERS ....................................................................... 852 Cylinder Liners, Inspection .......................................................................... 852 Replacement Of A Cylinder Liner ...................................................................... 853 LUBRICATION SYSTEM ....................................................................................... 854 Oil Pump, Removal And Disassembly .................................................................... 854 Oil Pump, Inspection ................................................................................. 854 Oil Pump, Assembly And Installation .................................................................. 855 Oil Filter ........................................................................................... 855 COOLING SYSTEM ........................................................................................... 856 Coolant Pump, Removal ................................................................................ 856 Coolant Pump, Disassembly ............................................................................ 856 Coolant Pump, Assembly And Installation .............................................................. 856 Thermostat, Replacement .............................................................................. 857 CHECKS AND ADJUSTMENTS ....................................................................................... 857 VALVE CLEARANCE ADJUSTMENT ............................................................................... 857 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE .................................................... 858 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A .................................................. 859 FUEL INJECTORS ........................................................................................... 859 Fuel Injectors, Removal .............................................................................. 860 Fuel Injectors, Inspection ........................................................................... 860 Fuel Injectors, Installation ......................................................................... 861 DIESEL FUEL FILTERS ...................................................................................... 861 Filter Replacement, Models With A Water Separator .................................................... 861 Filter Replacement, Models Without A Water Separator ................................................. 862 Filter For The Fuel Injection Pump, Model PE4A ....................................................... 862 REMOVE AIR FROM THE FUEL SYSTEM .......................................................................... 862 Throttle Linkage, Adjustment ......................................................................... 863 Idle Speed, Adjustment ............................................................................... 863 Check The Elements For The Cold Start Aid System ..................................................... 863 ENGINE SPECIFICATIONS ........................................................................................ 863 TORQUE SPECIFICATIONS ........................................................................................ 865 Lift Cylinders.................................................................................................... 866 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.................................................................. 866 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................. 866 LIFT CYLINDERS................................................................................................ 869 GENERAL................................................................................................... 869 DESCRIPTION............................................................................................... 869 Lowering Control Valve................................................................................ 869 Cylinders (General)................................................................................... 872 Cylinders (H520-620B,H700-800A)....................................................................... 874 Cylinders (H360-460B)................................................................................. 875 Cylinders (Two-Speed)................................................................................. 875 REPAIRS....................................................................................................... 876 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST.................................................... 876 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.............. 876 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead............................... 880 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder......................... 878 DISASSEMBLY............................................................................................... 878 ASSEMBLY.................................................................................................. 880 INSTALLATION OF THE LIFT CYLINDER IN THE MAST............................................................. 880 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.............. 880 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead...................... 880 CHEVRON PACKING........................................................................................... 881 LIFT CYLINDERS FOR VISTA MASTS................................................................................ 884 DESCRIPTION............................................................................................... 884 Lowering Control Valve................................................................................ 886 REMOVAL................................................................................................... 887 DISASSEMBLY............................................................................................... 887 ASSEMBLY.................................................................................................. 887 INSTALLATION.............................................................................................. 888 Main Lift Cylinders................................................................................... 888 Free-Lift Cylinders................................................................................... 888 CHECKS AND ADJUSTMENTS........................................................................................ 889 CHECK FOR LEAKS IN LIFT SYSTEM............................................................................ 889 TROUBLESHOOTING............................................................................................... 890 SPECIFICATIONS................................................................................................ 891 LPG Fuel System................................................................................................... 892 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)..................................................................... 892 GENERAL................................................................................................... 892 DESCRIPTION............................................................................................... 892 Fuel Tank............................................................................................. 893 Fuel Filter And Fuel Valve Unit....................................................................... 894 Vaporizer............................................................................................. 894 The IMPCO CA 100 Carbureto............................................................................ 896 IMPCO CA 50 Carburetor................................................................................ 898 The Governor (GM Engines Only)........................................................................ 899 Governor With Electronic Controller................................................................... 900 REPAIRS....................................................................................................... 901 LPG TANK.................................................................................................. 901 Removal............................................................................................... 901 Installation.......................................................................................... 902 REPLACE THE HOSES......................................................................................... 902 HYDROSTATIC RELIEF VALVE.................................................................................. 902 Removal and Installation.............................................................................. 902 FILTER UNIT............................................................................................... 903 Replacement Of the Fuel Filter Element................................................................ 903 Replacement of the Diaphragm and Fuel Valve........................................................... 904 VAPORIZER................................................................................................. 904 Removal............................................................................................... 904 Disassembly........................................................................................... 904 Cleaning.............................................................................................. 904 Inspection............................................................................................ 904 Assembly.............................................................................................. 906 Installation.......................................................................................... 906 CARBURETOR (IMPCO CA 100)................................................................................. 908 Removal............................................................................................... 908 Disassembly........................................................................................... 908 Cleaning.............................................................................................. 908 Assembly.............................................................................................. 908 Installation.......................................................................................... 911 CARBURETER (IMPCO CA 50).................................................................................. 910 Removal............................................................................................... 910 Disassembly........................................................................................... 910 Cleaning.............................................................................................. 911 Inspection............................................................................................ 911 Assembly (See FIGURE 26.)............................................................................. 911 Installation.......................................................................................... 911 CHECKS AND ADJUSTMENTS........................................................................................ 912 CHECK THE FILTER UNIT..................................................................................... 912 CHECK THE VAPORIZER....................................................................................... 912 Pressure Reducer Valve................................................................................ 912 Vapor Valve........................................................................................... 912 ADJUST THE CARBURETOR..................................................................................... 912 Idle Mixture.......................................................................................... 912 Idle Speed............................................................................................ 912 Power Mixture......................................................................................... 912 ADJUST THE GOVERNOR (GM Engines Only)..................................................................... 913 Checks................................................................................................ 913 Main Adjusting Screw.................................................................................. 913 Secondary Adjusting Screw............................................................................. 913 AISAN Governor........................................................................................ 914 Adjustment, AISAN Governor............................................................................ 914 TROUBLESHOOTING............................................................................................... 915 Main Control Valve................................................................................................ 919 INTRODUCTION.................................................................................................. 919 GENERAL................................................................................................... 919 DESCRIPTION............................................................................................... 919 OPERATION................................................................................................. 920 Lift Section.......................................................................................... 921 Tilt Section.......................................................................................... 921 Relief Valve.......................................................................................... 923 SOLENOID VALVE FOR AUXILIARY FUNCTION..................................................................... 924 Operation............................................................................................. 924 REPAIRS....................................................................................................... 924 MAIN CONTROL VALVE........................................................................................ 924 Removal and Disassembly............................................................................... 924 Cleaning and Inspection............................................................................... 925 Assembly.............................................................................................. 925 Installation.......................................................................................... 925 SOLENOID VALVE FOR AUXILIARY FUNCTION..................................................................... 925 Removal and Disassembly............................................................................... 925 Assembly and Installation............................................................................. 927 CHECKS AND ADJUSTMENTS........................................................................................ 927 PRESSURE RELIEF VALVES.................................................................................... 927 Primary Relief Valve.................................................................................. 927 Seconday Relief Valve................................................................................. 928 CONTROL LEVER ARRANGEMENT................................................................................. 928 TROUBLESHOOTING............................................................................................... 931 SPECIFICATIONS................................................................................................ 933 Mazda M4-121G Engine.............................................................................................. 934 MAZDA M4-121G ENGINE.......................................................................................... 934 GENERAL................................................................................................... 934 DESCRIPTION............................................................................................... 935 REMOVAL AND INSTALLATION OF THE ENGINE.................................................................... 935 CYLINDER HEAD AND VALVE MECHANISM......................................................................... 935 Cylinder Head, Removal................................................................................ 935 Cylinder Head, Inspection and Repairs................................................................. 936 Rocker Arm Assembly................................................................................... 936 Valve Guides.......................................................................................... 936 Valve Seats........................................................................................... 937 Valves................................................................................................ 937 Valve Springs......................................................................................... 937 Cylinder Head, Installation........................................................................... 937 TIMING GEAR CASE, REMOVAL................................................................................. 938 TIMING GEAR CASE, INSTALLATION............................................................................ 939 CAMSHAFT.................................................................................................. 939 Removal............................................................................................... 939 Inspection............................................................................................ 940 Cam Followers, Inspection............................................................................. 940 Installation.......................................................................................... 940 CRANKSHAFT AND MAIN BEARINGS.............................................................................. 940 Crankshaft, Removal................................................................................... 940 Crankshaft, Inspection And Repair..................................................................... 941 Main Bearings......................................................................................... 942 Crankshaft, Installation.............................................................................. 942 PISTONS AND CONNECTING RODS............................................................................... 943 Removal............................................................................................... 943 Disassembly........................................................................................... 943 Pistons, Inspection And Repair........................................................................ 943 Piston Rings.......................................................................................... 944 Piston Pin and Bushing................................................................................ 944 Connecting Rods and Bearings, Inspection.............................................................. 944 Pistons and Connecting Rods, Assembly................................................................. 944 Pistons and Connecting Rods, Installation............................................................. 945 CYLINDER BLOCK AND CYLINDER LINERS........................................................................ 945 Cylinder Block, Repairs............................................................................... 945 Cylinder Liners....................................................................................... 945 DISTRIBUTOR............................................................................................... 946 Removal............................................................................................... 946 Installation.......................................................................................... 946 OIL PUMP.................................................................................................. 948 Removal............................................................................................... 948 Repairs............................................................................................... 948 Installation.......................................................................................... 949 GOVERNOR.................................................................................................. 949 Description........................................................................................... 949 Removal............................................................................................... 949 Disassembly........................................................................................... 950 Assembly.............................................................................................. 951 Installation.......................................................................................... 952 COOLANT PUMP.............................................................................................. 952 Removal............................................................................................... 952 Disassembly and Repair................................................................................ 953 Assembly.............................................................................................. 953 Installation.......................................................................................... 954 FLYWHEEL.................................................................................................. 954 Repairs............................................................................................... 954 Installation.......................................................................................... 954 CHECKS AND ADJUSTMENTS........................................................................................ 954 ADJUST THE VALVES......................................................................................... 954 ADJUST THE THROTTLE LINKAGE............................................................................... 955 ENGINE SPECIFICATIONS......................................................................................... 955 ENGINE SPECIFICATIONS..................................................................................... 955 Engine Data........................................................................................... 955 Cooling System........................................................................................ 955 Cylinder Head and Valve Mechanism..................................................................... 955 Camshaft.............................................................................................. 957 Timing Gear........................................................................................... 958 Camshaft.............................................................................................. 958 Connecting Rods....................................................................................... 958 Cylinder Liners....................................................................................... 958 Pistons............................................................................................... 958 Lubrication System.................................................................................... 959 Fuel Pump............................................................................................. 959 TORQUE SPECIFICATIONS..................................................................................... 960 TROUBLESHOOTING............................................................................................... 961 MSTS-GM (Early Control Models).................................................................................... 965 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)..................................................................... 965 GENERAL................................................................................................... 965 DESCRIPTION............................................................................................... 965 What MSTS Does........................................................................................ 967 How MSTS Begins Operation............................................................................. 967 OPERATION................................................................................................. 967 Pulse Generator....................................................................................... 967 HEI Module............................................................................................ 968 When the Engine Is Being Started...................................................................... 968 When the Engine Is Running............................................................................ 970 Manifold Absolute Pressure (MAP)...................................................................... 970 Coolant Temperature Sensor (CTS)...................................................................... 970 Electronic Control Module (ECM), Corrections.......................................................... 971 The Initial Timing Connector.......................................................................... 971 Gasoline and LPG Conversions.......................................................................... 972 TROUBLESHOOTING............................................................................................... 974 GENERAL................................................................................................... 974 TOOLS AND TEST EQUIPMENT.................................................................................. 974 MSTS TROUBLESHOOTING...................................................................................... 975 Test Description...................................................................................... 975 IGNITION SYSTEM TROUBLESHOOTING........................................................................... 977 Test Description...................................................................................... 977 ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING............................................................. 980 Circuit Description................................................................................... 980 Test Description...................................................................................... 980 MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING.......................................................... 983 Circuit Description................................................................................... 983 Test Description...................................................................................... 983 COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING.......................................................... 986 Circuit Description................................................................................... 986 Test Description...................................................................................... 986 REPAIRS....................................................................................................... 988 DISTRIBUTOR............................................................................................... 988 Removal............................................................................................... 988 Disassembly........................................................................................... 989 Inspection............................................................................................ 989 Assembly.............................................................................................. 990 Installation.......................................................................................... 990 Igntion Timing........................................................................................ 990 HEI MODULE................................................................................................ 991 Test For A Fault...................................................................................... 991 HEI Module Replacement................................................................................ 991 SENSING COIL.............................................................................................. 992 Test For A Fault...................................................................................... 992 Sensing Coil Replacement.............................................................................. 992 IGNITION COIL............................................................................................. 992 Test For A Fault...................................................................................... 992 ELECTRONIC CONTROL MODULE (ECM)........................................................................... 993 Removal............................................................................................... 993 Installation.......................................................................................... 993 COOLANT TEMPERATURE SENSOR (CTS).......................................................................... 993 Removal............................................................................................... 993 Installation.......................................................................................... 994 MANIFOLD ABSOLUTE PRESSURE (MAP).......................................................................... 994 Removal............................................................................................... 994 Installation.......................................................................................... 994 PRESSURE CONVERSION CHART............................................................................. 995 MSTS-GM (Later Models)............................................................................................ 996 INTRODUCTION.................................................................................................. 996 GENERAL................................................................................................... 996 DESCRIPTION............................................................................................... 996 What MSTS Does........................................................................................ 996 How MSTS Begins Operation............................................................................. 997 OPERATION................................................................................................. 998 Distributor........................................................................................... 998 Ignition Coil ........................................................................................ 998 Ignition Module....................................................................................... 998 When the Engine Is Being Started...................................................................... 999 When the Engine Is Running ........................................................................... 999 Manifold Absolute Pressure (MAP) Sensor...............................................................1000 Engine Coolant Temperature (ECT) Sensor...............................................................1001 MSTS Module Corrections...............................................................................1001 TROUBLESHOOTING...............................................................................................1003 GENERAL...................................................................................................1003 TOOLS AND EQUIPMENT.......................................................................................1004 MSTS......................................................................................................1005 TROUBLESHOOTING PROCEDURE.................................................................................1005 Where To Start........................................................................................1005 Visual/Physical Inspection................................................................................1005 Knowledge/Tools Required..................................................................................1005 Damage From Static Discharge (Static Electricity).........................................................1006 TROUBLESHOOTING INFORMATION...............................................................................1006 Malfunction Indicator Lamp (MIL)......................................................................1006 Connecting The CodeMate Tester........................................................................1006 Reading Diagnostic Trouble Codes (DTC)................................................................1007 Clearing Diagnostic Trouble Codes (DTC's).............................................................1007 On-Board DIAGNOSTIC (ODB) System Check................................................................1008 NO MALFUNCTION INDICATOR LAMP.............................................................................1010 Circuit Description...................................................................................1010 Test Description......................................................................................1010 NO DTC-12, MALFUNCTION INDICATOR LAMP ON..................................................................1012 Circuit Description...................................................................................1012 Test Description......................................................................................1012 STARTER ROTATES ENGINE, ENGINE DOES NOT RUN...............................................................1014 Test Description......................................................................................1014 DTC-14 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (LOW TEMPERATURE INDICATED)................................1017 Circuit Description...................................................................................1017 Test Description......................................................................................1017 DTC-15 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (HIGH TEMPERATURE INDICATED)...............................1019 Circuit Description...................................................................................1019 Test Description......................................................................................1019 DTC-34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR............................................................1021 Circuit Description...................................................................................1021 Test Description......................................................................................1021 DTC-41 ELECTRONIC SPARK TIMING (EST OPEN CIRCUIT).........................................................1024 Circuit Description...................................................................................1024 Test Description......................................................................................1024 DTC-42 ELECTRONIC SPARK TIMING (EST GROUNDED CIRCUIT).....................................................1026 Circuit Description...................................................................................1026 Test Description......................................................................................1026 DTC 51 MSTS FAILURE.......................................................................................1028 Circuit Description...................................................................................1028 REPAIRS.......................................................................................................1028 DISTRIBUTOR...............................................................................................1028 Removal...............................................................................................1028 Disassembly...........................................................................................1029 Inspection............................................................................................1029 Assembly..............................................................................................1029 Installation..........................................................................................1030 Ignition Timing.......................................................................................1030 IGNITION MODULE...........................................................................................1030 Test For A Fault......................................................................................1030 Ignition Module Replacement...........................................................................1031 SENSING COIL..............................................................................................1032 Test For A Fault......................................................................................1032 Sensing Coil Replacement..............................................................................1032 IGNITION COIL.............................................................................................1032 Test For A Fault......................................................................................1032 Removal...............................................................................................1033 Installation..........................................................................................1033 MSTS MODULE...............................................................................................1033 Removal...............................................................................................1033 Installation..........................................................................................1033 ECT SENSOR REPLACEMENT....................................................................................1033 MAP SENSOR REPLACEMENT....................................................................................1034 Periodic Maintenance..............................................................................................1036 PERIODIC MAINTENANCE..........................................................................................1036 GENERAL...................................................................................................1036 Serial Number Data....................................................................................1036 HOW TO MOVE A DISABLED LIFT TRUCK.........................................................................1037 How To Tow the Lift Truck.............................................................................1037 HOW TO PUT A LIFT TRUCK ON BLOCKS.........................................................................1037 How To Raise the Drive Tires..........................................................................1037 How To Raise the Steering Tires.......................................................................1038 MAINTENANCE PROCEDURES........................................................................................1042 EVERY 8 HOURS OR DAILY........................................................................................1042 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED................................................................1042 Engine Oil............................................................................................1042 Drive Belts...........................................................................................1042 Cooling System........................................................................................1042 Battery...............................................................................................1043 Fuel System...........................................................................................1045 Air Filter............................................................................................1045 Hydraulic System Oil..................................................................................1045 Tires and Wheels......................................................................................1046 Forks.................................................................................................1046 Forks, Adjustment.....................................................................................1047 Forks, Removal And Installation.......................................................................1047 Inspection Of Forks, Mast, and Lift Chains............................................................1048 Safety Labels.........................................................................................1049 Operator Restraint System.............................................................................1049 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING................................................................1050 Gauges, Lights, Horn, and Fuses.......................................................................1050 Fuel Filter, Diesel Engine............................................................................1051 How To Drain The Water From The Fuel Filter...........................................................1051 Oil Level, Powershift Transmission....................................................................1051 Control Levers and Pedals.............................................................................1051 Lift System Operation.................................................................................1051 Inching/Brake Pedal...................................................................................1052 Service Brakes........................................................................................1052 Parking Brake.........................................................................................1052 Steering System.......................................................................................1052 EVERY 250 HOURS OR TWO MONTHS.................................................................................1053 ENGINE OIL AND FILTER.....................................................................................1053 Mazda, GM, And Later Production Isuzu Engines.........................................................1053 Earlier Production Isuzu C240 Engines.................................................................1053 GOVERNOR, MAZDA ENGINE....................................................................................1054 DRIVE BELTS...............................................................................................1054 Mazda Engine..........................................................................................1054 Isuzu, GM 4-181, And GM 4-153 Engines.................................................................1054 BRAKE FLUID...............................................................................................1055 HYDRAULIC TANK BREATHER, CLEAN AND CHECK..................................................................1055 FORKS, CHECK FOR WEAR AND DAMAGE..........................................................................1055 LIFT CHAINS...............................................................................................1055 Lubrication...........................................................................................1055 Check For Wear........................................................................................1055 MAST, LUBRICATION.........................................................................................1056 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...............................................................1056 CONTROL LEVERS AND PEDALS, LUBRICATION....................................................................1057 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.......................................................................1057 Idle Speed, Diesel....................................................................................1057 LPG Carburetor........................................................................................1058 Gasoline Carburetor...................................................................................1058 EVERY 1000 HOURS OR SIX MONTHS................................................................................1059 DIESEL FUEL FILTER........................................................................................1059 Filter Replacement, Models Without A Water Separator..................................................1060 Filter Replacement, Models With A Water Separator.....................................................1060 Remove Air from the Diesel Fuel System................................................................1060 DIFFERENTIAL..............................................................................................1061 VALVE CLEARANCE ADJUSTMENT................................................................................1061 IGNITION SYSTEM, MAZDA AND GM ENGINES.....................................................................1061 PCV VALVE AND FILTER......................................................................................1063 EVERY 2000 HOURS OR YEARLY....................................................................................1063 HYDRAULIC SYSTEM..........................................................................................1063 Replace the Hydraulic Oil and Filter..................................................................1063 POWERSHIFT TRANSMISSION...................................................................................1063 COOLING SYSTEM............................................................................................1064 SERVICE BRAKES............................................................................................1064 DIFFERENTIAL..............................................................................................1064 WHEEL BEARINGS............................................................................................1065 Steering Wheels, lubrication..........................................................................1065 Drive Wheels, Lubrication.............................................................................1065 GASOLINE FUEL FILTER, REPLACEMENT.........................................................................1065 PCV VALVE, GM ENGINES.....................................................................................1065 LPG FILTER, REPLACEMENT...................................................................................1065 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A............................................................1065 GENERAL PROCEDURES............................................................................................1066 CHECK THE HOOD LATCH......................................................................................1066 LIFT CHAIN ADJUSTMENTS....................................................................................1066 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................1068 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................1069 Check the Lift Cylinders for Leaks....................................................................1069 Check the Tilt Cylinders for Leaks....................................................................1069 FUEL INJECTORS............................................................................................1070 WELDING REPAIRS...........................................................................................1070 CHANGES TO THE OVERHEAD GUARD.............................................................................1070 WHEELS AND TIRES..........................................................................................1070 Solid Rubber Tires (Press-on).........................................................................1070 Install The Wheels....................................................................................1071 Pneumatic Tires, Remove The Wheels From The Lift Truck................................................1072 Pneumatic Tires, Remove the Tire From The Wheel.......................................................1072 Pneumatic Tires, Install The Wheel In The Tire........................................................1073 Pneumatic Tires, Add Air To The Tires.................................................................1074 Pneumatic Tires, Install the Wheels...................................................................1075 Pneumatic Tires, Installation Procedures, Dual Drive Wheels...........................................1075 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.........................................................1076 Remove The Wheels From The Lift Truck.................................................................1076 Remove The Tire From The Wheel........................................................................1076 Install The Tire On The Wheel.........................................................................1077 REFERENCE TABLE...............................................................................................1078 Rochester Carburetor (GM Engine)..................................................................................1079 INTRODUCTION..................................................................................................1079 GENERAL...................................................................................................1079 DESCRIPTION...............................................................................................1079 OPERATION.................................................................................................1080 The Float System......................................................................................1080 The Idle System.......................................................................................1080 The Main Metering System (GM 6-250)...................................................................1081 The Power System (GM 6-250)...........................................................................1082 The Accelerator Pump System...........................................................................1082 Choke System..........................................................................................1082 REPAIRS.......................................................................................................1083 REMOVAL...................................................................................................1083 DISASSEMBLY...............................................................................................1083 Cleaning..................................................................................................1083 ASSEMBLY..................................................................................................1083 INSTALLATION..............................................................................................1083 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)...........................................................1088 GOVERNOR (PNEUMATIC) (Early Units)........................................................................1089 CHECKS AND ADJUSTMENTS........................................................................................1090 GENERAL...................................................................................................1090 ADJUST THE CHOKE CONTROL..................................................................................1090 ADJUST THE IDLE SPEED.....................................................................................1090 ADJSUT THE IDLE MIXTURE...................................................................................1091 ADJUST THE FAST IDLE......................................................................................1091 ADJUST THE THROTTLE LINKAGE,(Later Models)................................................................1092 ADJUST THE THROTTLE LINKAGE,(Early Models)................................................................1093 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only).............................................1093 Check the Governor....................................................................................1093 GOVERNOR (AISAN Type) (Early GM Engines Only).............................................................1094 Checks................................................................................................1095 Adjustments...........................................................................................1095 GOVERNOR (HOOF Type) (Early GM Engines Only)..............................................................1095 Adjust the Governor...................................................................................1095 TROUBLESHOOTING...............................................................................................1097 Single SPD SP Trans-Description & Operation (T41, T42, T43).......................................................1098 INTRODUCTION..................................................................................................1098 GENERAL...................................................................................................1098 DESCRIPTION AND OPERATION.....................................................................................1099 GENERAL...................................................................................................1099 TORQE CONVERTER...........................................................................................1099 Description...........................................................................................1099 Operation.............................................................................................1099 CLUTCH ASSEMBLIES.........................................................................................1102 Description...........................................................................................1102 Operation.............................................................................................1104 HYDRAULIC SYSTEM..........................................................................................1104 General...............................................................................................1104 CONTROL VALVE.............................................................................................1104 Regulator for Clutch Pressure.........................................................................1107 Inching Spool Assembly................................................................................1107 Direction Spool.......................................................................................1107 MONOTROL Control Valve................................................................................1107 Neutral Start Switch, MONOTROL Pedal Only.............................................................1108 Neutral Start Switch, Direction Control Lever Only....................................................1108 Modulator Circuit.....................................................................................1108 Regulator for the Toruqe Converter....................................................................1109 By-Pass Valve for the Oil Cooler......................................................................1109 DIFFERENTIAL..............................................................................................1110 OIL FLOW DIAGRAMS.........................................................................................1110 Single-SPD SP Trans_Repair (T41, T42, T43)........................................................................1119 INTRODUCTION..................................................................................................1119 GENERAL...................................................................................................1119 REPAIRS.......................................................................................................1121 REPAIRS...................................................................................................1121 Torque Converter, Removal.............................................................................1121 Torque Converter, Installation........................................................................1121 Front Cover And Transmission Pump, Removal and Disassembly............................................1122 Front Cover And Transmission Pump, Assembly and Installation..........................................1122 Clutch Assemblies, Removal and Disassembly............................................................1123 Clutch Assemblies, Inspection.........................................................................1126 Clutch Assemblies, Assembly and Installation..........................................................1127 Differential, Removal and Disassembly.................................................................1130 Differential, Inspection..............................................................................1132 Differential, Assembly And Installation...............................................................1132 CONTROL VALVE.............................................................................................1142 Control Valve, Removal and Disassembly................................................................1142 Control Valve, Inspection.............................................................................1142 Control Valve, Assembly and Installation..............................................................1144 MONOTROL Pedal, Removal and Disassembly...............................................................1146 MONOTROL Pedal, Assembly and Installation.............................................................1146 CHECKS AND ADJUSTMENTS........................................................................................1148 Stall Test................................................................................................1148 Adjustment Of The Direction Control Linkage...............................................................1149 Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1).............1150 Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)..............1153 Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187).......................1154 Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)....................1155 Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)....1159 Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)............1160 Check The Oil Pressures...................................................................................1160 Check The Relief Valve for the Transmission Pump..........................................................1160 Check The Clutch Pressure.................................................................................1160 Check The Torque Converter Regulator......................................................................1161 Check The Oil Pressure from the Oil Cooler................................................................1161 Check The Modulator Pressure..............................................................................1162 TROUBLESHOOTING...............................................................................................1162 TROUBLESHOOTING, PRESSURE TESTS...............................................................................1164 Starter...........................................................................................................1167 INTRODUCTION..................................................................................................1167 GENERAL...................................................................................................1167 DESCRIPTION AND OPERATION.................................................................................1167 REPAIRS.......................................................................................................1169 REMOVAL...................................................................................................1169 DISSASEMBLY...............................................................................................1169 CLEANING..................................................................................................1170 ASSEMBLY..................................................................................................1170 INSTALLATION..............................................................................................1170 CHECKS AND ADJUSTMENTS........................................................................................1171 GENERAL...................................................................................................1171 TROUBLESHOOTING...............................................................................................1173 Steer Axle........................................................................................................1175 INTRODUCTION..................................................................................................1175 DESCRIPTION...............................................................................................1175 GENERAL...................................................................................................1175 REPAIRS.......................................................................................................1176 STEERING AXLE.............................................................................................1176 Removal...................................................................................................1176 Installation..............................................................................................1177 STEERING CYLINDER.........................................................................................1177 Removal...................................................................................................1177 Service...................................................................................................1178 Installation..............................................................................................1178 HUBS......................................................................................................1178 Removal...................................................................................................1178 Installation..............................................................................................1179 SPINDLES..................................................................................................1179 Removal...................................................................................................1179 Installation..............................................................................................1180 CHECKS AND ADJUSTMENTS........................................................................................1180 REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................1180 SET THE PRESSURE RELIEF VALVE.............................................................................1180 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...................................................1180 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION........................................................1180 H2.00-3.00J (H40-60J) With Powershift Transmission........................................................1180 TROUBLESHOOTING...............................................................................................1182 Steer Control Unit................................................................................................1183 STEERING CONTROL UNIT.........................................................................................1183 GENERAL...................................................................................................1183 DESCRIPTION...............................................................................................1183 Control Valve Section.................................................................................1183 Metering Section......................................................................................1183 DISASSEMBLY AND INSPECTION................................................................................1185 ASSEMBLY..................................................................................................1195 TROUBLESHOOTING...............................................................................................1209 Steering System...................................................................................................1210 THE STEERING SYSTEM...........................................................................................1210 GENERAL...................................................................................................1210 DESCRIPTION...............................................................................................1210 Hydraulic Pump Assembly...............................................................................1211 Flow Control Valve....................................................................................1212 Relief Valve..........................................................................................1212 OPERATION.................................................................................................1212 Steering System.......................................................................................1212 Hydraulic Pump........................................................................................1213 Flow Control Valve....................................................................................1213 Relief Valve..........................................................................................1213 STEERING WHEEL AND COLUMN ASSEMBLY........................................................................1214 Removal (Serial Code C177 And C187)...................................................................1214 Installation (Serial Code C177 And C187)..............................................................1214 Removal (Serial Code B177 And B187)...................................................................1217 Installation (Serial Code B177 And B187)..............................................................1217 STEERING CONTROL UNIT.....................................................................................1218 Description...........................................................................................1218 Operation, Control Valve Section......................................................................1218 Operation, Metering Section...........................................................................1219 CHECKS AND ADJUSTMENTS....................................................................................1219 Remove Air From The Steering System...................................................................1219 Check And Adjust Steering Relief Pressure.............................................................1219 Check Hydraulic Pump For Correct Flow.................................................................1219 TROUBLESHOOTING...............................................................................................1220 Tilt Cylinders....................................................................................................1221 INTRODUCTION..................................................................................................1221 GENERAL...................................................................................................1221 DESCRIPTION...............................................................................................1221 REPAIRS.......................................................................................................1221 REMOVAL...................................................................................................1221 DISASSEMBLY...............................................................................................1221 CLEANING..................................................................................................1221 ASSEMBLY..................................................................................................1221 Tilt Cylinders with O-Rings or Single Lip Seals.......................................................1221 Tilt Cylinders for the XM and XMS Models..............................................................1222 Tilt Cylinders for H700 800A and Early Model H700 920B................................................1224 INSTALLATION..............................................................................................1224 Tilt Cylinders Using Chevron Packing..................................................................1225 CHECKS AND ADJUSTMENTS........................................................................................1227 CHECK THE TILT CYLINDERS FOR LEAKS........................................................................1227 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...................................................1227 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS......................................................1228 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS.....................................................1229 TROUBLESHOOTING...............................................................................................1231 Vista Mast Description............................................................................................1232 INTRODUCTION..................................................................................................1232 GENERAL...................................................................................................1232 MAST WELDMENTS............................................................................................1232 CARRIAGE..................................................................................................1232 MAST MOUNTS...............................................................................................1233 VISTA® TWO-STAGE MAST.........................................................................................1234 DESCRIPTION AND OPERATION.................................................................................1234 VISTA® FREE-LIFT MAST.........................................................................................1236 DESCRIPTION...............................................................................................1236 OPERATION.................................................................................................1236 VISTA® THREE-STAGE MAST.......................................................................................1238 DESCRIPTION...............................................................................................1238 OPERATION.................................................................................................1238 VISTA® FOUR-STAGE MAST........................................................................................1239 DESCRIPTION...............................................................................................1239 OPERATION.................................................................................................1240 Vista Mast Repair.................................................................................................1242 VISTA MAST, REPAIR............................................................................................1242 GENERAL...................................................................................................1242 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................1242 FORKS.....................................................................................................1243 Forks, Removal And Installation.......................................................................1243 CARRIAGE..................................................................................................1244 Removal...............................................................................................1244 Installation..........................................................................................1245 MASTS.....................................................................................................1245 Removal...............................................................................................1245 Disassembly...........................................................................................1246 Cleaning and Inspection...............................................................................1251 Assembly..............................................................................................1251 Installation..........................................................................................1255 SIDE-SHIFT CARRIAGE (EARLIER DESIGN)......................................................................1256 Removal...............................................................................................1256 Repairs...............................................................................................1256 Installation..........................................................................................1256 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)...............................................................1257 Removal...............................................................................................1257 Repairs...............................................................................................1257 Installation..........................................................................................1258 CHECKS AND ADJUSTMENTS........................................................................................1259 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................1259 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...............................................1260 LIFT CHAIN ADJUSTMENTS....................................................................................1261 MAST ADJUSTMENTS..........................................................................................1261 CARRIAGE ADJUSTMENT.......................................................................................1263 HEADER HOSE ARRANGEMENTS..................................................................................1263 Two-Stage Header Hose.................................................................................1264 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts.........................................1264 TROUBLESHOOTING...............................................................................................1269
HYSTER B177 (H40-60XL) SERVICE MANUAL – PDF DOWNLOAD:
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