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Hyster C001 (H1.25-1.75XL Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster C001 (H1.25-1.75XL Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C001 (H1.25-1.75XL Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 504
Downloadable : Yes
File Type : PDF
Size: 15.6 MB
TABLE OF CONTENTS:
Hyster C001 (H1.25-1.75XL Europe) Service Manual – PDF DOWNLOAD
13008............................................................................................................. 1 INTRODUCTION.................................................................................................. 1 General................................................................................................... 1 Removal of The Transmission........................................................................... 1 Installation of the Transmission...................................................................... 1 REPAIRS....................................................................................................... 3 Torque Converter.......................................................................................... 3 Front Cover and Oil Pump.................................................................................. 3 Clutch Assemblies......................................................................................... 5 Differential.............................................................................................. 13 Control Valve............................................................................................. 22 CHECKS AND ADJUSTMENTS........................................................................................ 24 Stall Test................................................................................................ 24 Adjusting the Direction Control Linkage................................................................... 25 Adjusting the Brake and Inching Pedals.................................................................... 26 Checking the Oil Pressures................................................................................ 28 SPECIFICATIONS................................................................................................ 30 TROUBLESHOOTING............................................................................................... 30 60066............................................................................................................. 33 MAZDA M4-121G ENGINE.......................................................................................... 33 GENERAL................................................................................................... 33 DESCRIPTION............................................................................................... 34 REMOVAL AND INSTALLATION OF THE ENGINE.................................................................... 34 CYLINDER HEAD AND VALVE MECHANISM......................................................................... 34 Cylinder Head, Removal................................................................................ 34 Cylinder Head, Inspection and Repairs................................................................. 35 Rocker Arm Assembly................................................................................... 35 Valve Guides.......................................................................................... 35 Valve Seats........................................................................................... 36 Valves................................................................................................ 36 Valve Springs......................................................................................... 36 Cylinder Head, Installation........................................................................... 36 TIMING GEAR CASE, REMOVAL................................................................................. 37 TIMING GEAR CASE, INSTALLATION............................................................................ 38 CAMSHAFT.................................................................................................. 38 Removal............................................................................................... 38 Inspection............................................................................................ 39 Cam Followers, Inspection............................................................................. 39 Installation.......................................................................................... 39 CRANKSHAFT AND MAIN BEARINGS.............................................................................. 39 Crankshaft, Removal................................................................................... 39 Crankshaft, Inspection And Repair..................................................................... 40 Main Bearings......................................................................................... 41 Crankshaft, Installation.............................................................................. 41 PISTONS AND CONNECTING RODS............................................................................... 42 Removal............................................................................................... 42 Disassembly........................................................................................... 42 Pistons, Inspection And Repair........................................................................ 42 Piston Rings.......................................................................................... 43 Piston Pin and Bushing................................................................................ 43 Connecting Rods and Bearings, Inspection.............................................................. 43 Pistons and Connecting Rods, Assembly................................................................. 43 Pistons and Connecting Rods, Installation............................................................. 44 CYLINDER BLOCK AND CYLINDER LINERS........................................................................ 44 Cylinder Block, Repairs............................................................................... 44 Cylinder Liners....................................................................................... 44 DISTRIBUTOR............................................................................................... 45 Removal............................................................................................... 45 Installation.......................................................................................... 45 OIL PUMP.................................................................................................. 47 Removal............................................................................................... 47 Repairs............................................................................................... 47 Installation.......................................................................................... 48 GOVERNOR.................................................................................................. 48 Description........................................................................................... 48 Removal............................................................................................... 48 Disassembly........................................................................................... 49 Assembly.............................................................................................. 50 Installation.......................................................................................... 51 COOLANT PUMP.............................................................................................. 51 Removal............................................................................................... 51 Disassembly and Repair................................................................................ 52 Assembly.............................................................................................. 52 Installation.......................................................................................... 53 FLYWHEEL.................................................................................................. 53 Repairs............................................................................................... 53 Installation.......................................................................................... 53 CHECKS AND ADJUSTMENTS........................................................................................ 53 ADJUST THE VALVES......................................................................................... 53 ADJUST THE THROTTLE LINKAGE............................................................................... 54 ENGINE SPECIFICATIONS......................................................................................... 54 ENGINE SPECIFICATIONS..................................................................................... 54 Engine Data........................................................................................... 54 Cooling System........................................................................................ 54 Cylinder Head and Valve Mechanism..................................................................... 54 Camshaft.............................................................................................. 56 Timing Gear........................................................................................... 57 Camshaft.............................................................................................. 57 Connecting Rods....................................................................................... 57 Cylinder Liners....................................................................................... 57 Pistons............................................................................................... 57 Lubrication System.................................................................................... 58 Fuel Pump............................................................................................. 58 TORQUE SPECIFICATIONS..................................................................................... 59 TROUBLESHOOTING............................................................................................... 60 60070............................................................................................................. 64 INTRODUCTION ................................................................................................. 64 GENERAL .................................................................................................. 64 DESCRIPTION .............................................................................................. 64 FUEL SYSTEM .............................................................................................. 65 Description .......................................................................................... 65 Operation, Fuel Injection Pump, Model VE ............................................................. 67 Operation, Fuel Injection Pump, Model PE4A ........................................................... 68 Pneumatic Governor For Fuel Injection Pump, Model PE4A ............................................... 69 Inlet Manifold For Fuel Injection Pump, Model PE4A ................................................... 70 REPAIRS ...................................................................................................... 71 FUEL INJECTION PUMP (ALL MODELS) ......................................................................... 71 Removal .............................................................................................. 71 Installation ......................................................................................... 71 REMOVAL AND INSTALLATION OF THE ENGINE ................................................................... 71 CYLINDER HEAD AND VALVE MECHANISM ........................................................................ 71 Cylinder Head, Removal ............................................................................... 71 Valve Guides, Replacement ............................................................................ 72 Cylinder Head, Inspection And Repair ................................................................. 73 Combustion Chamber Plugs, Inspection And Repair ...................................................... 73 Combustion Chamber Plugs, Installation ............................................................... 73 Valves, Inspection And Repair ........................................................................ 74 Valve Seat, Inspection ............................................................................... 74 Valve Seat, Removal .................................................................................. 75 Valve Seat, Installation ............................................................................. 75 Valve Spring, Inspection ............................................................................. 75 Rocker Arms, Inspection And Assembly ................................................................. 75 Installation Of The Cylinder Head .................................................................... 76 TIMING GEAR CASE ......................................................................................... 77 Removal .............................................................................................. 77 Installation ......................................................................................... 77 CAMSHAFT ................................................................................................. 79 Removal .............................................................................................. 79 Inspection ........................................................................................... 79 Camshaft Bearings .................................................................................... 80 Cam Followers ........................................................................................ 80 CAMSHAFT, INSTALLATION ................................................................................... 80 CRANKSHAFT AND MAIN BEARINGS ............................................................................. 81 Crankshaft, Removal .................................................................................. 81 Crankshaft, Inspection And Repair .................................................................... 81 Main Bearings ........................................................................................ 81 Pilot Bearing ........................................................................................ 82 Crankshaft, Installation ............................................................................. 82 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) .......................................................... 84 Flywheel, Removal .................................................................................... 84 Ring Gear, Replacement ............................................................................... 84 Flywheel, Installation ............................................................................... 84 PISTONS AND CONNECTING RODS .............................................................................. 85 Pistons And Connecting Rods, Removal ................................................................. 85 Disassembly .......................................................................................... 85 Pistons, Inspection And Repair ....................................................................... 86 Piston Rings, Inspection And Repair .................................................................. 86 Piston Pins, Inspection And Repair ................................................................... 87 Connecting Rods, Inspection And Repair ............................................................... 88 Pistons And Connecting Rods, Assembly And Installation ............................................... 88 CYLINDER BLOCK AND CYLINDER LINERS ....................................................................... 88 Cylinder Liners, Inspection .......................................................................... 88 Replacement Of A Cylinder Liner ...................................................................... 89 LUBRICATION SYSTEM ....................................................................................... 90 Oil Pump, Removal And Disassembly .................................................................... 90 Oil Pump, Inspection ................................................................................. 90 Oil Pump, Assembly And Installation .................................................................. 91 Oil Filter ........................................................................................... 91 COOLING SYSTEM ........................................................................................... 92 Coolant Pump, Removal ................................................................................ 92 Coolant Pump, Disassembly ............................................................................ 92 Coolant Pump, Assembly And Installation .............................................................. 92 Thermostat, Replacement .............................................................................. 93 CHECKS AND ADJUSTMENTS ....................................................................................... 93 VALVE CLEARANCE ADJUSTMENT ............................................................................... 93 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE .................................................... 94 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A .................................................. 95 FUEL INJECTORS ........................................................................................... 95 Fuel Injectors, Removal .............................................................................. 96 Fuel Injectors, Inspection ........................................................................... 96 Fuel Injectors, Installation ......................................................................... 97 DIESEL FUEL FILTERS ...................................................................................... 97 Filter Replacement, Models With A Water Separator .................................................... 97 Filter Replacement, Models Without A Water Separator ................................................. 98 Filter For The Fuel Injection Pump, Model PE4A ....................................................... 98 REMOVE AIR FROM THE FUEL SYSTEM .......................................................................... 98 Throttle Linkage, Adjustment ......................................................................... 99 Idle Speed, Adjustment ............................................................................... 99 Check The Elements For The Cold Start Aid System ..................................................... 99 ENGINE SPECIFICATIONS ........................................................................................ 99 TORQUE SPECIFICATIONS ........................................................................................101 90015.............................................................................................................102 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100).....................................................................102 GENERAL...................................................................................................102 DESCRIPTION...............................................................................................102 Fuel Tank.............................................................................................103 Fuel Filter And Fuel Valve Unit.......................................................................104 Vaporizer.............................................................................................104 The IMPCO CA 100 Carbureto............................................................................106 IMPCO CA 50 Carburetor................................................................................108 The Governor (GM Engines Only)........................................................................109 Governor With Electronic Controller...................................................................110 REPAIRS.......................................................................................................111 LPG TANK..................................................................................................111 Removal...............................................................................................111 Installation..........................................................................................112 REPLACE THE HOSES.........................................................................................112 HYDROSTATIC RELIEF VALVE..................................................................................112 Removal and Installation..............................................................................112 FILTER UNIT...............................................................................................113 Replacement Of the Fuel Filter Element................................................................113 Replacement of the Diaphragm and Fuel Valve...........................................................114 VAPORIZER.................................................................................................114 Removal...............................................................................................114 Disassembly...........................................................................................114 Cleaning..............................................................................................114 Inspection............................................................................................114 Assembly..............................................................................................116 Installation..........................................................................................116 CARBURETOR (IMPCO CA 100).................................................................................118 Removal...............................................................................................118 Disassembly...........................................................................................118 Cleaning..............................................................................................118 Assembly..............................................................................................118 Installation..........................................................................................121 CARBURETER (IMPCO CA 50)..................................................................................120 Removal...............................................................................................120 Disassembly...........................................................................................120 Cleaning..............................................................................................121 Inspection............................................................................................121 Assembly (See FIGURE 26.).............................................................................121 Installation..........................................................................................121 CHECKS AND ADJUSTMENTS........................................................................................122 CHECK THE FILTER UNIT.....................................................................................122 CHECK THE VAPORIZER.......................................................................................122 Pressure Reducer Valve................................................................................122 Vapor Valve...........................................................................................122 ADJUST THE CARBURETOR.....................................................................................122 Idle Mixture..........................................................................................122 Idle Speed............................................................................................122 Power Mixture.........................................................................................122 ADJUST THE GOVERNOR (GM Engines Only).....................................................................123 Checks................................................................................................123 Main Adjusting Screw..................................................................................123 Secondary Adjusting Screw.............................................................................123 AISAN Governor........................................................................................124 Adjustment, AISAN Governor............................................................................124 TROUBLESHOOTING...............................................................................................125 100218............................................................................................................129 INTRODUCTION..................................................................................................129 GENERAL...................................................................................................129 DESCRIPTION...............................................................................................129 REPAIRS.......................................................................................................129 COUNTERWEIGHT.............................................................................................129 Removal...............................................................................................129 Installation..........................................................................................130 OVERHEAD GUARD............................................................................................130 HOOD......................................................................................................130 Removal...............................................................................................130 Installation..........................................................................................130 OPERATOR RESTRAINT SYSTEM.................................................................................131 ENGINE....................................................................................................131 Removal...............................................................................................131 Installation (Engine Only)............................................................................132 Installation (Engine and Transmission)................................................................133 RADIATOR AND MUFFLER......................................................................................133 Removal and Installation..............................................................................133 FUEL AND HYDRAULIC TANKS..................................................................................133 Inspection............................................................................................133 Repairs...............................................................................................133 LABEL REPLACEMENT.........................................................................................135 130075............................................................................................................138 INTRODUCTION..................................................................................................138 General...................................................................................................138 DESCRIPTION AND OPERATION.....................................................................................138 General...................................................................................................138 Torque Converter..........................................................................................139 Description...........................................................................................139 Operation.............................................................................................139 Clutch Assemblies.........................................................................................141 Description...........................................................................................141 Operation.............................................................................................142 Hydraulic System..........................................................................................142 General...............................................................................................142 Oil Pump and Front Cover..................................................................................143 Torque Converter Regulator............................................................................143 Oil Cooler By-Pass....................................................................................143 Control Valve.............................................................................................143 General...............................................................................................143 Differential..............................................................................................148 Oil Flow Diagrams.........................................................................................149 Neutral...............................................................................................149 Forward...............................................................................................151 Forward-Inching.......................................................................................153 Reverse...............................................................................................155 160010............................................................................................................157 INTRODUCTION..................................................................................................157 DESCRIPTION...............................................................................................157 GENERAL...................................................................................................157 REPAIRS.......................................................................................................158 STEERING AXLE.............................................................................................158 Removal...................................................................................................158 Installation..............................................................................................159 STEERING CYLINDER.........................................................................................159 Removal...................................................................................................159 Service...................................................................................................160 Installation..............................................................................................160 HUBS......................................................................................................160 Removal...................................................................................................160 Installation..............................................................................................161 SPINDLES..................................................................................................161 Removal...................................................................................................161 Installation..............................................................................................162 CHECKS AND ADJUSTMENTS........................................................................................162 REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................162 SET THE PRESSURE RELIEF VALVE.............................................................................162 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...................................................162 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION........................................................162 H2.00-3.00J (H40-60J) With Powershift Transmission........................................................162 TROUBLESHOOTING...............................................................................................164 160054............................................................................................................165 INTRODUCTION..................................................................................................165 GENERAL...................................................................................................165 DESCRIPTION...............................................................................................165 OPERATION.................................................................................................165 REPAIRS.......................................................................................................165 STEERING WHEEL AND COLUMN ASSEMBLY........................................................................165 TYPE "A" STEERING COLUMN ASSEMBLY.........................................................................167 Removal And Disassembly...............................................................................167 Assembly And Installation.............................................................................167 TYPE "A" STEERING COLUMN..................................................................................168 TYPE "A" STEERING COLUMN..................................................................................169 TYPE "B" STEERING COLUMN..................................................................................170 Removal And Disassembly...............................................................................170 Assembly And Installation.............................................................................170 TYPE "B" STEERING COLUMN..................................................................................171 Disassembly of Steering Control Unit..................................................................172 Cleaning of Steering Control Unit.....................................................................172 Assembly of Steering Control Unit.....................................................................174 CHECKS AND ADJUSTMENTS........................................................................................177 REMOVE AIR FROM THE SYSTEM................................................................................177 TROUBLESHOOTING...............................................................................................178 200077............................................................................................................179 INTRODUCTION..................................................................................................179 GENERAL...................................................................................................179 DESCRIPTION...............................................................................................179 OPERATION.................................................................................................180 Lift Section..........................................................................................181 Tilt Section..........................................................................................181 Relief Valve..........................................................................................183 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................184 Operation.............................................................................................184 REPAIRS.......................................................................................................184 MAIN CONTROL VALVE........................................................................................184 Removal and Disassembly...............................................................................184 Cleaning and Inspection...............................................................................185 Assembly..............................................................................................185 Installation..........................................................................................185 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................185 Removal and Disassembly...............................................................................185 Assembly and Installation.............................................................................187 CHECKS AND ADJUSTMENTS........................................................................................187 PRESSURE RELIEF VALVES....................................................................................187 Primary Relief Valve..................................................................................187 Seconday Relief Valve.................................................................................188 CONTROL LEVER ARRANGEMENT.................................................................................188 TROUBLESHOOTING...............................................................................................191 SPECIFICATIONS................................................................................................193 700626............................................................................................................194 COOLING SYSTEM................................................................................................194 INTRODUCTION..............................................................................................194 DESCRIPTION...............................................................................................194 RADIATOR..................................................................................................194 RADIATOR CAP..............................................................................................194 THERMOSTAT................................................................................................194 WATER PUMP................................................................................................195 FAN AND FAN SHROUD .......................................................................................195 REPAIRS.......................................................................................................195 COOLING SYSTEM CHECKS.....................................................................................195 Exhaust Leaks.........................................................................................195 RADIATOR..................................................................................................195 Checks................................................................................................195 Cleaning The Radiator.................................................................................195 Drain The Cooling System..............................................................................197 Fill The Cooling System...............................................................................197 WATER PUMP................................................................................................197 Checks................................................................................................197 THERMOSTAT................................................................................................198 Checks................................................................................................198 FAN AND FAN SHROUD .......................................................................................198 TROUBLESHOOTING...............................................................................................199 900129............................................................................................................200 THE CARBURETOR, (MAZDA M4-121G ENGINE)........................................................................200 DESCRIPTION...............................................................................................200 REPAIRS, CARBURETOR.......................................................................................201 Removal...............................................................................................201 Cleaning..............................................................................................204 Inspection............................................................................................204 Assembly..............................................................................................204 Installation..........................................................................................206 CHECKS AND ADJUSTMENTS....................................................................................206 Carburetor, Idle Speed And Mixture Adjustment.........................................................206 Adjust The Governor...................................................................................207 ADJUST THE THROTTLE LINKAGE...............................................................................208 SPECIFICATIONS................................................................................................208 TROUBLESHOOTING...............................................................................................209 1300255...........................................................................................................211 INTRODUCTION..................................................................................................211 GENERAL...................................................................................................211 DESCRIPTION AND OPERATION.....................................................................................212 GENERAL...................................................................................................212 TORQE CONVERTER...........................................................................................212 Description...........................................................................................212 Operation.............................................................................................212 CLUTCH ASSEMBLIES.........................................................................................215 Description...........................................................................................215 Operation.............................................................................................217 HYDRAULIC SYSTEM..........................................................................................217 General...............................................................................................217 CONTROL VALVE.............................................................................................217 Regulator for Clutch Pressure.........................................................................220 Inching Spool Assembly................................................................................220 Direction Spool.......................................................................................220 MONOTROL Control Valve................................................................................220 Neutral Start Switch, MONOTROL Pedal Only.............................................................221 Neutral Start Switch, Direction Control Lever Only....................................................221 Modulator Circuit.....................................................................................221 Regulator for the Toruqe Converter....................................................................222 By-Pass Valve for the Oil Cooler......................................................................222 DIFFERENTIAL..............................................................................................223 OIL FLOW DIAGRAMS.........................................................................................223 1300256...........................................................................................................232 INTRODUCTION..................................................................................................232 GENERAL...................................................................................................232 REPAIRS.......................................................................................................234 REPAIRS...................................................................................................234 Torque Converter, Removal.............................................................................234 Torque Converter, Installation........................................................................234 Front Cover And Transmission Pump, Removal and Disassembly............................................235 Front Cover And Transmission Pump, Assembly and Installation..........................................235 Clutch Assemblies, Removal and Disassembly............................................................236 Clutch Assemblies, Inspection.........................................................................239 Clutch Assemblies, Assembly and Installation..........................................................240 Differential, Removal and Disassembly.................................................................243 Differential, Inspection..............................................................................245 Differential, Assembly And Installation...............................................................245 CONTROL VALVE.............................................................................................255 Control Valve, Removal and Disassembly................................................................255 Control Valve, Inspection.............................................................................255 Control Valve, Assembly and Installation..............................................................257 MONOTROL Pedal, Removal and Disassembly...............................................................259 MONOTROL Pedal, Assembly and Installation.............................................................259 CHECKS AND ADJUSTMENTS........................................................................................261 Stall Test................................................................................................261 Adjustment Of The Direction Control Linkage...............................................................262 Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1).............263 Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)..............266 Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187).......................267 Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)....................268 Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)....272 Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)............273 Check The Oil Pressures...................................................................................273 Check The Relief Valve for the Transmission Pump..........................................................273 Check The Clutch Pressure.................................................................................273 Check The Torque Converter Regulator......................................................................274 Check The Oil Pressure from the Oil Cooler................................................................274 Check The Modulator Pressure..............................................................................275 TROUBLESHOOTING...............................................................................................275 TROUBLESHOOTING, PRESSURE TESTS...............................................................................277 1400219...........................................................................................................280 INTRODUCTION..................................................................................................280 GENERAL...................................................................................................280 DESCRIPTION...............................................................................................280 REPAIRS.......................................................................................................281 REMOVAL...................................................................................................281 CLEANING..................................................................................................281 INSPECTION................................................................................................281 ASSEMBLY..................................................................................................281 TROUBLESHOOTING...............................................................................................283 1800221...........................................................................................................284 INTRODUCTION..................................................................................................284 General...................................................................................................284 Description and Operation.................................................................................284 REPAIRS.......................................................................................................285 Removal and Disassembly...................................................................................285 Cleaning..................................................................................................287 Inspection................................................................................................287 Assembly and Installation.................................................................................287 Master Cylinder...........................................................................................288 CHECKS AND ADJUSTMENTS........................................................................................290 Adjusting The Service Brakes..............................................................................290 Adjusting The Parking Brake...............................................................................290 Removing Air From The Brake System........................................................................290 Adjusting The Brake Pedal and Inching Pedal...............................................................290 TROUBLESHOOTING...............................................................................................293 1900130...........................................................................................................295 INTRODUCTION..................................................................................................295 GENERAL...................................................................................................295 DESCRIPTION...............................................................................................297 Hydraulic System......................................................................................297 Gear Pump Assembly....................................................................................297 Flow Control Valve....................................................................................298 Relief Valve (Early Model)............................................................................298 Relief Valve (Later Model)............................................................................298 OPERATION.................................................................................................300 Hydraulic System......................................................................................300 Gear Pump.............................................................................................300 Flow Control Valve....................................................................................300 Relief Valve (Early Model)............................................................................300 Relief Valve (Later Model)............................................................................300 REPAIR........................................................................................................302 GEAR PUMP ASSEMBLY........................................................................................302 Removal and Disassembly...............................................................................302 Assembly and Installation.............................................................................303 CHECKS AND ADJUSTMENTS........................................................................................303 CHECK AND ADJUST STEERING RELIEF PRESSURE.................................................................303 CHECK GEAR PUMP FOR CORRECT FLOW..........................................................................304 TROUBLESHOOTING...............................................................................................304 2100103...........................................................................................................306 INTRODUCTION..................................................................................................309 GENERAL...................................................................................................309 DESCRIPTION...............................................................................................309 REPAIRS.......................................................................................................309 REMOVAL...................................................................................................309 DISASSEMBLY...............................................................................................309 CLEANING..................................................................................................309 ASSEMBLY..................................................................................................309 Tilt Cylinders for the XM and XMS Models..............................................................309 Tilt Cylinders with O-Ring or Single Lip Seals........................................................311 Tilt Cylinders for H700-800A and Early Model H700-920B................................................311 INSTALLATION..............................................................................................311 Tilt Cylinders with Chevron Packing...................................................................311 CHECKS AND ADJUSTMENTS........................................................................................315 CHECK THE TILT CYLINDERS FOR LEAKS........................................................................315 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...................................................315 TROUBLESHOOTING...............................................................................................318 2200132...........................................................................................................321 INTRODUCTION..................................................................................................321 GENERAL...................................................................................................321 DESCRIPTION...............................................................................................321 Starting System.......................................................................................321 Ignition System.......................................................................................321 Charging System.......................................................................................322 REPAIR........................................................................................................324 STARTER...................................................................................................324 Removal And Disassembly...............................................................................324 Assembly And Installation.............................................................................324 BALLAST RESISTOR RELAY (Earlier Production)...............................................................326 DISTRIBUTOR (Earlier Production With Contact Points)......................................................326 Removal And Disassembly...............................................................................326 Assembly And Installation.............................................................................328 COIL REPLACEMENT..........................................................................................328 DISTRIBUTOR (Later Production with Electronic Ignition System)............................................328 Removal And Disassembly...............................................................................328 Assembly And Installation.............................................................................330 ALTERNATOR (All Models)...................................................................................330 Removal And Disassembly...............................................................................330 Assembly And Installation.............................................................................331 REGULATOR REPLACEMENT (Earlier Production)................................................................332 CHECKS AND ADJUSTMENTS........................................................................................333 GENERAL...................................................................................................333 STARTER...................................................................................................333 Check Operation.......................................................................................333 Check Brush Length....................................................................................334 Check Brush Holder....................................................................................334 Armature..............................................................................................334 Field Windings........................................................................................334 Clutch And Bearing....................................................................................334 BALLAST RESISTOR RELAY (Earlier Production)...............................................................334 DISTRIBUTOR...............................................................................................335 Distributor Contact Clearance.........................................................................335 SPARK PLUGS...............................................................................................336 COIL AND BALLAST RESISTOR (Earlier Production)............................................................336 ALTERNATOR................................................................................................336 Check For Low Output (Alternator With Separate Regulator).............................................336 Check For Low Output (Alternator With Integral Regulator).............................................338 Check For High Output (Alternator With Separate Regulator)............................................339 Check For High Output (Alternator With Integral Regulator)............................................339 Rotor Resistance (Alternator with Separate Regulator).................................................339 Diodes Circuit (Alternator with Separate Regulator)...................................................340 Diode Assembly (Alternator With Separate Regulator)...................................................340 Check The Diodes, Diode Trio (Alternator with Integral Regulator).....................................340 Check The Rectifier Bridge (Alternator with Integral Regulator).......................................341 Check Field Winding For The Rotor (All Alternators)...................................................341 Check Windings In The Stator (All Alternators)........................................................342 Brushes And Bearings..................................................................................342 Check The Voltage Regulator (Alternator with Separate Regulator)......................................342 Check The Voltage Regulator (Alternator with Integral Regulator)......................................343 ADJUSTMENTS...............................................................................................343 TROBLESHOOTING................................................................................................344 2200134...........................................................................................................346 INTRODUCTION..................................................................................................346 GENERAL...................................................................................................346 DESCRIPTION...............................................................................................346 Starting System.......................................................................................346 Charging System.......................................................................................346 Vacuum Pump On Alternator (On Units With Brake Booster)...............................................348 REPAIRS.......................................................................................................349 STARTER...................................................................................................349 Removal And Disassembly...............................................................................349 Assembly And Installation.............................................................................349 REPLACING GLOW PLUGS......................................................................................351 ALTERNATOR (With Vaccum Pump).............................................................................351 Removal And Disassembly...............................................................................351 Cleaning..............................................................................................353 Assembly And Installation.............................................................................353 ALTERNATOR (Without Vacuum Pump)..........................................................................354 Removal And Disassembly...............................................................................354 Cleaning..............................................................................................356 Assembly And Installation.............................................................................356 REGULATOR REPLACEMENT.....................................................................................357 CHECKS........................................................................................................357 GENERAL...................................................................................................357 STARTER...................................................................................................357 Starter Operation.....................................................................................357 Solenoid Coil Checks..................................................................................358 Brush Length..........................................................................................358 Brush Holder..........................................................................................358 Armature..............................................................................................358 Field Windings........................................................................................359 Clutch And Bearings...................................................................................359 COLD START AID............................................................................................359 Glow Plugs............................................................................................359 Resistor..............................................................................................359 CHARGING CIRCUIT..........................................................................................359 Check For Low Output..................................................................................359 Check Ford High Output................................................................................361 ALTERNATOR................................................................................................361 Rotor Resistance......................................................................................361 Diodes Circuit........................................................................................361 Rotor Coil............................................................................................362 Stator Coil...........................................................................................362 Diode Assembly........................................................................................362 Brushes And Bearings..................................................................................363 REGULATOR (At Hydraulic Tank).............................................................................363 TROUBLESHOOTING...............................................................................................364 2200143...........................................................................................................367 INTRODUCTION..................................................................................................367 GENERAL...................................................................................................367 DESCRIPTION...................................................................................................367 GENERAL...................................................................................................367 STEERING COLUMN GAUGES, METERS AND INDICATORS.............................................................370 LED DISPLAY PANEL.........................................................................................370 Battery Discharge Indicators .........................................................................370 Brush Wear Indicators.................................................................................371 Motor Temperature Indicators..........................................................................372 "LX" SERIES INSTRUMENT PANEL DISPLAY......................................................................373 Hourmeter Functions...................................................................................374 Battery Indicator Function............................................................................374 Status Code Function..................................................................................374 CHECKS AND ADJUSTMENTS........................................................................................374 GENERAL...................................................................................................374 REPLACEMENT...................................................................................................375 GENERAL...................................................................................................375 METER REPLACEMENT.........................................................................................375 SENDER REPLACEMENT........................................................................................376 Fuel Level Sender.....................................................................................376 Pressure And Temperature Sender.......................................................................377 I.T.W. DISPLAY PANEL......................................................................................377 Removal...............................................................................................377 SPECIFICATIONS................................................................................................378 TROUBLESHOOTING...............................................................................................379 2200144...........................................................................................................380 ELECTRICAL WARNING DEVICES....................................................................................380 GENERAL...................................................................................................380 DESCRIPTION...............................................................................................380 Operator Controlled Horns.............................................................................380 System Warning Lights, Buzzers and Bells..............................................................380 Reverse Warning Horns.................................................................................381 Warning Lights........................................................................................381 REPLACEMENT...............................................................................................382 General...............................................................................................382 Replacing Horns or Bells..............................................................................382 Replacing Horn Relay or Buzzer........................................................................382 Replacing Warning Lights..............................................................................382 Light Assemblies......................................................................................383 Replacing Flashing Units..............................................................................383 4000135...........................................................................................................384 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................384 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................384 LIFT CYLINDERS................................................................................................387 GENERAL...................................................................................................387 DESCRIPTION...............................................................................................387 Lowering Control Valve................................................................................387 Cylinders (General)...................................................................................390 Cylinders (H520-620B,H700-800A).......................................................................392 Cylinders (H360-460B).................................................................................393 Cylinders (Two-Speed).................................................................................393 REPAIRS.......................................................................................................394 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST....................................................394 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............394 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...............................398 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.........................396 DISASSEMBLY...............................................................................................396 ASSEMBLY..................................................................................................398 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.............................................................398 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............398 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead......................398 CHEVRON PACKING...........................................................................................399 LIFT CYLINDERS FOR VISTA MASTS................................................................................402 DESCRIPTION...............................................................................................402 Lowering Control Valve................................................................................404 REMOVAL...................................................................................................405 DISASSEMBLY...............................................................................................405 ASSEMBLY..................................................................................................405 INSTALLATION..............................................................................................406 Main Lift Cylinders...................................................................................406 Free-Lift Cylinders...................................................................................406 CHECKS AND ADJUSTMENTS........................................................................................407 CHECK FOR LEAKS IN LIFT SYSTEM............................................................................407 TROUBLESHOOTING...............................................................................................408 SPECIFICATIONS................................................................................................409 4000222...........................................................................................................410 INTRODUCTION..................................................................................................410 GENERAL...................................................................................................410 MAST WELDMENTS............................................................................................410 CARRIAGE..................................................................................................410 MAST MOUNTS...............................................................................................411 VISTA® TWO-STAGE MAST.........................................................................................412 DESCRIPTION AND OPERATION.................................................................................412 VISTA® FREE-LIFT MAST.........................................................................................414 DESCRIPTION...............................................................................................414 OPERATION.................................................................................................414 VISTA® THREE-STAGE MAST.......................................................................................416 DESCRIPTION...............................................................................................416 OPERATION.................................................................................................416 VISTA® FOUR-STAGE MAST........................................................................................417 DESCRIPTION...............................................................................................417 OPERATION.................................................................................................418 4000223...........................................................................................................420 VISTA MAST, REPAIR............................................................................................420 GENERAL...................................................................................................420 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................420 FORKS.....................................................................................................421 Forks, Removal And Installation.......................................................................421 CARRIAGE..................................................................................................422 Removal...............................................................................................422 Installation..........................................................................................423 MASTS.....................................................................................................423 Removal...............................................................................................423 Disassembly...........................................................................................424 Cleaning and Inspection...............................................................................429 Assembly..............................................................................................429 Installation..........................................................................................433 SIDE-SHIFT CARRIAGE (EARLIER DESIGN)......................................................................434 Removal...............................................................................................434 Repairs...............................................................................................434 Installation..........................................................................................434 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)...............................................................435 Removal...............................................................................................435 Repairs...............................................................................................435 Installation..........................................................................................436 CHECKS AND ADJUSTMENTS........................................................................................437 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................437 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...............................................438 LIFT CHAIN ADJUSTMENTS....................................................................................439 MAST ADJUSTMENTS..........................................................................................439 CARRIAGE ADJUSTMENT.......................................................................................441 HEADER HOSE ARRANGEMENTS..................................................................................441 Two-Stage Header Hose.................................................................................442 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts.........................................442 TROUBLESHOOTING...............................................................................................447 8000225...........................................................................................................448 8000231...........................................................................................................453 INTRODUCTION..................................................................................................453 NOMENCLATURE, THREADS.....................................................................................453 STRENGTH IDENTIFICATION...................................................................................454 TABLE 1. BOLTS AND SCREWS.....................................................................................454 TABLE 2. STUDS AND NUTS.......................................................................................455 TABLE 3. TORQUE NUTS..........................................................................................456 TABLE 4. TORQUE NUTS WITH NYLON INSERT........................................................................457 TABLE 5. TORQUE VALUES FOR INCH FASTENERS.....................................................................458 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...................................................................459 8000259...........................................................................................................462 PERIODIC MAINTENANCE..........................................................................................462 GENERAL...................................................................................................462 Serial Number Data....................................................................................462 HOW TO MOVE A DISABLED LIFT TRUCK.........................................................................463 How To Tow the Lift Truck.............................................................................463 HOW TO PUT A LIFT TRUCK ON BLOCKS.........................................................................463 How To Raise the Drive Tires..........................................................................463 How To Raise the Steering Tires.......................................................................464 MAINTENANCE PROCEDURES........................................................................................468 EVERY 8 HOURS OR DAILY........................................................................................468 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED................................................................468 Engine Oil............................................................................................468 Drive Belts...........................................................................................468 Cooling System........................................................................................468 Battery...............................................................................................469 Fuel System...........................................................................................471 Air Filter............................................................................................471 Hydraulic System Oil..................................................................................471 Tires and Wheels......................................................................................472 Forks.................................................................................................472 Forks, Adjustment.....................................................................................473 Forks, Removal And Installation.......................................................................473 Inspection Of Forks, Mast, and Lift Chains............................................................474 Safety Labels.........................................................................................475 Operator Restraint System.............................................................................475 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING................................................................476 Gauges, Lights, Horn, and Fuses.......................................................................476 Fuel Filter, Diesel Engine............................................................................477 How To Drain The Water From The Fuel Filter...........................................................477 Oil Level, Powershift Transmission....................................................................477 Control Levers and Pedals.............................................................................477 Lift System Operation.................................................................................477 Inching/Brake Pedal...................................................................................478 Service Brakes........................................................................................478 Parking Brake.........................................................................................478 Steering System.......................................................................................478 EVERY 250 HOURS OR TWO MONTHS.................................................................................479 ENGINE OIL AND FILTER.....................................................................................479 Mazda, GM, And Later Production Isuzu Engines.........................................................479 Earlier Production Isuzu C240 Engines.................................................................479 GOVERNOR, MAZDA ENGINE....................................................................................480 DRIVE BELTS...............................................................................................480 Mazda Engine..........................................................................................480 Isuzu, GM 4-181, And GM 4-153 Engines.................................................................480 BRAKE FLUID...............................................................................................481 HYDRAULIC TANK BREATHER, CLEAN AND CHECK..................................................................481 FORKS, CHECK FOR WEAR AND DAMAGE..........................................................................481 LIFT CHAINS...............................................................................................481 Lubrication...........................................................................................481 Check For Wear........................................................................................481 MAST, LUBRICATION.........................................................................................482 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...............................................................482 CONTROL LEVERS AND PEDALS, LUBRICATION....................................................................483 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.......................................................................483 Idle Speed, Diesel....................................................................................483 LPG Carburetor........................................................................................484 Gasoline Carburetor...................................................................................484 EVERY 1000 HOURS OR SIX MONTHS................................................................................485 DIESEL FUEL FILTER........................................................................................485 Filter Replacement, Models Without A Water Separator..................................................486 Filter Replacement, Models With A Water Separator.....................................................486 Remove Air from the Diesel Fuel System................................................................486 DIFFERENTIAL..............................................................................................487 VALVE CLEARANCE ADJUSTMENT................................................................................487 IGNITION SYSTEM, MAZDA AND GM ENGINES.....................................................................487 PCV VALVE AND FILTER......................................................................................489 EVERY 2000 HOURS OR YEARLY....................................................................................489 HYDRAULIC SYSTEM..........................................................................................489 Replace the Hydraulic Oil and Filter..................................................................489 POWERSHIFT TRANSMISSION...................................................................................489 COOLING SYSTEM............................................................................................490 SERVICE BRAKES............................................................................................490 DIFFERENTIAL..............................................................................................490 WHEEL BEARINGS............................................................................................491 Steering Wheels, lubrication..........................................................................491 Drive Wheels, Lubrication.............................................................................491 GASOLINE FUEL FILTER, REPLACEMENT.........................................................................491 PCV VALVE, GM ENGINES.....................................................................................491 LPG FILTER, REPLACEMENT...................................................................................491 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A............................................................491 GENERAL PROCEDURES............................................................................................492 CHECK THE HOOD LATCH......................................................................................492 LIFT CHAIN ADJUSTMENTS....................................................................................492 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................494 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................495 Check the Lift Cylinders for Leaks....................................................................495 Check the Tilt Cylinders for Leaks....................................................................495 FUEL INJECTORS............................................................................................496 WELDING REPAIRS...........................................................................................496 CHANGES TO THE OVERHEAD GUARD.............................................................................496 WHEELS AND TIRES..........................................................................................496 Solid Rubber Tires (Press-on).........................................................................496 Install The Wheels....................................................................................497 Pneumatic Tires, Remove The Wheels From The Lift Truck................................................498 Pneumatic Tires, Remove the Tire From The Wheel.......................................................498 Pneumatic Tires, Install The Wheel In The Tire........................................................499 Pneumatic Tires, Add Air To The Tires.................................................................500 Pneumatic Tires, Install the Wheels...................................................................501 Pneumatic Tires, Installation Procedures, Dual Drive Wheels...........................................501 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.........................................................502 Remove The Wheels From The Lift Truck.................................................................502 Remove The Tire From The Wheel........................................................................502 Install The Tire On The Wheel.........................................................................503 REFERENCE TABLE...............................................................................................504
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