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Hyster C001 (H25-35XL) Service Manual – PDF DOWNLOAD
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Description
Hyster C001 (H25-35XL) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C001 (H25-35XL) Service Manual – PDF DOWNLOAD
Language : English
Pages : 528
Downloadable : Yes
File Type : PDF
Size: 16.0 MB
TABLE OF CONTENTS:
Hyster C001 (H25-35XL) Service Manual – PDF DOWNLOAD
Brake System...................................................................................................... 1 INTRODUCTION.................................................................................................. 1 General................................................................................................... 1 Description and Operation................................................................................. 1 REPAIRS....................................................................................................... 2 Removal and Disassembly................................................................................... 2 Cleaning.................................................................................................. 4 Inspection................................................................................................ 4 Assembly and Installation................................................................................. 4 Master Cylinder........................................................................................... 5 CHECKS AND ADJUSTMENTS........................................................................................ 7 Adjusting The Service Brakes.............................................................................. 7 Adjusting The Parking Brake............................................................................... 7 Removing Air From The Brake System........................................................................ 7 Adjusting The Brake Pedal and Inching Pedal............................................................... 7 TROUBLESHOOTING............................................................................................... 10 Capacities & Specification........................................................................................ 12 Cooling System.................................................................................................... 17 COOLING SYSTEM................................................................................................ 17 INTRODUCTION.............................................................................................. 17 DESCRIPTION............................................................................................... 17 RADIATOR.................................................................................................. 17 RADIATOR CAP.............................................................................................. 17 THERMOSTAT................................................................................................ 17 WATER PUMP................................................................................................ 18 FAN AND FAN SHROUD........................................................................................ 18 REPAIRS....................................................................................................... 18 COOLING SYSTEM CHECKS..................................................................................... 18 Exhaust Leaks......................................................................................... 18 RADIATOR.................................................................................................. 18 Checks................................................................................................ 18 Cleaning The Radiator................................................................................. 18 Drain The Cooling System.............................................................................. 20 Fill The Cooling System............................................................................... 20 WATER PUMP................................................................................................ 20 Checks................................................................................................ 20 THERMOSTAT................................................................................................ 21 Checks................................................................................................ 21 FAN AND FAN SHROUD........................................................................................ 21 TROUBLESHOOTING............................................................................................... 22 Diagrams.......................................................................................................... 23 HYDRAULIC SCHEMATIC SYMBOLS................................................................................... 23 TRANSMISSION SCHEMATIC........................................................................................ 24 TRANSMISSION SCHEMATIC FOR UNITS WITH HYSTER T41,T42,T43 TRANSMISSIONS........................................ 25 HYDRAULIC SYSTEM SCHEMATIC.................................................................................... 26 GASOLINE/LPG ENGINE WIRING DIAGRAM (G and LPG Rating)......................................................... 28 GASOLINE/LPG (SAFETY) ENGINE WIRING DIAGRAM (GS and LPS Rating)............................................... 30 GASOLINE/LPG ENGINE CABLE DIAGRAM (G and LPG Rating).......................................................... 32 DIESEL ENGINE WIRING DIAGRAM (D Rating)....................................................................... 34 DIESEL (SAFETY) ENGINE WIRING DIAGRAM (DS Rating)............................................................. 36 DIESEL ENGINE CABLE DIAGRAM (D Rating)........................................................................ 38 ELECTRICAL DIAGRAM, INSTRUMENT PANEL.......................................................................... 40 Drive Axle........................................................................................................ 41 INTRODUCTION.................................................................................................. 41 GENERAL................................................................................................... 41 DESCRIPTION............................................................................................... 41 REPAIRS....................................................................................................... 42 REMOVAL................................................................................................... 42 CLEANING.................................................................................................. 42 INSPECTION................................................................................................ 42 ASSEMBLY.................................................................................................. 42 TROUBLESHOOTING............................................................................................... 44 Electrical System (Isuzu)......................................................................................... 45 INTRODUCTION.................................................................................................. 45 GENERAL................................................................................................... 45 DESCRIPTION............................................................................................... 45 Starting System....................................................................................... 45 Charging System....................................................................................... 45 Vacuum Pump On Alternator (On Units With Brake Booster)............................................... 47 REPAIRS....................................................................................................... 48 STARTER................................................................................................... 48 Removal And Disassembly............................................................................... 48 Assembly And Installation............................................................................. 48 REPLACING GLOW PLUGS...................................................................................... 50 ALTERNATOR (With Vaccum Pump)............................................................................. 50 Removal And Disassembly............................................................................... 50 Cleaning.............................................................................................. 52 Assembly And Installation............................................................................. 52 ALTERNATOR (Without Vacuum Pump).......................................................................... 53 Removal And Disassembly............................................................................... 53 Cleaning.............................................................................................. 55 Assembly And Installation............................................................................. 55 REGULATOR REPLACEMENT..................................................................................... 56 CHECKS........................................................................................................ 56 GENERAL................................................................................................... 56 STARTER................................................................................................... 56 Starter Operation..................................................................................... 56 Solenoid Coil Checks.................................................................................. 57 Brush Length.......................................................................................... 57 Brush Holder.......................................................................................... 57 Armature.............................................................................................. 57 Field Windings........................................................................................ 58 Clutch And Bearings................................................................................... 58 COLD START AID............................................................................................ 58 Glow Plugs............................................................................................ 58 Resistor.............................................................................................. 58 CHARGING CIRCUIT.......................................................................................... 58 Check For Low Output.................................................................................. 58 Check Ford High Output................................................................................ 60 ALTERNATOR................................................................................................ 60 Rotor Resistance...................................................................................... 60 Diodes Circuit........................................................................................ 60 Rotor Coil............................................................................................ 61 Stator Coil........................................................................................... 61 Diode Assembly........................................................................................ 61 Brushes And Bearings.................................................................................. 62 REGULATOR (At Hydraulic Tank)............................................................................. 62 TROUBLESHOOTING............................................................................................... 63 Electrical System (Mazda)......................................................................................... 66 INTRODUCTION.................................................................................................. 66 GENERAL................................................................................................... 66 DESCRIPTION............................................................................................... 66 Starting System....................................................................................... 66 Ignition System....................................................................................... 66 Charging System....................................................................................... 67 REPAIR........................................................................................................ 69 STARTER................................................................................................... 69 Removal And Disassembly............................................................................... 69 Assembly And Installation............................................................................. 69 BALLAST RESISTOR RELAY (Earlier Production)............................................................... 71 DISTRIBUTOR (Earlier Production With Contact Points)...................................................... 71 Removal And Disassembly............................................................................... 71 Assembly And Installation............................................................................. 73 COIL REPLACEMENT.......................................................................................... 73 DISTRIBUTOR (Later Production with Electronic Ignition System)............................................ 73 Removal And Disassembly............................................................................... 73 Assembly And Installation............................................................................. 75 ALTERNATOR (All Models)................................................................................... 75 Removal And Disassembly............................................................................... 75 Assembly And Installation............................................................................. 76 REGULATOR REPLACEMENT (Earlier Production)................................................................ 77 CHECKS AND ADJUSTMENTS........................................................................................ 78 GENERAL................................................................................................... 78 STARTER................................................................................................... 78 Check Operation....................................................................................... 78 Check Brush Length.................................................................................... 79 Check Brush Holder.................................................................................... 79 Armature.............................................................................................. 79 Field Windings........................................................................................ 79 Clutch And Bearing.................................................................................... 79 BALLAST RESISTOR RELAY (Earlier Production)............................................................... 79 DISTRIBUTOR............................................................................................... 80 Distributor Contact Clearance......................................................................... 80 SPARK PLUGS............................................................................................... 81 COIL AND BALLAST RESISTOR (Earlier Production)............................................................ 81 ALTERNATOR................................................................................................ 81 Check For Low Output (Alternator With Separate Regulator)............................................. 81 Check For Low Output (Alternator With Integral Regulator)............................................. 83 Check For High Output (Alternator With Separate Regulator)............................................ 84 Check For High Output (Alternator With Integral Regulator)............................................ 84 Rotor Resistance (Alternator with Separate Regulator)................................................. 84 Diodes Circuit (Alternator with Separate Regulator)................................................... 85 Diode Assembly (Alternator With Separate Regulator)................................................... 85 Check The Diodes, Diode Trio (Alternator with Integral Regulator)..................................... 85 Check The Rectifier Bridge (Alternator with Integral Regulator)....................................... 86 Check Field Winding For The Rotor (All Alternators)................................................... 86 Check Windings In The Stator (All Alternators)........................................................ 87 Brushes And Bearings.................................................................................. 87 Check The Voltage Regulator (Alternator with Separate Regulator)...................................... 87 Check The Voltage Regulator (Alternator with Integral Regulator)...................................... 88 ADJUSTMENTS............................................................................................... 88 TROBLESHOOTING................................................................................................ 89 Electrical Warning Devices........................................................................................ 91 ELECTRICAL WARNING DEVICES.................................................................................... 91 GENERAL................................................................................................... 91 DESCRIPTION............................................................................................... 91 Operator Controlled Horns............................................................................. 91 System Warning Lights, Buzzers and Bells.............................................................. 91 Reverse Warning Horns................................................................................. 92 Warning Lights........................................................................................ 92 REPLACEMENT............................................................................................... 93 General............................................................................................... 93 Replacing Horns or Bells.............................................................................. 93 Replacing Horn Relay or Buzzer........................................................................ 93 Replacing Warning Lights.............................................................................. 93 Light Assemblies...................................................................................... 94 Replacing Flashing Units.............................................................................. 94 Frame............................................................................................................. 95 INTRODUCTION.................................................................................................. 95 GENERAL................................................................................................... 95 DESCRIPTION............................................................................................... 95 REPAIRS....................................................................................................... 95 COUNTERWEIGHT............................................................................................. 95 Removal............................................................................................... 95 Installation.......................................................................................... 96 OVERHEAD GUARD............................................................................................ 96 HOOD...................................................................................................... 96 Removal............................................................................................... 96 Installation.......................................................................................... 96 OPERATOR RESTRAINT SYSTEM................................................................................. 97 ENGINE.................................................................................................... 97 Removal............................................................................................... 97 Installation (Engine Only)............................................................................ 98 Installation (Engine and Transmission)................................................................ 99 RADIATOR AND MUFFLER...................................................................................... 99 Removal and Installation.............................................................................. 99 FUEL AND HYDRAULIC TANKS.................................................................................. 99 Inspection............................................................................................ 99 Repairs............................................................................................... 99 LABEL REPLACEMENT.........................................................................................101 Gasoline Carburetor...............................................................................................104 THE CARBURETOR, (MAZDA M4-121G ENGINE)........................................................................104 DESCRIPTION...............................................................................................104 REPAIRS, CARBURETOR.......................................................................................105 Removal...............................................................................................105 Cleaning..............................................................................................108 Inspection............................................................................................108 Assembly..............................................................................................108 Installation..........................................................................................110 CHECKS AND ADJUSTMENTS....................................................................................110 Carburetor, Idle Speed And Mixture Adjustment.........................................................110 Adjust The Governor...................................................................................111 ADJUST THE THROTTLE LINKAGE...............................................................................112 SPECIFICATIONS................................................................................................112 TROUBLESHOOTING...............................................................................................113 Hydraulic System & Gear Pump......................................................................................115 INTRODUCTION..................................................................................................115 GENERAL...................................................................................................115 DESCRIPTION...............................................................................................117 Hydraulic System......................................................................................117 Gear Pump Assembly....................................................................................117 Flow Control Valve....................................................................................118 Relief Valve (Early Model)............................................................................118 Relief Valve (Later Model)............................................................................118 OPERATION.................................................................................................120 Hydraulic System......................................................................................120 Gear Pump.............................................................................................120 Flow Control Valve....................................................................................120 Relief Valve (Early Model)............................................................................120 Relief Valve (Later Model)............................................................................120 REPAIR........................................................................................................122 GEAR PUMP ASSEMBLY........................................................................................122 Removal and Disassembly...............................................................................122 Assembly and Installation.............................................................................123 CHECKS AND ADJUSTMENTS........................................................................................123 CHECK AND ADJUST STEERING RELIEF PRESSURE.................................................................123 CHECK GEAR PUMP FOR CORRECT FLOW..........................................................................124 TROUBLESHOOTING...............................................................................................124 Instrument Panel Indicators & Senders.............................................................................126 INTRODUCTION..................................................................................................126 GENERAL...................................................................................................126 DESCRIPTION...................................................................................................126 GENERAL...................................................................................................126 STEERING COLUMN GAUGES, METERS AND INDICATORS.............................................................129 LED DISPLAY PANEL.........................................................................................129 Battery Discharge Indicators..........................................................................129 Brush Wear Indicators.................................................................................130 Motor Temperature Indicators..........................................................................131 "LX" SERIES DISPLAY PANEL.................................................................................132 Hourmeter Functions...................................................................................133 Battery Indicator Function............................................................................133 Status Code Function..................................................................................133 "ZX" SERIES DISPLAY PANELS................................................................................133 Display Panel.........................................................................................134 Basic Display Panels..................................................................................134 Performance Display...................................................................................136 Brush Wear Indicators.................................................................................139 CHECKS AND ADJUSTMENTS........................................................................................139 GENERAL...................................................................................................139 REPLACEMENT...................................................................................................140 GENERAL...................................................................................................140 METER REPLACEMENT.........................................................................................140 SENDER REPLACEMENT........................................................................................141 Fuel Level Sender.....................................................................................141 Pressure And Temperature Sender.......................................................................141 I.T.W. DISPLAY PANEL......................................................................................142 Removal...............................................................................................142 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT.....................................143 Removal...............................................................................................143 Replacing Display Panel Assembly......................................................................143 Indicator LEDs........................................................................................143 Battery Indicators....................................................................................143 Digital Display (Performance Disply Panel Only).......................................................143 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only).........143 Replacing Parts Of The Basic Display Panel............................................................144 Replacing Parts Of The Performance Display Panel......................................................146 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT.........................................146 Removal And Replacement...............................................................................146 SPECIFICATIONS................................................................................................147 TROUBLESHOOTING...............................................................................................148 Isuzu C240 (2.4L) Engine..........................................................................................149 INTRODUCTION .................................................................................................149 GENERAL ..................................................................................................149 DESCRIPTION ..............................................................................................149 FUEL SYSTEM ..............................................................................................150 Description ..........................................................................................150 Operation, Fuel Injection Pump, Model VE .............................................................152 Operation, Fuel Injection Pump, Model PE4A ...........................................................153 Pneumatic Governor For Fuel Injection Pump, Model PE4A ...............................................154 Inlet Manifold For Fuel Injection Pump, Model PE4A ...................................................155 REPAIRS ......................................................................................................156 FUEL INJECTION PUMP (ALL MODELS) .........................................................................156 Removal ..............................................................................................156 Installation .........................................................................................156 REMOVAL AND INSTALLATION OF THE ENGINE ...................................................................156 CYLINDER HEAD AND VALVE MECHANISM ........................................................................156 Cylinder Head, Removal ...............................................................................156 Valve Guides, Replacement ............................................................................157 Cylinder Head, Inspection And Repair .................................................................158 Combustion Chamber Plugs, Inspection And Repair ......................................................158 Combustion Chamber Plugs, Installation ...............................................................158 Valves, Inspection And Repair ........................................................................159 Valve Seat, Inspection ...............................................................................159 Valve Seat, Removal ..................................................................................160 Valve Seat, Installation .............................................................................160 Valve Spring, Inspection .............................................................................160 Rocker Arms, Inspection And Assembly .................................................................160 Installation Of The Cylinder Head ....................................................................161 TIMING GEAR CASE .........................................................................................162 Removal ..............................................................................................162 Installation .........................................................................................162 CAMSHAFT .................................................................................................164 Removal ..............................................................................................164 Inspection ...........................................................................................164 Camshaft Bearings ....................................................................................165 Cam Followers ........................................................................................165 CAMSHAFT, INSTALLATION ...................................................................................165 CRANKSHAFT AND MAIN BEARINGS .............................................................................166 Crankshaft, Removal ..................................................................................166 Crankshaft, Inspection And Repair ....................................................................166 Main Bearings ........................................................................................166 Pilot Bearing ........................................................................................167 Crankshaft, Installation .............................................................................167 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) ..........................................................169 Flywheel, Removal ....................................................................................169 Ring Gear, Replacement ...............................................................................169 Flywheel, Installation ...............................................................................169 PISTONS AND CONNECTING RODS ..............................................................................170 Pistons And Connecting Rods, Removal .................................................................170 Disassembly ..........................................................................................170 Pistons, Inspection And Repair .......................................................................171 Piston Rings, Inspection And Repair ..................................................................171 Piston Pins, Inspection And Repair ...................................................................172 Connecting Rods, Inspection And Repair ...............................................................173 Pistons And Connecting Rods, Assembly And Installation ...............................................173 CYLINDER BLOCK AND CYLINDER LINERS .......................................................................173 Cylinder Liners, Inspection ..........................................................................173 Replacement Of A Cylinder Liner ......................................................................174 LUBRICATION SYSTEM .......................................................................................175 Oil Pump, Removal And Disassembly ....................................................................175 Oil Pump, Inspection .................................................................................175 Oil Pump, Assembly And Installation ..................................................................176 Oil Filter ...........................................................................................176 COOLING SYSTEM ...........................................................................................177 Coolant Pump, Removal ................................................................................177 Coolant Pump, Disassembly ............................................................................177 Coolant Pump, Assembly And Installation ..............................................................177 Thermostat, Replacement ..............................................................................178 CHECKS AND ADJUSTMENTS .......................................................................................178 VALVE CLEARANCE ADJUSTMENT ...............................................................................178 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ....................................................179 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A ..................................................180 FUEL INJECTORS ...........................................................................................180 Fuel Injectors, Removal ..............................................................................181 Fuel Injectors, Inspection ...........................................................................181 Fuel Injectors, Installation .........................................................................182 DIESEL FUEL FILTERS ......................................................................................182 Filter Replacement, Models With A Water Separator ....................................................182 Filter Replacement, Models Without A Water Separator .................................................183 Filter For The Fuel Injection Pump, Model PE4A .......................................................183 REMOVE AIR FROM THE FUEL SYSTEM ..........................................................................183 Throttle Linkage, Adjustment .........................................................................184 Idle Speed, Adjustment ...............................................................................184 Check The Elements For The Cold Start Aid System .....................................................184 ENGINE SPECIFICATIONS ........................................................................................184 TORQUE SPECIFICATIONS ........................................................................................186 Lift Cylinders....................................................................................................187 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................187 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................187 LIFT CYLINDERS................................................................................................190 GENERAL...................................................................................................190 DESCRIPTION...............................................................................................190 Lowering Control Valve................................................................................190 Cylinders (General)...................................................................................193 Cylinders (H520-620B,H700-800A).......................................................................195 Cylinders (H360-460B).................................................................................196 Cylinders (Two-Speed).................................................................................196 REPAIRS.......................................................................................................197 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST....................................................197 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............197 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...............................201 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.........................199 DISASSEMBLY...............................................................................................199 ASSEMBLY..................................................................................................201 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.............................................................201 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............201 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead......................201 CHEVRON PACKING...........................................................................................202 LIFT CYLINDERS FOR VISTA MASTS................................................................................205 DESCRIPTION...............................................................................................205 Lowering Control Valve................................................................................207 REMOVAL...................................................................................................208 DISASSEMBLY...............................................................................................208 ASSEMBLY..................................................................................................208 INSTALLATION..............................................................................................209 Main Lift Cylinders...................................................................................209 Free-Lift Cylinders...................................................................................209 CHECKS AND ADJUSTMENTS........................................................................................210 CHECK FOR LEAKS IN LIFT SYSTEM............................................................................210 TROUBLESHOOTING...............................................................................................211 SPECIFICATIONS................................................................................................212 LPG Fuel System...................................................................................................213 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100).....................................................................213 GENERAL...................................................................................................213 DESCRIPTION...............................................................................................213 Fuel Tank.............................................................................................214 Fuel Filter And Fuel Valve Unit.......................................................................215 Vaporizer.............................................................................................215 The IMPCO CA 100 Carbureto............................................................................217 IMPCO CA 50 Carburetor................................................................................219 The Governor (GM Engines Only)........................................................................220 Governor With Electronic Controller...................................................................221 REPAIRS.......................................................................................................222 LPG TANK..................................................................................................222 Removal...............................................................................................222 Installation..........................................................................................223 REPLACE THE HOSES.........................................................................................223 HYDROSTATIC RELIEF VALVE..................................................................................223 Removal and Installation..............................................................................223 FILTER UNIT...............................................................................................224 Replacement Of the Fuel Filter Element................................................................224 Replacement of the Diaphragm and Fuel Valve...........................................................225 VAPORIZER.................................................................................................225 Removal...............................................................................................225 Disassembly...........................................................................................225 Cleaning..............................................................................................225 Inspection............................................................................................225 Assembly..............................................................................................227 Installation..........................................................................................227 CARBURETOR (IMPCO CA 100).................................................................................229 Removal...............................................................................................229 Disassembly...........................................................................................229 Cleaning..............................................................................................229 Assembly..............................................................................................229 Installation..........................................................................................232 CARBURETER (IMPCO CA 50)..................................................................................231 Removal...............................................................................................231 Disassembly...........................................................................................231 Cleaning..............................................................................................232 Inspection............................................................................................232 Assembly (See FIGURE 26.).............................................................................232 Installation..........................................................................................232 CHECKS AND ADJUSTMENTS........................................................................................233 CHECK THE FILTER UNIT.....................................................................................233 CHECK THE VAPORIZER.......................................................................................233 Pressure Reducer Valve................................................................................233 Vapor Valve...........................................................................................233 ADJUST THE CARBURETOR.....................................................................................233 Idle Mixture..........................................................................................233 Idle Speed............................................................................................233 Power Mixture.........................................................................................233 ADJUST THE GOVERNOR (GM Engines Only).....................................................................234 Checks................................................................................................234 Main Adjusting Screw..................................................................................234 Secondary Adjusting Screw.............................................................................234 AISAN Governor........................................................................................235 Adjustment, AISAN Governor............................................................................235 TROUBLESHOOTING...............................................................................................236 Main Control Valve................................................................................................240 INTRODUCTION..................................................................................................240 GENERAL...................................................................................................240 DESCRIPTION...............................................................................................240 OPERATION.................................................................................................241 Lift Section..........................................................................................242 Tilt Section..........................................................................................242 Relief Valve..........................................................................................244 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................245 Operation.............................................................................................245 REPAIRS.......................................................................................................245 MAIN CONTROL VALVE........................................................................................245 Removal and Disassembly...............................................................................245 Cleaning and Inspection...............................................................................246 Assembly..............................................................................................246 Installation..........................................................................................246 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................246 Removal and Disassembly...............................................................................246 Assembly and Installation.............................................................................248 CHECKS AND ADJUSTMENTS........................................................................................248 PRESSURE RELIEF VALVES....................................................................................248 Primary Relief Valve..................................................................................248 Seconday Relief Valve.................................................................................249 CONTROL LEVER ARRANGEMENT.................................................................................249 TROUBLESHOOTING...............................................................................................252 SPECIFICATIONS................................................................................................254 Mazda M4 121G Engine..............................................................................................255 MAZDA M4-121G ENGINE..........................................................................................255 GENERAL...................................................................................................255 DESCRIPTION...............................................................................................256 REMOVAL AND INSTALLATION OF THE ENGINE....................................................................256 CYLINDER HEAD AND VALVE MECHANISM.........................................................................256 Cylinder Head, Removal................................................................................256 Cylinder Head, Inspection and Repairs.................................................................257 Rocker Arm Assembly...................................................................................257 Valve Guides..........................................................................................257 Valve Seats...........................................................................................258 Valves................................................................................................258 Valve Springs.........................................................................................258 Cylinder Head, Installation...........................................................................258 TIMING GEAR CASE, REMOVAL.................................................................................259 TIMING GEAR CASE, INSTALLATION............................................................................260 CAMSHAFT..................................................................................................260 Removal...............................................................................................260 Inspection............................................................................................261 Cam Followers, Inspection.............................................................................261 Installation..........................................................................................261 CRANKSHAFT AND MAIN BEARINGS..............................................................................261 Crankshaft, Removal...................................................................................261 Crankshaft, Inspection And Repair.....................................................................262 Main Bearings.........................................................................................263 Crankshaft, Installation..............................................................................263 PISTONS AND CONNECTING RODS...............................................................................264 Removal...............................................................................................264 Disassembly...........................................................................................264 Pistons, Inspection And Repair........................................................................264 Piston Rings..........................................................................................265 Piston Pin and Bushing................................................................................265 Connecting Rods and Bearings, Inspection..............................................................265 Pistons and Connecting Rods, Assembly.................................................................265 Pistons and Connecting Rods, Installation.............................................................266 CYLINDER BLOCK AND CYLINDER LINERS........................................................................266 Cylinder Block, Repairs...............................................................................266 Cylinder Liners.......................................................................................266 DISTRIBUTOR...............................................................................................267 Removal...............................................................................................267 Installation..........................................................................................267 OIL PUMP..................................................................................................269 Removal...............................................................................................269 Repairs...............................................................................................269 Installation..........................................................................................270 GOVERNOR..................................................................................................270 Description...........................................................................................270 Removal...............................................................................................270 Disassembly...........................................................................................271 Assembly..............................................................................................272 Installation..........................................................................................273 COOLANT PUMP..............................................................................................273 Removal...............................................................................................273 Disassembly and Repair................................................................................274 Assembly..............................................................................................274 Installation..........................................................................................275 FLYWHEEL..................................................................................................275 Repairs...............................................................................................275 Installation..........................................................................................275 CHECKS AND ADJUSTMENTS........................................................................................275 ADJUST THE VALVES.........................................................................................275 ADJUST THE THROTTLE LINKAGE...............................................................................276 ENGINE SPECIFICATIONS.........................................................................................276 ENGINE SPECIFICATIONS.....................................................................................276 Engine Data...........................................................................................276 Cooling System........................................................................................276 Cylinder Head and Valve Mechanism.....................................................................276 Camshaft..............................................................................................278 Timing Gear...........................................................................................279 Camshaft..............................................................................................279 Connecting Rods.......................................................................................279 Cylinder Liners.......................................................................................279 Pistons...............................................................................................279 Lubrication System....................................................................................280 Fuel Pump.............................................................................................280 TORQUE SPECIFICATIONS.....................................................................................281 TROUBLESHOOTING...............................................................................................282 Periodic Maintenance..............................................................................................286 PERIODIC MAINTENANCE..........................................................................................286 GENERAL...................................................................................................286 Serial Number Data....................................................................................286 HOW TO MOVE A DISABLED LIFT TRUCK.........................................................................287 How To Tow the Lift Truck.............................................................................287 HOW TO PUT A LIFT TRUCK ON BLOCKS.........................................................................287 How To Raise the Drive Tires..........................................................................287 How To Raise the Steering Tires.......................................................................288 MAINTENANCE PROCEDURES........................................................................................292 EVERY 8 HOURS OR DAILY........................................................................................292 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED................................................................292 Engine Oil............................................................................................292 Drive Belts...........................................................................................292 Cooling System........................................................................................292 Battery...............................................................................................293 Fuel System...........................................................................................295 Air Filter............................................................................................295 Hydraulic System Oil..................................................................................295 Tires and Wheels......................................................................................296 Forks.................................................................................................296 Forks, Adjustment.....................................................................................297 Forks, Removal And Installation.......................................................................297 Inspection Of Forks, Mast, and Lift Chains............................................................298 Safety Labels.........................................................................................299 Operator Restraint System.............................................................................299 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING................................................................300 Gauges, Lights, Horn, and Fuses.......................................................................300 Fuel Filter, Diesel Engine............................................................................301 How To Drain The Water From The Fuel Filter...........................................................301 Oil Level, Powershift Transmission....................................................................301 Control Levers and Pedals.............................................................................301 Lift System Operation.................................................................................301 Inching/Brake Pedal...................................................................................302 Service Brakes........................................................................................302 Parking Brake.........................................................................................302 Steering System.......................................................................................302 EVERY 250 HOURS OR TWO MONTHS.................................................................................303 ENGINE OIL AND FILTER.....................................................................................303 Mazda, GM, And Later Production Isuzu Engines.........................................................303 Earlier Production Isuzu C240 Engines.................................................................303 GOVERNOR, MAZDA ENGINE....................................................................................304 DRIVE BELTS...............................................................................................304 Mazda Engine..........................................................................................304 Isuzu, GM 4-181, And GM 4-153 Engines.................................................................304 BRAKE FLUID...............................................................................................305 HYDRAULIC TANK BREATHER, CLEAN AND CHECK..................................................................305 FORKS, CHECK FOR WEAR AND DAMAGE..........................................................................305 LIFT CHAINS...............................................................................................305 Lubrication...........................................................................................305 Check For Wear........................................................................................305 MAST, LUBRICATION.........................................................................................306 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...............................................................306 CONTROL LEVERS AND PEDALS, LUBRICATION....................................................................307 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.......................................................................307 Idle Speed, Diesel....................................................................................307 LPG Carburetor........................................................................................308 Gasoline Carburetor...................................................................................308 EVERY 1000 HOURS OR SIX MONTHS................................................................................309 DIESEL FUEL FILTER........................................................................................309 Filter Replacement, Models Without A Water Separator..................................................310 Filter Replacement, Models With A Water Separator.....................................................310 Remove Air from the Diesel Fuel System................................................................310 DIFFERENTIAL..............................................................................................311 VALVE CLEARANCE ADJUSTMENT................................................................................311 IGNITION SYSTEM, MAZDA AND GM ENGINES.....................................................................311 PCV VALVE AND FILTER......................................................................................313 EVERY 2000 HOURS OR YEARLY....................................................................................313 HYDRAULIC SYSTEM..........................................................................................313 Replace the Hydraulic Oil and Filter..................................................................313 POWERSHIFT TRANSMISSION...................................................................................313 COOLING SYSTEM............................................................................................314 SERVICE BRAKES............................................................................................314 DIFFERENTIAL..............................................................................................314 WHEEL BEARINGS............................................................................................315 Steering Wheels, lubrication..........................................................................315 Drive Wheels, Lubrication.............................................................................315 GASOLINE FUEL FILTER, REPLACEMENT.........................................................................315 PCV VALVE, GM ENGINES.....................................................................................315 LPG FILTER, REPLACEMENT...................................................................................315 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A............................................................315 GENERAL PROCEDURES............................................................................................316 CHECK THE HOOD LATCH......................................................................................316 LIFT CHAIN ADJUSTMENTS....................................................................................316 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................318 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................319 Check the Lift Cylinders for Leaks....................................................................319 Check the Tilt Cylinders for Leaks....................................................................319 FUEL INJECTORS............................................................................................320 WELDING REPAIRS...........................................................................................320 CHANGES TO THE OVERHEAD GUARD.............................................................................320 WHEELS AND TIRES..........................................................................................320 Solid Rubber Tires (Press-on).........................................................................320 Install The Wheels....................................................................................321 Pneumatic Tires, Remove The Wheels From The Lift Truck................................................322 Pneumatic Tires, Remove the Tire From The Wheel.......................................................322 Pneumatic Tires, Install The Wheel In The Tire........................................................323 Pneumatic Tires, Add Air To The Tires.................................................................324 Pneumatic Tires, Install the Wheels...................................................................325 Pneumatic Tires, Installation Procedures, Dual Drive Wheels...........................................325 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.........................................................326 Remove The Wheels From The Lift Truck.................................................................326 Remove The Tire From The Wheel........................................................................326 Install The Tire On The Wheel.........................................................................327 REFERENCE TABLE...............................................................................................328 SAE & Metric Fasteners............................................................................................329 INTRODUCTION..................................................................................................329 NOMENCLATURE, THREADS.....................................................................................329 STRENGTH IDENTIFICATION...................................................................................330 TABLE 1. BOLTS AND SCREWS.....................................................................................330 TABLE 2. STUDS AND NUTS.......................................................................................331 TABLE 3. TORQUE NUTS..........................................................................................332 TABLE 4. TORQUE NUTS WITH NYLON INSERT........................................................................333 TABLE 5. TORQUE VALUES FOR INCH FASTENERS.....................................................................334 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...................................................................335 Single Speed PS Transmission Description & Operator...............................................................338 INTRODUCTION..................................................................................................338 General...................................................................................................338 DESCRIPTION AND OPERATION.....................................................................................338 General...................................................................................................338 Torque Converter..........................................................................................339 Description...........................................................................................339 Operation.............................................................................................339 Clutch Assemblies.........................................................................................341 Description...........................................................................................341 Operation.............................................................................................342 Hydraulic System..........................................................................................342 General...............................................................................................342 Oil Pump and Front Cover..................................................................................343 Torque Converter Regulator............................................................................343 Oil Cooler By-Pass....................................................................................343 Control Valve.............................................................................................343 General...............................................................................................343 Differential..............................................................................................348 Oil Flow Diagrams.........................................................................................349 Neutral...............................................................................................349 Forward...............................................................................................351 Forward-Inching.......................................................................................353 Reverse...............................................................................................355 Single Speed PS Transmission Description & Repair (T41, T42, T43).................................................357 INTRODUCTION..................................................................................................357 GENERAL...................................................................................................357 DESCRIPTION AND OPERATION.....................................................................................358 GENERAL...................................................................................................358 TORQE CONVERTER...........................................................................................358 Description...........................................................................................358 Operation.............................................................................................358 CLUTCH ASSEMBLIES.........................................................................................361 Description...........................................................................................361 Operation.............................................................................................363 HYDRAULIC SYSTEM..........................................................................................363 General...............................................................................................363 CONTROL VALVE.............................................................................................363 Regulator for Clutch Pressure.........................................................................366 Inching Spool Assembly................................................................................366 Direction Spool.......................................................................................366 MONOTROL Control Valve................................................................................366 Neutral Start Switch, MONOTROL Pedal Only.............................................................367 Neutral Start Switch, Direction Control Lever Only....................................................367 Modulator Circuit.....................................................................................367 Regulator for the Toruqe Converter....................................................................368 By-Pass Valve for the Oil Cooler......................................................................368 DIFFERENTIAL..............................................................................................369 OIL FLOW DIAGRAMS.........................................................................................369 Single Speed PS Transmission Repair (T41, T41, T43)...............................................................378 INTRODUCTION..................................................................................................378 GENERAL...................................................................................................378 REPAIRS.......................................................................................................380 REPAIRS...................................................................................................380 Torque Converter, Removal.............................................................................380 Torque Converter, Installation........................................................................380 Front Cover And Transmission Pump, Removal and Disassembly............................................381 Front Cover And Transmission Pump, Assembly and Installation..........................................381 Clutch Assemblies, Removal and Disassembly............................................................382 Clutch Assemblies, Inspection.........................................................................385 Clutch Assemblies, Assembly and Installation..........................................................386 Differential, Removal and Disassembly.................................................................389 Differential, Inspection..............................................................................391 Differential, Assembly And Installation...............................................................391 CONTROL VALVE.............................................................................................401 Control Valve, Removal and Disassembly................................................................401 Control Valve, Inspection.............................................................................401 Control Valve, Assembly and Installation..............................................................403 MONOTROL Pedal, Removal and Disassembly...............................................................405 MONOTROL Pedal, Assembly and Installation.............................................................405 CHECKS AND ADJUSTMENTS........................................................................................407 Stall Test................................................................................................407 Adjustment Of The Direction Control Linkage...............................................................408 Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1).............409 Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)..............412 Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187).......................413 Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)....................414 Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)....418 Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)............419 Check The Oil Pressures...................................................................................419 Check The Relief Valve for the Transmission Pump..........................................................419 Check The Clutch Pressure.................................................................................419 Check The Torque Converter Regulator......................................................................420 Check The Oil Pressure from the Oil Cooler................................................................420 Check The Modulator Pressure..............................................................................421 TROUBLESHOOTING...............................................................................................421 TROUBLESHOOTING, PRESSURE TESTS...............................................................................423 Single Speed PS Transmission Repair...............................................................................426 INTRODUCTION..................................................................................................426 General...................................................................................................426 Removal of The Transmission...........................................................................426 Installation of the Transmission......................................................................426 REPAIRS.......................................................................................................428 Torque Converter..........................................................................................428 Front Cover and Oil Pump..................................................................................428 Clutch Assemblies.........................................................................................430 Differential..............................................................................................438 Control Valve.............................................................................................447 CHECKS AND ADJUSTMENTS........................................................................................449 Stall Test................................................................................................449 Adjusting the Direction Control Linkage...................................................................450 Adjusting the Brake and Inching Pedals....................................................................451 Checking the Oil Pressures................................................................................453 SPECIFICATIONS................................................................................................455 TROUBLESHOOTING...............................................................................................455 Steering Axle.....................................................................................................458 INTRODUCTION..................................................................................................458 DESCRIPTION...............................................................................................458 GENERAL...................................................................................................458 REPAIRS.......................................................................................................459 STEERING AXLE.............................................................................................459 Removal...................................................................................................459 Installation..............................................................................................460 STEERING CYLINDER.........................................................................................460 Removal...................................................................................................460 Service...................................................................................................461 Installation..............................................................................................461 HUBS......................................................................................................461 Removal...................................................................................................461 Installation..............................................................................................462 SPINDLES..................................................................................................462 Removal...................................................................................................462 Installation..............................................................................................463 CHECKS AND ADJUSTMENTS........................................................................................463 REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................463 SET THE PRESSURE RELIEF VALVE.............................................................................463 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...................................................463 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION........................................................463 H2.00-3.00J (H40-60J) With Powershift Transmission........................................................463 TROUBLESHOOTING...............................................................................................465 Steering Control Unit.............................................................................................466 INTRODUCTION..................................................................................................466 GENERAL...................................................................................................466 DESCRIPTION...............................................................................................466 OPERATION.................................................................................................466 REPAIRS.......................................................................................................466 STEERING WHEEL AND COLUMN ASSEMBLY........................................................................466 TYPE "A" STEERING COLUMN ASSEMBLY.........................................................................468 Removal And Disassembly...............................................................................468 Assembly And Installation.............................................................................468 TYPE "A" STEERING COLUMN..................................................................................469 TYPE "A" STEERING COLUMN..................................................................................470 TYPE "B" STEERING COLUMN..................................................................................471 Removal And Disassembly...............................................................................471 Assembly And Installation.............................................................................471 TYPE "B" STEERING COLUMN..................................................................................472 Disassembly of Steering Control Unit..................................................................473 Cleaning of Steering Control Unit.....................................................................473 Assembly of Steering Control Unit.....................................................................475 CHECKS AND ADJUSTMENTS........................................................................................478 REMOVE AIR FROM THE SYSTEM................................................................................478 TROUBLESHOOTING...............................................................................................479 Tilt Cylinders....................................................................................................480 INTRODUCTION..................................................................................................480 GENERAL...................................................................................................480 DESCRIPTION...............................................................................................480 REPAIRS.......................................................................................................480 REMOVAL...................................................................................................480 DISASSEMBLY...............................................................................................480 CLEANING..................................................................................................480 ASSEMBLY..................................................................................................480 Tilt Cylinders with O-Rings or Single Lip Seals.......................................................480 Tilt Cylinders for the XM and XMS Models..............................................................481 Tilt Cylinders for H700 800A and Early Model H700 920B................................................483 INSTALLATION..............................................................................................483 Tilt Cylinders Using Chevron Packing..................................................................484 CHECKS AND ADJUSTMENTS........................................................................................486 CHECK THE TILT CYLINDERS FOR LEAKS........................................................................486 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...................................................486 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS......................................................487 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS.....................................................488 TROUBLESHOOTING...............................................................................................490 Vista Mast Description............................................................................................491 INTRODUCTION..................................................................................................491 GENERAL...................................................................................................491 MAST WELDMENTS............................................................................................491 CARRIAGE..................................................................................................491 MAST MOUNTS...............................................................................................492 VISTA® TWO-STAGE MAST.........................................................................................493 DESCRIPTION AND OPERATION.................................................................................493 VISTA® FREE-LIFT MAST.........................................................................................495 DESCRIPTION...............................................................................................495 OPERATION.................................................................................................495 VISTA® THREE-STAGE MAST.......................................................................................497 DESCRIPTION...............................................................................................497 OPERATION.................................................................................................497 VISTA® FOUR-STAGE MAST........................................................................................498 DESCRIPTION...............................................................................................498 OPERATION.................................................................................................499 Vista Mast Repair.................................................................................................501 VISTA MAST, REPAIR............................................................................................501 GENERAL...................................................................................................501 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................501 FORKS.....................................................................................................502 Forks, Removal And Installation.......................................................................502 CARRIAGE..................................................................................................503 Removal...............................................................................................503 Installation..........................................................................................504 MASTS.....................................................................................................504 Removal...............................................................................................504 Disassembly...........................................................................................505 Cleaning and Inspection...............................................................................510 Assembly..............................................................................................510 Installation..........................................................................................514 SIDE-SHIFT CARRIAGE (EARLIER DESIGN)......................................................................515 Removal...............................................................................................515 Repairs...............................................................................................515 Installation..........................................................................................515 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)...............................................................516 Removal...............................................................................................516 Repairs...............................................................................................516 Installation..........................................................................................517 CHECKS AND ADJUSTMENTS........................................................................................518 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................518 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...............................................519 LIFT CHAIN ADJUSTMENTS....................................................................................520 MAST ADJUSTMENTS..........................................................................................520 CARRIAGE ADJUSTMENT.......................................................................................522 HEADER HOSE ARRANGEMENTS..................................................................................522 Two-Stage Header Hose.................................................................................523 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts.........................................523 TROUBLESHOOTING...............................................................................................528
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