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Hyster C177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster C177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 713
Downloadable : Yes
File Type : PDF
Size: 21.8 MB
TABLE OF CONTENTS:
Hyster C177 (H2.00-3.00XL Europe) Service Manual – PDF DOWNLOAD
6003.............................................................................................................. 1 INTRODUCTION.................................................................................................. 1 GENERAL................................................................................................... 1 DESCRIPTION............................................................................................... 2 REMOVAL AND INSTALLATION OF THE ENGINE.................................................................... 2 CYLINDER HEAD AND MECHANISM............................................................................... 2 Cylinder Head, Removal................................................................................ 2 Cylinder Head, Disassembly............................................................................ 3 Cleaning And Inspection............................................................................... 4 Valve And Valve Seats................................................................................. 5 Studs For The Rocker Arms............................................................................. 5 Hydraulic Valve Lifters, Replacement.................................................................. 5 Hydraulic Valve Lifters, Cleaning And Inspection...................................................... 6 Cylinder Head, Assembly............................................................................... 6 Cylinder Head, Installation........................................................................... 6 Rocker Arm Cover, Installation........................................................................ 7 TIMING GEAR COVER......................................................................................... 8 Removal............................................................................................... 8 Installation.......................................................................................... 8 CAMSHAFT.................................................................................................. 9 Removal............................................................................................... 9 Inspection............................................................................................ 10 Camshaft Bearings, Removal............................................................................ 10 Camshaft Bearings, Installation....................................................................... 10 DISTRIBUTOR............................................................................................... 11 Removal............................................................................................... 11 Installation.......................................................................................... 11 LUBRICATION SYSTEM........................................................................................ 12 Oil Sump, Removal..................................................................................... 12 Oil Sump, Installation................................................................................ 12 Oil Pump, Removal..................................................................................... 12 Oil Pump, Disassembly and Repair...................................................................... 12 Oil Pump, Assembly.................................................................................... 13 Oil Pump, Installation................................................................................ 13 PISTON AND CONNECTING ROD ASSEMBLIES...................................................................... 13 Connecting Rod Bearings, Replacement.................................................................. 13 Piston And Connecting Rod Assemblies, Removal......................................................... 14 Disassembly........................................................................................... 15 Piston, Cleaning And Inspection....................................................................... 15 Cylinder Bores, Inspection And Repair................................................................. 15 Piston Rings.......................................................................................... 16 Assembly.............................................................................................. 17 Piston And Connecting Rod Assemblies, Installation.................................................... 17 CRANKSHAFT................................................................................................ 18 Main Bearings, Replacement............................................................................ 18 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).............................. 19 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).............. 19 Crankshaft, Removal................................................................................... 20 Inspection and Repair................................................................................. 21 How To Check The Clearance Between The Main Bearings And Their Journals............................... 21 Installation.......................................................................................... 22 FLYWHEEL AND FLYWHEEL HOUSING............................................................................. 23 Flywheel, Removal..................................................................................... 23 Ring Gear, Replacement................................................................................ 24 Flywheel, Installation................................................................................ 24 COOLING SYSTEM............................................................................................ 24 Coolant Pump.......................................................................................... 24 Fan Drive............................................................................................. 25 Viscous Fan Drive..................................................................................... 25 ENGINE SPECIFICATIONS......................................................................................... 26 ENGINE DATA............................................................................................... 26 CYLINDER HEAD............................................................................................. 26 HYDRAULIC VALVE LIFTER.................................................................................... 27 CAMSHAFT.................................................................................................. 27 PISTONS................................................................................................... 27 CYLINDER BORE............................................................................................. 28 CRANKSHAFT................................................................................................ 28 CONNECTING RODS........................................................................................... 28 COOLING SYSTEM............................................................................................ 29 LUBRICATION SYSTEM........................................................................................ 29 TORQUE SPECIFICATIONS......................................................................................... 29 22002............................................................................................................. 32 INTRODUCTION.................................................................................................. 32 GENERAL................................................................................................... 32 DESCRIPTION............................................................................................... 32 REPAIRS....................................................................................................... 34 GENERAL................................................................................................... 34 REMOVAL AND DISASSEMBLY (Type A).......................................................................... 34 CLEANING.................................................................................................. 34 ASSEMBLY (Type A)......................................................................................... 35 REMOVAL AND DISAASSEMBLY (Type B)......................................................................... 37 CLEANING.................................................................................................. 39 ASSEMBLY (Type B)......................................................................................... 39 INSTALLATION (Type A and Type B).......................................................................... 40 CHECKS AND ADJUSTMENTS........................................................................................ 40 GENERAL................................................................................................... 40 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B).................................................... 41 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)................................................... 42 CHECK THE CIRCUIT FOR THE BRUSHES......................................................................... 44 Delco Alternators..................................................................................... 44 Motorola Alternators.................................................................................. 44 CHECK THE DIODES.......................................................................................... 44 CHECK THE DIODE BRIDGE.................................................................................... 44 Delco and Leece–Neville Alternators................................................................... 44 Motorola Alternators.................................................................................. 44 CHECK THE FIELD WINDING FOR THE ROTOR..................................................................... 45 CHECK THE WINDINGS IN THE STATOR.......................................................................... 45 CHECK THE VOLTAGE REGULATOR............................................................................... 46 TROUBLESHOOTING............................................................................................... 46 60066............................................................................................................. 47 MAZDA M4-121G ENGINE.......................................................................................... 47 GENERAL................................................................................................... 47 DESCRIPTION............................................................................................... 48 REMOVAL AND INSTALLATION OF THE ENGINE.................................................................... 48 CYLINDER HEAD AND VALVE MECHANISM......................................................................... 48 Cylinder Head, Removal................................................................................ 48 Cylinder Head, Inspection and Repairs................................................................. 49 Rocker Arm Assembly................................................................................... 49 Valve Guides.......................................................................................... 49 Valve Seats........................................................................................... 50 Valves................................................................................................ 50 Valve Springs......................................................................................... 50 Cylinder Head, Installation........................................................................... 50 TIMING GEAR CASE, REMOVAL................................................................................. 51 TIMING GEAR CASE, INSTALLATION............................................................................ 52 CAMSHAFT.................................................................................................. 52 Removal............................................................................................... 52 Inspection............................................................................................ 53 Cam Followers, Inspection............................................................................. 53 Installation.......................................................................................... 53 CRANKSHAFT AND MAIN BEARINGS.............................................................................. 53 Crankshaft, Removal................................................................................... 53 Crankshaft, Inspection And Repair..................................................................... 54 Main Bearings......................................................................................... 55 Crankshaft, Installation.............................................................................. 55 PISTONS AND CONNECTING RODS............................................................................... 56 Removal............................................................................................... 56 Disassembly........................................................................................... 56 Pistons, Inspection And Repair........................................................................ 56 Piston Rings.......................................................................................... 57 Piston Pin and Bushing................................................................................ 57 Connecting Rods and Bearings, Inspection.............................................................. 57 Pistons and Connecting Rods, Assembly................................................................. 57 Pistons and Connecting Rods, Installation............................................................. 58 CYLINDER BLOCK AND CYLINDER LINERS........................................................................ 58 Cylinder Block, Repairs............................................................................... 58 Cylinder Liners....................................................................................... 58 DISTRIBUTOR............................................................................................... 59 Removal............................................................................................... 59 Installation.......................................................................................... 59 OIL PUMP.................................................................................................. 61 Removal............................................................................................... 61 Repairs............................................................................................... 61 Installation.......................................................................................... 62 GOVERNOR.................................................................................................. 62 Description........................................................................................... 62 Removal............................................................................................... 62 Disassembly........................................................................................... 63 Assembly.............................................................................................. 64 Installation.......................................................................................... 65 COOLANT PUMP.............................................................................................. 65 Removal............................................................................................... 65 Disassembly and Repair................................................................................ 66 Assembly.............................................................................................. 66 Installation.......................................................................................... 67 FLYWHEEL.................................................................................................. 67 Repairs............................................................................................... 67 Installation.......................................................................................... 67 CHECKS AND ADJUSTMENTS........................................................................................ 67 ADJUST THE VALVES......................................................................................... 67 ADJUST THE THROTTLE LINKAGE............................................................................... 68 ENGINE SPECIFICATIONS......................................................................................... 68 ENGINE SPECIFICATIONS..................................................................................... 68 Engine Data........................................................................................... 68 Cooling System........................................................................................ 68 Cylinder Head and Valve Mechanism..................................................................... 68 Camshaft.............................................................................................. 70 Timing Gear........................................................................................... 71 Camshaft.............................................................................................. 71 Connecting Rods....................................................................................... 71 Cylinder Liners....................................................................................... 71 Pistons............................................................................................... 71 Lubrication System.................................................................................... 72 Fuel Pump............................................................................................. 72 TORQUE SPECIFICATIONS..................................................................................... 73 TROUBLESHOOTING............................................................................................... 74 60070............................................................................................................. 78 INTRODUCTION ................................................................................................. 78 GENERAL .................................................................................................. 78 DESCRIPTION .............................................................................................. 78 FUEL SYSTEM .............................................................................................. 79 Description .......................................................................................... 79 Operation, Fuel Injection Pump, Model VE ............................................................. 81 Operation, Fuel Injection Pump, Model PE4A ........................................................... 82 Pneumatic Governor For Fuel Injection Pump, Model PE4A ............................................... 83 Inlet Manifold For Fuel Injection Pump, Model PE4A ................................................... 84 REPAIRS ...................................................................................................... 85 FUEL INJECTION PUMP (ALL MODELS) ......................................................................... 85 Removal .............................................................................................. 85 Installation ......................................................................................... 85 REMOVAL AND INSTALLATION OF THE ENGINE ................................................................... 85 CYLINDER HEAD AND VALVE MECHANISM ........................................................................ 85 Cylinder Head, Removal ............................................................................... 85 Valve Guides, Replacement ............................................................................ 86 Cylinder Head, Inspection And Repair ................................................................. 87 Combustion Chamber Plugs, Inspection And Repair ...................................................... 87 Combustion Chamber Plugs, Installation ............................................................... 87 Valves, Inspection And Repair ........................................................................ 88 Valve Seat, Inspection ............................................................................... 88 Valve Seat, Removal .................................................................................. 89 Valve Seat, Installation ............................................................................. 89 Valve Spring, Inspection ............................................................................. 89 Rocker Arms, Inspection And Assembly ................................................................. 89 Installation Of The Cylinder Head .................................................................... 90 TIMING GEAR CASE ......................................................................................... 91 Removal .............................................................................................. 91 Installation ......................................................................................... 91 CAMSHAFT ................................................................................................. 93 Removal .............................................................................................. 93 Inspection ........................................................................................... 93 Camshaft Bearings .................................................................................... 94 Cam Followers ........................................................................................ 94 CAMSHAFT, INSTALLATION ................................................................................... 94 CRANKSHAFT AND MAIN BEARINGS ............................................................................. 95 Crankshaft, Removal .................................................................................. 95 Crankshaft, Inspection And Repair .................................................................... 95 Main Bearings ........................................................................................ 95 Pilot Bearing ........................................................................................ 96 Crankshaft, Installation ............................................................................. 96 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) .......................................................... 98 Flywheel, Removal .................................................................................... 98 Ring Gear, Replacement ............................................................................... 98 Flywheel, Installation ............................................................................... 98 PISTONS AND CONNECTING RODS .............................................................................. 99 Pistons And Connecting Rods, Removal ................................................................. 99 Disassembly .......................................................................................... 99 Pistons, Inspection And Repair .......................................................................100 Piston Rings, Inspection And Repair ..................................................................100 Piston Pins, Inspection And Repair ...................................................................101 Connecting Rods, Inspection And Repair ...............................................................102 Pistons And Connecting Rods, Assembly And Installation ...............................................102 CYLINDER BLOCK AND CYLINDER LINERS .......................................................................102 Cylinder Liners, Inspection ..........................................................................102 Replacement Of A Cylinder Liner ......................................................................103 LUBRICATION SYSTEM .......................................................................................104 Oil Pump, Removal And Disassembly ....................................................................104 Oil Pump, Inspection .................................................................................104 Oil Pump, Assembly And Installation ..................................................................105 Oil Filter ...........................................................................................105 COOLING SYSTEM ...........................................................................................106 Coolant Pump, Removal ................................................................................106 Coolant Pump, Disassembly ............................................................................106 Coolant Pump, Assembly And Installation ..............................................................106 Thermostat, Replacement ..............................................................................107 CHECKS AND ADJUSTMENTS .......................................................................................107 VALVE CLEARANCE ADJUSTMENT ...............................................................................107 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ....................................................108 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A ..................................................109 FUEL INJECTORS ...........................................................................................109 Fuel Injectors, Removal ..............................................................................110 Fuel Injectors, Inspection ...........................................................................110 Fuel Injectors, Installation .........................................................................111 DIESEL FUEL FILTERS ......................................................................................111 Filter Replacement, Models With A Water Separator ....................................................111 Filter Replacement, Models Without A Water Separator .................................................112 Filter For The Fuel Injection Pump, Model PE4A .......................................................112 REMOVE AIR FROM THE FUEL SYSTEM ..........................................................................112 Throttle Linkage, Adjustment .........................................................................113 Idle Speed, Adjustment ...............................................................................113 Check The Elements For The Cold Start Aid System .....................................................113 ENGINE SPECIFICATIONS ........................................................................................113 TORQUE SPECIFICATIONS ........................................................................................115 90011.............................................................................................................116 INTRODUCTION..................................................................................................116 GENERAL...................................................................................................116 DESCRIPTION...............................................................................................116 OPERATION.................................................................................................117 The Float System......................................................................................117 The Idle System.......................................................................................117 The Main Metering System (GM 6-250)...................................................................118 The Power System (GM 6-250)...........................................................................119 The Accelerator Pump System...........................................................................119 Choke System..........................................................................................119 REPAIRS.......................................................................................................120 REMOVAL...................................................................................................120 DISASSEMBLY...............................................................................................120 Cleaning..................................................................................................120 ASSEMBLY..................................................................................................120 INSTALLATION..............................................................................................120 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)...........................................................125 GOVERNOR (PNEUMATIC) (Early Units)........................................................................126 CHECKS AND ADJUSTMENTS........................................................................................127 GENERAL...................................................................................................127 ADJUST THE CHOKE CONTROL..................................................................................127 ADJUST THE IDLE SPEED.....................................................................................127 ADJSUT THE IDLE MIXTURE...................................................................................128 ADJUST THE FAST IDLE......................................................................................128 ADJUST THE THROTTLE LINKAGE,(Later Models)................................................................129 ADJUST THE THROTTLE LINKAGE,(Early Models)................................................................130 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only).............................................130 Check the Governor....................................................................................130 GOVERNOR (AISAN Type) (Early GM Engines Only).............................................................131 Checks................................................................................................132 Adjustments...........................................................................................132 GOVERNOR (HOOF Type) (Early GM Engines Only)..............................................................132 Adjust the Governor...................................................................................132 TROUBLESHOOTING...............................................................................................134 90015.............................................................................................................135 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100).....................................................................135 GENERAL...................................................................................................135 DESCRIPTION...............................................................................................135 Fuel Tank.............................................................................................136 Fuel Filter And Fuel Valve Unit.......................................................................137 Vaporizer.............................................................................................137 The IMPCO CA 100 Carbureto............................................................................139 IMPCO CA 50 Carburetor................................................................................141 The Governor (GM Engines Only)........................................................................142 Governor With Electronic Controller...................................................................143 REPAIRS.......................................................................................................144 LPG TANK..................................................................................................144 Removal...............................................................................................144 Installation..........................................................................................145 REPLACE THE HOSES.........................................................................................145 HYDROSTATIC RELIEF VALVE..................................................................................145 Removal and Installation..............................................................................145 FILTER UNIT...............................................................................................146 Replacement Of the Fuel Filter Element................................................................146 Replacement of the Diaphragm and Fuel Valve...........................................................147 VAPORIZER.................................................................................................147 Removal...............................................................................................147 Disassembly...........................................................................................147 Cleaning..............................................................................................147 Inspection............................................................................................147 Assembly..............................................................................................149 Installation..........................................................................................149 CARBURETOR (IMPCO CA 100).................................................................................151 Removal...............................................................................................151 Disassembly...........................................................................................151 Cleaning..............................................................................................151 Assembly..............................................................................................151 Installation..........................................................................................154 CARBURETER (IMPCO CA 50)..................................................................................153 Removal...............................................................................................153 Disassembly...........................................................................................153 Cleaning..............................................................................................154 Inspection............................................................................................154 Assembly (See FIGURE 26.).............................................................................154 Installation..........................................................................................154 CHECKS AND ADJUSTMENTS........................................................................................155 CHECK THE FILTER UNIT.....................................................................................155 CHECK THE VAPORIZER.......................................................................................155 Pressure Reducer Valve................................................................................155 Vapor Valve...........................................................................................155 ADJUST THE CARBURETOR.....................................................................................155 Idle Mixture..........................................................................................155 Idle Speed............................................................................................155 Power Mixture.........................................................................................155 ADJUST THE GOVERNOR (GM Engines Only).....................................................................156 Checks................................................................................................156 Main Adjusting Screw..................................................................................156 Secondary Adjusting Screw.............................................................................156 AISAN Governor........................................................................................157 Adjustment, AISAN Governor............................................................................157 TROUBLESHOOTING...............................................................................................158 100137............................................................................................................162 INTRODUCTION..................................................................................................162 GENERAL...................................................................................................162 DESCRIPTION...............................................................................................162 REPAIRS.......................................................................................................162 COUNTERWEIGHT.............................................................................................163 Removal...............................................................................................163 Installation..........................................................................................163 MUFFLER...................................................................................................164 HOOD......................................................................................................164 Removal...............................................................................................164 Installation..........................................................................................164 RADIATOR AND COOLANT SYSTEM...............................................................................164 Removal...............................................................................................164 Installation..........................................................................................164 OVERHEAD GUARD............................................................................................165 Removal And Installation..............................................................................165 OPERATOR RESTRAINT SYSTEM.................................................................................165 ENGINE REMOVAL AND INSTALLATION...........................................................................166 Removal of the Engine and Transmission................................................................166 Installation of the Engine and Transmission...........................................................170 FUEL AND HYDRAULIC TANKS..................................................................................172 Inspection............................................................................................172 Repairs, Small Leaks..................................................................................172 Repairs, Large Leaks..................................................................................172 Cleaning..............................................................................................172 Steam Method Of Cleaning..............................................................................172 Chemical Solution Method of Cleaning..................................................................173 Additional Preparations For Repair....................................................................173 SAFETY LABELS.............................................................................................173 CAB.......................................................................................................175 Cab Replacement.......................................................................................175 Window Replacement....................................................................................175 Windshield Wipers and Heater..........................................................................177 140085............................................................................................................178 INTRODUCTION..................................................................................................178 GENERAL...................................................................................................178 DESCRIPTION...............................................................................................178 REPAIRS.......................................................................................................179 REMOVAL...................................................................................................179 CLEANING..................................................................................................179 INSPECTION................................................................................................179 ASSEMBLY..................................................................................................179 TROUBLESHOOTING...............................................................................................182 SPECIFICATIONS................................................................................................182 160010............................................................................................................183 INTRODUCTION..................................................................................................183 DESCRIPTION...............................................................................................183 GENERAL...................................................................................................183 REPAIRS.......................................................................................................184 STEERING AXLE.............................................................................................184 Removal...................................................................................................184 Installation..............................................................................................185 STEERING CYLINDER.........................................................................................185 Removal...................................................................................................185 Service...................................................................................................186 Installation..............................................................................................186 HUBS......................................................................................................186 Removal...................................................................................................186 Installation..............................................................................................187 SPINDLES..................................................................................................187 Removal...................................................................................................187 Installation..............................................................................................188 CHECKS AND ADJUSTMENTS........................................................................................188 REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................188 SET THE PRESSURE RELIEF VALVE.............................................................................188 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...................................................188 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION........................................................188 H2.00-3.00J (H40-60J) With Powershift Transmission........................................................188 TROUBLESHOOTING...............................................................................................190 200077............................................................................................................191 INTRODUCTION..................................................................................................191 GENERAL...................................................................................................191 DESCRIPTION...............................................................................................191 OPERATION.................................................................................................192 Lift Section..........................................................................................193 Tilt Section..........................................................................................193 Relief Valve..........................................................................................195 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................196 Operation.............................................................................................196 REPAIRS.......................................................................................................196 MAIN CONTROL VALVE........................................................................................196 Removal and Disassembly...............................................................................196 Cleaning and Inspection...............................................................................197 Assembly..............................................................................................197 Installation..........................................................................................197 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................197 Removal and Disassembly...............................................................................197 Assembly and Installation.............................................................................199 CHECKS AND ADJUSTMENTS........................................................................................199 PRESSURE RELIEF VALVES....................................................................................199 Primary Relief Valve..................................................................................199 Seconday Relief Valve.................................................................................200 CONTROL LEVER ARRANGEMENT.................................................................................200 TROUBLESHOOTING...............................................................................................203 SPECIFICATIONS................................................................................................205 600467............................................................................................................206 INTRODUCTION .................................................................................................206 GENERAL ..................................................................................................206 DESCRIPTION ..............................................................................................207 FUEL SYSTEM ..............................................................................................207 Description ..........................................................................................207 Operation, Fuel Injection Pump, Model VE .............................................................207 REPAIRS ......................................................................................................209 FUEL INJECTION PUMP ......................................................................................209 Removal ..............................................................................................209 Installation .........................................................................................209 REMOVAL AND INSTALLATION OF THE ENGINE ...................................................................210 CYLINDER HEAD AND VALVE MECHANISM ........................................................................210 Cylinder Head, Removal ...............................................................................210 Valves, Removal ......................................................................................212 Cylinder Head, Inspection And Repair .................................................................213 Valves, Inspection And Repair ........................................................................213 Valve Guides, Replacement ............................................................................214 Valve Seats, Inspection ..............................................................................214 Valve Seats, Removal .................................................................................215 Valve Seats, Installation ............................................................................215 Valve Springs, Inspection ............................................................................215 Valves, Installation .................................................................................216 Push Rods, Inspection ................................................................................216 Rocker Arms, Disassembly And Inspection ..............................................................216 Rocker Arm Shaft, Assembly ...........................................................................218 Cylinder Head, Installation ..........................................................................218 TIMING GEAR CASE .........................................................................................220 Removal ..............................................................................................220 Inspection, Idler Gear "A" And Idler Gear Shaft ......................................................222 Inspection, Idler Gear "B" Bearings ..................................................................222 Installation .........................................................................................222 CAMSHAFT .................................................................................................224 Camshaft, Removal ....................................................................................224 Camshaft, Disassembly And Inspection .................................................................224 Camshaft Bearing Replacement .........................................................................225 Cam Followers (Tappets) ..............................................................................225 Camshaft, Assembly ...................................................................................226 Camshaft, Installation ...............................................................................226 LUBRICATION SYSTEM .......................................................................................226 Oil Pump, Removal And Disassembly ....................................................................226 Oil Pump, Inspection .................................................................................227 Oil Pump, Assembly And Installation ..................................................................229 Oil Sump, Installation ...............................................................................229 Oil Filter Assembly ..................................................................................229 PISTONS AND CONNECTING RODS ..............................................................................230 Pistons And Connecting Rods, Removal .................................................................230 Disassembly ..........................................................................................230 Pistons, Inspection And Repair .......................................................................231 Piston Rings, Inspection .............................................................................231 Piston Pins, Inspection And Repair ...................................................................231 Connecting Rods, Inspection And Repair ...............................................................232 New Pistons, Selection ...............................................................................232 Pistons And Connecting Rods, Assembly And Installation ...............................................233 CRANKSHAFT AND MAIN BEARINGS .............................................................................234 Crankshaft, Removal ..................................................................................234 Crankshaft, Inspection And Repair ....................................................................234 Crankshaft Timing Gear, Replacement ..................................................................235 Crankshaft, Installation .............................................................................236 FLYWHEEL AND RING GEAR, H2.00–3.00XL (H40–60XL) ..........................................................238 Flywheel, Removal ....................................................................................239 Ring Gear, Replacement ...............................................................................239 Flywheel, Installation ...............................................................................239 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) ..........................................................240 Flywheel, Removal ....................................................................................240 Ring Gear, Replacement ...............................................................................240 Flywheel, Installation ...............................................................................241 ENGINE BLOCK AND CYLINDER LINERS .........................................................................242 Cylinder Liners, Inspection ..........................................................................242 Replacement Of A Cylinder Liner ......................................................................242 COOLING SYSTEM ...........................................................................................244 Coolant Pump, Removal ................................................................................244 Coolant Pump, Disassembly ............................................................................244 Coolant Pump, Assembly And Installation ..............................................................245 Thermostat, Replacement ..............................................................................245 CHECKS AND ADJUSTMENTS .......................................................................................246 VALVE CLEARANCE ADJUSTMENT ...............................................................................246 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ....................................................246 FUEL INJECTORS ...........................................................................................247 DIESEL FUEL FILTER .......................................................................................249 THROTTLE LINKAGE, ADJUSTMENT .............................................................................250 IDLE SPEED, ADJUSTMENT ...................................................................................250 CHECK THE ELEMENTS FOR THE COLD START AID SYSTEM .........................................................250 SPECIFICATIONS ...............................................................................................250 TORQUE SPECIFICATIONS ........................................................................................255 700626............................................................................................................256 COOLING SYSTEM................................................................................................256 INTRODUCTION..............................................................................................256 DESCRIPTION...............................................................................................256 RADIATOR..................................................................................................256 RADIATOR CAP..............................................................................................256 THERMOSTAT................................................................................................256 WATER PUMP................................................................................................257 FAN AND FAN SHROUD .......................................................................................257 REPAIRS.......................................................................................................257 COOLING SYSTEM CHECKS.....................................................................................257 Exhaust Leaks.........................................................................................257 RADIATOR..................................................................................................257 Checks................................................................................................257 Cleaning The Radiator.................................................................................257 Drain The Cooling System..............................................................................259 Fill The Cooling System...............................................................................259 WATER PUMP................................................................................................259 Checks................................................................................................259 THERMOSTAT................................................................................................260 Checks................................................................................................260 FAN AND FAN SHROUD .......................................................................................260 TROUBLESHOOTING...............................................................................................261 800048............................................................................................................262 LIFT TRUCK WEIGHTS*...........................................................................................262 ENGINE SPECIFICATIONS.........................................................................................262 ENGINE ELECTRICAL SPECIFICATIONS..............................................................................263 HYDRAULIC SPECIFICATIONS......................................................................................263 CAPACITIES....................................................................................................264 LIFT TRUCK TRAVEL SPEEDS......................................................................................264 TIRE SPECIFICATIONS...........................................................................................264 MAST SPEEDS (Early A177* Units)...............................................................................265 MAST SPEEDS (Later A177* Units)...............................................................................265 MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines).........................................266 MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines).......................................................266 TORQUE SPECIFICATIONS.........................................................................................268 TORQUE SPECIFICATIONS.........................................................................................269 900129............................................................................................................271 THE CARBURETOR, (MAZDA M4-121G ENGINE)........................................................................271 DESCRIPTION...............................................................................................271 REPAIRS, CARBURETOR.......................................................................................272 Removal...............................................................................................272 Cleaning..............................................................................................275 Inspection............................................................................................275 Assembly..............................................................................................275 Installation..........................................................................................277 CHECKS AND ADJUSTMENTS....................................................................................277 Carburetor, Idle Speed And Mixture Adjustment.........................................................277 Adjust The Governor...................................................................................278 ADJUST THE THROTTLE LINKAGE...............................................................................279 SPECIFICATIONS................................................................................................279 TROUBLESHOOTING...............................................................................................280 1300255...........................................................................................................282 INTRODUCTION..................................................................................................282 GENERAL...................................................................................................282 DESCRIPTION AND OPERATION.....................................................................................283 GENERAL...................................................................................................283 TORQE CONVERTER...........................................................................................283 Description...........................................................................................283 Operation.............................................................................................283 CLUTCH ASSEMBLIES.........................................................................................286 Description...........................................................................................286 Operation.............................................................................................288 HYDRAULIC SYSTEM..........................................................................................288 General...............................................................................................288 CONTROL VALVE.............................................................................................288 Regulator for Clutch Pressure.........................................................................291 Inching Spool Assembly................................................................................291 Direction Spool.......................................................................................291 MONOTROL Control Valve................................................................................291 Neutral Start Switch, MONOTROL Pedal Only.............................................................292 Neutral Start Switch, Direction Control Lever Only....................................................292 Modulator Circuit.....................................................................................292 Regulator for the Toruqe Converter....................................................................293 By-Pass Valve for the Oil Cooler......................................................................293 DIFFERENTIAL..............................................................................................294 OIL FLOW DIAGRAMS.........................................................................................294 1300256...........................................................................................................303 INTRODUCTION..................................................................................................303 GENERAL...................................................................................................303 REPAIRS.......................................................................................................305 REPAIRS...................................................................................................305 Torque Converter, Removal.............................................................................305 Torque Converter, Installation........................................................................305 Front Cover And Transmission Pump, Removal and Disassembly............................................306 Front Cover And Transmission Pump, Assembly and Installation..........................................306 Clutch Assemblies, Removal and Disassembly............................................................307 Clutch Assemblies, Inspection.........................................................................310 Clutch Assemblies, Assembly and Installation..........................................................311 Differential, Removal and Disassembly.................................................................314 Differential, Inspection..............................................................................316 Differential, Assembly And Installation...............................................................316 CONTROL VALVE.............................................................................................326 Control Valve, Removal and Disassembly................................................................326 Control Valve, Inspection.............................................................................326 Control Valve, Assembly and Installation..............................................................328 MONOTROL Pedal, Removal and Disassembly...............................................................330 MONOTROL Pedal, Assembly and Installation.............................................................330 CHECKS AND ADJUSTMENTS........................................................................................332 Stall Test................................................................................................332 Adjustment Of The Direction Control Linkage...............................................................333 Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1).............334 Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)..............337 Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187).......................338 Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)....................339 Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)....343 Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)............344 Check The Oil Pressures...................................................................................344 Check The Relief Valve for the Transmission Pump..........................................................344 Check The Clutch Pressure.................................................................................344 Check The Torque Converter Regulator......................................................................345 Check The Oil Pressure from the Oil Cooler................................................................345 Check The Modulator Pressure..............................................................................346 TROUBLESHOOTING...............................................................................................346 TROUBLESHOOTING, PRESSURE TESTS...............................................................................348 1600257...........................................................................................................351 INTRODUCTION..................................................................................................351 DESCRIPTION...............................................................................................351 Control Valve Section.................................................................................351 Metering Section......................................................................................351 DISASSEMBLY AND INSPECTION................................................................................353 ASSEMBLY..................................................................................................363 TROUBLESHOOTING...........................................................................................375 1600459...........................................................................................................376 THE STEERING SYSTEM...........................................................................................376 GENERAL...................................................................................................376 DESCRIPTION...............................................................................................376 Hydraulic Pump Assembly...............................................................................377 Flow Control Valve....................................................................................378 Relief Valve..........................................................................................378 OPERATION.................................................................................................378 Steering System.......................................................................................378 Hydraulic Pump........................................................................................379 Flow Control Valve....................................................................................379 Relief Valve..........................................................................................379 STEERING WHEEL AND COLUMN ASSEMBLY........................................................................380 Removal (Serial Code C177 And C187)...................................................................380 Installation (Serial Code C177 And C187)..............................................................380 Removal (Serial Code B177 And B187)...................................................................383 Installation (Serial Code B177 And B187)..............................................................383 STEERING CONTROL UNIT.....................................................................................384 Description...........................................................................................384 Operation, Control Valve Section......................................................................384 Operation, Metering Section...........................................................................385 CHECKS AND ADJUSTMENTS....................................................................................385 Remove Air From The Steering System...................................................................385 Check And Adjust Steering Relief Pressure.............................................................385 Check Hydraulic Pump For Correct Flow.................................................................385 TROUBLESHOOTING...............................................................................................386 1800458...........................................................................................................387 INTRODUCTION..................................................................................................387 GENERAL...................................................................................................387 SERVICE BRAKES AND PARKING BRAKE..............................................................................387 DESCRIPTION AND OPERATION.................................................................................387 Service Brakes........................................................................................387 Parking Brake.........................................................................................388 REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES...........................................388 Parking Brake.........................................................................................390 CLEANING..................................................................................................391 INSPECTION................................................................................................391 ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES.........................................391 Adjustments...........................................................................................394 Parking Brake Installation............................................................................395 Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes........................395 REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES...........................................397 Parking Brake.........................................................................................399 CLEANING..................................................................................................400 INSPECTION................................................................................................400 ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES.........................................400 Adjustments...........................................................................................402 Parking brake.........................................................................................403 Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes........................403 MASTER CYLINDER...........................................................................................404 Removal...............................................................................................404 Repair................................................................................................404 Installation..........................................................................................404 Cleaning And Inspection...............................................................................406 MASTER CYLINDER WITH BRAKE BOOSTER........................................................................408 Operation.............................................................................................408 Repair................................................................................................408 CHECKS AND ADJUSTMENTS........................................................................................410 ADJUST THE SERVICE BRAKES.................................................................................410 TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY).......................................................410 REMOVE THE AIR FROM THE BRAKE SYSTEM......................................................................411 ADJUST THE INCHING/BRAKE PEDAL............................................................................411 ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL)..................................416 TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)............................................................416 Test 1................................................................................................416 Test 2................................................................................................417 TORQUE SPECIFICATIONS.........................................................................................417 TROUBLESHOOTING...............................................................................................417 1900130...........................................................................................................420 INTRODUCTION..................................................................................................420 GENERAL...................................................................................................420 DESCRIPTION...............................................................................................422 Hydraulic System......................................................................................422 Gear Pump Assembly....................................................................................422 Flow Control Valve....................................................................................423 Relief Valve (Early Model)............................................................................423 Relief Valve (Later Model)............................................................................423 OPERATION.................................................................................................425 Hydraulic System......................................................................................425 Gear Pump.............................................................................................425 Flow Control Valve....................................................................................425 Relief Valve (Early Model)............................................................................425 Relief Valve (Later Model)............................................................................425 REPAIR........................................................................................................427 GEAR PUMP ASSEMBLY........................................................................................427 Removal and Disassembly...............................................................................427 Assembly and Installation.............................................................................428 CHECKS AND ADJUSTMENTS........................................................................................428 CHECK AND ADJUST STEERING RELIEF PRESSURE.................................................................428 CHECK GEAR PUMP FOR CORRECT FLOW..........................................................................429 TROUBLESHOOTING...............................................................................................429 1900339...........................................................................................................431 INTRODUCTION..................................................................................................431 GENERAL...................................................................................................431 DESCRIPTION...............................................................................................431 REPAIRS.......................................................................................................433 REMOVAL AND DISASSEMBLY...................................................................................433 CLEANING..................................................................................................433 INSPECTION................................................................................................433 ASSEMBLY AND INSTALLATION.................................................................................434 TROUBLESHOOTING...............................................................................................435 GENERAL...................................................................................................435 2100103...........................................................................................................436 INTRODUCTION..................................................................................................439 GENERAL...................................................................................................439 DESCRIPTION...............................................................................................439 REPAIRS.......................................................................................................439 REMOVAL...................................................................................................439 DISASSEMBLY...............................................................................................439 CLEANING..................................................................................................439 ASSEMBLY..................................................................................................439 Tilt Cylinders for the XM and XMS Models..............................................................439 Tilt Cylinders with O-Ring or Single Lip Seals........................................................441 Tilt Cylinders for H700-800A and Early Model H700-920B................................................441 INSTALLATION..............................................................................................441 Tilt Cylinders with Chevron Packing...................................................................441 CHECKS AND ADJUSTMENTS........................................................................................445 CHECK THE TILT CYLINDERS FOR LEAKS........................................................................445 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...................................................445 TROUBLESHOOTING...............................................................................................448 2200106...........................................................................................................451 INTRODUCTION..................................................................................................451 GENERAL...................................................................................................451 DESCRIPTION AND OPERATION.................................................................................451 REPAIRS.......................................................................................................453 REMOVAL...................................................................................................453 DISSASEMBLY...............................................................................................453 CLEANING..................................................................................................454 ASSEMBLY..................................................................................................454 INSTALLATION..............................................................................................454 CHECKS AND ADJUSTMENTS........................................................................................455 GENERAL...................................................................................................455 TROUBLESHOOTING...............................................................................................457 2200132...........................................................................................................459 INTRODUCTION..................................................................................................459 GENERAL...................................................................................................459 DESCRIPTION...............................................................................................459 Starting System.......................................................................................459 Ignition System.......................................................................................459 Charging System.......................................................................................460 REPAIR........................................................................................................462 STARTER...................................................................................................462 Removal And Disassembly...............................................................................462 Assembly And Installation.............................................................................462 BALLAST RESISTOR RELAY (Earlier Production)...............................................................464 DISTRIBUTOR (Earlier Production With Contact Points)......................................................464 Removal And Disassembly...............................................................................464 Assembly And Installation.............................................................................466 COIL REPLACEMENT..........................................................................................466 DISTRIBUTOR (Later Production with Electronic Ignition System)............................................466 Removal And Disassembly...............................................................................466 Assembly And Installation.............................................................................468 ALTERNATOR (All Models)...................................................................................468 Removal And Disassembly...............................................................................468 Assembly And Installation.............................................................................469 REGULATOR REPLACEMENT (Earlier Production)................................................................470 CHECKS AND ADJUSTMENTS........................................................................................471 GENERAL...................................................................................................471 STARTER...................................................................................................471 Check Operation.......................................................................................471 Check Brush Length....................................................................................472 Check Brush Holder....................................................................................472 Armature..............................................................................................472 Field Windings........................................................................................472 Clutch And Bearing....................................................................................472 BALLAST RESISTOR RELAY (Earlier Production)...............................................................472 DISTRIBUTOR...............................................................................................473 Distributor Contact Clearance.........................................................................473 SPARK PLUGS...............................................................................................474 COIL AND BALLAST RESISTOR (Earlier Production)............................................................474 ALTERNATOR................................................................................................474 Check For Low Output (Alternator With Separate Regulator).............................................474 Check For Low Output (Alternator With Integral Regulator).............................................476 Check For High Output (Alternator With Separate Regulator)............................................477 Check For High Output (Alternator With Integral Regulator)............................................477 Rotor Resistance (Alternator with Separate Regulator).................................................477 Diodes Circuit (Alternator with Separate Regulator)...................................................478 Diode Assembly (Alternator With Separate Regulator)...................................................478 Check The Diodes, Diode Trio (Alternator with Integral Regulator).....................................478 Check The Rectifier Bridge (Alternator with Integral Regulator).......................................479 Check Field Winding For The Rotor (All Alternators)...................................................479 Check Windings In The Stator (All Alternators)........................................................480 Brushes And Bearings..................................................................................480 Check The Voltage Regulator (Alternator with Separate Regulator)......................................480 Check The Voltage Regulator (Alternator with Integral Regulator)......................................481 ADJUSTMENTS...............................................................................................481 TROBLESHOOTING................................................................................................482 2200134...........................................................................................................484 INTRODUCTION..................................................................................................484 GENERAL...................................................................................................484 DESCRIPTION...............................................................................................484 Starting System.......................................................................................484 Charging System.......................................................................................484 Vacuum Pump On Alternator (On Units With Brake Booster)...............................................486 REPAIRS.......................................................................................................487 STARTER...................................................................................................487 Removal And Disassembly...............................................................................487 Assembly And Installation.............................................................................487 REPLACING GLOW PLUGS......................................................................................489 ALTERNATOR (With Vaccum Pump).............................................................................489 Removal And Disassembly...............................................................................489 Cleaning..............................................................................................491 Assembly And Installation.............................................................................491 ALTERNATOR (Without Vacuum Pump)..........................................................................492 Removal And Disassembly...............................................................................492 Cleaning..............................................................................................494 Assembly And Installation.............................................................................494 REGULATOR REPLACEMENT.....................................................................................495 CHECKS........................................................................................................495 GENERAL...................................................................................................495 STARTER...................................................................................................495 Starter Operation.....................................................................................495 Solenoid Coil Checks..................................................................................496 Brush Length..........................................................................................496 Brush Holder..........................................................................................496 Armature..............................................................................................496 Field Windings........................................................................................497 Clutch And Bearings...................................................................................497 COLD START AID............................................................................................497 Glow Plugs............................................................................................497 Resistor..............................................................................................497 CHARGING CIRCUIT..........................................................................................497 Check For Low Output..................................................................................497 Check Ford High Output................................................................................499 ALTERNATOR................................................................................................499 Rotor Resistance......................................................................................499 Diodes Circuit........................................................................................499 Rotor Coil............................................................................................500 Stator Coil...........................................................................................500 Diode Assembly........................................................................................500 Brushes And Bearings..................................................................................501 REGULATOR (At Hydraulic Tank).............................................................................501 TROUBLESHOOTING...............................................................................................502 2200143...........................................................................................................505 INTRODUCTION..................................................................................................505 GENERAL...................................................................................................505 DESCRIPTION...................................................................................................505 GENERAL...................................................................................................505 STEERING COLUMN GAUGES, METERS AND INDICATORS.............................................................508 LED DISPLAY PANEL.........................................................................................508 Battery Discharge Indicators .........................................................................508 Brush Wear Indicators.................................................................................509 Motor Temperature Indicators..........................................................................510 "LX" SERIES INSTRUMENT PANEL DISPLAY......................................................................511 Hourmeter Functions...................................................................................512 Battery Indicator Function............................................................................512 Status Code Function..................................................................................512 CHECKS AND ADJUSTMENTS........................................................................................512 GENERAL...................................................................................................512 REPLACEMENT...................................................................................................513 GENERAL...................................................................................................513 METER REPLACEMENT.........................................................................................513 SENDER REPLACEMENT........................................................................................514 Fuel Level Sender.....................................................................................514 Pressure And Temperature Sender.......................................................................515 I.T.W. DISPLAY PANEL......................................................................................515 Removal...............................................................................................515 SPECIFICATIONS................................................................................................516 TROUBLESHOOTING...............................................................................................517 2200144...........................................................................................................518 ELECTRICAL WARNING DEVICES....................................................................................518 GENERAL...................................................................................................518 DESCRIPTION...............................................................................................518 Operator Controlled Horns.............................................................................518 System Warning Lights, Buzzers and Bells..............................................................518 Reverse Warning Horns.................................................................................519 Warning Lights........................................................................................519 REPLACEMENT...............................................................................................520 General...............................................................................................520 Replacing Horns or Bells..............................................................................520 Replacing Horn Relay or Buzzer........................................................................520 Replacing Warning Lights..............................................................................520 Light Assemblies......................................................................................521 Replacing Flashing Units..............................................................................521 2200463...........................................................................................................522 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS).....................................................................522 GENERAL...................................................................................................522 DESCRIPTION...............................................................................................522 What MSTS Does........................................................................................524 How MSTS Begins Operation.............................................................................524 OPERATION.................................................................................................524 Pulse Generator.......................................................................................524 HEI Module............................................................................................525 When the Engine Is Being Started......................................................................525 When the Engine Is Running............................................................................527 Manifold Absolute Pressure (MAP)......................................................................527 Coolant Temperature Sensor (CTS)......................................................................527 Electronic Control Module (ECM), Corrections..........................................................528 The Initial Timing Connector..........................................................................528 Gasoline and LPG Conversions..........................................................................529 TROUBLESHOOTING...............................................................................................531 GENERAL...................................................................................................531 TOOLS AND TEST EQUIPMENT..................................................................................531 MSTS TROUBLESHOOTING......................................................................................532 Test Description......................................................................................532 IGNITION SYSTEM TROUBLESHOOTING...........................................................................534 Test Description......................................................................................534 ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING.............................................................537 Circuit Description...................................................................................537 Test Description......................................................................................537 MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING..........................................................540 Circuit Description...................................................................................540 Test Description......................................................................................540 COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING..........................................................543 Circuit Description...................................................................................543 Test Description......................................................................................543 REPAIRS.......................................................................................................545 DISTRIBUTOR...............................................................................................545 Removal...............................................................................................545 Disassembly...........................................................................................546 Inspection............................................................................................546 Assembly..............................................................................................547 Installation..........................................................................................547 Igntion Timing........................................................................................547 HEI MODULE................................................................................................548 Test For A Fault......................................................................................548 HEI Module Replacement................................................................................548 SENSING COIL..............................................................................................549 Test For A Fault......................................................................................549 Sensing Coil Replacement..............................................................................549 IGNITION COIL.............................................................................................549 Test For A Fault......................................................................................549 ELECTRONIC CONTROL MODULE (ECM)...........................................................................550 Removal...............................................................................................550 Installation..........................................................................................550 COOLANT TEMPERATURE SENSOR (CTS)..........................................................................550 Removal...............................................................................................550 Installation..........................................................................................551 MANIFOLD ABSOLUTE PRESSURE (MAP)..........................................................................551 Removal...............................................................................................551 Installation..........................................................................................551 PRESSURE CONVERSION CHART.............................................................................552 2200520...........................................................................................................553 INTRODUCTION..................................................................................................553 GENERAL...................................................................................................553 DESCRIPTION...............................................................................................553 Starting System.......................................................................................553 Charging System.......................................................................................554 REPAIRS.......................................................................................................555 STARTER...................................................................................................555 Removal and Disassembly...............................................................................555 Assembly and Installation.............................................................................555 ALTERNATOR................................................................................................557 Removal and Disassembly, C - 240 Engine...............................................................558 Cleaning..............................................................................................559 Assembly and Installation, C - 240 Engine.............................................................559 Removal and Disassembly, 4JB1 and 4JG2 Engines........................................................560 Cleaning..............................................................................................562 Assembly and Installation, 4JB1 and 4JG2 Engines......................................................562 REPLACING GLOW PLUGS......................................................................................563 CHECKS........................................................................................................563 GENERAL...................................................................................................563 STARTER...................................................................................................563 Starter Operation.....................................................................................563 Solenoid Coil Checks..................................................................................564 Brush Length..........................................................................................564 Brush Holder..........................................................................................565 Armature..............................................................................................565 Field Windings........................................................................................565 Clutch and Bearings...................................................................................565 COLD START AID............................................................................................565 Glow Plugs............................................................................................565 Fuse..................................................................................................565 Relay and Timer.......................................................................................565 CHARGING CIRCUIT..........................................................................................566 Check for Low Output..................................................................................566 Check for High Output.................................................................................567 ALTERNATOR................................................................................................567 Diodes Circuit........................................................................................567 Rotor Coil............................................................................................568 Stator Coil...........................................................................................568 Brushes and Bearings..................................................................................569 Check the Voltage Regulator...........................................................................569 TROUBLESHOOTING...............................................................................................570 4000135...........................................................................................................572 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................572 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................572 LIFT CYLINDERS................................................................................................575 GENERAL...................................................................................................575 DESCRIPTION...............................................................................................575 Lowering Control Valve................................................................................575 Cylinders (General)...................................................................................578 Cylinders (H520-620B,H700-800A).......................................................................580 Cylinders (H360-460B).................................................................................581 Cylinders (Two-Speed).................................................................................581 REPAIRS.......................................................................................................582 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST....................................................582 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............582 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...............................586 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.........................584 DISASSEMBLY...............................................................................................584 ASSEMBLY..................................................................................................586 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.............................................................586 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............586 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead......................586 CHEVRON PACKING...........................................................................................587 LIFT CYLINDERS FOR VISTA MASTS................................................................................590 DESCRIPTION...............................................................................................590 Lowering Control Valve................................................................................592 REMOVAL...................................................................................................593 DISASSEMBLY...............................................................................................593 ASSEMBLY..................................................................................................593 INSTALLATION..............................................................................................594 Main Lift Cylinders...................................................................................594 Free-Lift Cylinders...................................................................................594 CHECKS AND ADJUSTMENTS........................................................................................595 CHECK FOR LEAKS IN LIFT SYSTEM............................................................................595 TROUBLESHOOTING...............................................................................................596 SPECIFICATIONS................................................................................................597 4000222...........................................................................................................598 INTRODUCTION..................................................................................................598 GENERAL...................................................................................................598 MAST WELDMENTS............................................................................................598 CARRIAGE..................................................................................................598 MAST MOUNTS...............................................................................................599 VISTA® TWO-STAGE MAST.........................................................................................600 DESCRIPTION AND OPERATION.................................................................................600 VISTA® FREE-LIFT MAST.........................................................................................602 DESCRIPTION...............................................................................................602 OPERATION.................................................................................................602 VISTA® THREE-STAGE MAST.......................................................................................604 DESCRIPTION...............................................................................................604 OPERATION.................................................................................................604 VISTA® FOUR-STAGE MAST........................................................................................605 DESCRIPTION...............................................................................................605 OPERATION.................................................................................................606 4000223...........................................................................................................608 VISTA MAST, REPAIR............................................................................................608 GENERAL...................................................................................................608 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................608 FORKS.....................................................................................................609 Forks, Removal And Installation.......................................................................609 CARRIAGE..................................................................................................610 Removal...............................................................................................610 Installation..........................................................................................611 MASTS.....................................................................................................611 Removal...............................................................................................611 Disassembly...........................................................................................612 Cleaning and Inspection...............................................................................617 Assembly..............................................................................................617 Installation..........................................................................................621 SIDE-SHIFT CARRIAGE (EARLIER DESIGN)......................................................................622 Removal...............................................................................................622 Repairs...............................................................................................622 Installation..........................................................................................622 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)...............................................................623 Removal...............................................................................................623 Repairs...............................................................................................623 Installation..........................................................................................624 CHECKS AND ADJUSTMENTS........................................................................................625 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................625 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...............................................626 LIFT CHAIN ADJUSTMENTS....................................................................................627 MAST ADJUSTMENTS..........................................................................................627 CARRIAGE ADJUSTMENT.......................................................................................629 HEADER HOSE ARRANGEMENTS..................................................................................629 Two-Stage Header Hose.................................................................................630 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts.........................................630 TROUBLESHOOTING...............................................................................................635 8000231...........................................................................................................636 INTRODUCTION..................................................................................................636 NOMENCLATURE, THREADS.....................................................................................636 STRENGTH IDENTIFICATION...................................................................................637 TABLE 1. BOLTS AND SCREWS.....................................................................................637 TABLE 2. STUDS AND NUTS.......................................................................................638 TABLE 3. TORQUE NUTS..........................................................................................639 TABLE 4. TORQUE NUTS WITH NYLON INSERT........................................................................640 TABLE 5. TORQUE VALUES FOR INCH FASTENERS.....................................................................641 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...................................................................642 8000259...........................................................................................................645 PERIODIC MAINTENANCE..........................................................................................645 GENERAL...................................................................................................645 Serial Number Data....................................................................................645 HOW TO MOVE A DISABLED LIFT TRUCK.........................................................................646 How To Tow the Lift Truck.............................................................................646 HOW TO PUT A LIFT TRUCK ON BLOCKS.........................................................................646 How To Raise the Drive Tires..........................................................................646 How To Raise the Steering Tires.......................................................................647 MAINTENANCE PROCEDURES........................................................................................651 EVERY 8 HOURS OR DAILY........................................................................................651 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED................................................................651 Engine Oil............................................................................................651 Drive Belts...........................................................................................651 Cooling System........................................................................................651 Battery...............................................................................................652 Fuel System...........................................................................................654 Air Filter............................................................................................654 Hydraulic System Oil..................................................................................654 Tires and Wheels......................................................................................655 Forks.................................................................................................655 Forks, Adjustment.....................................................................................656 Forks, Removal And Installation.......................................................................656 Inspection Of Forks, Mast, and Lift Chains............................................................657 Safety Labels.........................................................................................658 Operator Restraint System.............................................................................658 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING................................................................659 Gauges, Lights, Horn, and Fuses.......................................................................659 Fuel Filter, Diesel Engine............................................................................660 How To Drain The Water From The Fuel Filter...........................................................660 Oil Level, Powershift Transmission....................................................................660 Control Levers and Pedals.............................................................................660 Lift System Operation.................................................................................660 Inching/Brake Pedal...................................................................................661 Service Brakes........................................................................................661 Parking Brake.........................................................................................661 Steering System.......................................................................................661 EVERY 250 HOURS OR TWO MONTHS.................................................................................662 ENGINE OIL AND FILTER.....................................................................................662 Mazda, GM, And Later Production Isuzu Engines.........................................................662 Earlier Production Isuzu C240 Engines.................................................................662 GOVERNOR, MAZDA ENGINE....................................................................................663 DRIVE BELTS...............................................................................................663 Mazda Engine..........................................................................................663 Isuzu, GM 4-181, And GM 4-153 Engines.................................................................663 BRAKE FLUID...............................................................................................664 HYDRAULIC TANK BREATHER, CLEAN AND CHECK..................................................................664 FORKS, CHECK FOR WEAR AND DAMAGE..........................................................................664 LIFT CHAINS...............................................................................................664 Lubrication...........................................................................................664 Check For Wear........................................................................................664 MAST, LUBRICATION.........................................................................................665 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...............................................................665 CONTROL LEVERS AND PEDALS, LUBRICATION....................................................................666 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.......................................................................666 Idle Speed, Diesel....................................................................................666 LPG Carburetor........................................................................................667 Gasoline Carburetor...................................................................................667 EVERY 1000 HOURS OR SIX MONTHS................................................................................668 DIESEL FUEL FILTER........................................................................................668 Filter Replacement, Models Without A Water Separator..................................................669 Filter Replacement, Models With A Water Separator.....................................................669 Remove Air from the Diesel Fuel System................................................................669 DIFFERENTIAL..............................................................................................670 VALVE CLEARANCE ADJUSTMENT................................................................................670 IGNITION SYSTEM, MAZDA AND GM ENGINES.....................................................................670 PCV VALVE AND FILTER......................................................................................672 EVERY 2000 HOURS OR YEARLY....................................................................................672 HYDRAULIC SYSTEM..........................................................................................672 Replace the Hydraulic Oil and Filter..................................................................672 POWERSHIFT TRANSMISSION...................................................................................672 COOLING SYSTEM............................................................................................673 SERVICE BRAKES............................................................................................673 DIFFERENTIAL..............................................................................................673 WHEEL BEARINGS............................................................................................674 Steering Wheels, lubrication..........................................................................674 Drive Wheels, Lubrication.............................................................................674 GASOLINE FUEL FILTER, REPLACEMENT.........................................................................674 PCV VALVE, GM ENGINES.....................................................................................674 LPG FILTER, REPLACEMENT...................................................................................674 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A............................................................674 GENERAL PROCEDURES............................................................................................675 CHECK THE HOOD LATCH......................................................................................675 LIFT CHAIN ADJUSTMENTS....................................................................................675 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................677 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................678 Check the Lift Cylinders for Leaks....................................................................678 Check the Tilt Cylinders for Leaks....................................................................678 FUEL INJECTORS............................................................................................679 WELDING REPAIRS...........................................................................................679 CHANGES TO THE OVERHEAD GUARD.............................................................................679 WHEELS AND TIRES..........................................................................................679 Solid Rubber Tires (Press-on).........................................................................679 Install The Wheels....................................................................................680 Pneumatic Tires, Remove The Wheels From The Lift Truck................................................681 Pneumatic Tires, Remove the Tire From The Wheel.......................................................681 Pneumatic Tires, Install The Wheel In The Tire........................................................682 Pneumatic Tires, Add Air To The Tires.................................................................683 Pneumatic Tires, Install the Wheels...................................................................684 Pneumatic Tires, Installation Procedures, Dual Drive Wheels...........................................684 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.........................................................685 Remove The Wheels From The Lift Truck.................................................................685 Remove The Tire From The Wheel........................................................................685 Install The Tire On The Wheel.........................................................................686 REFERENCE TABLE...............................................................................................687 8000461...........................................................................................................688 FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC..........................................................................689 FIGURE 2. TRANSMISSION SCHEMATIC..............................................................................690 FIGURE 3. INSTRUMENT PANEL ELECTRICAL DIAGRAM.................................................................691 FIGURE 4. MAZDA ENGINE, GASOLINE/LPG WIRING SCHEMATIC.........................................................693 FIGURE 5. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating).........................................695 FIGURE 6. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)........................................697 FIGURE 7. DIESEL ENGINE WIRING SCHEMATIC......................................................................699 FIGURE 8. DIESEL ENGINE CABLE DIAGRAM (D Rating)..............................................................701 FIGURE 9. DIESEL (SAFETY) ENGINE CABLE DIAGRAM (DS RATING)....................................................703 FIGURE 10. GM ENGINE, GASOLINE/LPG WIRING DIAGRAM (GS and LPS Rating).........................................705 FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)...........................................707 FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)..........................................709
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