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Hyster C177 (H40-60XL) Service Manual – PDF DOWNLOAD
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Description
Hyster C177 (H40-60XL) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C177 (H40-60XL) Service Manual – PDF DOWNLOAD
Language : English
Pages : 688
Downloadable : Yes
File Type : PDF
Size: 19.4 MB
TABLE OF CONTENTS:
Hyster C177 (H40-60XL) Service Manual – PDF DOWNLOAD
Alternator........................................................................................................ 1 INTRODUCTION.................................................................................................. 1 GENERAL................................................................................................... 1 DESCRIPTION............................................................................................... 1 REPAIRS....................................................................................................... 3 GENERAL................................................................................................... 3 REMOVAL AND DISASSEMBLY (Type A).......................................................................... 3 CLEANING.................................................................................................. 3 ASSEMBLY (Type A)......................................................................................... 4 REMOVAL AND DISAASSEMBLY (Type B)......................................................................... 6 CLEANING.................................................................................................. 8 ASSEMBLY (Type B)......................................................................................... 8 INSTALLATION (Type A and Type B).......................................................................... 9 CHECKS AND ADJUSTMENTS........................................................................................ 9 GENERAL................................................................................................... 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B).................................................... 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)................................................... 11 CHECK THE CIRCUIT FOR THE BRUSHES......................................................................... 13 Delco Alternators..................................................................................... 13 Motorola Alternators.................................................................................. 13 CHECK THE DIODES.......................................................................................... 13 CHECK THE DIODE BRIDGE.................................................................................... 13 Delco and Leece–Neville Alternators................................................................... 13 Motorola Alternators.................................................................................. 13 CHECK THE FIELD WINDING FOR THE ROTOR..................................................................... 14 CHECK THE WINDINGS IN THE STATOR.......................................................................... 14 CHECK THE VOLTAGE REGULATOR............................................................................... 15 TROUBLESHOOTING............................................................................................... 15 Brake System...................................................................................................... 16 INTRODUCTION.................................................................................................. 16 GENERAL................................................................................................... 16 SERVICE BRAKES AND PARKING BRAKE.............................................................................. 16 DESCRIPTION AND OPERATION................................................................................. 16 Service Brakes........................................................................................ 16 Parking Brake......................................................................................... 17 REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES........................................... 17 Parking Brake......................................................................................... 19 CLEANING.................................................................................................. 20 INSPECTION................................................................................................ 20 ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES......................................... 20 Adjustments........................................................................................... 23 Parking Brake Installation............................................................................ 24 Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes........................ 24 REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES........................................... 26 Parking Brake......................................................................................... 28 CLEANING.................................................................................................. 29 INSPECTION................................................................................................ 29 ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES......................................... 29 Adjustments........................................................................................... 31 Parking brake......................................................................................... 32 Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes........................ 32 MASTER CYLINDER........................................................................................... 33 Removal............................................................................................... 33 Repair................................................................................................ 33 Installation.......................................................................................... 33 Cleaning And Inspection............................................................................... 35 MASTER CYLINDER WITH BRAKE BOOSTER........................................................................ 37 Operation............................................................................................. 37 Repair................................................................................................ 37 CHECKS AND ADJUSTMENTS........................................................................................ 39 ADJUST THE SERVICE BRAKES................................................................................. 39 TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)....................................................... 39 REMOVE THE AIR FROM THE BRAKE SYSTEM...................................................................... 40 ADJUST THE INCHING/BRAKE PEDAL............................................................................ 40 ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL).................................. 45 TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)............................................................ 45 Test 1................................................................................................ 45 Test 2................................................................................................ 46 TORQUE SPECIFICATIONS......................................................................................... 46 TROUBLESHOOTING............................................................................................... 46 Capacities & Specifications....................................................................................... 49 LIFT TRUCK WEIGHTS*........................................................................................... 49 ENGINE SPECIFICATIONS......................................................................................... 49 ENGINE ELECTRICAL SPECIFICATIONS.............................................................................. 50 HYDRAULIC SPECIFICATIONS...................................................................................... 50 CAPACITIES.................................................................................................... 51 LIFT TRUCK TRAVEL SPEEDS...................................................................................... 51 TIRE SPECIFICATIONS........................................................................................... 51 MAST SPEEDS (Early A177* Units)............................................................................... 52 MAST SPEEDS (Later A177* Units)............................................................................... 52 MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)......................................... 53 MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)....................................................... 53 TORQUE SPECIFICATIONS......................................................................................... 55 TORQUE SPECIFICATIONS......................................................................................... 56 Cooling System.................................................................................................... 58 COOLING SYSTEM................................................................................................ 58 INTRODUCTION.............................................................................................. 58 DESCRIPTION............................................................................................... 58 RADIATOR.................................................................................................. 58 RADIATOR CAP.............................................................................................. 58 THERMOSTAT................................................................................................ 58 WATER PUMP................................................................................................ 59 FAN AND FAN SHROUD........................................................................................ 59 REPAIRS....................................................................................................... 59 COOLING SYSTEM CHECKS..................................................................................... 59 Exhaust Leaks......................................................................................... 59 RADIATOR.................................................................................................. 59 Checks................................................................................................ 59 Cleaning The Radiator................................................................................. 59 Drain The Cooling System.............................................................................. 61 Fill The Cooling System............................................................................... 61 WATER PUMP................................................................................................ 61 Checks................................................................................................ 61 THERMOSTAT................................................................................................ 62 Checks................................................................................................ 62 FAN AND FAN SHROUD........................................................................................ 62 TROUBLESHOOTING............................................................................................... 63 Diagrams.......................................................................................................... 64 FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC.......................................................................... 65 FIGURE 2. TRANSMISSION SCHEMATIC.............................................................................. 66 FIGURE 3. INSTRUMENT PANEL ELECTRICAL DIAGRAM................................................................. 67 FIGURE 4. MAZDA ENGINE, GASOLINE/LPG WIRING SCHEMATIC......................................................... 69 FIGURE 5. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)......................................... 71 FIGURE 6. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)........................................ 73 FIGURE 7. DIESEL ENGINE WIRING SCHEMATIC...................................................................... 75 FIGURE 8. DIESEL ENGINE CABLE DIAGRAM (D Rating).............................................................. 77 FIGURE 9. DIESEL (SAFETY) ENGINE CABLE DIAGRAM (DS RATING).................................................... 79 FIGURE 10. GM ENGINE, GASOLINE/LPG WIRING DIAGRAM (GS and LPS Rating)......................................... 81 FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)........................................... 83 FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating).......................................... 85 Drive Axle........................................................................................................ 90 INTRODUCTION.................................................................................................. 90 GENERAL................................................................................................... 90 DESCRIPTION............................................................................................... 90 REPAIRS....................................................................................................... 91 REMOVAL................................................................................................... 91 CLEANING.................................................................................................. 91 INSPECTION................................................................................................ 91 ASSEMBLY.................................................................................................. 91 TROUBLESHOOTING............................................................................................... 94 SPECIFICATIONS................................................................................................ 94 Electrical System (Isuzu)......................................................................................... 95 INTRODUCTION.................................................................................................. 95 GENERAL................................................................................................... 95 DESCRIPTION............................................................................................... 95 Starting System....................................................................................... 95 Charging System....................................................................................... 95 Vacuum Pump On Alternator (On Units With Brake Booster)............................................... 97 REPAIRS....................................................................................................... 98 STARTER................................................................................................... 98 Removal And Disassembly............................................................................... 98 Assembly And Installation............................................................................. 98 REPLACING GLOW PLUGS......................................................................................100 ALTERNATOR (With Vaccum Pump).............................................................................100 Removal And Disassembly...............................................................................100 Cleaning..............................................................................................102 Assembly And Installation.............................................................................102 ALTERNATOR (Without Vacuum Pump)..........................................................................103 Removal And Disassembly...............................................................................103 Cleaning..............................................................................................105 Assembly And Installation.............................................................................105 REGULATOR REPLACEMENT.....................................................................................106 CHECKS........................................................................................................106 GENERAL...................................................................................................106 STARTER...................................................................................................106 Starter Operation.....................................................................................106 Solenoid Coil Checks..................................................................................107 Brush Length..........................................................................................107 Brush Holder..........................................................................................107 Armature..............................................................................................107 Field Windings........................................................................................108 Clutch And Bearings...................................................................................108 COLD START AID............................................................................................108 Glow Plugs............................................................................................108 Resistor..............................................................................................108 CHARGING CIRCUIT..........................................................................................108 Check For Low Output..................................................................................108 Check Ford High Output................................................................................110 ALTERNATOR................................................................................................110 Rotor Resistance......................................................................................110 Diodes Circuit........................................................................................110 Rotor Coil............................................................................................111 Stator Coil...........................................................................................111 Diode Assembly........................................................................................111 Brushes And Bearings..................................................................................112 REGULATOR (At Hydraulic Tank).............................................................................112 TROUBLESHOOTING...............................................................................................113 Electrical System (Mazdz).........................................................................................116 INTRODUCTION..................................................................................................116 GENERAL...................................................................................................116 DESCRIPTION...............................................................................................116 Starting System.......................................................................................116 Ignition System.......................................................................................116 Charging System.......................................................................................117 REPAIR........................................................................................................119 STARTER...................................................................................................119 Removal And Disassembly...............................................................................119 Assembly And Installation.............................................................................119 BALLAST RESISTOR RELAY (Earlier Production)...............................................................121 DISTRIBUTOR (Earlier Production With Contact Points)......................................................121 Removal And Disassembly...............................................................................121 Assembly And Installation.............................................................................123 COIL REPLACEMENT..........................................................................................123 DISTRIBUTOR (Later Production with Electronic Ignition System)............................................123 Removal And Disassembly...............................................................................123 Assembly And Installation.............................................................................125 ALTERNATOR (All Models)...................................................................................125 Removal And Disassembly...............................................................................125 Assembly And Installation.............................................................................126 REGULATOR REPLACEMENT (Earlier Production)................................................................127 CHECKS AND ADJUSTMENTS........................................................................................128 GENERAL...................................................................................................128 STARTER...................................................................................................128 Check Operation.......................................................................................128 Check Brush Length....................................................................................129 Check Brush Holder....................................................................................129 Armature..............................................................................................129 Field Windings........................................................................................129 Clutch And Bearing....................................................................................129 BALLAST RESISTOR RELAY (Earlier Production)...............................................................129 DISTRIBUTOR...............................................................................................130 Distributor Contact Clearance.........................................................................130 SPARK PLUGS...............................................................................................131 COIL AND BALLAST RESISTOR (Earlier Production)............................................................131 ALTERNATOR................................................................................................131 Check For Low Output (Alternator With Separate Regulator).............................................131 Check For Low Output (Alternator With Integral Regulator).............................................133 Check For High Output (Alternator With Separate Regulator)............................................134 Check For High Output (Alternator With Integral Regulator)............................................134 Rotor Resistance (Alternator with Separate Regulator).................................................134 Diodes Circuit (Alternator with Separate Regulator)...................................................135 Diode Assembly (Alternator With Separate Regulator)...................................................135 Check The Diodes, Diode Trio (Alternator with Integral Regulator).....................................135 Check The Rectifier Bridge (Alternator with Integral Regulator).......................................136 Check Field Winding For The Rotor (All Alternators)...................................................136 Check Windings In The Stator (All Alternators)........................................................137 Brushes And Bearings..................................................................................137 Check The Voltage Regulator (Alternator with Separate Regulator)......................................137 Check The Voltage Regulator (Alternator with Integral Regulator)......................................138 ADJUSTMENTS...............................................................................................138 TROBLESHOOTING................................................................................................139 Frame.............................................................................................................141 INTRODUCTION..................................................................................................141 GENERAL...................................................................................................141 DESCRIPTION...............................................................................................141 REPAIRS.......................................................................................................141 COUNTERWEIGHT.............................................................................................142 Removal...............................................................................................142 Installation..........................................................................................142 MUFFLER...................................................................................................143 HOOD......................................................................................................143 Removal...............................................................................................143 Installation..........................................................................................143 RADIATOR AND COOLANT SYSTEM...............................................................................143 Removal...............................................................................................143 Installation..........................................................................................143 OVERHEAD GUARD............................................................................................144 Removal And Installation..............................................................................144 OPERATOR RESTRAINT SYSTEM.................................................................................144 ENGINE REMOVAL AND INSTALLATION...........................................................................145 Removal of the Engine and Transmission................................................................145 Installation of the Engine and Transmission...........................................................149 FUEL AND HYDRAULIC TANKS..................................................................................151 Inspection............................................................................................151 Repairs, Small Leaks..................................................................................151 Repairs, Large Leaks..................................................................................151 Cleaning..............................................................................................151 Steam Method Of Cleaning..............................................................................151 Chemical Solution Method of Cleaning..................................................................152 Additional Preparations For Repair....................................................................152 SAFETY LABELS.............................................................................................152 CAB.......................................................................................................154 Cab Replacement.......................................................................................154 Window Replacement....................................................................................154 Windshield Wipers and Heater..........................................................................156 Gasoline Carburetor (Mazda).......................................................................................157 THE CARBURETOR, (MAZDA M4-121G ENGINE)........................................................................157 DESCRIPTION...............................................................................................157 REPAIRS, CARBURETOR.......................................................................................158 Removal...............................................................................................158 Cleaning..............................................................................................161 Inspection............................................................................................161 Assembly..............................................................................................161 Installation..........................................................................................163 CHECKS AND ADJUSTMENTS....................................................................................163 Carburetor, Idle Speed And Mixture Adjustment.........................................................163 Adjust The Governor...................................................................................164 ADJUST THE THROTTLE LINKAGE...............................................................................165 SPECIFICATIONS................................................................................................165 TROUBLESHOOTING...............................................................................................166 GM Engine.........................................................................................................168 INTRODUCTION..................................................................................................168 GENERAL...................................................................................................168 DESCRIPTION...............................................................................................169 REMOVAL AND INSTALLATION OF THE ENGINE....................................................................169 CYLINDER HEAD AND MECHANISM...............................................................................169 Cylinder Head, Removal................................................................................169 Cylinder Head, Disassembly............................................................................170 Cleaning And Inspection...............................................................................171 Valve And Valve Seats.................................................................................172 Studs For The Rocker Arms.............................................................................172 Hydraulic Valve Lifters, Replacement..................................................................172 Hydraulic Valve Lifters, Cleaning And Inspection......................................................173 Cylinder Head, Assembly...............................................................................173 Cylinder Head, Installation...........................................................................173 Rocker Arm Cover, Installation........................................................................174 TIMING GEAR COVER.........................................................................................175 Removal...............................................................................................175 Installation..........................................................................................175 CAMSHAFT..................................................................................................176 Removal...............................................................................................176 Inspection............................................................................................177 Camshaft Bearings, Removal............................................................................177 Camshaft Bearings, Installation.......................................................................177 DISTRIBUTOR...............................................................................................178 Removal...............................................................................................178 Installation..........................................................................................178 LUBRICATION SYSTEM........................................................................................179 Oil Sump, Removal.....................................................................................179 Oil Sump, Installation................................................................................179 Oil Pump, Removal.....................................................................................179 Oil Pump, Disassembly and Repair......................................................................179 Oil Pump, Assembly....................................................................................180 Oil Pump, Installation................................................................................180 PISTON AND CONNECTING ROD ASSEMBLIES......................................................................180 Connecting Rod Bearings, Replacement..................................................................180 Piston And Connecting Rod Assemblies, Removal.........................................................181 Disassembly...........................................................................................182 Piston, Cleaning And Inspection.......................................................................182 Cylinder Bores, Inspection And Repair.................................................................182 Piston Rings..........................................................................................183 Assembly..............................................................................................184 Piston And Connecting Rod Assemblies, Installation....................................................184 CRANKSHAFT................................................................................................185 Main Bearings, Replacement............................................................................185 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only)..............................186 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal)..............186 Crankshaft, Removal...................................................................................187 Inspection and Repair.................................................................................188 How To Check The Clearance Between The Main Bearings And Their Journals...............................188 Installation..........................................................................................189 FLYWHEEL AND FLYWHEEL HOUSING.............................................................................190 Flywheel, Removal.....................................................................................190 Ring Gear, Replacement................................................................................191 Flywheel, Installation................................................................................191 COOLING SYSTEM............................................................................................191 Coolant Pump..........................................................................................191 Fan Drive.............................................................................................192 Viscous Fan Drive.....................................................................................192 ENGINE SPECIFICATIONS.........................................................................................193 ENGINE DATA...............................................................................................193 CYLINDER HEAD.............................................................................................193 HYDRAULIC VALVE LIFTER....................................................................................194 CAMSHAFT..................................................................................................194 PISTONS...................................................................................................194 CYLINDER BORE.............................................................................................195 CRANKSHAFT................................................................................................195 CONNECTING RODS...........................................................................................195 COOLING SYSTEM............................................................................................196 LUBRICATION SYSTEM........................................................................................196 TORQUE SPECIFICATIONS.........................................................................................196 Hydraulic Pump & Drive Assembly...................................................................................199 INTRODUCTION..................................................................................................199 GENERAL...................................................................................................199 DESCRIPTION...............................................................................................199 REPAIRS.......................................................................................................201 REMOVAL AND DISASSEMBLY...................................................................................201 CLEANING..................................................................................................201 INSPECTION................................................................................................201 ASSEMBLY AND INSTALLATION.................................................................................202 TROUBLESHOOTING...............................................................................................203 GENERAL...................................................................................................203 Hydraulic System & Gear Pump......................................................................................204 INTRODUCTION..................................................................................................204 GENERAL...................................................................................................204 DESCRIPTION...............................................................................................206 Hydraulic System......................................................................................206 Gear Pump Assembly....................................................................................206 Flow Control Valve....................................................................................207 Relief Valve (Early Model)............................................................................207 Relief Valve (Later Model)............................................................................207 OPERATION.................................................................................................209 Hydraulic System......................................................................................209 Gear Pump.............................................................................................209 Flow Control Valve....................................................................................209 Relief Valve (Early Model)............................................................................209 Relief Valve (Later Model)............................................................................209 REPAIR........................................................................................................211 GEAR PUMP ASSEMBLY........................................................................................211 Removal and Disassembly...............................................................................211 Assembly and Installation.............................................................................212 CHECKS AND ADJUSTMENTS........................................................................................212 CHECK AND ADJUST STEERING RELIEF PRESSURE.................................................................212 CHECK GEAR PUMP FOR CORRECT FLOW..........................................................................213 TROUBLESHOOTING...............................................................................................213 INCH (SAE) & Metric Fasteners.....................................................................................215 INTRODUCTION..................................................................................................215 NOMENCLATURE, THREADS.....................................................................................215 STRENGTH IDENTIFICATION...................................................................................216 TABLE 1. BOLTS AND SCREWS.....................................................................................216 TABLE 2. STUDS AND NUTS.......................................................................................217 TABLE 3. TORQUE NUTS..........................................................................................218 TABLE 4. TORQUE NUTS WITH NYLON INSERT........................................................................219 TABLE 5. TORQUE VALUES FOR INCH FASTENERS.....................................................................220 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...................................................................221 Instrument Panel indicators & Senders.............................................................................224 INTRODUCTION..................................................................................................224 GENERAL...................................................................................................224 DESCRIPTION...................................................................................................224 GENERAL...................................................................................................224 STEERING COLUMN GAUGES, METERS AND INDICATORS.............................................................227 LED DISPLAY PANEL.........................................................................................227 Battery Discharge Indicators..........................................................................227 Brush Wear Indicators.................................................................................228 Motor Temperature Indicators..........................................................................229 "LX" SERIES DISPLAY PANEL.................................................................................230 Hourmeter Functions...................................................................................231 Battery Indicator Function............................................................................231 Status Code Function..................................................................................231 "ZX" SERIES DISPLAY PANELS................................................................................231 Display Panel.........................................................................................232 Basic Display Panels..................................................................................232 Performance Display...................................................................................234 Brush Wear Indicators.................................................................................237 CHECKS AND ADJUSTMENTS........................................................................................237 GENERAL...................................................................................................237 REPLACEMENT...................................................................................................238 GENERAL...................................................................................................238 METER REPLACEMENT.........................................................................................238 SENDER REPLACEMENT........................................................................................239 Fuel Level Sender.....................................................................................239 Pressure And Temperature Sender.......................................................................239 I.T.W. DISPLAY PANEL......................................................................................240 Removal...............................................................................................240 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT.....................................241 Removal...............................................................................................241 Replacing Display Panel Assembly......................................................................241 Indicator LEDs........................................................................................241 Battery Indicators....................................................................................241 Digital Display (Performance Disply Panel Only).......................................................241 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only).........241 Replacing Parts Of The Basic Display Panel............................................................242 Replacing Parts Of The Performance Display Panel......................................................244 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT.........................................244 Removal And Replacement...............................................................................244 SPECIFICATIONS................................................................................................245 TROUBLESHOOTING...............................................................................................246 Isuzu C240 (2.4L) Engine..........................................................................................247 INTRODUCTION .................................................................................................247 GENERAL ..................................................................................................247 DESCRIPTION ..............................................................................................247 FUEL SYSTEM ..............................................................................................248 Description ..........................................................................................248 Operation, Fuel Injection Pump, Model VE .............................................................250 Operation, Fuel Injection Pump, Model PE4A ...........................................................251 Pneumatic Governor For Fuel Injection Pump, Model PE4A ...............................................252 Inlet Manifold For Fuel Injection Pump, Model PE4A ...................................................253 REPAIRS ......................................................................................................254 FUEL INJECTION PUMP (ALL MODELS) .........................................................................254 Removal ..............................................................................................254 Installation .........................................................................................254 REMOVAL AND INSTALLATION OF THE ENGINE ...................................................................254 CYLINDER HEAD AND VALVE MECHANISM ........................................................................254 Cylinder Head, Removal ...............................................................................254 Valve Guides, Replacement ............................................................................255 Cylinder Head, Inspection And Repair .................................................................256 Combustion Chamber Plugs, Inspection And Repair ......................................................256 Combustion Chamber Plugs, Installation ...............................................................256 Valves, Inspection And Repair ........................................................................257 Valve Seat, Inspection ...............................................................................257 Valve Seat, Removal ..................................................................................258 Valve Seat, Installation .............................................................................258 Valve Spring, Inspection .............................................................................258 Rocker Arms, Inspection And Assembly .................................................................258 Installation Of The Cylinder Head ....................................................................259 TIMING GEAR CASE .........................................................................................260 Removal ..............................................................................................260 Installation .........................................................................................260 CAMSHAFT .................................................................................................262 Removal ..............................................................................................262 Inspection ...........................................................................................262 Camshaft Bearings ....................................................................................263 Cam Followers ........................................................................................263 CAMSHAFT, INSTALLATION ...................................................................................263 CRANKSHAFT AND MAIN BEARINGS .............................................................................264 Crankshaft, Removal ..................................................................................264 Crankshaft, Inspection And Repair ....................................................................264 Main Bearings ........................................................................................264 Pilot Bearing ........................................................................................265 Crankshaft, Installation .............................................................................265 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) ..........................................................267 Flywheel, Removal ....................................................................................267 Ring Gear, Replacement ...............................................................................267 Flywheel, Installation ...............................................................................267 PISTONS AND CONNECTING RODS ..............................................................................268 Pistons And Connecting Rods, Removal .................................................................268 Disassembly ..........................................................................................268 Pistons, Inspection And Repair .......................................................................269 Piston Rings, Inspection And Repair ..................................................................269 Piston Pins, Inspection And Repair ...................................................................270 Connecting Rods, Inspection And Repair ...............................................................271 Pistons And Connecting Rods, Assembly And Installation ...............................................271 CYLINDER BLOCK AND CYLINDER LINERS .......................................................................271 Cylinder Liners, Inspection ..........................................................................271 Replacement Of A Cylinder Liner ......................................................................272 LUBRICATION SYSTEM .......................................................................................273 Oil Pump, Removal And Disassembly ....................................................................273 Oil Pump, Inspection .................................................................................273 Oil Pump, Assembly And Installation ..................................................................274 Oil Filter ...........................................................................................274 COOLING SYSTEM ...........................................................................................275 Coolant Pump, Removal ................................................................................275 Coolant Pump, Disassembly ............................................................................275 Coolant Pump, Assembly And Installation ..............................................................275 Thermostat, Replacement ..............................................................................276 CHECKS AND ADJUSTMENTS .......................................................................................276 VALVE CLEARANCE ADJUSTMENT ...............................................................................276 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ....................................................277 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A ..................................................278 FUEL INJECTORS ...........................................................................................278 Fuel Injectors, Removal ..............................................................................279 Fuel Injectors, Inspection ...........................................................................279 Fuel Injectors, Installation .........................................................................280 DIESEL FUEL FILTERS ......................................................................................280 Filter Replacement, Models With A Water Separator ....................................................280 Filter Replacement, Models Without A Water Separator .................................................281 Filter For The Fuel Injection Pump, Model PE4A .......................................................281 REMOVE AIR FROM THE FUEL SYSTEM ..........................................................................281 Throttle Linkage, Adjustment .........................................................................282 Idle Speed, Adjustment ...............................................................................282 Check The Elements For The Cold Start Aid System .....................................................282 ENGINE SPECIFICATIONS ........................................................................................282 TORQUE SPECIFICATIONS ........................................................................................284 Lift Cylinders....................................................................................................285 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................285 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................285 LIFT CYLINDERS................................................................................................288 GENERAL...................................................................................................288 DESCRIPTION...............................................................................................288 Lowering Control Valve................................................................................288 Cylinders (General)...................................................................................291 Cylinders (H520-620B,H700-800A).......................................................................293 Cylinders (H360-460B).................................................................................294 Cylinders (Two-Speed).................................................................................294 REPAIRS.......................................................................................................295 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST....................................................295 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............295 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...............................299 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.........................297 DISASSEMBLY...............................................................................................297 ASSEMBLY..................................................................................................299 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.............................................................299 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............299 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead......................299 CHEVRON PACKING...........................................................................................300 LIFT CYLINDERS FOR VISTA MASTS................................................................................303 DESCRIPTION...............................................................................................303 Lowering Control Valve................................................................................305 REMOVAL...................................................................................................306 DISASSEMBLY...............................................................................................306 ASSEMBLY..................................................................................................306 INSTALLATION..............................................................................................307 Main Lift Cylinders...................................................................................307 Free-Lift Cylinders...................................................................................307 CHECKS AND ADJUSTMENTS........................................................................................308 CHECK FOR LEAKS IN LIFT SYSTEM............................................................................308 TROUBLESHOOTING...............................................................................................309 SPECIFICATIONS................................................................................................310 LPG Fuel System...................................................................................................311 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100).....................................................................311 GENERAL...................................................................................................311 DESCRIPTION...............................................................................................311 Fuel Tank.............................................................................................312 Fuel Filter And Fuel Valve Unit.......................................................................313 Vaporizer.............................................................................................313 The IMPCO CA 100 Carbureto............................................................................315 IMPCO CA 50 Carburetor................................................................................317 The Governor (GM Engines Only)........................................................................318 Governor With Electronic Controller...................................................................319 REPAIRS.......................................................................................................320 LPG TANK..................................................................................................320 Removal...............................................................................................320 Installation..........................................................................................321 REPLACE THE HOSES.........................................................................................321 HYDROSTATIC RELIEF VALVE..................................................................................321 Removal and Installation..............................................................................321 FILTER UNIT...............................................................................................322 Replacement Of the Fuel Filter Element................................................................322 Replacement of the Diaphragm and Fuel Valve...........................................................323 VAPORIZER.................................................................................................323 Removal...............................................................................................323 Disassembly...........................................................................................323 Cleaning..............................................................................................323 Inspection............................................................................................323 Assembly..............................................................................................325 Installation..........................................................................................325 CARBURETOR (IMPCO CA 100).................................................................................327 Removal...............................................................................................327 Disassembly...........................................................................................327 Cleaning..............................................................................................327 Assembly..............................................................................................327 Installation..........................................................................................330 CARBURETER (IMPCO CA 50)..................................................................................329 Removal...............................................................................................329 Disassembly...........................................................................................329 Cleaning..............................................................................................330 Inspection............................................................................................330 Assembly (See FIGURE 26.).............................................................................330 Installation..........................................................................................330 CHECKS AND ADJUSTMENTS........................................................................................331 CHECK THE FILTER UNIT.....................................................................................331 CHECK THE VAPORIZER.......................................................................................331 Pressure Reducer Valve................................................................................331 Vapor Valve...........................................................................................331 ADJUST THE CARBURETOR.....................................................................................331 Idle Mixture..........................................................................................331 Idle Speed............................................................................................331 Power Mixture.........................................................................................331 ADJUST THE GOVERNOR (GM Engines Only).....................................................................332 Checks................................................................................................332 Main Adjusting Screw..................................................................................332 Secondary Adjusting Screw.............................................................................332 AISAN Governor........................................................................................333 Adjustment, AISAN Governor............................................................................333 TROUBLESHOOTING...............................................................................................334 Main Control Valve................................................................................................338 INTRODUCTION..................................................................................................338 GENERAL...................................................................................................338 DESCRIPTION...............................................................................................338 OPERATION.................................................................................................339 Lift Section..........................................................................................340 Tilt Section..........................................................................................340 Relief Valve..........................................................................................342 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................343 Operation.............................................................................................343 REPAIRS.......................................................................................................343 MAIN CONTROL VALVE........................................................................................343 Removal and Disassembly...............................................................................343 Cleaning and Inspection...............................................................................344 Assembly..............................................................................................344 Installation..........................................................................................344 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................344 Removal and Disassembly...............................................................................344 Assembly and Installation.............................................................................346 CHECKS AND ADJUSTMENTS........................................................................................346 PRESSURE RELIEF VALVES....................................................................................346 Primary Relief Valve..................................................................................346 Seconday Relief Valve.................................................................................347 CONTROL LEVER ARRANGEMENT.................................................................................347 TROUBLESHOOTING...............................................................................................350 SPECIFICATIONS................................................................................................352 Mazda M4-121G Engine..............................................................................................353 MAZDA M4-121G ENGINE..........................................................................................353 GENERAL...................................................................................................353 DESCRIPTION...............................................................................................354 REMOVAL AND INSTALLATION OF THE ENGINE....................................................................354 CYLINDER HEAD AND VALVE MECHANISM.........................................................................354 Cylinder Head, Removal................................................................................354 Cylinder Head, Inspection and Repairs.................................................................355 Rocker Arm Assembly...................................................................................355 Valve Guides..........................................................................................355 Valve Seats...........................................................................................356 Valves................................................................................................356 Valve Springs.........................................................................................356 Cylinder Head, Installation...........................................................................356 TIMING GEAR CASE, REMOVAL.................................................................................357 TIMING GEAR CASE, INSTALLATION............................................................................358 CAMSHAFT..................................................................................................358 Removal...............................................................................................358 Inspection............................................................................................359 Cam Followers, Inspection.............................................................................359 Installation..........................................................................................359 CRANKSHAFT AND MAIN BEARINGS..............................................................................359 Crankshaft, Removal...................................................................................359 Crankshaft, Inspection And Repair.....................................................................360 Main Bearings.........................................................................................361 Crankshaft, Installation..............................................................................361 PISTONS AND CONNECTING RODS...............................................................................362 Removal...............................................................................................362 Disassembly...........................................................................................362 Pistons, Inspection And Repair........................................................................362 Piston Rings..........................................................................................363 Piston Pin and Bushing................................................................................363 Connecting Rods and Bearings, Inspection..............................................................363 Pistons and Connecting Rods, Assembly.................................................................363 Pistons and Connecting Rods, Installation.............................................................364 CYLINDER BLOCK AND CYLINDER LINERS........................................................................364 Cylinder Block, Repairs...............................................................................364 Cylinder Liners.......................................................................................364 DISTRIBUTOR...............................................................................................365 Removal...............................................................................................365 Installation..........................................................................................365 OIL PUMP..................................................................................................367 Removal...............................................................................................367 Repairs...............................................................................................367 Installation..........................................................................................368 GOVERNOR..................................................................................................368 Description...........................................................................................368 Removal...............................................................................................368 Disassembly...........................................................................................369 Assembly..............................................................................................370 Installation..........................................................................................371 COOLANT PUMP..............................................................................................371 Removal...............................................................................................371 Disassembly and Repair................................................................................372 Assembly..............................................................................................372 Installation..........................................................................................373 FLYWHEEL..................................................................................................373 Repairs...............................................................................................373 Installation..........................................................................................373 CHECKS AND ADJUSTMENTS........................................................................................373 ADJUST THE VALVES.........................................................................................373 ADJUST THE THROTTLE LINKAGE...............................................................................374 ENGINE SPECIFICATIONS.........................................................................................374 ENGINE SPECIFICATIONS.....................................................................................374 Engine Data...........................................................................................374 Cooling System........................................................................................374 Cylinder Head and Valve Mechanism.....................................................................374 Camshaft..............................................................................................376 Timing Gear...........................................................................................377 Camshaft..............................................................................................377 Connecting Rods.......................................................................................377 Cylinder Liners.......................................................................................377 Pistons...............................................................................................377 Lubrication System....................................................................................378 Fuel Pump.............................................................................................378 TORQUE SPECIFICATIONS.....................................................................................379 TROUBLESHOOTING...............................................................................................380 MSTS-GM (Early Control Models)....................................................................................384 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS).....................................................................384 GENERAL...................................................................................................384 DESCRIPTION...............................................................................................384 What MSTS Does........................................................................................386 How MSTS Begins Operation.............................................................................386 OPERATION.................................................................................................386 Pulse Generator.......................................................................................386 HEI Module............................................................................................387 When the Engine Is Being Started......................................................................387 When the Engine Is Running............................................................................389 Manifold Absolute Pressure (MAP)......................................................................389 Coolant Temperature Sensor (CTS)......................................................................389 Electronic Control Module (ECM), Corrections..........................................................390 The Initial Timing Connector..........................................................................390 Gasoline and LPG Conversions..........................................................................391 TROUBLESHOOTING...............................................................................................393 GENERAL...................................................................................................393 TOOLS AND TEST EQUIPMENT..................................................................................393 MSTS TROUBLESHOOTING......................................................................................394 Test Description......................................................................................394 IGNITION SYSTEM TROUBLESHOOTING...........................................................................396 Test Description......................................................................................396 ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING.............................................................399 Circuit Description...................................................................................399 Test Description......................................................................................399 MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING..........................................................402 Circuit Description...................................................................................402 Test Description......................................................................................402 COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING..........................................................405 Circuit Description...................................................................................405 Test Description......................................................................................405 REPAIRS.......................................................................................................407 DISTRIBUTOR...............................................................................................407 Removal...............................................................................................407 Disassembly...........................................................................................408 Inspection............................................................................................408 Assembly..............................................................................................409 Installation..........................................................................................409 Igntion Timing........................................................................................409 HEI MODULE................................................................................................410 Test For A Fault......................................................................................410 HEI Module Replacement................................................................................410 SENSING COIL..............................................................................................411 Test For A Fault......................................................................................411 Sensing Coil Replacement..............................................................................411 IGNITION COIL.............................................................................................411 Test For A Fault......................................................................................411 ELECTRONIC CONTROL MODULE (ECM)...........................................................................412 Removal...............................................................................................412 Installation..........................................................................................412 COOLANT TEMPERATURE SENSOR (CTS)..........................................................................412 Removal...............................................................................................412 Installation..........................................................................................413 MANIFOLD ABSOLUTE PRESSURE (MAP)..........................................................................413 Removal...............................................................................................413 Installation..........................................................................................413 PRESSURE CONVERSION CHART.............................................................................414 MSTS-GM (Later Models)............................................................................................415 INTRODUCTION..................................................................................................415 GENERAL...................................................................................................415 DESCRIPTION...............................................................................................415 What MSTS Does........................................................................................415 How MSTS Begins Operation.............................................................................416 OPERATION.................................................................................................417 Distributor...........................................................................................417 Ignition Coil ........................................................................................417 Ignition Module.......................................................................................417 When the Engine Is Being Started......................................................................418 When the Engine Is Running ...........................................................................418 Manifold Absolute Pressure (MAP) Sensor...............................................................419 Engine Coolant Temperature (ECT) Sensor...............................................................420 MSTS Module Corrections...............................................................................420 TROUBLESHOOTING...............................................................................................422 GENERAL...................................................................................................422 TOOLS AND EQUIPMENT.......................................................................................423 MSTS......................................................................................................424 TROUBLESHOOTING PROCEDURE.................................................................................424 Where To Start........................................................................................424 Visual/Physical Inspection................................................................................424 Knowledge/Tools Required..................................................................................424 Damage From Static Discharge (Static Electricity).........................................................425 TROUBLESHOOTING INFORMATION...............................................................................425 Malfunction Indicator Lamp (MIL)......................................................................425 Connecting The CodeMate Tester........................................................................425 Reading Diagnostic Trouble Codes (DTC)................................................................426 Clearing Diagnostic Trouble Codes (DTC's).............................................................426 On-Board DIAGNOSTIC (ODB) System Check................................................................427 NO MALFUNCTION INDICATOR LAMP.............................................................................429 Circuit Description...................................................................................429 Test Description......................................................................................429 NO DTC-12, MALFUNCTION INDICATOR LAMP ON..................................................................431 Circuit Description...................................................................................431 Test Description......................................................................................431 STARTER ROTATES ENGINE, ENGINE DOES NOT RUN...............................................................433 Test Description......................................................................................433 DTC-14 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (LOW TEMPERATURE INDICATED)................................436 Circuit Description...................................................................................436 Test Description......................................................................................436 DTC-15 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (HIGH TEMPERATURE INDICATED)...............................438 Circuit Description...................................................................................438 Test Description......................................................................................438 DTC-34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR............................................................440 Circuit Description...................................................................................440 Test Description......................................................................................440 DTC-41 ELECTRONIC SPARK TIMING (EST OPEN CIRCUIT).........................................................443 Circuit Description...................................................................................443 Test Description......................................................................................443 DTC-42 ELECTRONIC SPARK TIMING (EST GROUNDED CIRCUIT).....................................................445 Circuit Description...................................................................................445 Test Description......................................................................................445 DTC 51 MSTS FAILURE.......................................................................................447 Circuit Description...................................................................................447 REPAIRS.......................................................................................................447 DISTRIBUTOR...............................................................................................447 Removal...............................................................................................447 Disassembly...........................................................................................448 Inspection............................................................................................448 Assembly..............................................................................................448 Installation..........................................................................................449 Ignition Timing.......................................................................................449 IGNITION MODULE...........................................................................................449 Test For A Fault......................................................................................449 Ignition Module Replacement...........................................................................450 SENSING COIL..............................................................................................451 Test For A Fault......................................................................................451 Sensing Coil Replacement..............................................................................451 IGNITION COIL.............................................................................................451 Test For A Fault......................................................................................451 Removal...............................................................................................452 Installation..........................................................................................452 MSTS MODULE...............................................................................................452 Removal...............................................................................................452 Installation..........................................................................................452 ECT SENSOR REPLACEMENT....................................................................................452 MAP SENSOR REPLACEMENT....................................................................................453 Periodic Maintenance..............................................................................................455 PERIODIC MAINTENANCE..........................................................................................455 GENERAL...................................................................................................455 Serial Number Data....................................................................................455 HOW TO MOVE A DISABLED LIFT TRUCK.........................................................................456 How To Tow the Lift Truck.............................................................................456 HOW TO PUT A LIFT TRUCK ON BLOCKS.........................................................................456 How To Raise the Drive Tires..........................................................................456 How To Raise the Steering Tires.......................................................................457 MAINTENANCE PROCEDURES........................................................................................461 EVERY 8 HOURS OR DAILY........................................................................................461 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED................................................................461 Engine Oil............................................................................................461 Drive Belts...........................................................................................461 Cooling System........................................................................................461 Battery...............................................................................................462 Fuel System...........................................................................................464 Air Filter............................................................................................464 Hydraulic System Oil..................................................................................464 Tires and Wheels......................................................................................465 Forks.................................................................................................465 Forks, Adjustment.....................................................................................466 Forks, Removal And Installation.......................................................................466 Inspection Of Forks, Mast, and Lift Chains............................................................467 Safety Labels.........................................................................................468 Operator Restraint System.............................................................................468 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING................................................................469 Gauges, Lights, Horn, and Fuses.......................................................................469 Fuel Filter, Diesel Engine............................................................................470 How To Drain The Water From The Fuel Filter...........................................................470 Oil Level, Powershift Transmission....................................................................470 Control Levers and Pedals.............................................................................470 Lift System Operation.................................................................................470 Inching/Brake Pedal...................................................................................471 Service Brakes........................................................................................471 Parking Brake.........................................................................................471 Steering System.......................................................................................471 EVERY 250 HOURS OR TWO MONTHS.................................................................................472 ENGINE OIL AND FILTER.....................................................................................472 Mazda, GM, And Later Production Isuzu Engines.........................................................472 Earlier Production Isuzu C240 Engines.................................................................472 GOVERNOR, MAZDA ENGINE....................................................................................473 DRIVE BELTS...............................................................................................473 Mazda Engine..........................................................................................473 Isuzu, GM 4-181, And GM 4-153 Engines.................................................................473 BRAKE FLUID...............................................................................................474 HYDRAULIC TANK BREATHER, CLEAN AND CHECK..................................................................474 FORKS, CHECK FOR WEAR AND DAMAGE..........................................................................474 LIFT CHAINS...............................................................................................474 Lubrication...........................................................................................474 Check For Wear........................................................................................474 MAST, LUBRICATION.........................................................................................475 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...............................................................475 CONTROL LEVERS AND PEDALS, LUBRICATION....................................................................476 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.......................................................................476 Idle Speed, Diesel....................................................................................476 LPG Carburetor........................................................................................477 Gasoline Carburetor...................................................................................477 EVERY 1000 HOURS OR SIX MONTHS................................................................................478 DIESEL FUEL FILTER........................................................................................478 Filter Replacement, Models Without A Water Separator..................................................479 Filter Replacement, Models With A Water Separator.....................................................479 Remove Air from the Diesel Fuel System................................................................479 DIFFERENTIAL..............................................................................................480 VALVE CLEARANCE ADJUSTMENT................................................................................480 IGNITION SYSTEM, MAZDA AND GM ENGINES.....................................................................480 PCV VALVE AND FILTER......................................................................................482 EVERY 2000 HOURS OR YEARLY....................................................................................482 HYDRAULIC SYSTEM..........................................................................................482 Replace the Hydraulic Oil and Filter..................................................................482 POWERSHIFT TRANSMISSION...................................................................................482 COOLING SYSTEM............................................................................................483 SERVICE BRAKES............................................................................................483 DIFFERENTIAL..............................................................................................483 WHEEL BEARINGS............................................................................................484 Steering Wheels, lubrication..........................................................................484 Drive Wheels, Lubrication.............................................................................484 GASOLINE FUEL FILTER, REPLACEMENT.........................................................................484 PCV VALVE, GM ENGINES.....................................................................................484 LPG FILTER, REPLACEMENT...................................................................................484 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A............................................................484 GENERAL PROCEDURES............................................................................................485 CHECK THE HOOD LATCH......................................................................................485 LIFT CHAIN ADJUSTMENTS....................................................................................485 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................487 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................488 Check the Lift Cylinders for Leaks....................................................................488 Check the Tilt Cylinders for Leaks....................................................................488 FUEL INJECTORS............................................................................................489 WELDING REPAIRS...........................................................................................489 CHANGES TO THE OVERHEAD GUARD.............................................................................489 WHEELS AND TIRES..........................................................................................489 Solid Rubber Tires (Press-on).........................................................................489 Install The Wheels....................................................................................490 Pneumatic Tires, Remove The Wheels From The Lift Truck................................................491 Pneumatic Tires, Remove the Tire From The Wheel.......................................................491 Pneumatic Tires, Install The Wheel In The Tire........................................................492 Pneumatic Tires, Add Air To The Tires.................................................................493 Pneumatic Tires, Install the Wheels...................................................................494 Pneumatic Tires, Installation Procedures, Dual Drive Wheels...........................................494 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.........................................................495 Remove The Wheels From The Lift Truck.................................................................495 Remove The Tire From The Wheel........................................................................495 Install The Tire On The Wheel.........................................................................496 REFERENCE TABLE...............................................................................................497 Rochester Carburetor (GM Engine)..................................................................................498 INTRODUCTION..................................................................................................498 GENERAL...................................................................................................498 DESCRIPTION...............................................................................................498 OPERATION.................................................................................................499 The Float System......................................................................................499 The Idle System.......................................................................................499 The Main Metering System (GM 6-250)...................................................................500 The Power System (GM 6-250)...........................................................................501 The Accelerator Pump System...........................................................................501 Choke System..........................................................................................501 REPAIRS.......................................................................................................502 REMOVAL...................................................................................................502 DISASSEMBLY...............................................................................................502 Cleaning..................................................................................................502 ASSEMBLY..................................................................................................502 INSTALLATION..............................................................................................502 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)...........................................................507 GOVERNOR (PNEUMATIC) (Early Units)........................................................................508 CHECKS AND ADJUSTMENTS........................................................................................509 GENERAL...................................................................................................509 ADJUST THE CHOKE CONTROL..................................................................................509 ADJUST THE IDLE SPEED.....................................................................................509 ADJSUT THE IDLE MIXTURE...................................................................................510 ADJUST THE FAST IDLE......................................................................................510 ADJUST THE THROTTLE LINKAGE,(Later Models)................................................................511 ADJUST THE THROTTLE LINKAGE,(Early Models)................................................................512 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only).............................................512 Check the Governor....................................................................................512 GOVERNOR (AISAN Type) (Early GM Engines Only).............................................................513 Checks................................................................................................514 Adjustments...........................................................................................514 GOVERNOR (HOOF Type) (Early GM Engines Only)..............................................................514 Adjust the Governor...................................................................................514 TROUBLESHOOTING...............................................................................................516 Single SPD SP Trans-Description & Operation (T41, T42, T43).......................................................517 INTRODUCTION..................................................................................................517 GENERAL...................................................................................................517 DESCRIPTION AND OPERATION.....................................................................................518 GENERAL...................................................................................................518 TORQE CONVERTER...........................................................................................518 Description...........................................................................................518 Operation.............................................................................................518 CLUTCH ASSEMBLIES.........................................................................................521 Description...........................................................................................521 Operation.............................................................................................523 HYDRAULIC SYSTEM..........................................................................................523 General...............................................................................................523 CONTROL VALVE.............................................................................................523 Regulator for Clutch Pressure.........................................................................526 Inching Spool Assembly................................................................................526 Direction Spool.......................................................................................526 MONOTROL Control Valve................................................................................526 Neutral Start Switch, MONOTROL Pedal Only.............................................................527 Neutral Start Switch, Direction Control Lever Only....................................................527 Modulator Circuit.....................................................................................527 Regulator for the Toruqe Converter....................................................................528 By-Pass Valve for the Oil Cooler......................................................................528 DIFFERENTIAL..............................................................................................529 OIL FLOW DIAGRAMS.........................................................................................529 Single-SPD SP Trans_Repair (T41, T42, T43)........................................................................538 INTRODUCTION..................................................................................................538 GENERAL...................................................................................................538 REPAIRS.......................................................................................................540 REPAIRS...................................................................................................540 Torque Converter, Removal.............................................................................540 Torque Converter, Installation........................................................................540 Front Cover And Transmission Pump, Removal and Disassembly............................................541 Front Cover And Transmission Pump, Assembly and Installation..........................................541 Clutch Assemblies, Removal and Disassembly............................................................542 Clutch Assemblies, Inspection.........................................................................545 Clutch Assemblies, Assembly and Installation..........................................................546 Differential, Removal and Disassembly.................................................................549 Differential, Inspection..............................................................................551 Differential, Assembly And Installation...............................................................551 CONTROL VALVE.............................................................................................561 Control Valve, Removal and Disassembly................................................................561 Control Valve, Inspection.............................................................................561 Control Valve, Assembly and Installation..............................................................563 MONOTROL Pedal, Removal and Disassembly...............................................................565 MONOTROL Pedal, Assembly and Installation.............................................................565 CHECKS AND ADJUSTMENTS........................................................................................567 Stall Test................................................................................................567 Adjustment Of The Direction Control Linkage...............................................................568 Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1).............569 Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)..............572 Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187).......................573 Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)....................574 Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)....578 Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)............579 Check The Oil Pressures...................................................................................579 Check The Relief Valve for the Transmission Pump..........................................................579 Check The Clutch Pressure.................................................................................579 Check The Torque Converter Regulator......................................................................580 Check The Oil Pressure from the Oil Cooler................................................................580 Check The Modulator Pressure..............................................................................581 TROUBLESHOOTING...............................................................................................581 TROUBLESHOOTING, PRESSURE TESTS...............................................................................583 Starter...........................................................................................................586 INTRODUCTION..................................................................................................586 GENERAL...................................................................................................586 DESCRIPTION AND OPERATION.................................................................................586 REPAIRS.......................................................................................................588 REMOVAL...................................................................................................588 DISSASEMBLY...............................................................................................588 CLEANING..................................................................................................589 ASSEMBLY..................................................................................................589 INSTALLATION..............................................................................................589 CHECKS AND ADJUSTMENTS........................................................................................590 GENERAL...................................................................................................590 TROUBLESHOOTING...............................................................................................592 Steer Axle........................................................................................................594 INTRODUCTION..................................................................................................594 DESCRIPTION...............................................................................................594 GENERAL...................................................................................................594 REPAIRS.......................................................................................................595 STEERING AXLE.............................................................................................595 Removal...................................................................................................595 Installation..............................................................................................596 STEERING CYLINDER.........................................................................................596 Removal...................................................................................................596 Service...................................................................................................597 Installation..............................................................................................597 HUBS......................................................................................................597 Removal...................................................................................................597 Installation..............................................................................................598 SPINDLES..................................................................................................598 Removal...................................................................................................598 Installation..............................................................................................599 CHECKS AND ADJUSTMENTS........................................................................................599 REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................599 SET THE PRESSURE RELIEF VALVE.............................................................................599 S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...................................................599 H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION........................................................599 H2.00-3.00J (H40-60J) With Powershift Transmission........................................................599 TROUBLESHOOTING...............................................................................................601 Steer Control Unit................................................................................................602 STEERING CONTROL UNIT.........................................................................................602 GENERAL...................................................................................................602 DESCRIPTION...............................................................................................602 Control Valve Section.................................................................................602 Metering Section......................................................................................602 DISASSEMBLY AND INSPECTION................................................................................604 ASSEMBLY..................................................................................................614 TROUBLESHOOTING...............................................................................................628 Steering System...................................................................................................629 THE STEERING SYSTEM...........................................................................................629 GENERAL...................................................................................................629 DESCRIPTION...............................................................................................629 Hydraulic Pump Assembly...............................................................................630 Flow Control Valve....................................................................................631 Relief Valve..........................................................................................631 OPERATION.................................................................................................631 Steering System.......................................................................................631 Hydraulic Pump........................................................................................632 Flow Control Valve....................................................................................632 Relief Valve..........................................................................................632 STEERING WHEEL AND COLUMN ASSEMBLY........................................................................633 Removal (Serial Code C177 And C187)...................................................................633 Installation (Serial Code C177 And C187)..............................................................633 Removal (Serial Code B177 And B187)...................................................................636 Installation (Serial Code B177 And B187)..............................................................636 STEERING CONTROL UNIT.....................................................................................637 Description...........................................................................................637 Operation, Control Valve Section......................................................................637 Operation, Metering Section...........................................................................638 CHECKS AND ADJUSTMENTS....................................................................................638 Remove Air From The Steering System...................................................................638 Check And Adjust Steering Relief Pressure.............................................................638 Check Hydraulic Pump For Correct Flow.................................................................638 TROUBLESHOOTING...............................................................................................639 Tilt Cylinders....................................................................................................640 INTRODUCTION..................................................................................................640 GENERAL...................................................................................................640 DESCRIPTION...............................................................................................640 REPAIRS.......................................................................................................640 REMOVAL...................................................................................................640 DISASSEMBLY...............................................................................................640 CLEANING..................................................................................................640 ASSEMBLY..................................................................................................640 Tilt Cylinders with O-Rings or Single Lip Seals.......................................................640 Tilt Cylinders for the XM and XMS Models..............................................................641 Tilt Cylinders for H700 800A and Early Model H700 920B................................................643 INSTALLATION..............................................................................................643 Tilt Cylinders Using Chevron Packing..................................................................644 CHECKS AND ADJUSTMENTS........................................................................................646 CHECK THE TILT CYLINDERS FOR LEAKS........................................................................646 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...................................................646 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS......................................................647 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS.....................................................648 TROUBLESHOOTING...............................................................................................650 Vista Mast Description............................................................................................651 INTRODUCTION..................................................................................................651 GENERAL...................................................................................................651 MAST WELDMENTS............................................................................................651 CARRIAGE..................................................................................................651 MAST MOUNTS...............................................................................................652 VISTA® TWO-STAGE MAST.........................................................................................653 DESCRIPTION AND OPERATION.................................................................................653 VISTA® FREE-LIFT MAST.........................................................................................655 DESCRIPTION...............................................................................................655 OPERATION.................................................................................................655 VISTA® THREE-STAGE MAST.......................................................................................657 DESCRIPTION...............................................................................................657 OPERATION.................................................................................................657 VISTA® FOUR-STAGE MAST........................................................................................658 DESCRIPTION...............................................................................................658 OPERATION.................................................................................................659 Vista Mast Repair.................................................................................................661 VISTA MAST, REPAIR............................................................................................661 GENERAL...................................................................................................661 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................661 FORKS.....................................................................................................662 Forks, Removal And Installation.......................................................................662 CARRIAGE..................................................................................................663 Removal...............................................................................................663 Installation..........................................................................................664 MASTS.....................................................................................................664 Removal...............................................................................................664 Disassembly...........................................................................................665 Cleaning and Inspection...............................................................................670 Assembly..............................................................................................670 Installation..........................................................................................674 SIDE-SHIFT CARRIAGE (EARLIER DESIGN)......................................................................675 Removal...............................................................................................675 Repairs...............................................................................................675 Installation..........................................................................................675 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)...............................................................676 Removal...............................................................................................676 Repairs...............................................................................................676 Installation..........................................................................................677 CHECKS AND ADJUSTMENTS........................................................................................678 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................678 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...............................................679 LIFT CHAIN ADJUSTMENTS....................................................................................680 MAST ADJUSTMENTS..........................................................................................680 CARRIAGE ADJUSTMENT.......................................................................................682 HEADER HOSE ARRANGEMENTS..................................................................................682 Two-Stage Header Hose.................................................................................683 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts.........................................683 TROUBLESHOOTING...............................................................................................688
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