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Hyster C187 (S40-60XL) Service Manual – PDF DOWNLOAD
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Description
Hyster C187 (S40-60XL) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster C187 (S40-60XL) Service Manual – PDF DOWNLOAD
Language : English
Pages : 812
Downloadable : Yes
File Type : PDF
Size: 23.0 MB
TABLE OF CONTENTS:
Hyster C187 (S40-60XL) 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 (A187)...................................................................................................... 16 INTRODUCTION......................................................................................................... 16 GENERAL.......................................................................................................... 16 DESCRIPTION AND OPERATION........................................................................................ 16 Service and Parking Brakes................................................................................... 18 REPAIRS.............................................................................................................. 18 REMOVAL AND DISASSEMBLY.......................................................................................... 18 Service and Parking Brakes................................................................................... 18 Master Cylinder.............................................................................................. 19 CLEANING AND INSPECTION.......................................................................................... 20 ASSEMBLY AND INSTALLATION........................................................................................ 20 Service and Parking Brakes................................................................................... 20 Master Cylinder.............................................................................................. 25 CHECKS AND ADJUSTMENTS............................................................................................... 25 ADJUST THE SERVICE BRAKES........................................................................................ 25 ADJUST THE PARKING BRAKE......................................................................................... 26 Units with Monotrol Pedal.................................................................................... 26 REMOVE THE AIR FROM THE BRAKE SYSTEM............................................................................. 27 ADJUST THE BRAKE PEDAL AND INCHING PEDAL......................................................................... 27 CHECK AND ADJUST THE NEUTRAL START SWITCH (Monotrol Control Only)................................................ 31 TROUBLESHOOTING...................................................................................................... 33 SPECIFICATIONS....................................................................................................... 34 Brake System (B187-C187)................................................................................................. 35 INTRODUCTION......................................................................................................... 35 GENERAL.......................................................................................................... 35 SERVICE BRAKES AND PARKING BRAKE..................................................................................... 35 DESCRIPTION AND OPERATION........................................................................................ 35 Service Brakes............................................................................................... 35 Parking Brake................................................................................................ 36 REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES.................................................. 36 Parking Brake................................................................................................ 38 CLEANING......................................................................................................... 39 INSPECTION....................................................................................................... 39 ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES................................................ 39 Adjustments.................................................................................................. 42 Parking Brake Installation................................................................................... 43 Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes............................... 43 REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES.................................................. 45 Parking Brake................................................................................................ 47 CLEANING......................................................................................................... 48 INSPECTION....................................................................................................... 48 ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES................................................ 48 Adjustments.................................................................................................. 50 Parking brake................................................................................................ 51 Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes............................... 51 MASTER CYLINDER.................................................................................................. 52 Removal...................................................................................................... 52 Repair....................................................................................................... 52 Installation................................................................................................. 52 Cleaning And Inspection...................................................................................... 54 MASTER CYLINDER WITH BRAKE BOOSTER............................................................................... 56 Operation.................................................................................................... 56 Repair....................................................................................................... 56 CHECKS AND ADJUSTMENTS............................................................................................... 58 ADJUST THE SERVICE BRAKES........................................................................................ 58 TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY).............................................................. 58 REMOVE THE AIR FROM THE BRAKE SYSTEM............................................................................. 59 ADJUST THE INCHING/BRAKE PEDAL................................................................................... 59 ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL)......................................... 64 TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)................................................................... 64 Test 1....................................................................................................... 64 Test 2....................................................................................................... 65 TORQUE SPECIFICATIONS................................................................................................ 65 TROUBLESHOOTING...................................................................................................... 65 Capacities & Specification............................................................................................... 68 LIFT TRUCK WEIGHTS*.................................................................................................. 68 HYDRAULIC SYSTEM..................................................................................................... 68 ELECTRICAL SYSTEM.................................................................................................... 69 CAPACITIES........................................................................................................... 69 MAST SPEEDS (MAZDA Gasoline/LPG - A187*& B187* Units)................................................................ 70 MAST SPEEDS (ISUZU Diesel - A187*& B187* Units)...................................................................... 70 MAST SPEEDS (GM 4-153 Gasoline/LPG - A187*).......................................................................... 71 MAST SPEEDS (GM 4-181 Gasoline/LPG - B187*).......................................................................... 71 MAST CREEP SPEEDS.................................................................................................... 72 WHEELS AND TIRES..................................................................................................... 72 TRANSMISSION PRESSURES............................................................................................... 72 ENGINE SPECIFICATIONS................................................................................................ 73 ENGINE SPECIFICATIONS................................................................................................ 74 TORQUE SPECIFICATIONS................................................................................................ 75 TORQUE SPECIFICATIONS................................................................................................ 76 Cooling System........................................................................................................... 77 COOLING SYSTEM....................................................................................................... 77 INTRODUCTION..................................................................................................... 77 DESCRIPTION...................................................................................................... 77 RADIATOR......................................................................................................... 77 RADIATOR CAP..................................................................................................... 77 THERMOSTAT....................................................................................................... 77 WATER PUMP....................................................................................................... 78 FAN AND FAN SHROUD............................................................................................... 78 REPAIRS.............................................................................................................. 78 COOLING SYSTEM CHECKS............................................................................................ 78 Exhaust Leaks................................................................................................ 78 RADIATOR......................................................................................................... 78 Checks....................................................................................................... 78 Cleaning The Radiator........................................................................................ 78 Drain The Cooling System..................................................................................... 80 Fill The Cooling System...................................................................................... 80 WATER PUMP....................................................................................................... 80 Checks....................................................................................................... 80 THERMOSTAT....................................................................................................... 81 Checks....................................................................................................... 81 FAN AND FAN SHROUD............................................................................................... 81 TROUBLESHOOTING...................................................................................................... 82 Diagrams (A187).......................................................................................................... 83 FIGURE 1. HYDRAULIC SCHEMATIC SYMBOLS................................................................................ 83 FIGURE 2. HYDRAULIC SYSTEM SCHEMATIC................................................................................. 84 FIGURE 3. TRANSMISSION SCHEMATIC..................................................................................... 86 FIGURE 4. INSTRUMENT PANEL ELECTRICAL DIAGRAM........................................................................ 87 FIGURE 5. GASOLINE/LPG ENGINE WIRING DIAGRAM, MAZDA ENGINE, (G and LPS Rating)....................................... 88 FIGURE 6. GASOLINE/LPG ENGINE WIRING DIAGRAM, MAZDA ENGINE, (GS and LPS Rating)...................................... 90 FIGURE 7. GASOLINE/LPG CABLE DIAGRAM, MAZDA ENGINE, (G and LPG Rating)............................................... 92 FIGURE 8. GASOLINE/LPG ENGINE WIRING DIAGRAM, GM ENGINE(G and LPG Rating/GS and LPS Rating).......................... 94 FIGURE 9. GASOLINE/LPG ENGINE CABLE DIAGRMGM ENGINE,................................................................. 96 FIGURE 10. DIESEL ENGINE WIRING DIAGRAM ISUZU ENGINE (D Rating)...................................................... 98 FIGURE 11. DIESEL ENGINE WIRING DIAGRAM ISUZU ENGINE (DS Rating).....................................................100 FIGURE 12. DIESEL ENGINE CABLE DIAGRAM, ISUZU ENGINE.................................................................102 Diagrams (B187-C187).....................................................................................................104 FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC.................................................................................105 FIGURE 2. TRANSMISSION SCHEMATIC.....................................................................................106 FIGURE 3. WIRE SCHEMATIC, GM 4-181 ENGINE, GASOLINE AND LPG (1 OF 2).................................................107 FIGURE 4. WIRE SCHEMATIC, MAZDA 4-121G ENGINE, GASOLINE AND LPG......................................................111 FIGURE 5. WIRE SCHEMATIC, ISUZU DIESEL ENGINE (1OF 2 )...............................................................113 FIGURE 6. ELECTRICAL DIAGRAM, INSTRUMENT PANEL.......................................................................115 FIGURE 7. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)................................................117 FIGURE 8. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)...............................................119 FIGURE 9. DIESEL ENGINE CABLE DIAGRAM (D Rating).....................................................................121 FIGURE 10. DIESEL ENGINE CABLE DIAGRAM (DS Rating)...................................................................123 FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)..................................................125 FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating).................................................127 Drive Axle...............................................................................................................129 INTRODUCTION.........................................................................................................129 GENERAL..........................................................................................................129 DESCRIPTION......................................................................................................129 REPAIRS..............................................................................................................130 REMOVAL..........................................................................................................130 CLEANING.........................................................................................................130 INSPECTION.......................................................................................................130 ASSEMBLY.........................................................................................................130 TROUBLESHOOTING......................................................................................................133 SPECIFICATIONS.......................................................................................................133 Electrical System (Isuzu)................................................................................................134 INTRODUCTION.........................................................................................................134 GENERAL..........................................................................................................134 DESCRIPTION......................................................................................................134 Starting System..............................................................................................134 Charging System..............................................................................................134 Vacuum Pump On Alternator (On Units With Brake Booster)......................................................136 REPAIRS..............................................................................................................137 STARTER..........................................................................................................137 Removal And Disassembly......................................................................................137 Assembly And Installation....................................................................................137 REPLACING GLOW PLUGS.............................................................................................139 ALTERNATOR (With Vaccum Pump)....................................................................................139 Removal And Disassembly......................................................................................139 Cleaning.....................................................................................................141 Assembly And Installation....................................................................................141 ALTERNATOR (Without Vacuum Pump).................................................................................142 Removal And Disassembly......................................................................................142 Cleaning.....................................................................................................144 Assembly And Installation....................................................................................144 REGULATOR REPLACEMENT............................................................................................145 CHECKS...............................................................................................................145 GENERAL..........................................................................................................145 STARTER..........................................................................................................145 Starter Operation............................................................................................145 Solenoid Coil Checks.........................................................................................146 Brush Length.................................................................................................146 Brush Holder.................................................................................................146 Armature.....................................................................................................146 Field Windings...............................................................................................147 Clutch And Bearings..........................................................................................147 COLD START AID...................................................................................................147 Glow Plugs...................................................................................................147 Resistor.....................................................................................................147 CHARGING CIRCUIT.................................................................................................147 Check For Low Output.........................................................................................147 Check Ford High Output.......................................................................................149 ALTERNATOR.......................................................................................................149 Rotor Resistance.............................................................................................149 Diodes Circuit...............................................................................................149 Rotor Coil...................................................................................................150 Stator Coil..................................................................................................150 Diode Assembly...............................................................................................150 Brushes And Bearings.........................................................................................151 REGULATOR (At Hydraulic Tank)....................................................................................151 TROUBLESHOOTING......................................................................................................152 Electrical System (Mazda)................................................................................................155 INTRODUCTION.........................................................................................................155 GENERAL..........................................................................................................155 DESCRIPTION......................................................................................................155 Starting System..............................................................................................155 Ignition System..............................................................................................155 Charging System..............................................................................................156 REPAIR...............................................................................................................158 STARTER..........................................................................................................158 Removal And Disassembly......................................................................................158 Assembly And Installation....................................................................................158 BALLAST RESISTOR RELAY (Earlier Production)......................................................................160 DISTRIBUTOR (Earlier Production With Contact Points).............................................................160 Removal And Disassembly......................................................................................160 Assembly And Installation....................................................................................162 COIL REPLACEMENT.................................................................................................162 DISTRIBUTOR (Later Production with Electronic Ignition System)...................................................162 Removal And Disassembly......................................................................................162 Assembly And Installation....................................................................................164 ALTERNATOR (All Models)..........................................................................................164 Removal And Disassembly......................................................................................164 Assembly And Installation....................................................................................165 REGULATOR REPLACEMENT (Earlier Production).......................................................................166 CHECKS AND ADJUSTMENTS...............................................................................................167 GENERAL..........................................................................................................167 STARTER..........................................................................................................167 Check Operation..............................................................................................167 Check Brush Length...........................................................................................168 Check Brush Holder...........................................................................................168 Armature.....................................................................................................168 Field Windings...............................................................................................168 Clutch And Bearing...........................................................................................168 BALLAST RESISTOR RELAY (Earlier Production)......................................................................168 DISTRIBUTOR......................................................................................................169 Distributor Contact Clearance................................................................................169 SPARK PLUGS......................................................................................................170 COIL AND BALLAST RESISTOR (Earlier Production)...................................................................170 ALTERNATOR.......................................................................................................170 Check For Low Output (Alternator With Separate Regulator)....................................................170 Check For Low Output (Alternator With Integral Regulator)....................................................172 Check For High Output (Alternator With Separate Regulator)...................................................173 Check For High Output (Alternator With Integral Regulator)...................................................173 Rotor Resistance (Alternator with Separate Regulator)........................................................173 Diodes Circuit (Alternator with Separate Regulator)..........................................................174 Diode Assembly (Alternator With Separate Regulator)..........................................................174 Check The Diodes, Diode Trio (Alternator with Integral Regulator)............................................174 Check The Rectifier Bridge (Alternator with Integral Regulator)..............................................175 Check Field Winding For The Rotor (All Alternators)..........................................................175 Check Windings In The Stator (All Alternators)...............................................................176 Brushes And Bearings.........................................................................................176 Check The Voltage Regulator (Alternator with Separate Regulator).............................................176 Check The Voltage Regulator (Alternator with Integral Regulator).............................................177 ADJUSTMENTS......................................................................................................177 TROBLESHOOTING.......................................................................................................178 Four Stage Upright Mast Repair...........................................................................................180 INTRODUCTION.........................................................................................................180 GENERAL..........................................................................................................180 REPAIRS..............................................................................................................180 FORKS............................................................................................................180 CARRIAGE.........................................................................................................180 Removal......................................................................................................180 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................181 Installation.................................................................................................182 MAST.............................................................................................................183 Removal......................................................................................................183 Disassembly..................................................................................................184 Cleaning.....................................................................................................187 Inspection, Forks, Mast, And Lift Chains.....................................................................187 Assembly, Mast Components....................................................................................188 Installation.................................................................................................189 CHECKS AND ADJUSTMENTS...............................................................................................190 CHECK FOR LEAKS IN THE LIFT SYSTEM...............................................................................190 Check the Lift Cylinders for Leaks...........................................................................190 Check The Tilt Cylinders For Leaks...........................................................................190 ADJUST THE TILT CYLINDER STROKE AND BACKWARD TILT ANGLE..........................................................190 LIFT CHAIN ADJUSTMENTS...........................................................................................191 MAST ADJUSTMENTS.................................................................................................191 CARRIAGE ADJUSTMENTS.............................................................................................193 TROUBLESHOOTING......................................................................................................194 Frame....................................................................................................................195 INTRODUCTION.........................................................................................................195 GENERAL..........................................................................................................195 DESCRIPTION......................................................................................................195 REPAIRS..............................................................................................................195 COUNTERWEIGHT....................................................................................................196 Removal......................................................................................................196 Installation.................................................................................................196 MUFFLER..........................................................................................................197 HOOD.............................................................................................................197 Removal......................................................................................................197 Installation.................................................................................................197 OVERHEAD GUARD...................................................................................................198 Removal and Installation.....................................................................................198 RADIATOR AND COOLANG SYSTEM......................................................................................198 Removal......................................................................................................198 Installation.................................................................................................198 OPERATOR RESTRAINT SYSTEM........................................................................................198 ENGINE REMOVAL AND INSTALLATION..................................................................................199 Removal of the Engine and Transmission.......................................................................199 Installation of the Engine and Transmission..................................................................202 FUEL AND HYDRAULIC TANKS.........................................................................................204 Inspection...................................................................................................204 Repairs, Small Leaks.........................................................................................204 Repairs, Large Leaks.........................................................................................204 Cleaning.....................................................................................................204 Steam Method of Cleaning.....................................................................................204 Chemical Solution Method of Cleaning.........................................................................204 Other Methods Of Preparation For Repair......................................................................205 SAFETY LABELS....................................................................................................205 Gasoline Carburetor (Mazda)..............................................................................................209 THE CARBURETOR, (MAZDA M4-121G ENGINE)...............................................................................209 DESCRIPTION......................................................................................................209 REPAIRS, CARBURETOR..............................................................................................210 Removal......................................................................................................210 Cleaning.....................................................................................................213 Inspection...................................................................................................213 Assembly.....................................................................................................213 Installation.................................................................................................215 CHECKS AND ADJUSTMENTS...........................................................................................215 Carburetor, Idle Speed And Mixture Adjustment................................................................215 Adjust The Governor..........................................................................................216 ADJUST THE THROTTLE LINKAGE......................................................................................217 SPECIFICATIONS.......................................................................................................217 TROUBLESHOOTING......................................................................................................218 Global Mast Repair.......................................................................................................220 INTRODUCTION ........................................................................................................220 GENERAL .........................................................................................................220 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ........................................................................220 REPAIRS .............................................................................................................221 FORKS ...........................................................................................................221 Removal .....................................................................................................221 Installation ................................................................................................222 CARRIAGES .......................................................................................................222 Removal, Standard Carriage ..................................................................................222 Removal, Side–Shift Carriage ................................................................................223 Repairs .....................................................................................................223 Installation, Standard Carriage .............................................................................223 Installation, Side–Shift Carriage ...........................................................................224 MAST ............................................................................................................225 Removal .....................................................................................................225 Disassembly, Three–Stage FFL Mast ...........................................................................231 Disassembly, Two–Stage LFL And Two–Stage FFL Masts ..........................................................225 Cleaning and Inspection .....................................................................................231 Assembly, Two–Stage LFL And Two–Stage FFL Mast ..............................................................234 Assembly, Three–Stage FFL Mast ..............................................................................235 Installation, Mast ..........................................................................................236 LIFT CYLINDERS ..................................................................................................237 Removal, Main Lift Cylinders ................................................................................237 Removal, Free–Lift Cylinder .................................................................................237 Disassembly, Lift Cylinders .................................................................................237 Assembly, Lift Cylinders ....................................................................................238 Installation, Main Lift Cylinders ...........................................................................239 Installation, Free–Lift Cylinder ............................................................................240 HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) ....................241 New Hose Installation, Two–Stage, LFL Mast ..................................................................241 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................241 New Hose Installation, Two–Stage FFL Mast ...................................................................245 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................245 New Hose Installation, Three–Stage FFL Mast .................................................................249 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................254 HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) ....256 New Hose Installation, Two–Stage LFL Mast ...................................................................257 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................257 New Hose Installation, Two–Stage FFL Mast ...................................................................260 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................260 New Hose Installation, Three–Stage, FFL Mast ................................................................264 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................269 CHECKS AND ADJUSTMENTS ..............................................................................................270 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ....................................................................270 Check The Lift Cylinders For Leaks .........................................................................270 Check The Tilt Cylinders For Leaks .........................................................................270 ADJUST THE TILT CYLINDERS ......................................................................................270 ADJUST THE LIFT CHAINS .........................................................................................271 ADJUST THE MAST ................................................................................................272 ADJUST THE CARRIAGE ............................................................................................273 TROUBLESHOOTING......................................................................................................274 Global Mast-Description..................................................................................................275 INTRODUCTION.........................................................................................................275 GENERAL..........................................................................................................275 DESCRIPTION AND OPERATION........................................................................................275 Carriages....................................................................................................275 Mast Mounts..................................................................................................276 TWO-STAGE MAST, LIMITED FREE-LIFT................................................................................277 Description and Operation....................................................................................277 TWO-STAGE MAST, FULL FREE-LIFT...................................................................................279 Description..................................................................................................279 Operation....................................................................................................279 THREE-STAGE, FULL FREE-LIFT MAST.................................................................................281 Description..................................................................................................281 Operation....................................................................................................281 GM Engine................................................................................................................283 INTRODUCTION.........................................................................................................283 GENERAL..........................................................................................................283 DESCRIPTION......................................................................................................284 REMOVAL AND INSTALLATION OF THE ENGINE...........................................................................284 CYLINDER HEAD AND MECHANISM......................................................................................284 Cylinder Head, Removal.......................................................................................284 Cylinder Head, Disassembly...................................................................................285 Cleaning And Inspection......................................................................................286 Valve And Valve Seats........................................................................................287 Studs For The Rocker Arms....................................................................................287 Hydraulic Valve Lifters, Replacement.........................................................................287 Hydraulic Valve Lifters, Cleaning And Inspection.............................................................288 Cylinder Head, Assembly......................................................................................288 Cylinder Head, Installation..................................................................................288 Rocker Arm Cover, Installation...............................................................................289 TIMING GEAR COVER................................................................................................290 Removal......................................................................................................290 Installation.................................................................................................290 CAMSHAFT.........................................................................................................291 Removal......................................................................................................291 Inspection...................................................................................................292 Camshaft Bearings, Removal...................................................................................292 Camshaft Bearings, Installation..............................................................................292 DISTRIBUTOR......................................................................................................293 Removal......................................................................................................293 Installation.................................................................................................293 LUBRICATION SYSTEM...............................................................................................294 Oil Sump, Removal............................................................................................294 Oil Sump, Installation.......................................................................................294 Oil Pump, Removal............................................................................................294 Oil Pump, Disassembly and Repair.............................................................................294 Oil Pump, Assembly...........................................................................................295 Oil Pump, Installation.......................................................................................295 PISTON AND CONNECTING ROD ASSEMBLIES.............................................................................295 Connecting Rod Bearings, Replacement.........................................................................295 Piston And Connecting Rod Assemblies, Removal................................................................296 Disassembly..................................................................................................297 Piston, Cleaning And Inspection..............................................................................297 Cylinder Bores, Inspection And Repair........................................................................297 Piston Rings.................................................................................................298 Assembly.....................................................................................................299 Piston And Connecting Rod Assemblies, Installation...........................................................299 CRANKSHAFT.......................................................................................................300 Main Bearings, Replacement...................................................................................300 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).....................................301 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).....................301 Crankshaft, Removal..........................................................................................302 Inspection and Repair........................................................................................303 How To Check The Clearance Between The Main Bearings And Their Journals......................................303 Installation.................................................................................................304 FLYWHEEL AND FLYWHEEL HOUSING....................................................................................305 Flywheel, Removal............................................................................................305 Ring Gear, Replacement.......................................................................................306 Flywheel, Installation.......................................................................................306 COOLING SYSTEM...................................................................................................306 Coolant Pump.................................................................................................306 Fan Drive....................................................................................................307 Viscous Fan Drive............................................................................................307 ENGINE SPECIFICATIONS................................................................................................308 ENGINE DATA......................................................................................................308 CYLINDER HEAD....................................................................................................308 HYDRAULIC VALVE LIFTER...........................................................................................309 CAMSHAFT.........................................................................................................309 PISTONS..........................................................................................................309 CYLINDER BORE....................................................................................................310 CRANKSHAFT.......................................................................................................310 CONNECTING RODS..................................................................................................310 COOLING SYSTEM...................................................................................................311 LUBRICATION SYSTEM...............................................................................................311 TORQUE SPECIFICATIONS................................................................................................311 High Engery Ignition System..............................................................................................314 HIGH ENERGY IGNITION (HEI)...........................................................................................314 DESCRIPTION......................................................................................................314 REPAIRS..............................................................................................................316 DISTRIBUTOR......................................................................................................316 Removal......................................................................................................316 Disassembly..................................................................................................316 Assembly.....................................................................................................321 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.....................................322 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED......................................323 IGNITION COIL....................................................................................................323 Removal, Some 4 And 6 Cylinder Models........................................................................323 Installation, Some 4 And 6 Cylinder Models...................................................................324 Removal, V8, Some 4 And 6 Cylinder Models....................................................................324 Installation, V8, Some 4 And 6 Cylinder Models...............................................................325 ELECTRONIC MODULE................................................................................................326 Removal......................................................................................................326 Installation.................................................................................................326 SENSING COIL.....................................................................................................327 Removal......................................................................................................327 Installation.................................................................................................327 SPARK PLUGS......................................................................................................327 Removal......................................................................................................327 Installation.................................................................................................328 CHECKS AND ADJUSTMENTS...........................................................................................328 Visual Checks................................................................................................328 Check The High Voltage Wires.................................................................................328 Checking The Ignition Coil...................................................................................328 Coil In Distributor Cap Design...............................................................................328 Separate Coil Design.........................................................................................329 Checking The Sensing Coil....................................................................................329 Check The Electronic Module..................................................................................330 Ignition Timing Adjustment...................................................................................330 Ignition System, GM V8-366 (6-litre).........................................................................331 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).............................................331 SPECIFICATIONS.......................................................................................................331 TROUBLESHOOTING......................................................................................................332 Hydraulic Pump Drive Assembly............................................................................................333 INTRODUCTION.........................................................................................................333 GENERAL..........................................................................................................333 DESCRIPTION......................................................................................................333 REPAIRS..............................................................................................................335 REMOVAL AND DISASSEMBLY..........................................................................................335 CLEANING.........................................................................................................335 INSPECTION.......................................................................................................335 ASSEMBLY AND INSTALLATION........................................................................................336 TROUBLESHOOTING......................................................................................................337 GENERAL..........................................................................................................337 Hydraulic System & Gear Pump.............................................................................................338 INTRODUCTION.........................................................................................................338 GENERAL..........................................................................................................338 DESCRIPTION......................................................................................................340 Hydraulic System.............................................................................................340 Gear Pump Assembly...........................................................................................340 Flow Control Valve...........................................................................................341 Relief Valve (Early Model)...................................................................................341 Relief Valve (Later Model)...................................................................................341 OPERATION........................................................................................................343 Hydraulic System.............................................................................................343 Gear Pump....................................................................................................343 Flow Control Valve...........................................................................................343 Relief Valve (Early Model)...................................................................................343 Relief Valve (Later Model)...................................................................................343 REPAIR...............................................................................................................345 GEAR PUMP ASSEMBLY...............................................................................................345 Removal and Disassembly......................................................................................345 Assembly and Installation....................................................................................346 CHECKS AND ADJUSTMENTS...............................................................................................346 CHECK AND ADJUST STEERING RELIEF PRESSURE........................................................................346 CHECK GEAR PUMP FOR CORRECT FLOW.................................................................................347 TROUBLESHOOTING......................................................................................................347 Instrument Panel Incicators & Senders....................................................................................349 INTRODUCTION.........................................................................................................349 GENERAL..........................................................................................................349 DESCRIPTION..........................................................................................................349 GENERAL..........................................................................................................349 STEERING COLUMN GAUGES, METERS AND INDICATORS....................................................................352 LED DISPLAY PANEL................................................................................................352 Battery Discharge Indicators.................................................................................352 Brush Wear Indicators........................................................................................353 Motor Temperature Indicators.................................................................................354 "LX" SERIES DISPLAY PANEL........................................................................................355 Hourmeter Functions..........................................................................................356 Battery Indicator Function...................................................................................356 Status Code Function.........................................................................................356 "ZX" SERIES DISPLAY PANELS.......................................................................................356 Display Panel................................................................................................357 Basic Display Panels.........................................................................................357 Performance Display..........................................................................................359 Brush Wear Indicators........................................................................................362 CHECKS AND ADJUSTMENTS...............................................................................................362 GENERAL..........................................................................................................362 REPLACEMENT..........................................................................................................363 GENERAL..........................................................................................................363 METER REPLACEMENT................................................................................................363 SENDER REPLACEMENT...............................................................................................364 Fuel Level Sender............................................................................................364 Pressure And Temperature Sender..............................................................................364 I.T.W. DISPLAY PANEL.............................................................................................365 Removal......................................................................................................365 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT............................................366 Removal......................................................................................................366 Replacing Display Panel Assembly.............................................................................366 Indicator LEDs...............................................................................................366 Battery Indicators...........................................................................................366 Digital Display (Performance Disply Panel Only)..............................................................366 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)................366 Replacing Parts Of The Basic Display Panel...................................................................367 Replacing Parts Of The Performance Display Panel.............................................................369 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT................................................369 Removal And Replacement......................................................................................369 SPECIFICATIONS.......................................................................................................370 TROUBLESHOOTING......................................................................................................371 Isuzi C240 (2.4L) Engine.................................................................................................372 INTRODUCTION ........................................................................................................372 GENERAL .........................................................................................................372 DESCRIPTION .....................................................................................................372 FUEL SYSTEM .....................................................................................................373 Description .................................................................................................373 Operation, Fuel Injection Pump, Model VE ....................................................................375 Operation, Fuel Injection Pump, Model PE4A ..................................................................376 Pneumatic Governor For Fuel Injection Pump, Model PE4A ......................................................377 Inlet Manifold For Fuel Injection Pump, Model PE4A ..........................................................378 REPAIRS .............................................................................................................379 FUEL INJECTION PUMP (ALL MODELS) ................................................................................379 Removal .....................................................................................................379 Installation ................................................................................................379 REMOVAL AND INSTALLATION OF THE ENGINE ..........................................................................379 CYLINDER HEAD AND VALVE MECHANISM ...............................................................................379 Cylinder Head, Removal ......................................................................................379 Valve Guides, Replacement ...................................................................................380 Cylinder Head, Inspection And Repair ........................................................................381 Combustion Chamber Plugs, Inspection And Repair .............................................................381 Combustion Chamber Plugs, Installation ......................................................................381 Valves, Inspection And Repair ...............................................................................382 Valve Seat, Inspection ......................................................................................382 Valve Seat, Removal .........................................................................................383 Valve Seat, Installation ....................................................................................383 Valve Spring, Inspection ....................................................................................383 Rocker Arms, Inspection And Assembly ........................................................................383 Installation Of The Cylinder Head ...........................................................................384 TIMING GEAR CASE ................................................................................................385 Removal .....................................................................................................385 Installation ................................................................................................385 CAMSHAFT ........................................................................................................387 Removal .....................................................................................................387 Inspection ..................................................................................................387 Camshaft Bearings ...........................................................................................388 Cam Followers ...............................................................................................388 CAMSHAFT, INSTALLATION ..........................................................................................388 CRANKSHAFT AND MAIN BEARINGS ....................................................................................389 Crankshaft, Removal .........................................................................................389 Crankshaft, Inspection And Repair ...........................................................................389 Main Bearings ...............................................................................................389 Pilot Bearing ...............................................................................................390 Crankshaft, Installation ....................................................................................390 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) .................................................................392 Flywheel, Removal ...........................................................................................392 Ring Gear, Replacement ......................................................................................392 Flywheel, Installation ......................................................................................392 PISTONS AND CONNECTING RODS .....................................................................................393 Pistons And Connecting Rods, Removal ........................................................................393 Disassembly .................................................................................................393 Pistons, Inspection And Repair ..............................................................................394 Piston Rings, Inspection And Repair .........................................................................394 Piston Pins, Inspection And Repair ..........................................................................395 Connecting Rods, Inspection And Repair ......................................................................396 Pistons And Connecting Rods, Assembly And Installation ......................................................396 CYLINDER BLOCK AND CYLINDER LINERS ..............................................................................396 Cylinder Liners, Inspection .................................................................................396 Replacement Of A Cylinder Liner .............................................................................397 LUBRICATION SYSTEM ..............................................................................................398 Oil Pump, Removal And Disassembly ...........................................................................398 Oil Pump, Inspection ........................................................................................398 Oil Pump, Assembly And Installation .........................................................................399 Oil Filter ..................................................................................................399 COOLING SYSTEM ..................................................................................................400 Coolant Pump, Removal .......................................................................................400 Coolant Pump, Disassembly ...................................................................................400 Coolant Pump, Assembly And Installation .....................................................................400 Thermostat, Replacement .....................................................................................401 CHECKS AND ADJUSTMENTS ..............................................................................................401 VALVE CLEARANCE ADJUSTMENT ......................................................................................401 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ...........................................................402 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A .........................................................403 FUEL INJECTORS ..................................................................................................403 Fuel Injectors, Removal .....................................................................................404 Fuel Injectors, Inspection ..................................................................................404 Fuel Injectors, Installation ................................................................................405 DIESEL FUEL FILTERS .............................................................................................405 Filter Replacement, Models With A Water Separator ...........................................................405 Filter Replacement, Models Without A Water Separator ........................................................406 Filter For The Fuel Injection Pump, Model PE4A ..............................................................406 REMOVE AIR FROM THE FUEL SYSTEM .................................................................................406 Throttle Linkage, Adjustment ................................................................................407 Idle Speed, Adjustment ......................................................................................407 Check The Elements For The Cold Start Aid System ............................................................407 ENGINE SPECIFICATIONS ...............................................................................................407 TORQUE SPECIFICATIONS ...............................................................................................409 Lift Cylinders...........................................................................................................410 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................................410 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................410 LIFT CYLINDERS.......................................................................................................413 GENERAL..........................................................................................................413 DESCRIPTION......................................................................................................413 Lowering Control Valve.......................................................................................413 Cylinders (General)..........................................................................................416 Cylinders (H520-620B,H700-800A)..............................................................................418 Cylinders (H360-460B)........................................................................................419 Cylinders (Two-Speed)........................................................................................419 REPAIRS..............................................................................................................420 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...........................................................420 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.....................420 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead......................................424 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder................................422 DISASSEMBLY......................................................................................................422 ASSEMBLY.........................................................................................................424 INSTALLATION OF THE LIFT CYLINDER IN THE MAST....................................................................424 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.....................424 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.............................424 CHEVRON PACKING..................................................................................................425 LIFT CYLINDERS FOR VISTA MASTS.......................................................................................428 DESCRIPTION......................................................................................................428 Lowering Control Valve.......................................................................................430 REMOVAL..........................................................................................................431 DISASSEMBLY......................................................................................................431 ASSEMBLY.........................................................................................................431 INSTALLATION.....................................................................................................432 Main Lift Cylinders..........................................................................................432 Free-Lift Cylinders..........................................................................................432 CHECKS AND ADJUSTMENTS...............................................................................................433 CHECK FOR LEAKS IN LIFT SYSTEM...................................................................................433 TROUBLESHOOTING......................................................................................................434 SPECIFICATIONS.......................................................................................................435 LPG Fuel System..........................................................................................................436 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)............................................................................436 GENERAL..........................................................................................................436 DESCRIPTION......................................................................................................436 Fuel Tank....................................................................................................437 Fuel Filter And Fuel Valve Unit..............................................................................438 Vaporizer....................................................................................................438 The IMPCO CA 100 Carbureto...................................................................................440 IMPCO CA 50 Carburetor.......................................................................................442 The Governor (GM Engines Only)...............................................................................443 Governor With Electronic Controller..........................................................................444 REPAIRS..............................................................................................................445 LPG TANK.........................................................................................................445 Removal......................................................................................................445 Installation.................................................................................................446 REPLACE THE HOSES................................................................................................446 HYDROSTATIC RELIEF VALVE.........................................................................................446 Removal and Installation.....................................................................................446 FILTER UNIT......................................................................................................447 Replacement Of the Fuel Filter Element.......................................................................447 Replacement of the Diaphragm and Fuel Valve..................................................................448 VAPORIZER........................................................................................................448 Removal......................................................................................................448 Disassembly..................................................................................................448 Cleaning.....................................................................................................448 Inspection...................................................................................................448 Assembly.....................................................................................................450 Installation.................................................................................................450 CARBURETOR (IMPCO CA 100)........................................................................................452 Removal......................................................................................................452 Disassembly..................................................................................................452 Cleaning.....................................................................................................452 Assembly.....................................................................................................452 Installation.................................................................................................455 CARBURETER (IMPCO CA 50).........................................................................................454 Removal......................................................................................................454 Disassembly..................................................................................................454 Cleaning.....................................................................................................455 Inspection...................................................................................................455 Assembly (See FIGURE 26.)....................................................................................455 Installation.................................................................................................455 CHECKS AND ADJUSTMENTS...............................................................................................456 CHECK THE FILTER UNIT............................................................................................456 CHECK THE VAPORIZER..............................................................................................456 Pressure Reducer Valve.......................................................................................456 Vapor Valve..................................................................................................456 ADJUST THE CARBURETOR............................................................................................456 Idle Mixture.................................................................................................456 Idle Speed...................................................................................................456 Power Mixture................................................................................................456 ADJUST THE GOVERNOR (GM Engines Only)............................................................................457 Checks.......................................................................................................457 Main Adjusting Screw.........................................................................................457 Secondary Adjusting Screw....................................................................................457 AISAN Governor...............................................................................................458 Adjustment, AISAN Governor...................................................................................458 TROUBLESHOOTING......................................................................................................459 Main Control Valve.......................................................................................................463 INTRODUCTION.........................................................................................................463 GENERAL..........................................................................................................463 DESCRIPTION......................................................................................................463 OPERATION........................................................................................................464 Lift Section.................................................................................................465 Tilt Section.................................................................................................465 Relief Valve.................................................................................................467 SOLENOID VALVE FOR AUXILIARY FUNCTION............................................................................468 Operation....................................................................................................468 REPAIRS..............................................................................................................468 MAIN CONTROL VALVE...............................................................................................468 Removal and Disassembly......................................................................................468 Cleaning and Inspection......................................................................................469 Assembly.....................................................................................................469 Installation.................................................................................................469 SOLENOID VALVE FOR AUXILIARY FUNCTION............................................................................469 Removal and Disassembly......................................................................................469 Assembly and Installation....................................................................................471 CHECKS AND ADJUSTMENTS...............................................................................................471 PRESSURE RELIEF VALVES...........................................................................................471 Primary Relief Valve.........................................................................................471 Seconday Relief Valve........................................................................................472 CONTROL LEVER ARRANGEMENT........................................................................................472 TROUBLESHOOTING......................................................................................................475 SPECIFICATIONS.......................................................................................................477 Mazda M4 121G Engine.....................................................................................................478 MAZDA M4-121G ENGINE.................................................................................................478 GENERAL..........................................................................................................478 DESCRIPTION......................................................................................................479 REMOVAL AND INSTALLATION OF THE ENGINE...........................................................................479 CYLINDER HEAD AND VALVE MECHANISM................................................................................479 Cylinder Head, Removal.......................................................................................479 Cylinder Head, Inspection and Repairs........................................................................480 Rocker Arm Assembly..........................................................................................480 Valve Guides.................................................................................................480 Valve Seats..................................................................................................481 Valves.......................................................................................................481 Valve Springs................................................................................................481 Cylinder Head, Installation..................................................................................481 TIMING GEAR CASE, REMOVAL........................................................................................482 TIMING GEAR CASE, INSTALLATION...................................................................................483 CAMSHAFT.........................................................................................................483 Removal......................................................................................................483 Inspection...................................................................................................484 Cam Followers, Inspection....................................................................................484 Installation.................................................................................................484 CRANKSHAFT AND MAIN BEARINGS.....................................................................................484 Crankshaft, Removal..........................................................................................484 Crankshaft, Inspection And Repair............................................................................485 Main Bearings................................................................................................486 Crankshaft, Installation.....................................................................................486 PISTONS AND CONNECTING RODS......................................................................................487 Removal......................................................................................................487 Disassembly..................................................................................................487 Pistons, Inspection And Repair...............................................................................487 Piston Rings.................................................................................................488 Piston Pin and Bushing.......................................................................................488 Connecting Rods and Bearings, Inspection.....................................................................488 Pistons and Connecting Rods, Assembly........................................................................488 Pistons and Connecting Rods, Installation....................................................................489 CYLINDER BLOCK AND CYLINDER LINERS...............................................................................489 Cylinder Block, Repairs......................................................................................489 Cylinder Liners..............................................................................................489 DISTRIBUTOR......................................................................................................490 Removal......................................................................................................490 Installation.................................................................................................490 OIL PUMP.........................................................................................................492 Removal......................................................................................................492 Repairs......................................................................................................492 Installation.................................................................................................493 GOVERNOR.........................................................................................................493 Description..................................................................................................493 Removal......................................................................................................493 Disassembly..................................................................................................494 Assembly.....................................................................................................495 Installation.................................................................................................496 COOLANT PUMP.....................................................................................................496 Removal......................................................................................................496 Disassembly and Repair.......................................................................................497 Assembly.....................................................................................................497 Installation.................................................................................................498 FLYWHEEL.........................................................................................................498 Repairs......................................................................................................498 Installation.................................................................................................498 CHECKS AND ADJUSTMENTS...............................................................................................498 ADJUST THE VALVES................................................................................................498 ADJUST THE THROTTLE LINKAGE......................................................................................499 ENGINE SPECIFICATIONS................................................................................................499 ENGINE SPECIFICATIONS............................................................................................499 Engine Data..................................................................................................499 Cooling System...............................................................................................499 Cylinder Head and Valve Mechanism............................................................................499 Camshaft.....................................................................................................501 Timing Gear..................................................................................................502 Camshaft.....................................................................................................502 Connecting Rods..............................................................................................502 Cylinder Liners..............................................................................................502 Pistons......................................................................................................502 Lubrication System...........................................................................................503 Fuel Pump....................................................................................................503 TORQUE SPECIFICATIONS............................................................................................504 TROUBLESHOOTING......................................................................................................505 MSTS- GM LPG (Early Control Modules).....................................................................................509 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)............................................................................509 GENERAL..........................................................................................................509 DESCRIPTION......................................................................................................509 What MSTS Does...............................................................................................511 How MSTS Begins Operation....................................................................................511 OPERATION........................................................................................................511 Pulse Generator..............................................................................................511 HEI Module...................................................................................................512 When the Engine Is Being Started.............................................................................512 When the Engine Is Running...................................................................................514 Manifold Absolute Pressure (MAP).............................................................................514 Coolant Temperature Sensor (CTS).............................................................................514 Electronic Control Module (ECM), Corrections.................................................................515 The Initial Timing Connector.................................................................................515 Gasoline and LPG Conversions.................................................................................516 TROUBLESHOOTING......................................................................................................518 GENERAL..........................................................................................................518 TOOLS AND TEST EQUIPMENT.........................................................................................518 MSTS TROUBLESHOOTING.............................................................................................519 Test Description.............................................................................................519 IGNITION SYSTEM TROUBLESHOOTING..................................................................................521 Test Description.............................................................................................521 ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING....................................................................524 Circuit Description..........................................................................................524 Test Description.............................................................................................524 MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING.................................................................527 Circuit Description..........................................................................................527 Test Description.............................................................................................527 COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING.................................................................530 Circuit Description..........................................................................................530 Test Description.............................................................................................530 REPAIRS..............................................................................................................532 DISTRIBUTOR......................................................................................................532 Removal......................................................................................................532 Disassembly..................................................................................................533 Inspection...................................................................................................533 Assembly.....................................................................................................534 Installation.................................................................................................534 Igntion Timing...............................................................................................534 HEI MODULE.......................................................................................................535 Test For A Fault.............................................................................................535 HEI Module Replacement.......................................................................................535 SENSING COIL.....................................................................................................536 Test For A Fault.............................................................................................536 Sensing Coil Replacement.....................................................................................536 IGNITION COIL....................................................................................................536 Test For A Fault.............................................................................................536 ELECTRONIC CONTROL MODULE (ECM)..................................................................................537 Removal......................................................................................................537 Installation.................................................................................................537 COOLANT TEMPERATURE SENSOR (CTS).................................................................................537 Removal......................................................................................................537 Installation.................................................................................................538 MANIFOLD ABSOLUTE PRESSURE (MAP).................................................................................538 Removal......................................................................................................538 Installation.................................................................................................538 PRESSURE CONVERSION CHART....................................................................................539 MSTS-GM LPG (Later Control Modules)......................................................................................540 INTRODUCTION.........................................................................................................540 GENERAL..........................................................................................................540 DESCRIPTION......................................................................................................540 What MSTS Does...............................................................................................540 How MSTS Begins Operation....................................................................................541 OPERATION........................................................................................................542 Distributor..................................................................................................542 Ignition Coil ...............................................................................................542 Ignition Module..............................................................................................542 When the Engine Is Being Started.............................................................................543 When the Engine Is Running ..................................................................................543 Manifold Absolute Pressure (MAP) Sensor......................................................................544 Engine Coolant Temperature (ECT) Sensor......................................................................545 MSTS Module Corrections......................................................................................545 TROUBLESHOOTING......................................................................................................547 GENERAL..........................................................................................................547 TOOLS AND EQUIPMENT..............................................................................................548 MSTS.............................................................................................................549 TROUBLESHOOTING PROCEDURE........................................................................................549 Where To Start...............................................................................................549 Visual/Physical Inspection.......................................................................................549 Knowledge/Tools Required.........................................................................................549 Damage From Static Discharge (Static Electricity)................................................................550 TROUBLESHOOTING INFORMATION......................................................................................550 Malfunction Indicator Lamp (MIL).............................................................................550 Connecting The CodeMate Tester...............................................................................550 Reading Diagnostic Trouble Codes (DTC).......................................................................551 Clearing Diagnostic Trouble Codes (DTC's)....................................................................551 On-Board DIAGNOSTIC (ODB) System Check.......................................................................552 NO MALFUNCTION INDICATOR LAMP....................................................................................554 Circuit Description..........................................................................................554 Test Description.............................................................................................554 NO DTC-12, MALFUNCTION INDICATOR LAMP ON.........................................................................556 Circuit Description..........................................................................................556 Test Description.............................................................................................556 STARTER ROTATES ENGINE, ENGINE DOES NOT RUN......................................................................558 Test Description.............................................................................................558 DTC-14 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (LOW TEMPERATURE INDICATED).......................................561 Circuit Description..........................................................................................561 Test Description.............................................................................................561 DTC-15 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (HIGH TEMPERATURE INDICATED)......................................563 Circuit Description..........................................................................................563 Test Description.............................................................................................563 DTC-34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR...................................................................565 Circuit Description..........................................................................................565 Test Description.............................................................................................565 DTC-41 ELECTRONIC SPARK TIMING (EST OPEN CIRCUIT)................................................................568 Circuit Description..........................................................................................568 Test Description.............................................................................................568 DTC-42 ELECTRONIC SPARK TIMING (EST GROUNDED CIRCUIT)............................................................570 Circuit Description..........................................................................................570 Test Description.............................................................................................570 DTC 51 MSTS FAILURE..............................................................................................572 Circuit Description..........................................................................................572 REPAIRS..............................................................................................................572 DISTRIBUTOR......................................................................................................572 Removal......................................................................................................572 Disassembly..................................................................................................573 Inspection...................................................................................................573 Assembly.....................................................................................................573 Installation.................................................................................................574 Ignition Timing..............................................................................................574 IGNITION MODULE..................................................................................................574 Test For A Fault.............................................................................................574 Ignition Module Replacement..................................................................................575 SENSING COIL.....................................................................................................576 Test For A Fault.............................................................................................576 Sensing Coil Replacement.....................................................................................576 IGNITION COIL....................................................................................................576 Test For A Fault.............................................................................................576 Removal......................................................................................................577 Installation.................................................................................................577 MSTS MODULE......................................................................................................577 Removal......................................................................................................577 Installation.................................................................................................577 ECT SENSOR REPLACEMENT...........................................................................................577 MAP SENSOR REPLACEMENT...........................................................................................578 Periodic Maintenance.....................................................................................................580 PERIODIC MAINTENANCE.................................................................................................580 GENERAL..........................................................................................................580 Serial Number Data...........................................................................................580 HOW TO MOVE A DISABLED LIFT TRUCK................................................................................581 How To Tow the Lift Truck....................................................................................581 HOW TO PUT A LIFT TRUCK ON BLOCKS................................................................................581 How To Raise the Drive Tires.................................................................................581 How To Raise the Steering Tires..............................................................................582 MAINTENANCE PROCEDURES...............................................................................................586 EVERY 8 HOURS OR DAILY...............................................................................................586 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED.......................................................................586 Engine Oil...................................................................................................586 Drive Belts..................................................................................................586 Cooling System...............................................................................................586 Battery......................................................................................................587 Fuel System..................................................................................................589 Air Filter...................................................................................................589 Hydraulic System Oil.........................................................................................589 Tires and Wheels.............................................................................................590 Forks........................................................................................................590 Forks, Adjustment............................................................................................591 Forks, Removal And Installation..............................................................................591 Inspection Of Forks, Mast, and Lift Chains...................................................................592 Safety Labels................................................................................................593 Operator Restraint System....................................................................................593 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING.......................................................................594 Gauges, Lights, Horn, and Fuses..............................................................................594 Fuel Filter, Diesel Engine...................................................................................595 How To Drain The Water From The Fuel Filter..................................................................595 Oil Level, Powershift Transmission...........................................................................595 Control Levers and Pedals....................................................................................595 Lift System Operation........................................................................................595 Inching/Brake Pedal..........................................................................................596 Service Brakes...............................................................................................596 Parking Brake................................................................................................596 Steering System..............................................................................................596 EVERY 250 HOURS OR TWO MONTHS........................................................................................597 ENGINE OIL AND FILTER............................................................................................597 Mazda, GM, And Later Production Isuzu Engines................................................................597 Earlier Production Isuzu C240 Engines........................................................................597 GOVERNOR, MAZDA ENGINE...........................................................................................598 DRIVE BELTS......................................................................................................598 Mazda Engine.................................................................................................598 Isuzu, GM 4-181, And GM 4-153 Engines........................................................................598 BRAKE FLUID......................................................................................................599 HYDRAULIC TANK BREATHER, CLEAN AND CHECK.........................................................................599 FORKS, CHECK FOR WEAR AND DAMAGE.................................................................................599 LIFT CHAINS......................................................................................................599 Lubrication..................................................................................................599 Check For Wear...............................................................................................599 MAST, LUBRICATION................................................................................................600 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE......................................................................600 CONTROL LEVERS AND PEDALS, LUBRICATION...........................................................................601 FUEL SYSTEM, CHECKS AND ADJUSTMENTS..............................................................................601 Idle Speed, Diesel...........................................................................................601 LPG Carburetor...............................................................................................602 Gasoline Carburetor..........................................................................................602 EVERY 1000 HOURS OR SIX MONTHS.......................................................................................603 DIESEL FUEL FILTER...............................................................................................603 Filter Replacement, Models Without A Water Separator.........................................................604 Filter Replacement, Models With A Water Separator............................................................604 Remove Air from the Diesel Fuel System.......................................................................604 DIFFERENTIAL.....................................................................................................605 VALVE CLEARANCE ADJUSTMENT.......................................................................................605 IGNITION SYSTEM, MAZDA AND GM ENGINES............................................................................605 PCV VALVE AND FILTER.............................................................................................607 EVERY 2000 HOURS OR YEARLY...........................................................................................607 HYDRAULIC SYSTEM.................................................................................................607 Replace the Hydraulic Oil and Filter.........................................................................607 POWERSHIFT TRANSMISSION..........................................................................................607 COOLING SYSTEM...................................................................................................608 SERVICE BRAKES...................................................................................................608 DIFFERENTIAL.....................................................................................................608 WHEEL BEARINGS...................................................................................................609 Steering Wheels, lubrication.................................................................................609 Drive Wheels, Lubrication....................................................................................609 GASOLINE FUEL FILTER, REPLACEMENT................................................................................609 PCV VALVE, GM ENGINES............................................................................................609 LPG FILTER, REPLACEMENT..........................................................................................609 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A...................................................................609 GENERAL PROCEDURES...................................................................................................610 CHECK THE HOOD LATCH.............................................................................................610 LIFT CHAIN ADJUSTMENTS...........................................................................................610 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................612 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM......................................................................613 Check the Lift Cylinders for Leaks...........................................................................613 Check the Tilt Cylinders for Leaks...........................................................................613 FUEL INJECTORS...................................................................................................614 WELDING REPAIRS..................................................................................................614 CHANGES TO THE OVERHEAD GUARD....................................................................................614 WHEELS AND TIRES.................................................................................................614 Solid Rubber Tires (Press-on)................................................................................614 Install The Wheels...........................................................................................615 Pneumatic Tires, Remove The Wheels From The Lift Truck.......................................................616 Pneumatic Tires, Remove the Tire From The Wheel..............................................................616 Pneumatic Tires, Install The Wheel In The Tire...............................................................617 Pneumatic Tires, Add Air To The Tires........................................................................618 Pneumatic Tires, Install the Wheels..........................................................................619 Pneumatic Tires, Installation Procedures, Dual Drive Wheels..................................................619 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES................................................................620 Remove The Wheels From The Lift Truck........................................................................620 Remove The Tire From The Wheel...............................................................................620 Install The Tire On The Wheel................................................................................621 REFERENCE TABLE......................................................................................................622 Rochester Carburetor (GM Engine).........................................................................................623 INTRODUCTION.........................................................................................................623 GENERAL..........................................................................................................623 DESCRIPTION......................................................................................................623 OPERATION........................................................................................................624 The Float System.............................................................................................624 The Idle System..............................................................................................624 The Main Metering System (GM 6-250)..........................................................................625 The Power System (GM 6-250)..................................................................................626 The Accelerator Pump System..................................................................................626 Choke System.................................................................................................626 REPAIRS..............................................................................................................627 REMOVAL..........................................................................................................627 DISASSEMBLY......................................................................................................627 Cleaning.........................................................................................................627 ASSEMBLY.........................................................................................................627 INSTALLATION.....................................................................................................627 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)..................................................................632 GOVERNOR (PNEUMATIC) (Early Units)...............................................................................633 CHECKS AND ADJUSTMENTS...............................................................................................634 GENERAL..........................................................................................................634 ADJUST THE CHOKE CONTROL.........................................................................................634 ADJUST THE IDLE SPEED............................................................................................634 ADJSUT THE IDLE MIXTURE..........................................................................................635 ADJUST THE FAST IDLE.............................................................................................635 ADJUST THE THROTTLE LINKAGE,(Later Models).......................................................................636 ADJUST THE THROTTLE LINKAGE,(Early Models).......................................................................637 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)....................................................637 Check the Governor...........................................................................................637 GOVERNOR (AISAN Type) (Early GM Engines Only)....................................................................638 Checks.......................................................................................................639 Adjustments..................................................................................................639 GOVERNOR (HOOF Type) (Early GM Engines Only).....................................................................639 Adjust the Governor..........................................................................................639 TROUBLESHOOTING......................................................................................................641 Single-SPD PS Trans-Description & Operation(T41, T42, T43)...............................................................642 INTRODUCTION.........................................................................................................642 GENERAL..........................................................................................................642 DESCRIPTION AND OPERATION............................................................................................643 GENERAL..........................................................................................................643 TORQE CONVERTER..................................................................................................643 Description..................................................................................................643 Operation....................................................................................................643 CLUTCH ASSEMBLIES................................................................................................646 Description..................................................................................................646 Operation....................................................................................................648 HYDRAULIC SYSTEM.................................................................................................648 General......................................................................................................648 CONTROL VALVE....................................................................................................648 Regulator for Clutch Pressure................................................................................651 Inching Spool Assembly.......................................................................................651 Direction Spool..............................................................................................651 MONOTROL Control Valve.......................................................................................651 Neutral Start Switch, MONOTROL Pedal Only....................................................................652 Neutral Start Switch, Direction Control Lever Only...........................................................652 Modulator Circuit............................................................................................652 Regulator for the Toruqe Converter...........................................................................653 By-Pass Valve for the Oil Cooler.............................................................................653 DIFFERENTIAL.....................................................................................................654 OIL FLOW DIAGRAMS................................................................................................654 Single-SPD PS Trans-Repair (T41, T42, T43)...............................................................................663 INTRODUCTION.........................................................................................................663 GENERAL..........................................................................................................663 REPAIRS..............................................................................................................665 REPAIRS..........................................................................................................665 Torque Converter, Removal....................................................................................665 Torque Converter, Installation...............................................................................665 Front Cover And Transmission Pump, Removal and Disassembly...................................................666 Front Cover And Transmission Pump, Assembly and Installation.................................................666 Clutch Assemblies, Removal and Disassembly...................................................................667 Clutch Assemblies, Inspection................................................................................670 Clutch Assemblies, Assembly and Installation.................................................................671 Differential, Removal and Disassembly........................................................................674 Differential, Inspection.....................................................................................676 Differential, Assembly And Installation......................................................................676 CONTROL VALVE....................................................................................................686 Control Valve, Removal and Disassembly.......................................................................686 Control Valve, Inspection....................................................................................686 Control Valve, Assembly and Installation.....................................................................688 MONOTROL Pedal, Removal and Disassembly......................................................................690 MONOTROL Pedal, Assembly and Installation....................................................................690 CHECKS AND ADJUSTMENTS...............................................................................................692 Stall Test.......................................................................................................692 Adjustment Of The Direction Control Linkage......................................................................693 Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1)....................694 Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187).....................697 Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)..............................698 Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)...........................699 Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)...........703 Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)...................704 Check The Oil Pressures..........................................................................................704 Check The Relief Valve for the Transmission Pump.................................................................704 Check The Clutch Pressure........................................................................................704 Check The Torque Converter Regulator.............................................................................705 Check The Oil Pressure from the Oil Cooler.......................................................................705 Check The Modulator Pressure.....................................................................................706 TROUBLESHOOTING......................................................................................................706 TROUBLESHOOTING, PRESSURE TESTS......................................................................................708 Starter..................................................................................................................711 INTRODUCTION.........................................................................................................711 GENERAL..........................................................................................................711 DESCRIPTION AND OPERATION........................................................................................711 REPAIRS..............................................................................................................713 REMOVAL..........................................................................................................713 DISSASEMBLY......................................................................................................713 CLEANING.........................................................................................................714 ASSEMBLY.........................................................................................................714 INSTALLATION.....................................................................................................714 CHECKS AND ADJUSTMENTS...............................................................................................715 GENERAL..........................................................................................................715 TROUBLESHOOTING......................................................................................................717 Steer Axle...............................................................................................................719 INTRODUCTION.........................................................................................................719 GENERAL..........................................................................................................719 DESCRIPTION......................................................................................................719 REPAIRS..............................................................................................................720 STEERING AXLE ASSEMBLY...........................................................................................720 Removal......................................................................................................720 Installation.................................................................................................720 WHEELS...........................................................................................................720 Removal And Disassembly......................................................................................720 Cleaning.....................................................................................................720 Assembly And Installation....................................................................................721 SPINDLES, BEARINGS, AND TIE RODS.................................................................................721 Removal And Disassembly......................................................................................721 Assembly And Installation....................................................................................722 STEERING CYLINDER................................................................................................723 Removal And Disassembly......................................................................................723 Cleaning And Inspection......................................................................................723 Assembly And Installation....................................................................................723 TROUBLESHOOTING......................................................................................................724 TORQUE SPECIFICATIONS................................................................................................724 Steer Control Unit.......................................................................................................726 STEERING CONTROL UNIT................................................................................................726 GENERAL..........................................................................................................726 DESCRIPTION......................................................................................................726 Control Valve Section........................................................................................726 Metering Section.............................................................................................726 DISASSEMBLY AND INSPECTION.......................................................................................728 ASSEMBLY.........................................................................................................738 TROUBLESHOOTING......................................................................................................752 Steering System..........................................................................................................753 THE STEERING SYSTEM..................................................................................................753 GENERAL..........................................................................................................753 DESCRIPTION......................................................................................................753 Hydraulic Pump Assembly......................................................................................754 Flow Control Valve...........................................................................................755 Relief Valve.................................................................................................755 OPERATION........................................................................................................755 Steering System..............................................................................................755 Hydraulic Pump...............................................................................................756 Flow Control Valve...........................................................................................756 Relief Valve.................................................................................................756 STEERING WHEEL AND COLUMN ASSEMBLY...............................................................................757 Removal (Serial Code C177 And C187)..........................................................................757 Installation (Serial Code C177 And C187).....................................................................757 Removal (Serial Code B177 And B187)..........................................................................760 Installation (Serial Code B177 And B187).....................................................................760 STEERING CONTROL UNIT............................................................................................761 Description..................................................................................................761 Operation, Control Valve Section.............................................................................761 Operation, Metering Section..................................................................................762 CHECKS AND ADJUSTMENTS...........................................................................................762 Remove Air From The Steering System..........................................................................762 Check And Adjust Steering Relief Pressure....................................................................762 Check Hydraulic Pump For Correct Flow........................................................................762 TROUBLESHOOTING......................................................................................................763 Tilt Cylinders...........................................................................................................764 INTRODUCTION.........................................................................................................764 GENERAL..........................................................................................................764 DESCRIPTION......................................................................................................764 REPAIRS..............................................................................................................764 REMOVAL..........................................................................................................764 DISASSEMBLY......................................................................................................764 CLEANING.........................................................................................................764 ASSEMBLY.........................................................................................................764 Tilt Cylinders with O-Rings or Single Lip Seals..............................................................764 Tilt Cylinders for the XM and XMS Models.....................................................................765 Tilt Cylinders for H700 800A and Early Model H700 920B.......................................................767 INSTALLATION.....................................................................................................767 Tilt Cylinders Using Chevron Packing.........................................................................768 CHECKS AND ADJUSTMENTS...............................................................................................770 CHECK THE TILT CYLINDERS FOR LEAKS...............................................................................770 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..........................................................770 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.............................................................771 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS............................................................772 TROUBLESHOOTING......................................................................................................774 Vista Mast-Description...................................................................................................775 INTRODUCTION.........................................................................................................775 GENERAL..........................................................................................................775 MAST WELDMENTS...................................................................................................775 CARRIAGE.........................................................................................................775 MAST MOUNTS......................................................................................................776 VISTA® TWO-STAGE MAST................................................................................................777 DESCRIPTION AND OPERATION........................................................................................777 VISTA® FREE-LIFT MAST................................................................................................779 DESCRIPTION......................................................................................................779 OPERATION........................................................................................................779 VISTA® THREE-STAGE MAST..............................................................................................781 DESCRIPTION......................................................................................................781 OPERATION........................................................................................................781 VISTA® FOUR-STAGE MAST...............................................................................................782 DESCRIPTION......................................................................................................782 OPERATION........................................................................................................783 Vista Mast-Repair........................................................................................................785 VISTA MAST, REPAIR...................................................................................................785 GENERAL..........................................................................................................785 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................785 FORKS............................................................................................................786 Forks, Removal And Installation..............................................................................786 CARRIAGE.........................................................................................................787 Removal......................................................................................................787 Installation.................................................................................................788 MASTS............................................................................................................788 Removal......................................................................................................788 Disassembly..................................................................................................789 Cleaning and Inspection......................................................................................794 Assembly.....................................................................................................794 Installation.................................................................................................798 SIDE-SHIFT CARRIAGE (EARLIER DESIGN).............................................................................799 Removal......................................................................................................799 Repairs......................................................................................................799 Installation.................................................................................................799 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)......................................................................800 Removal......................................................................................................800 Repairs......................................................................................................800 Installation.................................................................................................801 CHECKS AND ADJUSTMENTS...............................................................................................802 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM......................................................................802 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE......................................................803 LIFT CHAIN ADJUSTMENTS...........................................................................................804 MAST ADJUSTMENTS.................................................................................................804 CARRIAGE ADJUSTMENT..............................................................................................806 HEADER HOSE ARRANGEMENTS.........................................................................................806 Two-Stage Header Hose........................................................................................807 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts................................................807 TROUBLESHOOTING......................................................................................................812
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