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Hyster D001 (H25-40XM, 40XMS) Service Manual – PDF DOWNLOAD
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Description
Hyster D001 (H25-40XM, 40XMS) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster D001 (H25-40XM, 40XMS) Service Manual – PDF DOWNLOAD
Language : English
Pages : 571
Downloadable : Yes
File Type : PDF
Size: 18.2 MB
TABLE OF CONTENTS:
Hyster D001 (H25-40XM, 40XMS) Service Manual – PDF DOWNLOAD
100545................................................................................................................... 1 INTRODUCTION......................................................................................................... 3 GENERAL.......................................................................................................... 3 DESCRIPTION...................................................................................................... 3 REPAIRS.............................................................................................................. 4 OPERATOR MODULE.................................................................................................. 4 REMOVAL...................................................................................................... 4 INSTALLATION................................................................................................. 4 HOOD AND SIDE COVERS............................................................................................. 5 REMOVAL...................................................................................................... 5 INSTALLATION................................................................................................. 5 OVERHEAD GUARD................................................................................................... 7 REMOVAL AND INSTALLATION..................................................................................... 7 COUNTERWEIGHT.................................................................................................... 7 REMOVAL...................................................................................................... 7 INSTALLATION................................................................................................. 8 EXHAUST SYSTEM................................................................................................... 9 MUFFLER REPLACEMENT.......................................................................................... 9 RADIATOR AND COOLING SYSTEM...................................................................................... 9 REMOVAL...................................................................................................... 9 INSTALLATION................................................................................................. 9 OPERATOR RESTRAINT SYSTEM........................................................................................ 12 ENGINE........................................................................................................... 12 REMOVAL...................................................................................................... 12 INSTALLATION................................................................................................. 13 FUEL AND HYDRAULIC TANK.......................................................................................... 14 INSPECTION................................................................................................... 14 REPAIRS, SMALL LEAKS......................................................................................... 14 REPAIRS, LARGE LEAKS......................................................................................... 14 CLEANING..................................................................................................... 14 STEAM METHOD OF CLEANING..................................................................................... 15 CHEMICAL SOLUTION METHOD OF CLEANING......................................................................... 15 ADDITIONAL PREPARATIONS FOR REAIR............................................................................ 15 SAFETY LABELS.................................................................................................... 16 600496................................................................................................................... 20 INTRODUCTION ........................................................................................................ 20 GENERAL ......................................................................................................... 20 DESCRIPTION ..................................................................................................... 20 REPAIRS ............................................................................................................. 20 REMOVAL AND INSTALLATION OF THE ENGINE .......................................................................... 20 CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM ..................................................................... 20 Removal ..................................................................................................... 20 Cleaning .................................................................................................... 22 Inspection And Repairs ...................................................................................... 22 Cylinder Head, Installation ................................................................................. 25 CRANKSHAFT AND MAIN BEARINGS .................................................................................... 27 Removal ..................................................................................................... 27 Inspection And Repair ....................................................................................... 28 Installation ................................................................................................ 29 PISTONS AND CONNECTING RODS ..................................................................................... 29 Removal And Disassembly ..................................................................................... 29 Cleaning .................................................................................................... 30 Inspection And Repair ....................................................................................... 30 Assembly And Installation ................................................................................... 31 CYLINDER BLOCK .................................................................................................. 32 Repairs ..................................................................................................... 32 OIL PUMP ........................................................................................................ 32 Removal ..................................................................................................... 32 Disassembly ................................................................................................. 32 Cleaning .................................................................................................... 33 Inspection .................................................................................................. 33 Assembly .................................................................................................... 34 Installation ................................................................................................ 34 COOLING SYSTEM .................................................................................................. 34 Thermostat .................................................................................................. 34 Fan Assembly ................................................................................................ 34 Water Pump .................................................................................................. 35 DISTRIBUTOR ..................................................................................................... 36 Removal ..................................................................................................... 36 Installation ................................................................................................ 36 FLYWHEEL AND RING GEAR, S/H2.00–3.20XM (S/H40–65XM) ............................................................. 36 Flywheel, Removal ........................................................................................... 36 Ring Gear, Replacement ...................................................................................... 37 Flywheel, Installation ...................................................................................... 37 FLYWHEEL, S/H1.50–1.75XM, S/H2.00XMS (S/H25–35XM, S/H40XMS) ..................................................... 37 Removal ..................................................................................................... 37 Installation ................................................................................................ 37 CHECKS AND ADJUSTMENTS .......................................................................................... 39 ADJUST THE VALVES ............................................................................................... 39 CHECK THE COMPRESSION PRESSURE .................................................................................. 39 ENGINE SPECIFICATIONS ............................................................................................... 40 TORQUE SPECIFICATIONS ............................................................................................... 43 600537................................................................................................................... 46 INTRODUCTION......................................................................................................... 46 DESCRIPTION...................................................................................................... 46 REPAIRS.............................................................................................................. 47 CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM...................................................................... 47 Removal...................................................................................................... 47 Cleaning..................................................................................................... 48 Inspection And Repairs....................................................................................... 48 Installation................................................................................................. 51 CRANKSHAFT AND MAIN BEARINGS..................................................................................... 54 Removal...................................................................................................... 54 Inspection And Repair........................................................................................ 54 Installation................................................................................................. 55 PISTONS AND CONNECTING RODS...................................................................................... 56 Removal and Disassembly...................................................................................... 56 Cleaning..................................................................................................... 56 Inspection and Repair........................................................................................ 56 Assembly and Installation.................................................................................... 58 CYLINDER BLOCK................................................................................................... 59 Repairs...................................................................................................... 59 FLYWHEEL AND RING GEAR........................................................................................... 59 Flywheel , Removal........................................................................................... 59 Ring Gear.................................................................................................... 59 Flywheel, Installation....................................................................................... 59 CHECKS AND ADJUSTMENTS............................................................................................... 60 ADJUST THE VALVES................................................................................................ 60 CHECK THE COMPRESSION PRESSURE................................................................................... 60 ENGINE SPECIFICATIONS................................................................................................ 62 TORQUE SPECIFICATIONS................................................................................................ 64 TROUBLESHOOTING...................................................................................................... 65 700626................................................................................................................... 67 General.............................................................................................................. 69 Description.......................................................................................................... 70 Radiator......................................................................................................... 70 Radiator Cap..................................................................................................... 70 Thermostat....................................................................................................... 70 Water Pump....................................................................................................... 71 Fan and Fan Shroud............................................................................................... 71 Cooling System Checks................................................................................................ 71 Radiator......................................................................................................... 71 Thermostat....................................................................................................... 71 Water Pump....................................................................................................... 72 Exhaust Leaks.................................................................................................... 72 Fan and Fan Shroud............................................................................................... 72 Radiator Cleaning.................................................................................................... 72 Drain............................................................................................................ 72 Clean............................................................................................................ 72 Fill............................................................................................................. 73 Troubleshooting...................................................................................................... 74 900523................................................................................................................... 76 INTRODUCTION ........................................................................................................ 76 GENERAL ......................................................................................................... 76 DESCRIPTION AND OPERATION. ...................................................................................... 76 Fuel Tank ................................................................................................... 77 Fuel Filter and Fuel Valve Unit ............................................................................. 78 Vaporizer ................................................................................................... 79 Carburetor .................................................................................................. 80 Solenoid Valve .............................................................................................. 81 Idle Control Actuator ....................................................................................... 81 Governor .................................................................................................... 82 REPAIRS ............................................................................................................. 82 REPLACEMENT OF THE HOSES ........................................................................................ 82 LPG TANK ........................................................................................................ 82 Removal ..................................................................................................... 82 Installation ................................................................................................ 83 HYDROSTATIC RELIEF VALVE ........................................................................................ 83 Removal and Installation .................................................................................... 83 FILTER UNIT ..................................................................................................... 83 Replacement Of The Fuel Filter Element ...................................................................... 83 Replacement of the Diaphragm and Fuel Valve ................................................................. 84 VAPORIZER ....................................................................................................... 85 Removal ..................................................................................................... 85 Disassembly ................................................................................................. 85 Cleaning .................................................................................................... 85 Inspection .................................................................................................. 85 Assembly .................................................................................................... 87 Installation ................................................................................................ 87 CARBURETOR ...................................................................................................... 89 Removal ..................................................................................................... 89 Disassembly ................................................................................................. 89 Cleaning .................................................................................................... 90 Assembly .................................................................................................... 91 Installation ................................................................................................ 91 SOLENOID VALVE .................................................................................................. 92 GOVERNOR ........................................................................................................ 92 CHECK THE VAPORIZER ............................................................................................. 92 CHECKS AND ADJUSTMENTS .............................................................................................. 76 CHECK THE FILTER UNIT ........................................................................................... 92 Pressure Reducer Valve ...................................................................................... 92 Vapor Valve ................................................................................................. 92 ADJUST THE CARBURETOR ........................................................................................... 93 Idle Mixture ................................................................................................ 93 Idle Adjustments ............................................................................................ 93 Power Mixture Adjustment .................................................................................... 93 GOVERNOR ........................................................................................................ 94 Checks ...................................................................................................... 94 Adjustments ................................................................................................ 94 ADJUST THE THROTTLE LINKAGE, S/H2.00–3.20XM (S/H40–65XM) ........................................................ 95 ADJUST THE THROTTLE LINKAGE, S/H1.50–1.75XM, S/H2.00XMS (S/H25–35XM, H40XMS) .................................... 95 CHECK THE MONOTROL PEDAL ........................................................................................ 96 TROUBLESHOOTING ..................................................................................................... 96 900547................................................................................................................... 99 INTRODUCTION.........................................................................................................101 DESCRIPTION......................................................................................................101 GOVERNOR.........................................................................................................101 REPAIRS..............................................................................................................102 CARBURETOR.......................................................................................................102 Removal......................................................................................................102 Diasassembly.................................................................................................103 Cleaning.....................................................................................................103 Inspection...................................................................................................106 Assembly.....................................................................................................107 Installation.................................................................................................108 CHECKS AND ADJUSTMENTS...............................................................................................108 CARBURETOR.......................................................................................................108 Idle Speed And Mixture Adjustment............................................................................108 Throttle Linkage Adjustment..................................................................................109 GOVERNOR.........................................................................................................110 TROUBLESHOOTING......................................................................................................111 900548...................................................................................................................115 INTRODUCTION.........................................................................................................115 DESCRIPTION......................................................................................................115 FUEL TANK........................................................................................................115 Description..................................................................................................115 Removal......................................................................................................116 Installation.................................................................................................116 HYDROSTATIC RELIEF VALVE.........................................................................................117 Removal and Installation.....................................................................................117 FUEL FILTER AND FUEL VALVE UNIT..................................................................................117 Description..................................................................................................117 Install A New Fuel Filter Element............................................................................118 Install A New Diaphragm and Fuel Valve.......................................................................118 Check The Filter Unit........................................................................................118 VAPORIZER........................................................................................................119 Description..................................................................................................119 Removal......................................................................................................122 Disassembly..................................................................................................122 Cleaning.....................................................................................................122 Inspection...................................................................................................122 Assembly.....................................................................................................122 Installation.................................................................................................122 Check The Pressure Reducer Valve.............................................................................122 Check The Vapor Valve........................................................................................122 CARBURETOR.......................................................................................................124 Description..................................................................................................124 Removal......................................................................................................126 Disassembly..................................................................................................126 Cleaning.....................................................................................................127 Assembly.....................................................................................................127 Installation.................................................................................................127 GOVERNOR.........................................................................................................127 INSTALLING NEW HOSES.............................................................................................127 CHECKS AND ADJUSTMENTS...............................................................................................128 CARBURETOR.......................................................................................................128 Adjustments..................................................................................................128 GOVERNOR.........................................................................................................128 Checks.......................................................................................................128 Adjustments..................................................................................................128 ADJUST THE THROTTLE LINKAGE......................................................................................129 TROUBLESHOOTING......................................................................................................130 900948...................................................................................................................133 toc..................................................................................................................133 LPG Fuel System..................................................................................................133 Safety Precautions Maintenance and Repair........................................................................134 General..........................................................................................................137 Description and Operation........................................................................................137 Fuel Tank....................................................................................................138 Oxygen Sensor................................................................................................138 Regulator....................................................................................................138 Start Mode...............................................................................................140 Idle Mode................................................................................................140 Run Mode.................................................................................................140 Resonator....................................................................................................140 Carburetor...................................................................................................141 Start Mode...............................................................................................141 Idle Mode................................................................................................142 Run Mode.................................................................................................142 Governor.................................................................................................142 Hoses Replacement................................................................................................143 LPG Tank Repair..................................................................................................143 Remove.......................................................................................................143 Install......................................................................................................144 Relief Valve Repair..............................................................................................144 Remove and Install...........................................................................................144 Carburetor Repair................................................................................................144 Remove.......................................................................................................144 Disassemble..................................................................................................144 Clean........................................................................................................145 Assemble.....................................................................................................145 Install......................................................................................................146 Fuel Injector Repair.............................................................................................146 Remove.......................................................................................................146 Clean and Inspect............................................................................................146 Install......................................................................................................146 Governor Repair..................................................................................................147 Remove.......................................................................................................147 Inspect......................................................................................................147 Install......................................................................................................147 Regulator Repair.................................................................................................147 Remove.......................................................................................................147 Install......................................................................................................147 Oxygen Sensor Repair.............................................................................................148 Remove and Install...........................................................................................148 Vacuum Switches Repair...........................................................................................148 Remove and Install...........................................................................................148 Inspect......................................................................................................148 Resistor Repair..................................................................................................148 Remove and Install...........................................................................................148 Inspect......................................................................................................148 Carburetor and New Regulator Adjustment..........................................................................149 Idle Speed and Fuel Mixture..................................................................................149 Idle Control Adjustment......................................................................................150 Governor Checks and Adjustments..................................................................................150 Checks.......................................................................................................150 Adjustments..................................................................................................151 Throttle Linkage Adjustment......................................................................................151 MONOTROL Pedal Check.............................................................................................152 Check Engine Light...............................................................................................152 Inspect Warning Lamp.........................................................................................152 Check Feedback Operation.....................................................................................153 Check VAC1 and VAC2 Signals..................................................................................153 Check Resistor...............................................................................................153 Check Fuel Injector..........................................................................................153 Check Oxygen Sensor..........................................................................................153 Check Vacuum Switch 1........................................................................................153 Check Vacuum Switch 2........................................................................................154 After Completing Checks......................................................................................154 Troubleshooting..................................................................................................154 tables...............................................................................................................133 Table 1. Adjusting Screw.........................................................................................146 1300543..................................................................................................................163 INTRODUCTION.........................................................................................................164 GENERAL..........................................................................................................164 Description..................................................................................................164 TORQUE CONVERTER.................................................................................................164 Description..................................................................................................164 Operation....................................................................................................165 CLUTCH ASSEMBLIES................................................................................................166 Description..................................................................................................166 Operation....................................................................................................168 HYDRAULIC SYSTEM.................................................................................................168 General......................................................................................................168 CONTROL VALVE....................................................................................................169 Regulator for Clutch Pressure................................................................................169 Inching Spool Assembly.......................................................................................169 Direction Spool .............................................................................................169 Modulator Circuit............................................................................................169 Regulator for the Torque Converter...........................................................................169 MONOTROL PEDAL...................................................................................................170 DIRECTION CONTROL LEVER..........................................................................................170 DIFFERENTIAL.....................................................................................................170 REPAIRS..............................................................................................................171 TORQUE CONVERTER AND TRANSMISSION PUMP...........................................................................171 Removal And Disassembly......................................................................................171 Inspection...................................................................................................172 Assembly and Installation....................................................................................172 CLUCTH ASSEMBLIES................................................................................................172 Removal And Disassembly......................................................................................172 Inspection...................................................................................................175 Assembly.....................................................................................................175 Installation.................................................................................................176 DIFFERENTIAL.....................................................................................................175 Removal And Disassembly......................................................................................176 Inspection...................................................................................................176 Assembly And Installation....................................................................................176 CONTROL VALVE....................................................................................................181 Removal and Disassembly......................................................................................181 Inspection...................................................................................................181 Assembly and Installation....................................................................................181 MONOTROL PEDAL...................................................................................................182 Removal and Disassembly......................................................................................182 Assembly and Installation....................................................................................182 DIRECTION CONTROL LEVER..........................................................................................185 Removal and Disassembly......................................................................................185 Assembly and Installation....................................................................................185 CHECKS AND ADJUSTMENTS...............................................................................................186 TORQUE CONVERTERS STALL TEST.....................................................................................186 TRANSMISSION PRESSURE TESTS......................................................................................187 Check The Transmission Pump Pressure, TEST PORT NO. 1........................................................187 Check The Torque Converter Inlet Pressure, TEST PORT NO. 2.................................................187 Check The Clutch Pressure, TEST PORT NO. 3...................................................................187 ADJUST THE INCHING/BRAKE PEDAL...............................................................................188 TROUBLESHOOTING......................................................................................................190 1400542..................................................................................................................196 INTRODUCTION.........................................................................................................198 GENERAL..........................................................................................................198 DESCRIPTION......................................................................................................198 REPAIRS..............................................................................................................199 REMOVAL AND DISASSEMBLY..........................................................................................199 CLEANING AND INSPECTION..........................................................................................199 ASSEMBLY AND INSTALLATION........................................................................................200 TROUBLESHOOTING......................................................................................................202 TORQUE SPECIFICATIONS................................................................................................202 1600257..................................................................................................................206 STEERING CONTROL UNIT................................................................................................206 GENERAL..........................................................................................................206 DESCRIPTION......................................................................................................206 Control Valve Section........................................................................................206 Metering Section.............................................................................................206 DISASSEMBLY AND INSPECTION.......................................................................................208 ASSEMBLY.........................................................................................................218 TROUBLESHOOTING......................................................................................................232 1600532..................................................................................................................233 INTRODUCTION.........................................................................................................233 GENERAL..........................................................................................................233 DESCRIPTION......................................................................................................233 REPAIRS..............................................................................................................234 HOW TO PUT THE LIFT TRUCK ON BLOCKS..............................................................................234 STEERING AXLE ASSEMBLY...........................................................................................234 Removal......................................................................................................234 Installation.................................................................................................234 WHEELS AND HUBS..................................................................................................234 Removal and Disassembly H1.50-1.75XM,H2.00XMS (H25-35XM, H40XMS).............................................234 Removal and Disaasembly S25-35XM, S40XMS.....................................................................236 Cleaning.....................................................................................................236 Assembly And Installation H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS)..........................................236 Assembly And Installation S25-35XM, S40XMS...................................................................236 SPINDLES, BEARINGS, AND TIE RODS.................................................................................237 Removal H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS)............................................................237 Installation.................................................................................................237 Removal S25-35XM, S40XMS.....................................................................................237 Installation.................................................................................................237 STEERING CYLINDER................................................................................................238 Removal And Disassembly......................................................................................238 Cleaning and Inspection......................................................................................238 Assembly and Installation....................................................................................238 TROUBLESHOOTING......................................................................................................240 TORQUE SPECIFICATIONS................................................................................................240 1600565..................................................................................................................242 INTRODUCTION.........................................................................................................242 GENERAL..........................................................................................................242 DESCRIPTION......................................................................................................242 REPAIRS..............................................................................................................243 STEERING HOUSING ................................................................................................243 Removal And Disassembly......................................................................................243 Assembly And Installation....................................................................................243 1600720..................................................................................................................246 INTRODUCTION.........................................................................................................246 GENERAL..........................................................................................................246 DESCRIPTION......................................................................................................246 OPERATION........................................................................................................246 REPAIRS..............................................................................................................247 STEERING WHEEL AND COLUMN ASSEMBLY...............................................................................247 Removal Of The Assembly Components...........................................................................251 Disassembly Of The Steering Control Unit.....................................................................253 Cleaning Of The Steering Control Unit........................................................................253 Assembly Of The Steering Control Unit........................................................................253 Installation Of The Steering Control Unit....................................................................253 Installation Of The Assembly Components......................................................................253 CHECKS AND ADJUSTMENTS...............................................................................................256 REMOVE AIR FROM THE SYSTEM.......................................................................................256 TROUBLESHOOTING......................................................................................................256 1800540..................................................................................................................257 INTRODUCTION.........................................................................................................258 GENERAL..........................................................................................................258 DESCRIPTION AND OPERATION........................................................................................258 Service Brake................................................................................................258 Parking Brake................................................................................................258 SERVICE BRAKES.......................................................................................................259 Removal And Disassembly..........................................................................................259 Cleaning.........................................................................................................262 Inspection.......................................................................................................263 Assembly And Installation........................................................................................263 Adjustments......................................................................................................265 PARKING BRAKE........................................................................................................265 Removal And Disassembly..........................................................................................265 Assembly And Installation........................................................................................266 Adjust The Parking Brake.........................................................................................266 MASTER CYLINDER......................................................................................................268 Removal..........................................................................................................268 Repair...........................................................................................................268 Disassembly......................................................................................................268 Cleaning And Inspection .........................................................................................268 Assembly.........................................................................................................268 Installation.....................................................................................................268 CHECKS AND ADJUSTMENT................................................................................................270 ADJUST THE SERVICE BRAKES........................................................................................270 REMOVE THE AIR FROM THE BRAKE SYSTEM.............................................................................270 TEST THE "PARKING BRAKE NOT APPLIED" SWITCH......................................................................270 TEST THE PARKING BRAKE SWITCH(MONOTROL PEDAL ONLY)...............................................................270 ADJUST THE INCHING/BRAKE PEDAL...................................................................................271 TROUBLESHOOTING......................................................................................................273 TORQUE SPECIFICATIONS................................................................................................275 1900539..................................................................................................................277 INTRODUCTION.........................................................................................................278 GENERAL..........................................................................................................278 DESCRIPTION AND OPERATION........................................................................................278 Hydraulic System.............................................................................................278 Gear Pump Assembly...........................................................................................280 Pump Drive Shaft.............................................................................................283 Steering Flow Divider........................................................................................283 Relief Valve (Steering)......................................................................................283 Relief Valve (Main Hydraulic)................................................................................283 REPAIR...............................................................................................................284 GEAR PUMP ASSEMBLY...............................................................................................284 Removal and Disassembly......................................................................................284 Assembly and Installation....................................................................................285 PUMP DRIVE SHAFT.................................................................................................285 Disassembly..................................................................................................285 Assembly and Installation....................................................................................285 CHECK AND ADJUST STEERING RELIEF PRESSURE........................................................................285 CHECK GEAR PUMP FOR CORRECT FLOW.................................................................................286 TROUBLESHOOTING......................................................................................................287 2000541..................................................................................................................288 INTRODUCTION.........................................................................................................289 GENERAL..........................................................................................................289 DESCRIPTION......................................................................................................289 OPERATION........................................................................................................290 Lift Section.................................................................................................291 Tilt Section.................................................................................................292 Steering Flow Divider........................................................................................293 Relief Valve (Steering)......................................................................................293 Relief Valve (Main Hydraulic)................................................................................293 REPAIRS..............................................................................................................294 MAIN CONTROL VALVE...............................................................................................294 Removal......................................................................................................294 Disassembly..................................................................................................294 Cleaning And Inspection.....................................................................................294 Assembly.....................................................................................................298 Installation.................................................................................................298 CHECKS AND ADJUSTMENTS...............................................................................................299 PRESSURE RELIEF VALVES...........................................................................................299 Steering Relief Valve........................................................................................299 Main Hydraulic Relief Valve..................................................................................299 TROUBLESHOOTING......................................................................................................300 2100103..................................................................................................................302 General..............................................................................................................304 Description..........................................................................................................304 Tilt Cylinder........................................................................................................304 Remove...........................................................................................................304 Disassemble......................................................................................................304 Clean............................................................................................................304 Assemble.........................................................................................................304 Tilt Cylinders with O-Ring or Single-Lip Seals...............................................................304 Tilt Cylinders for XM and XMS Models.........................................................................306 Tilt Cylinders for H700-800A and Early Model H700-920B.......................................................307 Install..........................................................................................................308 Tilt Cylinders Using Chevron Packing.........................................................................309 Install..................................................................................................310 Tilt Cylinder Leak Check.............................................................................................312 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment..................................................................313 Torque Specifications................................................................................................313 Piston Rod Nut...................................................................................................313 Retainer.........................................................................................................315 Troubleshooting......................................................................................................316 2200144..................................................................................................................319 ELECTRICAL WARNING DEVICES...........................................................................................319 GENERAL..........................................................................................................319 DESCRIPTION......................................................................................................319 Operator Controlled Horns....................................................................................319 System Warning Lights, Buzzers and Bells.....................................................................319 Reverse Warning Horns........................................................................................320 Warning Lights...............................................................................................320 REPLACEMENT......................................................................................................321 General......................................................................................................321 Replacing Horns or Bells.....................................................................................321 Replacing Horn Relay or Buzzer...............................................................................321 Replacing Warning Lights.....................................................................................321 Light Assemblies.............................................................................................322 Replacing Flashing Units.....................................................................................322 2200514..................................................................................................................323 INTRODUCTION.........................................................................................................323 GENERAL..........................................................................................................323 DESCRIPTION......................................................................................................323 REPAIRS..............................................................................................................327 REMOVAL AND DISASSEMBLY..........................................................................................327 ASSEMBLY AND INSTALLATION........................................................................................327 2200524..................................................................................................................330 INTRODUCTION.........................................................................................................330 GENERAL .........................................................................................................330 DESCRIPTION .....................................................................................................330 Starting System .............................................................................................330 Ignition System .............................................................................................330 Charging System .............................................................................................331 REPAIRS .............................................................................................................332 GENERAL .........................................................................................................332 STARTER .........................................................................................................332 Removal and Disassembly .....................................................................................332 Assembly and Installation ...................................................................................333 COIL REPLACEMENT ................................................................................................334 DISTRIBUTOR, H1.50–1.75XM, H2.00XMS (S/H25–35XM, S/H40XMS) ......................................................334 Removal And Disassembly .....................................................................................334 Assembly and Installation ...................................................................................335 DISTRIBUTOR, S/H2.00–3.20XM (S/H40–65XM) ........................................................................336 Removal and Disassembly .....................................................................................336 Assembly and Installation ..................................................................................337 ALTERNATOR ......................................................................................................338 Removal And Disassembly .....................................................................................338 Assembly and Installation ...................................................................................339 CHECKS AND ADJUSTMENTS ..............................................................................................340 GENERAL .........................................................................................................340 STARTER .........................................................................................................340 Check Operation .............................................................................................340 Check Brush Holder ..........................................................................................341 Check Armature ..............................................................................................341 Check Field Windings ........................................................................................341 Check Clutch And Bearing ....................................................................................341 IGNITION SYSTEM .................................................................................................341 Adjust Engine Timing ........................................................................................341 Spark Plugs .................................................................................................342 CHARGING CIRCUIT ................................................................................................342 Check For Low Output ........................................................................................343 Check For High Output .......................................................................................343 Check The Diodes ............................................................................................344 Check Field Winding For The Rotor ...........................................................................344 Check Windings In The Stator.................................................................................345 Brushes And Bearings.........................................................................................345 Check The Voltage Regulator .................................................................................345 TROUBLESHOOTING......................................................................................................346 2200549..................................................................................................................348 INTRODUCTION.........................................................................................................348 GENERAL..........................................................................................................348 DESCRIPTION......................................................................................................348 Starting System..............................................................................................348 Ignition System..............................................................................................348 Charging System..............................................................................................349 REPAIRS..............................................................................................................350 GENERAL..........................................................................................................350 STARTER..........................................................................................................350 Removal And Disassembly......................................................................................350 Assembly And Installation....................................................................................351 COIL REPLACEMENT.................................................................................................352 DISTRIBUTOR......................................................................................................352 Removal And Disassembly......................................................................................352 Assembly and Installation....................................................................................352 ALTERNATOR.......................................................................................................354 Removal And Disassembly......................................................................................354 Assembly And Installation....................................................................................355 CHECKS AND ADJUSTMENTS...............................................................................................355 GENERAL..........................................................................................................355 STARTER..........................................................................................................355 Check Operation..............................................................................................355 Check Brush Holder...........................................................................................356 Check Armature...............................................................................................356 Check Field Windings.........................................................................................356 Check Clutch And Bearing.....................................................................................357 IGNITION SYSTEM..................................................................................................357 Adjust Engine Timing.........................................................................................357 Spark Plugs..................................................................................................357 CHARGING CIRCUIT.................................................................................................357 Check For Low Output.........................................................................................357 Check For High Output........................................................................................357 Check The Diodes.............................................................................................358 Check Field Winding For The Rotor............................................................................359 Check Windings In The Stator.................................................................................359 Brushes And Bearings.........................................................................................360 Check The Voltage Regulator..................................................................................360 TROUBLESHOOTING......................................................................................................360 2200550..................................................................................................................362 INTRODUCTION.........................................................................................................363 GENERAL..........................................................................................................363 DESCRIPTION......................................................................................................363 Starting Circuit.............................................................................................363 Charging System..............................................................................................364 REPAIRS..............................................................................................................365 GENERAL..........................................................................................................365 STARTER..........................................................................................................365 Removal And Disassembly......................................................................................365 Assembly And Installation....................................................................................365 ALTERNATOR.......................................................................................................367 Removal And Disassembly......................................................................................367 Assembly And Installation....................................................................................368 CHECKS AND ADJUSTMENTS...............................................................................................368 GENERAL..........................................................................................................368 STARTER..........................................................................................................368 Check Operation..............................................................................................368 Solenoid Coil Checks.........................................................................................369 Check Brush Holder...........................................................................................369 Check Armature...............................................................................................369 Check Field Windings.........................................................................................370 Check Clutch And Bearings....................................................................................370 COLD START AID...................................................................................................370 Glow Plugs...................................................................................................370 Check The Glow Plugs.........................................................................................370 Fuse.........................................................................................................370 Relay And Controller.........................................................................................370 CHARGING UNIT....................................................................................................371 Check For low Output.........................................................................................371 Check For High Output........................................................................................372 Check For Diodes.............................................................................................372 Check Field Winding For The Rotor............................................................................373 Check Windings In The Stator.................................................................................373 Brushes And Bearings.........................................................................................374 Check The Voltage Regulator..................................................................................374 TROUBLESHOOTING......................................................................................................374 4000135..................................................................................................................377 Safety Procedures When Working Near Mast.............................................................................379 General..............................................................................................................384 Description..........................................................................................................384 Lowering Control Valve...........................................................................................384 Cylinders (General)..............................................................................................387 Cylinders (H520-620B, H700-800A).................................................................................387 Retainer, Install............................................................................................387 Cylinders (H360-460B)............................................................................................389 Cylinders (Two-Speed)............................................................................................392 Lift Cylinder Repair.................................................................................................393 Lift Cylinder Removal Without Removing Mast......................................................................393 Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast................................393 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...................................394 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder.....................................395 Disasemble.......................................................................................................395 Assemble.........................................................................................................395 Lift Cylinder Installation in Mast...............................................................................397 Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast.................................397 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...................................397 Chevron-Style Packing............................................................................................397 Chevron-Style Packing Installation on Piston.................................................................398 Chevron-Style Packing Installation in Packing Gland..........................................................400 Lift Cylinders for Vista Masts.......................................................................................401 Description......................................................................................................401 Lowering Control Valve.......................................................................................401 Remove...........................................................................................................403 Disassemble......................................................................................................404 Assemble.........................................................................................................405 Install..........................................................................................................406 Main Lift Cylinders..........................................................................................406 Free-Lift Cylinder...........................................................................................406 Lift System Leak Check...............................................................................................406 Specifications.......................................................................................................407 Troubleshooting......................................................................................................408 4000521..................................................................................................................411 INTRODUCTION.........................................................................................................411 GENERAL..........................................................................................................411 DESCRIPTION AND OPERATION........................................................................................411 Carriages....................................................................................................411 Mast Mounts..................................................................................................412 TWO-STAGE MAST, LIMITED FREE-LIFT................................................................................413 Description and Operation....................................................................................413 TWO-STAGE MAST, FULL FREE-LIFT...................................................................................415 Description..................................................................................................415 Operation....................................................................................................415 THREE-STAGE, FULL FREE-LIFT MAST.................................................................................417 Description..................................................................................................417 Operation....................................................................................................417 4000522..................................................................................................................419 INTRODUCTION ........................................................................................................419 GENERAL .........................................................................................................419 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ........................................................................419 REPAIRS .............................................................................................................420 FORKS ...........................................................................................................420 Removal .....................................................................................................420 Installation ................................................................................................421 CARRIAGES .......................................................................................................421 Removal, Standard Carriage ..................................................................................421 Removal, Side–Shift Carriage ................................................................................422 Repairs .....................................................................................................422 Installation, Standard Carriage .............................................................................422 Installation, Side–Shift Carriage ...........................................................................423 MAST ............................................................................................................424 Removal .....................................................................................................424 Disassembly, Three–Stage FFL Mast ...........................................................................430 Disassembly, Two–Stage LFL And Two–Stage FFL Masts ..........................................................424 Cleaning and Inspection .....................................................................................430 Assembly, Two–Stage LFL And Two–Stage FFL Mast ..............................................................433 Assembly, Three–Stage FFL Mast ..............................................................................434 Installation, Mast ..........................................................................................435 LIFT CYLINDERS ..................................................................................................436 Removal, Main Lift Cylinders ................................................................................436 Removal, Free–Lift Cylinder .................................................................................436 Disassembly, Lift Cylinders .................................................................................436 Assembly, Lift Cylinders ....................................................................................437 Installation, Main Lift Cylinders ...........................................................................438 Installation, Free–Lift Cylinder ............................................................................439 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) ....................440 New Hose Installation, Two–Stage, LFL Mast ..................................................................440 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................440 New Hose Installation, Two–Stage FFL Mast ...................................................................444 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................444 New Hose Installation, Three–Stage FFL Mast .................................................................448 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................453 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) ....455 New Hose Installation, Two–Stage LFL Mast ...................................................................456 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................456 New Hose Installation, Two–Stage FFL Mast ...................................................................459 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................459 New Hose Installation, Three–Stage, FFL Mast ................................................................463 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................468 CHECKS AND ADJUSTMENTS ..............................................................................................469 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ....................................................................469 Check The Lift Cylinders For Leaks .........................................................................469 Check The Tilt Cylinders For Leaks .........................................................................469 ADJUST THE TILT CYLINDERS ......................................................................................469 ADJUST THE LIFT CHAINS .........................................................................................470 ADJUST THE MAST ................................................................................................471 ADJUST THE CARRIAGE ............................................................................................472 TROUBLESHOOTING......................................................................................................473 8000231..................................................................................................................474 General..............................................................................................................476 Nomenclature, Threads............................................................................................476 Strength Identification..........................................................................................477 Fastener Torque Tables...........................................................................................481 Conversion Table.................................................................................................483 8000531..................................................................................................................485 toc..................................................................................................................485 Periodic Maintenance.............................................................................................485 Safety Precautions Maintenance and Repair........................................................................486 General..........................................................................................................491 Serial Number................................................................................................491 How to Move Disabled Lift Truck..............................................................................491 How to Tow Lift Truck....................................................................................491 How to Put Lift Truck on Blocks..............................................................................492 How to Raise Drive Tires.................................................................................492 How to Raise Steering Tires..............................................................................492 Maintenance Schedule.............................................................................................493 Maintenance Procedures Every 8 Hours or Daily....................................................................501 How to Make Checks with Engine Stopped.......................................................................501 Tires and Wheels.........................................................................................501 Forks....................................................................................................502 Adjust...............................................................................................502 Remove...............................................................................................502 Install..............................................................................................502 Forks, Mast, and Lift Chains, Inspect....................................................................502 Safety Labels............................................................................................505 Operator Restraint System................................................................................505 Steering Column Latch....................................................................................505 Fuel, Oil, or Coolant Leaks, Check.......................................................................506 Drive Belt...............................................................................................506 Engine Oil...............................................................................................507 Hydraulic System.........................................................................................507 How to Make Checks with Engine Running.......................................................................507 Battery..................................................................................................507 Gauges, Indicator Lights, Horn, Fuses, and Relays........................................................508 Transmission Oil Level...................................................................................508 Steering System..........................................................................................508 Service Brakes...........................................................................................509 Brake Fluid Level....................................................................................509 Operation, Check.....................................................................................509 Parking Brake............................................................................................509 Cooling System...........................................................................................509 Control Levers and Pedals................................................................................510 Lift System Operation....................................................................................510 Maintenance Procedures Every 250 Hours or 6 Weeks................................................................511 Parking Brake Linkage........................................................................................511 Engine Filter and Oil........................................................................................511 Oil Filter and Oil.......................................................................................511 Air Filter...............................................................................................511 Gasoline and LPG Fuel Filters............................................................................511 Fuel Filter, Diesel Engine...............................................................................512 How to Drain Water from Fuel Filter......................................................................512 Transmission Oil Level.......................................................................................512 Battery......................................................................................................512 Hydraulic Tank Breather......................................................................................513 Wheel Nuts...................................................................................................513 Engine Speed.................................................................................................513 LPG Carburetor...........................................................................................513 Gasoline Carburetor......................................................................................514 Diesel...................................................................................................514 Lift Chains..................................................................................................514 Lubrication..............................................................................................514 Wear Check...............................................................................................514 Mast.........................................................................................................515 Steering Axle................................................................................................515 Pedals, Levers, Cables, and Other Linkages...................................................................515 Spark Plugs (Mazda M4-1.5G or M4-2.0G Engine)................................................................515 Differential.................................................................................................515 Drive Belts..................................................................................................515 Mazda M4-1.5G Gasoline/LPG Engine........................................................................515 Mazda M4-2.0G Gasoline/LPG Engine........................................................................516 Fan and Alternator Drive Belt........................................................................516 Timing Belt..........................................................................................516 Mazda M4-2.5D Diesel Engine..............................................................................516 Inching Brake................................................................................................517 PCV Valve....................................................................................................517 Forks........................................................................................................517 Brake Fluid..................................................................................................517 Maintenance Procedures Every 1000 Hours or 6 Months..............................................................518 Air Filter...................................................................................................518 Diesel Fuel System...........................................................................................518 Fuel Filter Replacement..................................................................................518 Fuel System, Remove Air..................................................................................518 Gasoline Fuel Filter.........................................................................................518 LPG Fuel Filter..............................................................................................519 Spark Plugs..................................................................................................519 Ignition System..............................................................................................519 Mazda M4-1.5G or M4-2.0G Engine..........................................................................519 Injection Pump Timing, Mazda M4-2.5D Diesel Engine...........................................................520 Valve Clearance, Check and Adjust............................................................................521 Maintenance Procedures Every 2000 Hours or Yearly................................................................521 Throttle Cable...............................................................................................521 Differential.................................................................................................521 Hydraulic System.............................................................................................521 Hydraulic Oil and Filter, Replace........................................................................521 Mazda M4-2.0G Engine Timing Belt.............................................................................522 PCV Valve....................................................................................................522 Cooling System...............................................................................................522 Transmission.................................................................................................522 Transmission Oil and Filter, Replace.....................................................................522 Wheel Bearings...............................................................................................523 Steer Wheels.............................................................................................523 Drive Wheels.............................................................................................523 Hood Latch Check.................................................................................................523 Latch, Adjust................................................................................................523 Safety Procedures When Working Near Mast.........................................................................525 Lift and Tilt System Leak Check..................................................................................527 Lift Cylinders, Leak Check...................................................................................527 Tilt Cylinders, Leak Check...................................................................................527 Tilt Cylinder Adjustment.........................................................................................528 Lift Chain Adjustments...........................................................................................529 Service Brake Check..............................................................................................531 Diesel Engine Fuel Injector Check................................................................................531 Welding Repairs..................................................................................................532 Overhead Guard Changes...........................................................................................532 Wheel and Tire Replacement.......................................................................................532 General......................................................................................................532 How to Change Solid Rubber Tire (S Series) ..................................................................532 Remove and Install Tire on Wheel.........................................................................533 Pneumatic Tire, Repair.......................................................................................534 Remove Wheels From Lift Truck............................................................................534 Remove Tire From Wheel...................................................................................534 Remove Tire From Two-Piece Wheel.....................................................................535 Remove Tire From Three- and Four-Piece Wheels........................................................536 Install Wheel in Tire....................................................................................537 Install Two-Piece Wheel in Tire......................................................................538 Install Three- or Four-Piece Wheel in Tire...........................................................539 Add Air to Pneumatic Tires...............................................................................540 Wheels, Install..........................................................................................540 Solid Rubber Tires on Pneumatic Wheels, Change...............................................................540 Remove Tire From Wheel...................................................................................541 Install Tire on Wheel....................................................................................542 Operating Procedures for New or Rebuilt Engine...................................................................544 tables...............................................................................................................485 Table 1. Maintenance Schedule....................................................................................493 Table 2. Hook-Type Carriage Chain Adjustment.....................................................................529 Table 3. Pin-Type Carriage Chain Adjustment......................................................................529 8000544..................................................................................................................547 FIGURE 1. WIRING SCHEMATIC FOR THE MAZDA M4-2.0 GASOLINE OR LPG ENGINE...............................................550 FIGURE 2. WIRING SCHEMATIC FOR THE MAZDA M4-2.5D DIESEL ENGINE (Pneumatic Trucks Only)...............................551 FIGURE 3. LIGHTS WIRING SCHEMATIC, US................................................................................553 FIGURE 4. LIGHTS WIRING SCHEMATIC, EUROPE(Pneumatic Trucks Only).....................................................555 FIGURE 5. INSTRUMENT CLUSTER WIRING SCHEMATIC........................................................................557 FIGURE 6. HYDRAULIC SYSTEM SCHEMATIC.................................................................................558 FIGURE 7. HYDRAULIC SYSTEM ARRANGEMENT.............................................................................559 FIGURE 8. ELECTRICAL SCHEMATIC FOR THE HAND LEVER DIRECTION CONTROL..................................................559 FIGURE 9. ELECTRICAL SCHEMATIC FOR MONOTROL..........................................................................560 FIGURE 10. HYDRAULIC SCHEMATIC FOR THE TRANSMISSION (Neutral)........................................................560 8000546..................................................................................................................563 ENGINE SPECIFICATIONS................................................................................................564 ELECTRICAL SYSTEM....................................................................................................564 HYDRAULIC SYSTEM.....................................................................................................565 LIFT TRUCK WEIGHTS...................................................................................................565 TIRE PRESSURE........................................................................................................565 TORQUE CONVERTER STALL SPEEDS........................................................................................565 CAPACITIES..........................................................................................................565 MAST SPEEDS-MAZDA M4-1.5 ENGINE......................................................................................566 MAST SPEEDS-MAZDA M4-2.0G ENGINE.....................................................................................566 MAST SPEEDS-MAZDA M4-2.5D ENGINE.....................................................................................567 TRANSMISSION OIL PRESSURES...........................................................................................567 TORQUE SPECIFICATIONS................................................................................................568
HYSTER D001 (H25-40XM, 40XMS) SERVICE MANUAL – PDF DOWNLOAD:
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