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Hyster E001 (H1.50-2.00XMS) Service Manual – PDF DOWNLOAD
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Hyster E001 (H1.50-2.00XMS) Service Manual – PDF DOWNLOAD
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Description
Hyster E001 (H1.50-2.00XMS) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster E001 (H1.50-2.00XMS) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR :
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster E001 (H1.50-2.00XMS) Service Manual – PDF DOWNLOAD
0100SRM545-897559(06-2004)-EN................................................... 1 toc......................................................................... 1 Frame................................................................... 1 Safety Precautions Maintenance and Repair............................... 2 General................................................................. 5 Description............................................................. 5 Operator Module Repair.................................................. 5 Remove.............................................................. 5 Install............................................................. 6 Hood and Side Covers Repair............................................. 8 Remove.............................................................. 8 Install............................................................. 9 Overhead Guard Repair................................................... 9 Remove and Install.................................................. 9 LED Backup and Brake Lights, Replace................................ 10 Remove.......................................................... 10 Install......................................................... 10 Counterweight Repair.................................................... 10 Remove.............................................................. 11 Install............................................................. 12 Exhaust System Repair................................................... 12 Muffler, Replace.................................................... 12 Radiator and Cooling System Repair...................................... 16 Remove.............................................................. 16 Install............................................................. 16 Operator Restraint System Repair........................................ 17 Engine Repair........................................................... 18 Remove (Engine Only)................................................ 18 Remove (Engine and Transmission).................................... 18 Install (Engine Only)............................................... 18 Install (Engine and Transmission)................................... 19 Fuel and Hydraulic Tanks Repair......................................... 20 Clean............................................................... 20 Steam Method of Cleaning........................................ 20 Chemical Solution Method of Cleaning............................ 20 Inspect............................................................. 20 Repair.............................................................. 21 Small Leaks..................................................... 21 Large Leaks..................................................... 21 Safety Labels........................................................... 21 tables...................................................................... 1 Table 1. Weight of Counterweights....................................... 10 0600SRM496-897477(02-2001)-EN................................................... 27 General..................................................................... 29 Description................................................................. 29 Engine Removal and Installation............................................. 29 Cylinder Head, Camshaft, and Valve Mechanism Repair......................... 30 Remove.................................................................. 30 Clean................................................................... 31 Inspect and Repair...................................................... 32 Cylinder Head....................................................... 32 Rocker Shaft Assembly............................................... 32 Camshaft............................................................ 32 Valve Guides........................................................ 33 Valve Seats......................................................... 34 Valves.............................................................. 34 Valve Springs....................................................... 35 Install................................................................. 35 Crankshaft and Main Bearings Repair......................................... 38 Remove.................................................................. 38 Inspect and Repair...................................................... 38 Crankshaft.......................................................... 38 Main Bearings....................................................... 38 Install................................................................. 39 Pistons and Connecting Rods Repair.......................................... 40 Remove and Disassemble.................................................. 40 Clean................................................................... 40 Inspect and Repair...................................................... 40 Pistons............................................................. 40 Piston Rings........................................................ 40 Connecting Rods and Bearings........................................ 41 Assemble and Install.................................................... 41 Cylinder Block Repair....................................................... 43 Oil Pump Repair............................................................. 43 Remove.................................................................. 43 Disassemble............................................................. 44 Clean................................................................... 44 Inspect................................................................. 45 Assemble................................................................ 45 Install................................................................. 46 Cooling System Repair....................................................... 46 Thermostat.............................................................. 46 Replace............................................................. 46 Fan Assembly........................................................ 46 Remove and Disassemble.............................................. 46 Assemble and Install................................................ 47 Water Pump.............................................................. 47 Remove and Disassemble.............................................. 47 Assemble and Install................................................ 48 Distributor Repair.......................................................... 49 Remove.................................................................. 49 Install................................................................. 49 Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)................... 50 Remove.................................................................. 50 Ring Gear, Replace...................................................... 50 Install................................................................. 50 Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)................ 51 Remove.................................................................. 51 Install................................................................. 51 Valve Adjustment............................................................ 52 Compression Pressure Check.................................................. 53 Engine Timing Adjustment.................................................... 53 Throttle Linkage Adjustment................................................. 54 Gasoline Engines........................................................ 54 LPG Engines (IMPCO)..................................................... 54 LPG Engines (AISAN)..................................................... 54 Engine Specifications....................................................... 54 Engine Data............................................................. 54 Thermostat.............................................................. 54 Cylinder Head........................................................... 54 Valve Mechanism......................................................... 54 Camshaft................................................................ 55 Crankshaft.............................................................. 55 Connecting Rods......................................................... 56 Cylinder Block.......................................................... 56 Pistons................................................................. 56 Oil Pump................................................................ 56 Torque Specifications....................................................... 57 Troubleshooting............................................................. 58 0600SRM538-897551(02-2001)-EN................................................... 63 General..................................................................... 65 Description................................................................. 65 Engine Removal and Installation............................................. 66 Cylinder Head and Valve Mechanism Repair.................................... 66 Remove.................................................................. 66 Clean................................................................... 67 Inspect and Repair...................................................... 67 Cylinder Head....................................................... 67 Rocker Shaft Assembly............................................... 67 Valve Guides........................................................ 68 Valve Seats......................................................... 68 Valves.............................................................. 68 Valve Springs....................................................... 69 Push Rods........................................................... 70 Cylinder Head........................................................... 70 Assemble............................................................ 70 Install............................................................. 70 Timing Gears Repair......................................................... 72 Remove.................................................................. 72 Clean and Inspect....................................................... 72 Install................................................................. 72 Crankshaft and Main Bearings Repair......................................... 74 Remove.................................................................. 74 Inspect and Repair...................................................... 74 Crankshaft.......................................................... 74 Main Bearings....................................................... 75 Install................................................................. 75 Pistons and Connecting Rods Repair.......................................... 75 Remove and Disassemble.................................................. 75 Clean................................................................... 76 Inspect and Repair...................................................... 76 Pistons............................................................. 76 Piston Rings........................................................ 76 Connecting Rods and Bearings........................................ 76 Assemble and Install.................................................... 77 Cylinder Block and Liners Repair............................................ 78 Inspect and Repair...................................................... 78 Lubrication System Repair................................................... 80 Oil Pump................................................................ 80 Remove.............................................................. 80 Disassemble......................................................... 80 Clean............................................................... 80 Inspect............................................................. 80 Assemble............................................................ 82 Install............................................................. 82 Oil Filter Mount........................................................ 82 Remove.............................................................. 82 Install............................................................. 82 Cooling System Repair....................................................... 83 Thermostat.............................................................. 83 Remove and Install.................................................. 83 Water Pump.............................................................. 83 Remove.............................................................. 83 Disassemble......................................................... 83 Inspect............................................................. 84 Assemble............................................................ 84 Install............................................................. 85 Fuel System Description and Operation....................................... 85 Fuel Injection Pump Repair.................................................. 87 Remove.................................................................. 87 Install................................................................. 88 Fuel Filter Repair.......................................................... 88 New Filter, Install..................................................... 88 Water Sendor, Check..................................................... 88 Fuel System Air Removal..................................................... 89 Fuel Injectors Repair....................................................... 90 Remove and Disassemble.................................................. 90 Assemble................................................................ 90 Inspect and Adjust...................................................... 90 Install................................................................. 91 Flywheel Repair......................................................... 92 Remove.............................................................. 92 Install............................................................. 92 Valves Adjustment........................................................... 93 Compression Pressure Check.................................................. 93 Throttle Linkage Adjustment................................................. 94 Fuel Injection Pump Timing Check............................................ 94 Engine Specifications....................................................... 95 Engine Model M4-2.5D.................................................... 95 Torque Specifications....................................................... 96 Troubleshooting............................................................. 97 0700SRM626-897934(11-2001)-EN...................................................105 toc.........................................................................105 Cooling System..........................................................105 Safety Precautions Maintenance and Repair...............................106 General.................................................................109 Description.............................................................110 Radiator............................................................110 Radiator Cap........................................................110 Thermostat..........................................................110 Water Pump..........................................................111 Fan and Fan Shroud..................................................111 Cooling System Checks...................................................111 Radiator............................................................111 Thermostat..........................................................111 Water Pump..........................................................112 Exhaust Leaks.......................................................112 Fan and Fan Shroud..................................................112 Radiator Cleaning.......................................................112 Drain...............................................................112 Clean...............................................................112 Fill................................................................113 Troubleshooting.........................................................114 0900SRM925-1488917(08-2002)-EN..................................................117 toc.........................................................................117 LPG Fuel System.........................................................117 Safety Precautions Maintenance and Repair...............................118 General.................................................................121 Description and Operation...............................................121 Fuel Tank...........................................................122 Regulator...........................................................122 Start Mode......................................................124 Idle Mode.......................................................124 Run Mode........................................................124 Resonator...........................................................124 Carburetor..........................................................125 Start Mode......................................................125 Idle Mode.......................................................125 Run Mode........................................................125 Governor........................................................126 Hoses Replacement.......................................................127 LPG Tank Repair.........................................................127 Remove..............................................................127 Install.............................................................128 Relief Valve Repair.....................................................128 Remove and Install..................................................128 Carburetor Repair.......................................................128 Remove..............................................................128 Disassemble.........................................................128 Clean...............................................................129 Assemble............................................................130 Install.............................................................130 Governor Repair.........................................................130 Remove..............................................................130 Inspect.............................................................130 Install.............................................................130 Regulator Repair........................................................131 Remove..............................................................131 Disassemble.........................................................131 Clean...............................................................131 Inspect.............................................................131 Assemble............................................................133 Install.............................................................134 Regulator Adjustment....................................................134 Regulator Height Adjustment.........................................134 Regulator Assembly Air Tightness Test...............................135 Carburetor Adjustment...................................................136 Idle Speed and Fuel Mixture.........................................136 Idle Control Adjustment.............................................136 Governor Adjustment.....................................................137 Checks..............................................................137 Adjustments.........................................................137 Throttle Linkage Adjustment S/H2.00-3.20XM (S/H40-65XM).................138 MONOTROL® Pedal Check...................................................139 Throttle Linkage Adjustment S/H1.50-2.00XMS (S/H25-40XMS)...............140 Troubleshooting.........................................................141 tables......................................................................117 Table 1. Power Adjusting Screw..........................................130 Table 2. Air Adjusting Screw............................................130 Table 3. Idle Mixture Adjusting Screw...................................133 Table 4. Idle Mixture Adjusting Screw...................................136 1300SRM543-897557(12-2003)-EN...................................................149 toc.........................................................................149 Single-Speed Powershift Transmission....................................149 Safety Precautions Maintenance and Repair...............................150 General.................................................................153 Torque Converter Description and Operation..............................154 Description.........................................................154 Operation...........................................................154 Clutch Assemblies Description and Operation.............................156 Description.........................................................156 Operation...........................................................157 Hydraulic System Operation..............................................158 Control Valve Operation.................................................160 Regulator for Clutch Pressure.......................................160 Inching Spool Assembly..............................................160 Direction Spool.....................................................160 Modulator Circuit...................................................160 Regulator for the Torque Converter..................................160 MONOTROL® Pedal Operation...............................................161 Direction Control Lever Operation.......................................161 Differential Operation..................................................161 Torque Converter and Transmission Pump Repair...........................161 Remove and Disassemble..............................................161 Inspect.............................................................162 Assemble and Install................................................162 Clutch Assemblies Repair................................................163 Remove and Disassemble..............................................163 Inspect.............................................................166 Assemble and Install................................................166 Differential Repair.....................................................167 Remove and Disassemble..............................................167 Inspect.............................................................167 Assemble and Install................................................167 New Ring and Pinion Assembly, Install...........................168 Pinion Assembly, Install........................................171 Differential and Ring Gear Assembly, Assemble...................172 Control Valve Repair....................................................173 Remove..............................................................173 Disassemble, Earlier Models.........................................173 Disassemble, Later Models...........................................174 Inspect.............................................................174 Assemble, Earlier Models............................................174 Assemble, Later Models..............................................175 Install.............................................................175 MONOTROL® Pedal Repair..................................................176 Remove and Disassemble..............................................176 Assemble and Install................................................176 Direction Control Lever Repair..........................................179 Remove and Disassemble..............................................179 Assemble and Install................................................179 Torque Converter Stall Test.............................................180 Transmission Pressure Tests.............................................181 Transmission Pump Pressure Check, Test Port No. 1...................182 Torque Converter Inlet Pressure Check, Test Port No. 2..............182 Clutch Pressure Check, Test Port No. 3..............................182 Inching/Brake Pedal Adjustment..........................................182 Troubleshooting.........................................................182 tables......................................................................149 Table 1. Pinion Assembly Shims Adjustment...............................169 Table 2. Ring and Pinion Tooth Contact Adjustment.......................170 Table 3. Stall Speeds...................................................181 Table 4. Pressure Test Ports............................................181 1400SRM542-897556(02-2001)-EN...................................................191 General.....................................................................193 Description.................................................................194 Drive Axle Repair...........................................................194 Remove and Disassemble..................................................194 Clean and Inspect.......................................................195 Assemble and Install....................................................195 Torque Specifications.......................................................197 Troubleshooting.............................................................197 1600SRM532-897545(02-2001)-EN...................................................201 General.....................................................................203 Description.................................................................203 Steering Axle Assenbly Repair...............................................204 Remove..................................................................204 Install.................................................................204 Wheels and Hubs Repair......................................................204 Pneumatic Tires, Remove and Disassemble.................................204 Cushion Tires, Remove and Disassemble...................................206 Pneumatic Tires, Assemble and Install...................................206 Cushion Tires, Assemble and Install.....................................206 Spindles, Bearings, and Tie Rods Repair.....................................207 Pneumatic Tires, Remove.................................................207 Cushion Tires, Remove...................................................207 Pneumatic Tires, Install................................................207 Cushion Tires, Install..................................................208 Steering Cylinder Repair....................................................208 Remove and Disassemble..................................................208 Clean and Inspect.......................................................208 Assemble and Install....................................................208 Torque Specifications.......................................................209 Troubleshooting.............................................................210 1600SRM720-1459370(05-2004)-EN..................................................213 toc.........................................................................213 Steering Housing and Control Unit.......................................213 Safety Precautions Maintenance and Repair...............................214 General.................................................................217 Description.............................................................217 Operation...............................................................218 Steering Wheel and Column Assembly Repair...............................219 Assembly Components, Remove.........................................219 Steering Control Unit, Disassemble..................................222 Steering Control Unit, Clean........................................224 Steering Control Unit, Assemble.....................................224 Assembly Components, Install........................................226 System Air Removal......................................................228 Troubleshooting.........................................................228 1800SRM540-897554(02-2001)-EN...................................................233 General.....................................................................235 Description and Operation...................................................235 Service Brake...........................................................235 Parking Brake...........................................................236 Service Brakes Repair.......................................................236 Remove and Disassemble..................................................236 Clean...................................................................239 Inspect.................................................................239 Assemble and Install....................................................240 Adjust..................................................................242 Parking Brake Repair........................................................243 Remove and Disassemble..................................................243 Assemble and Install....................................................244 Adjust..................................................................244 Master Cylinder Repair......................................................244 Remove..................................................................244 Disassemble.............................................................244 Clean and Inspect.......................................................244 Assemble................................................................246 Install.................................................................246 Service Brakes Adjustment...................................................246 Brake System Air Removal....................................................247 Parking Brake Not Applied Switch Test.......................................247 Parking Brake Switch Test (MONOTROL ® Pedal Only)...........................247 Inching/Brake Pedal Adjustment..............................................248 Torque Specifications.......................................................250 Troubleshooting.............................................................250 1900SRM539-897553(02-2001)-EN...................................................253 General.....................................................................255 Description and Operation...................................................255 Hydraulic System........................................................255 Gear Pump Assembly......................................................257 Pump Drive Shaft........................................................259 Steering Flow Divider...................................................260 Relief Valve (Steering).................................................260 Relief Valve (Main Hydraulic)...........................................261 Gear Pump Assembly Repair...................................................262 Remove and Disassemble..................................................262 Assemble and Install....................................................262 Pump Drive Shaft Repair.....................................................262 Disassemble.............................................................262 Assemble and Install....................................................263 Steering Relief Pressure Check and Adjust...................................263 Gear Pump Flow Check........................................................263 Troubleshooting.............................................................264 2000SRM541-897555(02-2001)-EN...................................................269 General.....................................................................271 Description.................................................................271 Operation...................................................................272 Lift Section............................................................273 Tilt Section............................................................273 Tilt Backward.......................................................273 Tilt Forward........................................................273 Steering Flow Divider...................................................276 Relief Valve (Steering).................................................276 Relief Valve (Main Hydraulic)...........................................276 Main Control Valve Repair...................................................277 Remove..................................................................277 Disassemble.............................................................277 Clean and Inspect.......................................................277 Assemble................................................................277 Install.................................................................277 Pressure Relief Valve Check and Adjustment..................................284 Steering Relief Valve...................................................284 Main Hydraulic Relief Valve ............................................284 Troubleshooting.............................................................285 2100SRM103-910102(10-2003)-EN...................................................287 toc.........................................................................287 Tilt Cylinders..........................................................287 Safety Precautions Maintenance and Repair...............................288 General.................................................................291 Description.............................................................291 Tilt Cylinder Repair....................................................291 Remove..............................................................291 Disassemble.........................................................291 Clean...............................................................291 Assemble............................................................292 Tilt Cylinders With O-Ring or Single-Lip Seals..................292 Tilt Cylinders for XM and XMS Models............................293 Tilt Cylinders for H700-800A and Early Model H700-920B..........294 Install.............................................................295 Tilt Cylinders Using Chevron Packing............................296 Install.....................................................297 Tilt Cylinder Leak Check................................................299 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.....................300 Torque Specifications...................................................301 Piston Rod Nut......................................................301 Retainer............................................................302 Troubleshooting.........................................................304 tables......................................................................287 Table 1. Movement Rates (Maximum) for Tilt Cylinders....................300 2200SRM514-897495(01-2004)-EN...................................................307 toc.........................................................................307 Instrument Cluster......................................................307 Safety Precautions Maintenance and Repair...............................308 General.................................................................311 Description.............................................................311 Display Panels on Steering Column, Internal Combustion..............311 Display Panels on Steering Column, Electric Lift Trucks.............316 Standard Display Panel..........................................316 Enhanced Display Panel..........................................317 Curtis 1215 Display Panel...........................................321 Description and Features........................................321 Operation.......................................................321 Cluster-Type Display Panel (Internal Combustion) Replacement............322 Remove and Disassemble..............................................322 Assemble and Install................................................325 Cluster Display Panel (Electric Lift Truck) Replacement.................327 Display Panel Assembly, Replace.....................................327 LED Indicators......................................................327 Battery Indicators..................................................328 Digital Display (Enhanced Display Panel Only).......................328 Status Code or Performance Level Switches and LED indicators (En....328 Standard Display Panel Parts, Replace...............................328 Enhanced Display Panel Parts, Replace...............................329 Curtis 1215 Display Panel Replacement...................................329 Remove..............................................................329 Install.............................................................329 tables......................................................................307 Table 1. Instrument Cluster, Internal Combustion........................311 2200SRM524-897509(02-2001)-EN...................................................333 INTRODUCTION................................................................333 GENERAL ................................................................333 DESCRIPTION ............................................................333 Starting System ....................................................333 Ignition System ....................................................333 Charging System ....................................................334 REPAIRS ....................................................................335 GENERAL ................................................................335 STARTER ................................................................335 Removal and Disassembly ............................................335 Assembly and Installation ..........................................336 COIL REPLACEMENT .......................................................337 DISTRIBUTOR, H1.50–1.75XM, H2.00XMS (S/H25–35XM, S/H40XMS) .............337 Removal And Disassembly ............................................337 Assembly and Installation ..........................................338 DISTRIBUTOR, S/H2.00–3.20XM (S/H40–65XM) ...............................339 Removal and Disassembly ............................................339 Assembly and Installation .........................................340 ALTERNATOR .............................................................341 Removal And Disassembly ............................................341 Assembly and Installation ..........................................342 CHECKS AND ADJUSTMENTS .....................................................343 GENERAL ................................................................343 STARTER ................................................................343 Check Operation ....................................................343 Check Brush Holder .................................................344 Check Armature .....................................................344 Check Field Windings ...............................................344 Check Clutch And Bearing ...........................................344 IGNITION SYSTEM ........................................................344 Adjust Engine Timing ...............................................344 Spark Plugs ........................................................345 CHARGING CIRCUIT .......................................................345 Check For Low Output ...............................................346 Check For High Output ..............................................346 Check The Diodes ...................................................347 Check Field Winding For The Rotor ..................................347 Check Windings In The Stator........................................348 Brushes And Bearings................................................348 Check The Voltage Regulator ........................................348 TROUBLESHOOTING.............................................................349 2200SRM550-897594(02-2001)-EN...................................................351 General.....................................................................353 Description.................................................................353 Starting Circuit........................................................353 Charging System.........................................................354 Starter Repair..............................................................355 Remove and Disassemble..................................................355 Assemble and Install....................................................355 Alternator Repair...........................................................357 Remove and Disassemble..................................................357 Assemble and Install....................................................358 General Checks and Adjustments..............................................359 Starter Checks..............................................................359 Operation Check.........................................................359 Solenoid Coil Checks....................................................360 Brush Holder Check......................................................360 Armature Check..........................................................360 Field Wingdings Check...................................................360 Clutch and Bearing Check................................................360 Cold Start Aid Checks.......................................................361 Glow Plugs..............................................................361 Fuse....................................................................361 Relay and Controller....................................................361 Charging Circuit Checks.....................................................362 Low-Output Check........................................................362 High-Output Check.......................................................363 Diodes Check............................................................363 Rotor Field Winding Check...............................................364 Stator Wingdings Check..................................................365 Brushes and Bearings....................................................365 Voltage Regulator Check.................................................365 Troubleshooting.............................................................366 4000SRM521-897506(05-2004)-EN...................................................369 toc.........................................................................369 Mast....................................................................369 Safety Precautions Maintenance and Repair...............................370 General.................................................................373 Description and Operation...............................................373 Carriages...........................................................373 Mast Mounts.........................................................375 Two-Stage Mast, Limited Free-Lift (LFL).................................377 Description and Operation...........................................377 Two-Stage Mast, Full Free-Lift (FFL)....................................378 Description and Operation...........................................378 Three-Stage Mast, Full Free-Lift (FFL)..................................380 Description and Operation...........................................380 Cylinder Cushion During Lifting Sequence................................383 Cylinder Cushion During Lowering Sequence...............................384 4000SRM522-897507(05-2004)-EN...................................................387 toc.........................................................................387 Mast....................................................................387 Safety Precautions Maintenance and Repair...............................388 General.................................................................391 Safety Procedures When Working Near Mast................................391 Forks Repair............................................................393 Remove..............................................................393 Install.............................................................394 Carriages Repair........................................................394 Standard Carriage, Remove...........................................394 Hang-On Sideshift Carriage, Remove..................................395 Standard Carriage and Hang-On Sideshift Carriage, Repair............396 Standard Carriage, Install..........................................396 Hang-On Sideshift Carriage, Install.................................397 Integral Sideshift Carriage.........................................397 Remove..........................................................397 Clean and Inspect...............................................399 Repair..........................................................399 Install.........................................................400 Mast Repair.............................................................400 Remove..............................................................400 Two-Stage LFL and Two-Stage FFL Masts, Disassemble..................402 Three-Stage FFL Mast................................................409 Disassemble.....................................................409 Mast and Chains, Clean and Inspect..............................412 Two-Stage LFL and Two-Stage FFL Mast, Assemble......................413 Three-Stage FFL Mast, Assemble......................................414 Install.............................................................416 Lift Cylinders Repair...................................................417 Main Lift Cylinders, Remove.........................................417 Free-Lift Cylinder, Remove..........................................417 Lift Cylinders, Disassemble.........................................418 Lift Cylinders, Assemble............................................418 Main Lift Cylinders, Install........................................421 Free-Lift Cylinder, Install.........................................422 Header Hose Arrangements................................................422 Two-Stage LFL Mast, New Hose Install................................422 Two-Stage LFL Mast, Adjust Hoses After Installation.................428 Two-Stage FFL Mast, New Hose Install................................428 Two-Stage FFL Mast, Adjust Hoses After Installation.................433 Three-Stage FFL Mast, New Hose Install..............................435 Three-Stage FFL Mast, Adjust Hoses After Installation...............445 Header Hose Arrangement.................................................446 Two-Stage LFL Mast, New Hose Install................................446 Two-Stage LFL Mast, Adjust Hoses After Installation.................446 Two-Stage FFL Mast, New Hose Install................................450 Two-Stage FFL Mast, Adjust Hoses After Installation.................455 Three-Stage FFL Mast, New Hose Install..............................457 Three-Stage FFL Mast, Adjust Hoses After Install....................462 Lift and Tilt System Leak Check.........................................466 Lift Cylinders Leak Check...........................................466 Tilt Cylinders Leak Check...........................................466 Tilt Cylinders Adjustment...............................................467 Lift Chains Adjustment..................................................468 Mast Adjustment.........................................................470 Carriage Adjustment.....................................................472 Troubleshooting.........................................................472 tables......................................................................387 Table 1. Hook-Type Carriage Chain Adjustment............................469 Table 2. Pin-Type Carriage Chain Adjustment.............................469 8000SRM231-910442(03-2004)-EN...................................................477 toc.........................................................................477 Metric and Inch (SAE) Fasteners.........................................477 Safety Precautions Maintenance and Repair...............................478 General.................................................................481 Threaded Fasteners..................................................481 Nomenclature, Threads...............................................481 Strength Identification.............................................482 Cotter (Split) Pins.................................................482 Fastener Torque Tables..............................................487 Conversion Table....................................................489 tables......................................................................477 Table 1. Bolts and Screws...............................................483 Table 2. Studs and Nuts.................................................484 Table 3. Torque Nuts....................................................485 Table 4. Torque Nuts With Nylon Insert..................................486 Table 5. Torque Values for Metric Fasteners*............................487 Table 6. Torque Values for Inch Fasteners*..............................488 Table 7. Conversion Table for Metric and English Units..................489 Table 8. Cotter Pin Dimensional Data....................................490 Table 9. Cotter Pin Dimensional Data....................................491 Table 10. Cotter Pin Dimensional Data...................................492 Table 11. Cotter Pin Dimensional Data...................................494 8000SRM544-897558(06-2004)-EN...................................................497 toc.........................................................................497 Diagrams................................................................497 Safety Precautions Maintenance and Repair...............................498 8000SRM546-897590(02-2001)-EN...................................................529 Engine Specifications.......................................................531 Electrical System...........................................................531 Hydraulic System............................................................532 Lift Truck Weights..........................................................532 Torque Converter Stall Speeds...............................................532 Tire Pressure...............................................................533 Capacities..................................................................533 Mast Speeds.................................................................534 Mazda M4-1.5G Engine Mast Speeds........................................534 Mazda M4-2.0G Engine Mast Speeds........................................534 Mazda M4-2.5D Engine Mast Speeds........................................535 Transmission Oil Pressures..............................................535 Torque Specifications.......................................................536 Brake System............................................................536 Drive Axle..............................................................536 Engine - Mazda M4-1.5G..................................................536 Engine - Mazda M4-2.0G..................................................536 Engine - Mazda M4-2.5D..................................................537 Frame...................................................................538 Mast....................................................................538 Steering System.........................................................538 Transmission and Differential...........................................538 8000SRM959-1529967(12-2003)-EN..................................................539 toc.........................................................................539 Periodic Maintenance....................................................539 Safety Precautions Maintenance and Repair...............................540 General.................................................................545 Serial Number.......................................................545 How to Move Disabled Lift Truck.....................................545 How to Tow Lift Truck...........................................545 How to Put Lift Truck on Blocks.....................................546 How to Raise Drive Tires........................................546 How to Raise Steering Tires.....................................546 Maintenance Schedule....................................................547 Maintenance Procedures Every 8 Hours or Daily...........................554 How to Make Checks With Engine Stopped..............................554 Tires and Wheels................................................554 Forks...........................................................555 Adjust......................................................556 Remove......................................................556 Install.....................................................556 Inspection of Forks, Mast, and Lift Chains......................556 Safety Labels...................................................557 Operator Restraint System.......................................558 Steering Column Latch...........................................558 Fuel, Oil, or Coolant Leaks Check...............................559 Drive Belts.....................................................559 Engine Oil Level................................................560 Brake Fluid.....................................................560 Hydraulic Oil Level.............................................560 Transmission Oil................................................560 LPG Fuel Filters................................................560 Diesel Fuel Filter..............................................561 How to Drain Water From Fuel Filter.............................561 Battery Electrolyte.............................................561 How to Make Checks With Engine Running..............................561 Gauges, Indicator Lights, Horn, Fuses, and Relays...............561 Control Levers and Pedals.......................................562 Steering System.................................................562 Service Brakes..................................................562 Parking Brake...................................................563 Cooling System..................................................563 Lift System Operation...........................................564 Maintenance Procedures Every 500 Hours or 3 Months......................564 Engine Oil and Filter...............................................564 Changing Engine Oil and Filter..................................564 Air Filter......................................................564 Transmission Oil Level..............................................565 Battery.............................................................566 Wheel Nuts..........................................................566 Engine Speed........................................................566 LPG Engine......................................................566 Diesel Engine...................................................566 Lift Chains.........................................................566 Lubrication.....................................................566 Wear Check......................................................566 Mast................................................................567 Steering Axle.......................................................567 Spark Plugs, Mazda M4-2.0G Engine...................................567 Differential........................................................568 Drive Belts.........................................................568 Mazda M4-2.0G LPG Engines.......................................568 Mazda M4-2.5D Diesel Engine.....................................569 Inching/Brake Pedal.................................................569 Forks...............................................................569 Diesel Fuel System..................................................569 Replace Diesel Fuel Filter......................................569 Remove Air From Fuel System.....................................570 Drain Tar From LPG Regulator........................................570 Steering Axle.......................................................570 Maintenance Procedures Every 1000 Hours or 6 Months.....................571 Pedals, Levers, Cables, and Other Linkages..........................571 Air Filter..........................................................571 LPG Fuel Filter.....................................................571 IMPCO Fuel Filter...............................................571 Regulator Pressure/Diaphragm and O-Ring Checks......................571 Spark Plugs.........................................................571 Ignition System, Mazda M4-2.0G Engines..............................571 Injection Pump Timing, Mazda M4-2.5D Diesel Engine..................572 Valve Clearance Adjustment..........................................573 Integral Sideshift Carriage, Check Bearings.........................573 Hydraulic Pump Drive Shaft..........................................574 PCV Valve...........................................................574 Maintenance Procedures Every 2000 Hours or Yearly.......................574 Throttle Cable......................................................574 Differential........................................................574 Main Solenoid Valve (LPG Engine)....................................574 Hydraulic System....................................................575 Replace Hydraulic Oil and Filter................................575 Clean Hydraulic Tank Breather...................................575 Timing Belt, Mazda..................................................575 Cooling System......................................................575 Transmission........................................................576 Replace Transmission Oil and Filter.............................576 Integral Sideshift Carriage, Replace Bearings.......................576 Gasoline Fuel Filter................................................576 LPG Fuel Filter.....................................................576 Aisan Fuel Filter...............................................576 Hood Latch Check........................................................577 Latch, Adjust.......................................................577 Safety Procedures When Working Near Mast................................578 Lift and Tilt System Leak Check.........................................580 Lift Cylinders, Leak Check..........................................580 Tilt Cylinders, Leak Check..........................................580 Tilt Cylinder Adjustment................................................581 Lift Chain Adjustments..................................................582 Service Brake Check.....................................................584 Diesel Engine Fuel Injector Check.......................................584 Welding Repairs.........................................................585 Overhead Guard Changes..................................................585 Wheel and Tire Replacement..............................................586 General.............................................................586 How to Change Solid Rubber Tire (S Series) .........................586 Remove and Install Tire on Wheel................................586 Pneumatic Tire, Repair..............................................587 Remove Wheels From Lift Truck...................................587 Remove Tire From Wheel..........................................587 Remove Tire From Two-Piece Wheel............................588 Remove Tire From Three- and Four-Piece Wheels...............589 Install Wheel in Tire...........................................590 Install Two-Piece Wheel in Tire.............................591 Install Three- or Four-Piece Wheel in Tire..................592 Add Air to Pneumatic Tires......................................593 Wheels, Install.................................................593 Solid Rubber Tires on Pneumatic Wheels, Change......................593 Remove Tire From Wheel..........................................594 Install Tire on Wheel...........................................595 Operating Procedures for New or Rebuilt Engine..........................597 tables......................................................................539 Table 1. Maintenance Schedule...........................................547 Table 2. Hook-Type Carriage Chain Adjustment............................582 Table 3. Pin-Type Carriage Chain Adjustment.............................583
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