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Hyster Forklift S25XM 35XM, H25XM 35XM, H40XMS, S40XMSC010D001 service manual – PDF DOWNLOAD
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Hyster Forklift S25XM 35XM, H25XM 35XM, H40XMS, S40XMSC010D001 service manual
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Hyster Forklift S25XM 35XM, H25XM 35XM, H40XMS, S40XMSC010D001 service manual
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HYSTER FORKLIFT S25XM 35XM, H25XM 35XM, H40XMS, S40XMSC010D001 SERVICE MANUAL – PDF DOWNLOAD:
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Hyster Forklift S25XM 35XM, H25XM 35XM, H40XMS, S40XMSC010D001 service manual
Table of Contents:
Hyster Forklift S25XM 35XM, H25XM 35XM, H40XMS, S40XMSC010D001 service manual
INTRODUCTION......................................................................................................... 1 GENERAL.......................................................................................................... 1 DESCRIPTION AND OPERATION........................................................................................ 1 Service Brake................................................................................................ 1 Parking Brake................................................................................................ 1 SERVICE BRAKES....................................................................................................... 2 Removal And Disassembly.......................................................................................... 2 Cleaning......................................................................................................... 5 Inspection....................................................................................................... 6 Assembly And Installation........................................................................................ 6 Adjustments...................................................................................................... 8 PARKING BRAKE........................................................................................................ 8 Removal And Disassembly.......................................................................................... 8 Assembly And Installation........................................................................................ 9 Adjust The Parking Brake......................................................................................... 9 MASTER CYLINDER...................................................................................................... 11 Removal.......................................................................................................... 11 Repair........................................................................................................... 11 Disassembly...................................................................................................... 11 Cleaning And Inspection ......................................................................................... 11 Assembly......................................................................................................... 11 Installation..................................................................................................... 11 CHECKS AND ADJUSTMENT................................................................................................ 13 ADJUST THE SERVICE BRAKES........................................................................................ 13 REMOVE THE AIR FROM THE BRAKE SYSTEM............................................................................. 13 TEST THE "PARKING BRAKE NOT APPLIED" SWITCH...................................................................... 13 TEST THE PARKING BRAKE SWITCH(MONOTROL PEDAL ONLY)............................................................... 13 ADJUST THE INCHING/BRAKE PEDAL................................................................................... 14 TROUBLESHOOTING...................................................................................................... 16 TORQUE SPECIFICATIONS................................................................................................ 18 ENGINE SPECIFICATIONS................................................................................................ 21 ELECTRICAL SYSTEM.................................................................................................... 21 HYDRAULIC SYSTEM..................................................................................................... 22 LIFT TRUCK WEIGHTS................................................................................................... 22 TIRE PRESSURE........................................................................................................ 22 TORQUE CONVERTER STALL SPEEDS........................................................................................ 22 CAPACITIES.......................................................................................................... 22 MAST SPEEDS-MAZDA M4-1.5 ENGINE...................................................................................... 23 MAST SPEEDS-MAZDA M4-2.0G ENGINE..................................................................................... 23 MAST SPEEDS-MAZDA M4-2.5D ENGINE..................................................................................... 24 TRANSMISSION OIL PRESSURES........................................................................................... 24 TORQUE SPECIFICATIONS................................................................................................ 25 General.............................................................................................................. 30 Description.......................................................................................................... 31 Radiator......................................................................................................... 31 Radiator Cap..................................................................................................... 31 Thermostat....................................................................................................... 31 Water Pump....................................................................................................... 32 Fan and Fan Shroud............................................................................................... 32 Cooling System Checks................................................................................................ 32 Radiator......................................................................................................... 32 Thermostat....................................................................................................... 32 Water Pump....................................................................................................... 33 Exhaust Leaks.................................................................................................... 33 Fan and Fan Shroud............................................................................................... 33 Radiator Cleaning.................................................................................................... 33 Drain............................................................................................................ 33 Clean............................................................................................................ 33 Fill............................................................................................................. 34 Troubleshooting...................................................................................................... 35 FIGURE 1. WIRING SCHEMATIC FOR THE MAZDA M4-2.0 GASOLINE OR LPG ENGINE............................................... 38 FIGURE 2. WIRING SCHEMATIC FOR THE MAZDA M4-2.5D DIESEL ENGINE (Pneumatic Trucks Only)............................... 39 FIGURE 3. LIGHTS WIRING SCHEMATIC, US................................................................................ 41 FIGURE 4. LIGHTS WIRING SCHEMATIC, EUROPE(Pneumatic Trucks Only)..................................................... 43 FIGURE 5. INSTRUMENT CLUSTER WIRING SCHEMATIC........................................................................ 45 FIGURE 6. HYDRAULIC SYSTEM SCHEMATIC................................................................................. 46 FIGURE 7. HYDRAULIC SYSTEM ARRANGEMENT............................................................................. 47 FIGURE 8. ELECTRICAL SCHEMATIC FOR THE HAND LEVER DIRECTION CONTROL.................................................. 47 FIGURE 9. ELECTRICAL SCHEMATIC FOR MONOTROL.......................................................................... 48 FIGURE 10. HYDRAULIC SCHEMATIC FOR THE TRANSMISSION (Neutral)........................................................ 48 INTRODUCTION......................................................................................................... 51 GENERAL.......................................................................................................... 51 DESCRIPTION...................................................................................................... 51 REPAIRS.............................................................................................................. 52 REMOVAL AND DISASSEMBLY.......................................................................................... 52 CLEANING AND INSPECTION.......................................................................................... 52 ASSEMBLY AND INSTALLATION........................................................................................ 53 TROUBLESHOOTING...................................................................................................... 55 TORQUE SPECIFICATIONS................................................................................................ 55 INTRODUCTION......................................................................................................... 58 GENERAL ......................................................................................................... 58 DESCRIPTION ..................................................................................................... 58 Starting System ............................................................................................. 58 Ignition System ............................................................................................. 58 Charging System ............................................................................................. 59 REPAIRS ............................................................................................................. 60 GENERAL ......................................................................................................... 60 STARTER ......................................................................................................... 60 Removal and Disassembly ..................................................................................... 60 Assembly and Installation ................................................................................... 61 COIL REPLACEMENT ................................................................................................ 62 DISTRIBUTOR, H1.50–1.75XM, H2.00XMS (S/H25–35XM, S/H40XMS) ...................................................... 62 Removal And Disassembly ..................................................................................... 62 Assembly and Installation ................................................................................... 63 DISTRIBUTOR, S/H2.00–3.20XM (S/H40–65XM) ........................................................................ 64 Removal and Disassembly ..................................................................................... 64 Assembly and Installation .................................................................................. 65 ALTERNATOR ...................................................................................................... 66 Removal And Disassembly ..................................................................................... 66 Assembly and Installation ................................................................................... 67 CHECKS AND ADJUSTMENTS .............................................................................................. 68 GENERAL ......................................................................................................... 68 STARTER ......................................................................................................... 68 Check Operation ............................................................................................. 68 Check Brush Holder .......................................................................................... 69 Check Armature .............................................................................................. 69 Check Field Windings ........................................................................................ 69 Check Clutch And Bearing .................................................................................... 69 IGNITION SYSTEM ................................................................................................. 69 Adjust Engine Timing ........................................................................................ 69 Spark Plugs ................................................................................................. 70 CHARGING CIRCUIT ................................................................................................ 70 Check For Low Output ........................................................................................ 71 Check For High Output ....................................................................................... 71 Check The Diodes ............................................................................................ 72 Check Field Winding For The Rotor ........................................................................... 72 Check Windings In The Stator................................................................................. 73 Brushes And Bearings......................................................................................... 73 Check The Voltage Regulator ................................................................................. 73 TROUBLESHOOTING...................................................................................................... 74 INTRODUCTION......................................................................................................... 76 GENERAL.......................................................................................................... 76 DESCRIPTION...................................................................................................... 76 Starting System.............................................................................................. 76 Ignition System.............................................................................................. 76 Charging System.............................................................................................. 77 REPAIRS.............................................................................................................. 78 GENERAL.......................................................................................................... 78 STARTER.......................................................................................................... 78 Removal And Disassembly...................................................................................... 78 Assembly And Installation.................................................................................... 79 COIL REPLACEMENT................................................................................................. 80 DISTRIBUTOR...................................................................................................... 80 Removal And Disassembly...................................................................................... 80 Assembly and Installation.................................................................................... 80 ALTERNATOR....................................................................................................... 82 Removal And Disassembly...................................................................................... 82 Assembly And Installation.................................................................................... 83 CHECKS AND ADJUSTMENTS............................................................................................... 83 GENERAL.......................................................................................................... 83 STARTER.......................................................................................................... 83 Check Operation.............................................................................................. 83 Check Brush Holder........................................................................................... 84 Check Armature............................................................................................... 84 Check Field Windings......................................................................................... 84 Check Clutch And Bearing..................................................................................... 85 IGNITION SYSTEM.................................................................................................. 85 Adjust Engine Timing......................................................................................... 85 Spark Plugs.................................................................................................. 85 CHARGING CIRCUIT................................................................................................. 85 Check For Low Output......................................................................................... 85 Check For High Output........................................................................................ 85 Check The Diodes............................................................................................. 86 Check Field Winding For The Rotor............................................................................ 87 Check Windings In The Stator................................................................................. 87 Brushes And Bearings......................................................................................... 88 Check The Voltage Regulator.................................................................................. 88 TROUBLESHOOTING...................................................................................................... 88 INTRODUCTION......................................................................................................... 90 GENERAL.......................................................................................................... 90 DESCRIPTION...................................................................................................... 90 REPAIRS.............................................................................................................. 91 REMOVAL AND INSTALLATION OF THE ENGINE........................................................................... 91 CYLINDER HEAD AND VALVE MECHANISM................................................................................ 91 Removal...................................................................................................... 91 Cleaning..................................................................................................... 92 Inspection And Repairs....................................................................................... 92 Cylinder Head, Assembly...................................................................................... 95 Cylinder Head, Installation.................................................................................. 96 TIMING GEARS..................................................................................................... 96 Removal...................................................................................................... 96 Cleaning And Inspection...................................................................................... 97 Installation................................................................................................. 97 CAMSHAFT......................................................................................................... 98 Removal...................................................................................................... 98 Inspection And Repairs....................................................................................... 98 Installation................................................................................................. 99 CRANKSHAFT AND MAIN BEARINGS..................................................................................... 99 Removal...................................................................................................... 99 Inspection And Repair........................................................................................ 99 Installation.................................................................................................100 PISTON AND CONNECTING RODS.......................................................................................101 Removal And Disassembly......................................................................................101 Cleaning.....................................................................................................101 Inspection And Repair........................................................................................101 Assembly And Installation....................................................................................102 CYLINDER BLOCK AND LINERS........................................................................................103 Inspection and Repairs.......................................................................................103 LUBRICATION SYSTEM...............................................................................................104 Oil Pump, Removal............................................................................................105 Oil Pump, Disassembly........................................................................................105 Oil Pump, Cleaning...........................................................................................105 Inspection...................................................................................................105 Assembly.....................................................................................................106 Installation.................................................................................................106 Oil Filter Mount, Removal....................................................................................107 Oil Filter Mount, Installation...............................................................................107 COOLING SYSTEM...................................................................................................107 Thermostat, Installation.....................................................................................107 Water Pump, Removal..........................................................................................108 Water Pump, Disassembly......................................................................................108 Water Pump, Inspection.......................................................................................109 Water Pump, Assembly.........................................................................................109 Water Pump, Installation.....................................................................................110 FUEL SYSTEM......................................................................................................110 Description And Operation ...................................................................................110 FUEL INJECTION PUMP..............................................................................................112 Removal......................................................................................................112 Installation.................................................................................................113 FUEL FILTER......................................................................................................113 Install a New Filter.........................................................................................113 Check the Water Sensor.......................................................................................113 REMOVE AIR FROM THE FUEL SYSTEM..................................................................................114 FUEL INJECTORS...................................................................................................114 Removal And Disassembly......................................................................................114 Assembly.....................................................................................................115 Inspection And Adjustment....................................................................................115 Installation.................................................................................................115 FLYWHEEL.........................................................................................................115 Removal......................................................................................................115 Installation.................................................................................................115 CHECKS AND ADJUSTMENTS...............................................................................................116 ADJUST THE VALVES................................................................................................116 CHECK THE COMPRESSION PRESSURE...................................................................................117 ADJUST THE THROTTLE LINKAGE......................................................................................117 CHECK THE TIMING OF THE FUEL INJECTION PUMP......................................................................118 ENGINE SPECIFICATIONS ...............................................................................................119 TORQUE SPECIFICATIONS................................................................................................121 TROUBLESHOOTING......................................................................................................121 INTRODUCTION ........................................................................................................125 GENERAL .........................................................................................................125 DESCRIPTION .....................................................................................................125 REPAIRS .............................................................................................................125 REMOVAL AND INSTALLATION OF THE ENGINE ..........................................................................125 CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM .....................................................................125 Removal .....................................................................................................125 Cleaning ....................................................................................................127 Inspection And Repairs ......................................................................................127 Cylinder Head, Installation .................................................................................130 CRANKSHAFT AND MAIN BEARINGS ....................................................................................132 Removal .....................................................................................................132 Inspection And Repair .......................................................................................133 Installation ................................................................................................134 PISTONS AND CONNECTING RODS .....................................................................................134 Removal And Disassembly .....................................................................................134 Cleaning ....................................................................................................135 Inspection And Repair .......................................................................................135 Assembly And Installation ...................................................................................136 CYLINDER BLOCK ..................................................................................................137 Repairs .....................................................................................................137 OIL PUMP ........................................................................................................137 Removal .....................................................................................................137 Disassembly .................................................................................................137 Cleaning ....................................................................................................138 Inspection ..................................................................................................138 Assembly ....................................................................................................139 Installation ................................................................................................139 COOLING SYSTEM ..................................................................................................139 Thermostat ..................................................................................................139 Fan Assembly ................................................................................................139 Water Pump ..................................................................................................140 DISTRIBUTOR .....................................................................................................141 Removal .....................................................................................................141 Installation ................................................................................................141 FLYWHEEL AND RING GEAR, S/H2.00–3.20XM (S/H40–65XM) .............................................................141 Flywheel, Removal ...........................................................................................141 Ring Gear, Replacement ......................................................................................142 Flywheel, Installation ......................................................................................142 FLYWHEEL, S/H1.50–1.75XM, S/H2.00XMS (S/H25–35XM, S/H40XMS) .....................................................142 Removal .....................................................................................................142 Installation ................................................................................................142 CHECKS AND ADJUSTMENTS ..........................................................................................144 ADJUST THE VALVES ...............................................................................................144 CHECK THE COMPRESSION PRESSURE ..................................................................................144 ENGINE SPECIFICATIONS ...............................................................................................145 TORQUE SPECIFICATIONS ...............................................................................................148 INTRODUCTION.........................................................................................................152 GENERAL..........................................................................................................152 DESCRIPTION......................................................................................................152 REPAIRS..............................................................................................................153 OPERATOR MODULE..................................................................................................153 REMOVAL......................................................................................................153 INSTALLATION.................................................................................................153 HOOD AND SIDE COVERS.............................................................................................154 REMOVAL......................................................................................................154 INSTALLATION.................................................................................................154 OVERHEAD GUARD...................................................................................................156 REMOVAL AND INSTALLATION.....................................................................................156 COUNTERWEIGHT....................................................................................................156 REMOVAL......................................................................................................156 INSTALLATION.................................................................................................157 EXHAUST SYSTEM...................................................................................................158 MUFFLER REPLACEMENT..........................................................................................158 RADIATOR AND COOLING SYSTEM......................................................................................158 REMOVAL......................................................................................................158 INSTALLATION.................................................................................................158 OPERATOR RESTRAINT SYSTEM........................................................................................161 ENGINE...........................................................................................................161 REMOVAL......................................................................................................161 INSTALLATION.................................................................................................162 FUEL AND HYDRAULIC TANK..........................................................................................163 INSPECTION...................................................................................................163 REPAIRS, SMALL LEAKS.........................................................................................163 REPAIRS, LARGE LEAKS.........................................................................................163 CLEANING.....................................................................................................163 STEAM METHOD OF CLEANING.....................................................................................164 CHEMICAL SOLUTION METHOD OF CLEANING.........................................................................164 ADDITIONAL PREPARATIONS FOR REAIR............................................................................164 SAFETY LABELS....................................................................................................165 INTRODUCTION.........................................................................................................169 DESCRIPTION......................................................................................................169 REPAIRS..............................................................................................................170 CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM......................................................................170 Removal......................................................................................................170 Cleaning.....................................................................................................171 Inspection And Repairs.......................................................................................171 Installation.................................................................................................174 CRANKSHAFT AND MAIN BEARINGS.....................................................................................177 Removal......................................................................................................177 Inspection And Repair........................................................................................177 Installation.................................................................................................178 PISTONS AND CONNECTING RODS......................................................................................179 Removal and Disassembly......................................................................................179 Cleaning.....................................................................................................179 Inspection and Repair........................................................................................179 Assembly and Installation....................................................................................181 CYLINDER BLOCK...................................................................................................182 Repairs......................................................................................................182 FLYWHEEL AND RING GEAR...........................................................................................182 Flywheel , Removal...........................................................................................182 Ring Gear....................................................................................................182 Flywheel, Installation.......................................................................................182 CHECKS AND ADJUSTMENTS...............................................................................................183 ADJUST THE VALVES................................................................................................183 CHECK THE COMPRESSION PRESSURE...................................................................................183 ENGINE SPECIFICATIONS................................................................................................185 TORQUE SPECIFICATIONS................................................................................................187 TROUBLESHOOTING......................................................................................................188 INTRODUCTION.........................................................................................................191 DESCRIPTION......................................................................................................191 GOVERNOR.........................................................................................................191 REPAIRS..............................................................................................................192 CARBURETOR.......................................................................................................192 Removal......................................................................................................192 Diasassembly.................................................................................................193 Cleaning.....................................................................................................193 Inspection...................................................................................................196 Assembly.....................................................................................................197 Installation.................................................................................................198 CHECKS AND ADJUSTMENTS...............................................................................................198 CARBURETOR.......................................................................................................198 Idle Speed And Mixture Adjustment............................................................................198 Throttle Linkage Adjustment..................................................................................199 GOVERNOR.........................................................................................................200 TROUBLESHOOTING......................................................................................................201 INTRODUCTION.........................................................................................................204 GENERAL..........................................................................................................204 DESCRIPTION AND OPERATION........................................................................................204 Hydraulic System.............................................................................................204 Gear Pump Assembly...........................................................................................206 Pump Drive Shaft.............................................................................................209 Steering Flow Divider........................................................................................209 Relief Valve (Steering)......................................................................................209 Relief Valve (Main Hydraulic)................................................................................209 REPAIR...............................................................................................................210 GEAR PUMP ASSEMBLY...............................................................................................210 Removal and Disassembly......................................................................................210 Assembly and Installation....................................................................................211 PUMP DRIVE SHAFT.................................................................................................211 Disassembly..................................................................................................211 Assembly and Installation....................................................................................211 CHECK AND ADJUST STEERING RELIEF PRESSURE........................................................................211 CHECK GEAR PUMP FOR CORRECT FLOW.................................................................................212 TROUBLESHOOTING......................................................................................................213 INTRODUCTION.........................................................................................................214 GENERAL..........................................................................................................214 DESCRIPTION......................................................................................................214 REPAIRS..............................................................................................................218 REMOVAL AND DISASSEMBLY..........................................................................................218 ASSEMBLY AND INSTALLATION........................................................................................218 Safety Procedures When Working Near Mast.............................................................................222 General..............................................................................................................227 Description..........................................................................................................227 Lowering Control Valve...........................................................................................227 Cylinders (General)..............................................................................................230 Cylinders (H520-620B, H700-800A).................................................................................230 Retainer, Install............................................................................................230 Cylinders (H360-460B)............................................................................................232 Cylinders (Two-Speed)............................................................................................235 Lift Cylinder Repair.................................................................................................236 Lift Cylinder Removal Without Removing Mast......................................................................236 Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast................................236 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...................................237 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder.....................................238 Disasemble.......................................................................................................238 Assemble.........................................................................................................238 Lift Cylinder Installation in Mast...............................................................................240 Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast.................................240 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...................................240 Chevron-Style Packing............................................................................................240 Chevron-Style Packing Installation on Piston.................................................................241 Chevron-Style Packing Installation in Packing Gland..........................................................243 Lift Cylinders for Vista Masts.......................................................................................244 Description......................................................................................................244 Lowering Control Valve.......................................................................................244 Remove...........................................................................................................246 Disassemble......................................................................................................247 Assemble.........................................................................................................248 Install..........................................................................................................249 Main Lift Cylinders..........................................................................................249 Free-Lift Cylinder...........................................................................................249 Lift System Leak Check...............................................................................................249 Specifications.......................................................................................................250 Troubleshooting......................................................................................................251 INTRODUCTION ........................................................................................................253 GENERAL .........................................................................................................253 DESCRIPTION AND OPERATION. ......................................................................................253 Fuel Tank ...................................................................................................254 Fuel Filter and Fuel Valve Unit .............................................................................255 Vaporizer ...................................................................................................256 Carburetor ..................................................................................................257 Solenoid Valve ..............................................................................................258 Idle Control Actuator .......................................................................................258 Governor ....................................................................................................259 REPAIRS .............................................................................................................259 REPLACEMENT OF THE HOSES ........................................................................................259 LPG TANK ........................................................................................................259 Removal .....................................................................................................259 Installation ................................................................................................260 HYDROSTATIC RELIEF VALVE ........................................................................................260 Removal and Installation ....................................................................................260 FILTER UNIT .....................................................................................................260 Replacement Of The Fuel Filter Element ......................................................................260 Replacement of the Diaphragm and Fuel Valve .................................................................261 VAPORIZER .......................................................................................................262 Removal .....................................................................................................262 Disassembly .................................................................................................262 Cleaning ....................................................................................................262 Inspection ..................................................................................................262 Assembly ....................................................................................................264 Installation ................................................................................................264 CARBURETOR ......................................................................................................266 Removal .....................................................................................................266 Disassembly .................................................................................................266 Cleaning ....................................................................................................267 Assembly ....................................................................................................268 Installation ................................................................................................268 SOLENOID VALVE ..................................................................................................269 GOVERNOR ........................................................................................................269 CHECK THE VAPORIZER .............................................................................................269 CHECKS AND ADJUSTMENTS ..............................................................................................253 CHECK THE FILTER UNIT ...........................................................................................269 Pressure Reducer Valve ......................................................................................269 Vapor Valve .................................................................................................269 ADJUST THE CARBURETOR ...........................................................................................270 Idle Mixture ................................................................................................270 Idle Adjustments ............................................................................................270 Power Mixture Adjustment ....................................................................................270 GOVERNOR ........................................................................................................271 Checks ......................................................................................................271 Adjustments ................................................................................................271 ADJUST THE THROTTLE LINKAGE, S/H2.00–3.20XM (S/H40–65XM) ........................................................272 ADJUST THE THROTTLE LINKAGE, S/H1.50–1.75XM, S/H2.00XMS (S/H25–35XM, H40XMS) ....................................272 CHECK THE MONOTROL PEDAL ........................................................................................273 TROUBLESHOOTING .....................................................................................................273 INTRODUCTION.........................................................................................................276 DESCRIPTION......................................................................................................276 FUEL TANK........................................................................................................276 Description..................................................................................................276 Removal......................................................................................................277 Installation.................................................................................................277 HYDROSTATIC RELIEF VALVE.........................................................................................278 Removal and Installation.....................................................................................278 FUEL FILTER AND FUEL VALVE UNIT..................................................................................278 Description..................................................................................................278 Install A New Fuel Filter Element............................................................................279 Install A New Diaphragm and Fuel Valve.......................................................................279 Check The Filter Unit........................................................................................279 VAPORIZER........................................................................................................280 Description..................................................................................................280 Removal......................................................................................................283 Disassembly..................................................................................................283 Cleaning.....................................................................................................283 Inspection...................................................................................................283 Assembly.....................................................................................................283 Installation.................................................................................................283 Check The Pressure Reducer Valve.............................................................................283 Check The Vapor Valve........................................................................................283 CARBURETOR.......................................................................................................285 Description..................................................................................................285 Removal......................................................................................................287 Disassembly..................................................................................................287 Cleaning.....................................................................................................288 Assembly.....................................................................................................288 Installation.................................................................................................288 GOVERNOR.........................................................................................................288 INSTALLING NEW HOSES.............................................................................................288 CHECKS AND ADJUSTMENTS...............................................................................................289 CARBURETOR.......................................................................................................289 Adjustments..................................................................................................289 GOVERNOR.........................................................................................................289 Checks.......................................................................................................289 Adjustments..................................................................................................289 ADJUST THE THROTTLE LINKAGE......................................................................................290 TROUBLESHOOTING......................................................................................................291 toc..................................................................................................................294 LPG Fuel System..................................................................................................294 General..........................................................................................................297 Description and Operation........................................................................................297 Fuel Tank....................................................................................................298 Oxygen Sensor................................................................................................298 Regulator....................................................................................................298 Start Mode...............................................................................................300 Idle Mode................................................................................................300 Run Mode.................................................................................................300 Resonator....................................................................................................300 Carburetor...................................................................................................301 Start Mode...............................................................................................301 Idle Mode................................................................................................302 Run Mode.................................................................................................302 Governor.................................................................................................302 Hoses Replacement................................................................................................303 LPG Tank Repair..................................................................................................303 Remove.......................................................................................................303 Install......................................................................................................304 Relief Valve Repair..............................................................................................304 Remove and Install...........................................................................................304 Carburetor Repair................................................................................................304 Remove.......................................................................................................304 Disassemble..................................................................................................304 Clean........................................................................................................305 Assemble.....................................................................................................305 Install......................................................................................................306 Fuel Injector Repair.............................................................................................306 Remove.......................................................................................................306 Clean and Inspect............................................................................................306 Install......................................................................................................306 Governor Repair..................................................................................................307 Remove.......................................................................................................307 Inspect......................................................................................................307 Install......................................................................................................307 Regulator Repair.................................................................................................307 Remove.......................................................................................................307 Install......................................................................................................307 Oxygen Sensor Repair.............................................................................................308 Remove and Install...........................................................................................308 Vacuum Switches Repair...........................................................................................308 Remove and Install...........................................................................................308 Inspect......................................................................................................308 Resistor Repair..................................................................................................308 Remove and Install...........................................................................................308 Inspect......................................................................................................308 Carburetor and New Regulator Adjustment..........................................................................309 Idle Speed and Fuel Mixture..................................................................................309 Idle Control Adjustment......................................................................................310 Governor Checks and Adjustments..................................................................................310 Checks.......................................................................................................310 Adjustments..................................................................................................311 Throttle Linkage Adjustment......................................................................................311 MONOTROL Pedal Check.............................................................................................312 Check Engine Light...............................................................................................312 Inspect Warning Lamp.........................................................................................312 Check Feedback Operation.....................................................................................313 Check VAC1 and VAC2 Signals..................................................................................313 Check Resistor...............................................................................................313 Check Fuel Injector..........................................................................................313 Check Oxygen Sensor..........................................................................................313 Check Vacuum Switch 1........................................................................................313 Check Vacuum Switch 2........................................................................................314 After Completing Checks......................................................................................314 Troubleshooting..................................................................................................314 tables...............................................................................................................294 Table 1. Adjusting Screw.........................................................................................306 INTRODUCTION.........................................................................................................322 GENERAL..........................................................................................................322 DESCRIPTION......................................................................................................322 OPERATION........................................................................................................323 Lift Section.................................................................................................324 Tilt Section.................................................................................................325 Steering Flow Divider........................................................................................326 Relief Valve (Steering)......................................................................................326 Relief Valve (Main Hydraulic)................................................................................326 REPAIRS..............................................................................................................327 MAIN CONTROL VALVE...............................................................................................327 Removal......................................................................................................327 Disassembly..................................................................................................327 Cleaning And Inspection.....................................................................................327 Assembly.....................................................................................................331 Installation.................................................................................................331 CHECKS AND ADJUSTMENTS...............................................................................................332 PRESSURE RELIEF VALVES...........................................................................................332 Steering Relief Valve........................................................................................332 Main Hydraulic Relief Valve..................................................................................332 TROUBLESHOOTING......................................................................................................333 INTRODUCTION.........................................................................................................335 GENERAL..........................................................................................................335 DESCRIPTION AND OPERATION........................................................................................335 Carriages....................................................................................................335 Mast Mounts..................................................................................................336 TWO-STAGE MAST, LIMITED FREE-LIFT................................................................................337 Description and Operation....................................................................................337 TWO-STAGE MAST, FULL FREE-LIFT...................................................................................339 Description..................................................................................................339 Operation....................................................................................................339 THREE-STAGE, FULL FREE-LIFT MAST.................................................................................341 Description..................................................................................................341 Operation....................................................................................................341 INTRODUCTION ........................................................................................................343 GENERAL .........................................................................................................343 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ........................................................................343 REPAIRS .............................................................................................................344 FORKS ...........................................................................................................344 Removal .....................................................................................................344 Installation ................................................................................................345 CARRIAGES .......................................................................................................345 Removal, Standard Carriage ..................................................................................345 Removal, Side–Shift Carriage ................................................................................346 Repairs .....................................................................................................346 Installation, Standard Carriage .............................................................................346 Installation, Side–Shift Carriage ...........................................................................347 MAST ............................................................................................................348 Removal .....................................................................................................348 Disassembly, Three–Stage FFL Mast ...........................................................................354 Disassembly, Two–Stage LFL And Two–Stage FFL Masts ..........................................................348 Cleaning and Inspection .....................................................................................354 Assembly, Two–Stage LFL And Two–Stage FFL Mast ..............................................................357 Assembly, Three–Stage FFL Mast ..............................................................................358 Installation, Mast ..........................................................................................359 LIFT CYLINDERS ..................................................................................................360 Removal, Main Lift Cylinders ................................................................................360 Removal, Free–Lift Cylinder .................................................................................360 Disassembly, Lift Cylinders .................................................................................360 Assembly, Lift Cylinders ....................................................................................361 Installation, Main Lift Cylinders ...........................................................................362 Installation, Free–Lift Cylinder ............................................................................363 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) ....................364 New Hose Installation, Two–Stage, LFL Mast ..................................................................364 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................364 New Hose Installation, Two–Stage FFL Mast ...................................................................368 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................368 New Hose Installation, Three–Stage FFL Mast .................................................................372 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................377 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) ....379 New Hose Installation, Two–Stage LFL Mast ...................................................................380 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................380 New Hose Installation, Two–Stage FFL Mast ...................................................................383 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................383 New Hose Installation, Three–Stage, FFL Mast ................................................................387 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................392 CHECKS AND ADJUSTMENTS ..............................................................................................393 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ....................................................................393 Check The Lift Cylinders For Leaks .........................................................................393 Check The Tilt Cylinders For Leaks .........................................................................393 ADJUST THE TILT CYLINDERS ......................................................................................393 ADJUST THE LIFT CHAINS .........................................................................................394 ADJUST THE MAST ................................................................................................395 ADJUST THE CARRIAGE ............................................................................................396 TROUBLESHOOTING......................................................................................................397 INTRODUCTION.........................................................................................................398 GENERAL..........................................................................................................398 DESCRIPTION......................................................................................................398 Starting Circuit.............................................................................................398 Charging System..............................................................................................399 REPAIRS..............................................................................................................400 GENERAL..........................................................................................................400 STARTER..........................................................................................................400 Removal And Disassembly......................................................................................400 Assembly And Installation....................................................................................400 ALTERNATOR.......................................................................................................402 Removal And Disassembly......................................................................................402 Assembly And Installation....................................................................................403 CHECKS AND ADJUSTMENTS...............................................................................................403 GENERAL..........................................................................................................403 STARTER..........................................................................................................403 Check Operation..............................................................................................403 Solenoid Coil Checks.........................................................................................404 Check Brush Holder...........................................................................................404 Check Armature...............................................................................................404 Check Field Windings.........................................................................................405 Check Clutch And Bearings....................................................................................405 COLD START AID...................................................................................................405 Glow Plugs...................................................................................................405 Check The Glow Plugs.........................................................................................405 Fuse.........................................................................................................405 Relay And Controller.........................................................................................405 CHARGING UNIT....................................................................................................406 Check For low Output.........................................................................................406 Check For High Output........................................................................................407 Check For Diodes.............................................................................................407 Check Field Winding For The Rotor............................................................................408 Check Windings In The Stator.................................................................................408 Brushes And Bearings.........................................................................................409 Check The Voltage Regulator..................................................................................409 TROUBLESHOOTING......................................................................................................409 General..............................................................................................................413 Nomenclature, Threads............................................................................................413 Strength Identification..........................................................................................414 Fastener Torque Tables...........................................................................................418 Conversion Table.................................................................................................420 toc..................................................................................................................421 Periodic Maintenance.............................................................................................421 General..........................................................................................................426 Serial Number................................................................................................426 How to Move Disabled Lift Truck..............................................................................426 How to Tow Lift Truck....................................................................................426 How to Put Lift Truck on Blocks..............................................................................427 How to Raise Drive Tires.................................................................................427 How to Raise Steering Tires..............................................................................427 Maintenance Schedule.............................................................................................428 Maintenance Procedures Every 8 Hours or Daily....................................................................436 How to Make Checks with Engine Stopped.......................................................................436 Tires and Wheels.........................................................................................436 Forks....................................................................................................437 Adjust...............................................................................................437 Remove...............................................................................................437 Install..............................................................................................437 Forks, Mast, and Lift Chains, Inspect....................................................................437 Safety Labels............................................................................................440 Operator Restraint System................................................................................440 Steering Column Latch....................................................................................440 Fuel, Oil, or Coolant Leaks, Check.......................................................................441 Drive Belt...............................................................................................441 Engine Oil...............................................................................................442 Hydraulic System.........................................................................................442 How to Make Checks with Engine Running.......................................................................442 Battery..................................................................................................442 Gauges, Indicator Lights, Horn, Fuses, and Relays........................................................443 Transmission Oil Level...................................................................................443 Steering System..........................................................................................443 Service Brakes...........................................................................................444 Brake Fluid Level....................................................................................444 Operation, Check.....................................................................................444 Parking Brake............................................................................................444 Cooling System...........................................................................................444 Control Levers and Pedals................................................................................445 Lift System Operation....................................................................................445 Maintenance Procedures Every 250 Hours or 6 Weeks................................................................446 Parking Brake Linkage........................................................................................446 Engine Filter and Oil........................................................................................446 Oil Filter and Oil.......................................................................................446 Air Filter...............................................................................................446 Gasoline and LPG Fuel Filters............................................................................446 Fuel Filter, Diesel Engine...............................................................................447 How to Drain Water from Fuel Filter......................................................................447 Transmission Oil Level.......................................................................................447 Battery......................................................................................................447 Hydraulic Tank Breather......................................................................................448 Wheel Nuts...................................................................................................448 Engine Speed.................................................................................................448 LPG Carburetor...........................................................................................448 Gasoline Carburetor......................................................................................449 Diesel...................................................................................................449 Lift Chains..................................................................................................449 Lubrication..............................................................................................449 Wear Check...............................................................................................449 Mast.........................................................................................................450 Steering Axle................................................................................................450 Pedals, Levers, Cables, and Other Linkages...................................................................450 Spark Plugs (Mazda M4-1.5G or M4-2.0G Engine)................................................................450 Differential.................................................................................................450 Drive Belts..................................................................................................450 Mazda M4-1.5G Gasoline/LPG Engine........................................................................450 Mazda M4-2.0G Gasoline/LPG Engine........................................................................451 Fan and Alternator Drive Belt........................................................................451 Timing Belt..........................................................................................451 Mazda M4-2.5D Diesel Engine..............................................................................451 Inching Brake................................................................................................452 PCV Valve....................................................................................................452 Forks........................................................................................................452 Brake Fluid..................................................................................................452 Maintenance Procedures Every 1000 Hours or 6 Months..............................................................453 Air Filter...................................................................................................453 Diesel Fuel System...........................................................................................453 Fuel Filter Replacement..................................................................................453 Fuel System, Remove Air..................................................................................453 Gasoline Fuel Filter.........................................................................................453 LPG Fuel Filter..............................................................................................454 Spark Plugs..................................................................................................454 Ignition System..............................................................................................454 Mazda M4-1.5G or M4-2.0G Engine..........................................................................454 Injection Pump Timing, Mazda M4-2.5D Diesel Engine...........................................................455 Valve Clearance, Check and Adjust............................................................................456 Maintenance Procedures Every 2000 Hours or Yearly................................................................456 Throttle Cable...............................................................................................456 Differential.................................................................................................456 Hydraulic System.............................................................................................456 Hydraulic Oil and Filter, Replace........................................................................456 Mazda M4-2.0G Engine Timing Belt.............................................................................457 PCV Valve....................................................................................................457 Cooling System...............................................................................................457 Transmission.................................................................................................457 Transmission Oil and Filter, Replace.....................................................................457 Wheel Bearings...............................................................................................458 Steer Wheels.............................................................................................458 Drive Wheels.............................................................................................458 Hood Latch Check.................................................................................................458 Latch, Adjust................................................................................................458 Safety Procedures When Working Near Mast.........................................................................460 Lift and Tilt System Leak Check..................................................................................462 Lift Cylinders, Leak Check...................................................................................462 Tilt Cylinders, Leak Check...................................................................................462 Tilt Cylinder Adjustment.........................................................................................463 Lift Chain Adjustments...........................................................................................464 Service Brake Check..............................................................................................466 Diesel Engine Fuel Injector Check................................................................................466 Welding Repairs..................................................................................................467 Overhead Guard Changes...........................................................................................467 Wheel and Tire Replacement.......................................................................................467 General......................................................................................................467 How to Change Solid Rubber Tire (S Series) ..................................................................467 Remove and Install Tire on Wheel.........................................................................468 Pneumatic Tire, Repair.......................................................................................469 Remove Wheels From Lift Truck............................................................................469 Remove Tire From Wheel...................................................................................469 Remove Tire From Two-Piece Wheel.....................................................................470 Remove Tire From Three- and Four-Piece Wheels........................................................471 Install Wheel in Tire....................................................................................472 Install Two-Piece Wheel in Tire......................................................................473 Install Three- or Four-Piece Wheel in Tire...........................................................474 Add Air to Pneumatic Tires...............................................................................475 Wheels, Install..........................................................................................475 Solid Rubber Tires on Pneumatic Wheels, Change...............................................................475 Remove Tire From Wheel...................................................................................476 Install Tire on Wheel....................................................................................477 Operating Procedures for New or Rebuilt Engine...................................................................479 tables...............................................................................................................421 Table 1. Maintenance Schedule....................................................................................428 Table 2. Hook-Type Carriage Chain Adjustment.....................................................................464 Table 3. Pin-Type Carriage Chain Adjustment......................................................................464 INTRODUCTION.........................................................................................................481 GENERAL..........................................................................................................481 Description..................................................................................................481 TORQUE CONVERTER.................................................................................................481 Description..................................................................................................481 Operation....................................................................................................482 CLUTCH ASSEMBLIES................................................................................................483 Description..................................................................................................483 Operation....................................................................................................485 HYDRAULIC SYSTEM.................................................................................................485 General......................................................................................................485 CONTROL VALVE....................................................................................................486 Regulator for Clutch Pressure................................................................................486 Inching Spool Assembly.......................................................................................486 Direction Spool .............................................................................................486 Modulator Circuit............................................................................................486 Regulator for the Torque Converter...........................................................................486 MONOTROL PEDAL...................................................................................................487 DIRECTION CONTROL LEVER..........................................................................................487 DIFFERENTIAL.....................................................................................................487 REPAIRS..............................................................................................................488 TORQUE CONVERTER AND TRANSMISSION PUMP...........................................................................488 Removal And Disassembly......................................................................................488 Inspection...................................................................................................489 Assembly and Installation....................................................................................489 CLUCTH ASSEMBLIES................................................................................................489 Removal And Disassembly......................................................................................489 Inspection...................................................................................................492 Assembly.....................................................................................................492 Installation.................................................................................................493 DIFFERENTIAL.....................................................................................................492 Removal And Disassembly......................................................................................493 Inspection...................................................................................................493 Assembly And Installation....................................................................................493 CONTROL VALVE....................................................................................................498 Removal and Disassembly......................................................................................498 Inspection...................................................................................................498 Assembly and Installation....................................................................................498 MONOTROL PEDAL...................................................................................................499 Removal and Disassembly......................................................................................499 Assembly and Installation....................................................................................499 DIRECTION CONTROL LEVER..........................................................................................502 Removal and Disassembly......................................................................................502 Assembly and Installation....................................................................................502 CHECKS AND ADJUSTMENTS...............................................................................................503 TORQUE CONVERTERS STALL TEST.....................................................................................503 TRANSMISSION PRESSURE TESTS......................................................................................504 Check The Transmission Pump Pressure, TEST PORT NO. 1........................................................504 Check The Torque Converter Inlet Pressure, TEST PORT NO. 2.................................................504 Check The Clutch Pressure, TEST PORT NO. 3...................................................................504 ADJUST THE INCHING/BRAKE PEDAL...............................................................................505 TROUBLESHOOTING......................................................................................................507
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
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