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Hyster Forklift S40 60XL service manual – PDF DOWNLOAD
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Description
Hyster Forklift S40 60XL service manual
File Details:
Hyster Forklift S40 60XL service manual
Language : English
Pages : 508
Size : 14.4 MB
Downloadable : Yes
Format : PDF
HYSTER FORKLIFT S40 60XL SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster Forklift S40 60XL service manual
- GENERAL This section has a description and the repair procedures for the alternator with a voltage regulator as part of the alternator. CAUTION When using an arc welder, always disconnect the ground lead from the lift truck battery to prevent alternator or battery damage. Attach the welding ground clamp as close to the weld area as possible to prevent welding current from damaging the bearings. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors in the electrical system.
- • Do not disconnect an electric wire before the engine is stopped and the switches are “OFF”. • Do not cause a short–circuit by connecting the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected. • Make sure a battery is the correct voltage and polarity before it is connected. • Do not check for current flow by making a spark because the electronic components can be damaged
- . NOTE: Information on alternators manufactured outside the United States is in the SRM (service repair manual) sections for lift trucks that use those alternators. DESCRIPTION (See FIGURE 1. and FIGURE 2.) NOTE: For this SRM section, the alternators are in two groups, Type A and Type B. The two types are very similar, but the Type A alternators have a set of three diodes (diode set) as well as the diode bridge. The Type B alternator has zener diodes as part of the diodes in the diode bridge.
- This alternator does not have a diode set, but does have an additional fan inside the rear housing. The basic operation of both types is very similar. The alternator generates an alternating current when the engine is running. The alternator is either ON or OFF. The alternator generates maximum current when it is ON and no current when it is OFF. The regulator switches the alternator between ON and OFF to get the average current needed to charge the battery.
- Alternator output is directly changed by engine speed and rotor field current. The alternating current is changed to a direct current by the diode bridge inside the alternator.
Table of Contents:
Hyster Forklift S40 60XL service manual
INTRODUCTION......................................................................................................... 1 GENERAL.......................................................................................................... 1 DESCRIPTION...................................................................................................... 1 REPAIRS.............................................................................................................. 3 GENERAL.......................................................................................................... 3 REMOVAL AND DISASSEMBLY (Type A)................................................................................. 3 CLEANING......................................................................................................... 3 ASSEMBLY (Type A)................................................................................................ 4 REMOVAL AND DISAASSEMBLY (Type B)................................................................................ 6 CLEANING......................................................................................................... 8 ASSEMBLY (Type B)................................................................................................ 8 INSTALLATION (Type A and Type B)................................................................................. 9 CHECKS AND ADJUSTMENTS............................................................................................... 9 GENERAL.......................................................................................................... 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)........................................................... 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B).......................................................... 11 CHECK THE CIRCUIT FOR THE BRUSHES................................................................................ 13 Delco Alternators............................................................................................ 13 Motorola Alternators......................................................................................... 13 CHECK THE DIODES................................................................................................. 13 CHECK THE DIODE BRIDGE........................................................................................... 13 Delco and Leece–Neville Alternators.......................................................................... 13 Motorola Alternators......................................................................................... 13 CHECK THE FIELD WINDING FOR THE ROTOR............................................................................ 14 CHECK THE WINDINGS IN THE STATOR................................................................................. 14 CHECK THE VOLTAGE REGULATOR...................................................................................... 15 TROUBLESHOOTING...................................................................................................... 15 INTRODUCTION......................................................................................................... 16 GENERAL.......................................................................................................... 16 DESCRIPTION AND OPERATION........................................................................................ 16 Service and Parking Brakes................................................................................... 18 REPAIRS.............................................................................................................. 18 REMOVAL AND DISASSEMBLY.......................................................................................... 18 Service and Parking Brakes................................................................................... 18 Master Cylinder.............................................................................................. 19 CLEANING AND INSPECTION.......................................................................................... 20 ASSEMBLY AND INSTALLATION........................................................................................ 20 Service and Parking Brakes................................................................................... 20 Master Cylinder.............................................................................................. 25 CHECKS AND ADJUSTMENTS............................................................................................... 25 ADJUST THE SERVICE BRAKES........................................................................................ 25 ADJUST THE PARKING BRAKE......................................................................................... 26 Units with Monotrol Pedal.................................................................................... 26 REMOVE THE AIR FROM THE BRAKE SYSTEM............................................................................. 27 ADJUST THE BRAKE PEDAL AND INCHING PEDAL......................................................................... 27 CHECK AND ADJUST THE NEUTRAL START SWITCH (Monotrol Control Only)................................................ 31 TROUBLESHOOTING...................................................................................................... 33 SPECIFICATIONS....................................................................................................... 34 INTRODUCTION......................................................................................................... 35 GENERAL.......................................................................................................... 35 SERVICE BRAKES AND PARKING BRAKE..................................................................................... 35 DESCRIPTION AND OPERATION........................................................................................ 35 Service Brakes............................................................................................... 35 Parking Brake................................................................................................ 36 REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES.................................................. 36 Parking Brake................................................................................................ 38 CLEANING......................................................................................................... 39 INSPECTION....................................................................................................... 39 ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES................................................ 39 Adjustments.................................................................................................. 42 Parking Brake Installation................................................................................... 43 Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes............................... 43 REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES.................................................. 45 Parking Brake................................................................................................ 47 CLEANING......................................................................................................... 48 INSPECTION....................................................................................................... 48 ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES................................................ 48 Adjustments.................................................................................................. 50 Parking brake................................................................................................ 51 Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes............................... 51 MASTER CYLINDER.................................................................................................. 52 Removal...................................................................................................... 52 Repair....................................................................................................... 52 Installation................................................................................................. 52 Cleaning And Inspection...................................................................................... 54 MASTER CYLINDER WITH BRAKE BOOSTER............................................................................... 56 Operation.................................................................................................... 56 Repair....................................................................................................... 56 CHECKS AND ADJUSTMENTS............................................................................................... 58 ADJUST THE SERVICE BRAKES........................................................................................ 58 TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY).............................................................. 58 REMOVE THE AIR FROM THE BRAKE SYSTEM............................................................................. 59 ADJUST THE INCHING/BRAKE PEDAL................................................................................... 59 ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL)......................................... 64 TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)................................................................... 64 Test 1....................................................................................................... 64 Test 2....................................................................................................... 65 TORQUE SPECIFICATIONS................................................................................................ 65 TROUBLESHOOTING...................................................................................................... 65 LIFT TRUCK WEIGHTS*.................................................................................................. 68 HYDRAULIC SYSTEM..................................................................................................... 68 ELECTRICAL SYSTEM.................................................................................................... 69 CAPACITIES........................................................................................................... 69 MAST SPEEDS (MAZDA Gasoline/LPG - A187*& B187* Units)................................................................ 70 MAST SPEEDS (ISUZU Diesel - A187*& B187* Units)...................................................................... 70 MAST SPEEDS (GM 4-153 Gasoline/LPG - A187*).......................................................................... 71 MAST SPEEDS (GM 4-181 Gasoline/LPG - B187*).......................................................................... 71 MAST CREEP SPEEDS.................................................................................................... 72 WHEELS AND TIRES..................................................................................................... 72 TRANSMISSION PRESSURES............................................................................................... 72 ENGINE SPECIFICATIONS................................................................................................ 73 ENGINE SPECIFICATIONS................................................................................................ 74 TORQUE SPECIFICATIONS................................................................................................ 75 TORQUE SPECIFICATIONS................................................................................................ 76 COOLING SYSTEM....................................................................................................... 77 INTRODUCTION..................................................................................................... 77 DESCRIPTION...................................................................................................... 77 RADIATOR......................................................................................................... 77 RADIATOR CAP..................................................................................................... 77 THERMOSTAT....................................................................................................... 77 WATER PUMP....................................................................................................... 78 FAN AND FAN SHROUD............................................................................................... 78 REPAIRS.............................................................................................................. 78 COOLING SYSTEM CHECKS............................................................................................ 78 Exhaust Leaks................................................................................................ 78 RADIATOR......................................................................................................... 78 Checks....................................................................................................... 78 Cleaning The Radiator........................................................................................ 78 Drain The Cooling System..................................................................................... 80 Fill The Cooling System...................................................................................... 80 WATER PUMP....................................................................................................... 80 Checks....................................................................................................... 80 THERMOSTAT....................................................................................................... 81 Checks....................................................................................................... 81 FAN AND FAN SHROUD............................................................................................... 81 TROUBLESHOOTING...................................................................................................... 82 FIGURE 1. HYDRAULIC SCHEMATIC SYMBOLS................................................................................ 83 FIGURE 2. HYDRAULIC SYSTEM SCHEMATIC................................................................................. 84 FIGURE 3. TRANSMISSION SCHEMATIC..................................................................................... 86 FIGURE 4. INSTRUMENT PANEL ELECTRICAL DIAGRAM........................................................................ 87 FIGURE 5. GASOLINE/LPG ENGINE WIRING DIAGRAM, MAZDA ENGINE, (G and LPS Rating)....................................... 88 FIGURE 6. GASOLINE/LPG ENGINE WIRING DIAGRAM, MAZDA ENGINE, (GS and LPS Rating)...................................... 90 FIGURE 7. GASOLINE/LPG CABLE DIAGRAM, MAZDA ENGINE, (G and LPG Rating)............................................... 92 FIGURE 8. GASOLINE/LPG ENGINE WIRING DIAGRAM, GM ENGINE(G and LPG Rating/GS and LPS Rating).......................... 94 FIGURE 9. GASOLINE/LPG ENGINE CABLE DIAGRMGM ENGINE,................................................................. 96 FIGURE 10. DIESEL ENGINE WIRING DIAGRAM ISUZU ENGINE (D Rating)...................................................... 98 FIGURE 11. DIESEL ENGINE WIRING DIAGRAM ISUZU ENGINE (DS Rating).....................................................100 FIGURE 12. DIESEL ENGINE CABLE DIAGRAM, ISUZU ENGINE.................................................................102 FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC.................................................................................105 FIGURE 2. TRANSMISSION SCHEMATIC.....................................................................................106 FIGURE 3. WIRE SCHEMATIC, GM 4-181 ENGINE, GASOLINE AND LPG (1 OF 2).................................................107 FIGURE 4. WIRE SCHEMATIC, MAZDA 4-121G ENGINE, GASOLINE AND LPG......................................................111 FIGURE 5. WIRE SCHEMATIC, ISUZU DIESEL ENGINE (1OF 2 )...............................................................113 FIGURE 6. ELECTRICAL DIAGRAM, INSTRUMENT PANEL.......................................................................115 FIGURE 7. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)................................................117 FIGURE 8. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)...............................................119 FIGURE 9. DIESEL ENGINE CABLE DIAGRAM (D Rating).....................................................................121 FIGURE 10. DIESEL ENGINE CABLE DIAGRAM (DS Rating)...................................................................123 FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)..................................................125 FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating).................................................127 INTRODUCTION.........................................................................................................129 GENERAL..........................................................................................................129 DESCRIPTION......................................................................................................129 REPAIRS..............................................................................................................130 REMOVAL..........................................................................................................130 CLEANING.........................................................................................................130 INSPECTION.......................................................................................................130 ASSEMBLY.........................................................................................................130 TROUBLESHOOTING......................................................................................................133 SPECIFICATIONS.......................................................................................................133 INTRODUCTION.........................................................................................................134 GENERAL..........................................................................................................134 DESCRIPTION......................................................................................................134 Starting System..............................................................................................134 Charging System..............................................................................................134 Vacuum Pump On Alternator (On Units With Brake Booster)......................................................136 REPAIRS..............................................................................................................137 STARTER..........................................................................................................137 Removal And Disassembly......................................................................................137 Assembly And Installation....................................................................................137 REPLACING GLOW PLUGS.............................................................................................139 ALTERNATOR (With Vaccum Pump)....................................................................................139 Removal And Disassembly......................................................................................139 Cleaning.....................................................................................................141 Assembly And Installation....................................................................................141 ALTERNATOR (Without Vacuum Pump).................................................................................142 Removal And Disassembly......................................................................................142 Cleaning.....................................................................................................144 Assembly And Installation....................................................................................144 REGULATOR REPLACEMENT............................................................................................145 CHECKS...............................................................................................................145 GENERAL..........................................................................................................145 STARTER..........................................................................................................145 Starter Operation............................................................................................145 Solenoid Coil Checks.........................................................................................146 Brush Length.................................................................................................146 Brush Holder.................................................................................................146 Armature.....................................................................................................146 Field Windings...............................................................................................147 Clutch And Bearings..........................................................................................147 COLD START AID...................................................................................................147 Glow Plugs...................................................................................................147 Resistor.....................................................................................................147 CHARGING CIRCUIT.................................................................................................147 Check For Low Output.........................................................................................147 Check Ford High Output.......................................................................................149 ALTERNATOR.......................................................................................................149 Rotor Resistance.............................................................................................149 Diodes Circuit...............................................................................................149 Rotor Coil...................................................................................................150 Stator Coil..................................................................................................150 Diode Assembly...............................................................................................150 Brushes And Bearings.........................................................................................151 REGULATOR (At Hydraulic Tank)....................................................................................151 TROUBLESHOOTING......................................................................................................152 INTRODUCTION.........................................................................................................155 GENERAL..........................................................................................................155 DESCRIPTION......................................................................................................155 Starting System..............................................................................................155 Ignition System..............................................................................................155 Charging System..............................................................................................156 REPAIR...............................................................................................................158 STARTER..........................................................................................................158 Removal And Disassembly......................................................................................158 Assembly And Installation....................................................................................158 BALLAST RESISTOR RELAY (Earlier Production)......................................................................160 DISTRIBUTOR (Earlier Production With Contact Points).............................................................160 Removal And Disassembly......................................................................................160 Assembly And Installation....................................................................................162 COIL REPLACEMENT.................................................................................................162 DISTRIBUTOR (Later Production with Electronic Ignition System)...................................................162 Removal And Disassembly......................................................................................162 Assembly And Installation....................................................................................164 ALTERNATOR (All Models)..........................................................................................164 Removal And Disassembly......................................................................................164 Assembly And Installation....................................................................................165 REGULATOR REPLACEMENT (Earlier Production).......................................................................166 CHECKS AND ADJUSTMENTS...............................................................................................167 GENERAL..........................................................................................................167 STARTER..........................................................................................................167 Check Operation..............................................................................................167 Check Brush Length...........................................................................................168 Check Brush Holder...........................................................................................168 Armature.....................................................................................................168 Field Windings...............................................................................................168 Clutch And Bearing...........................................................................................168 BALLAST RESISTOR RELAY (Earlier Production)......................................................................168 DISTRIBUTOR......................................................................................................169 Distributor Contact Clearance................................................................................169 SPARK PLUGS......................................................................................................170 COIL AND BALLAST RESISTOR (Earlier Production)...................................................................170 ALTERNATOR.......................................................................................................170 Check For Low Output (Alternator With Separate Regulator)....................................................170 Check For Low Output (Alternator With Integral Regulator)....................................................172 Check For High Output (Alternator With Separate Regulator)...................................................173 Check For High Output (Alternator With Integral Regulator)...................................................173 Rotor Resistance (Alternator with Separate Regulator)........................................................173 Diodes Circuit (Alternator with Separate Regulator)..........................................................174 Diode Assembly (Alternator With Separate Regulator)..........................................................174 Check The Diodes, Diode Trio (Alternator with Integral Regulator)............................................174 Check The Rectifier Bridge (Alternator with Integral Regulator)..............................................175 Check Field Winding For The Rotor (All Alternators)..........................................................175 Check Windings In The Stator (All Alternators)...............................................................176 Brushes And Bearings.........................................................................................176 Check The Voltage Regulator (Alternator with Separate Regulator).............................................176 Check The Voltage Regulator (Alternator with Integral Regulator).............................................177 ADJUSTMENTS......................................................................................................177 TROBLESHOOTING.......................................................................................................178 INTRODUCTION.........................................................................................................180 GENERAL..........................................................................................................180 REPAIRS..............................................................................................................180 FORKS............................................................................................................180 CARRIAGE.........................................................................................................180 Removal......................................................................................................180 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................181 Installation.................................................................................................182 MAST.............................................................................................................183 Removal......................................................................................................183 Disassembly..................................................................................................184 Cleaning.....................................................................................................187 Inspection, Forks, Mast, And Lift Chains.....................................................................187 Assembly, Mast Components....................................................................................188 Installation.................................................................................................189 CHECKS AND ADJUSTMENTS...............................................................................................190 CHECK FOR LEAKS IN THE LIFT SYSTEM...............................................................................190 Check the Lift Cylinders for Leaks...........................................................................190 Check The Tilt Cylinders For Leaks...........................................................................190 ADJUST THE TILT CYLINDER STROKE AND BACKWARD TILT ANGLE..........................................................190 LIFT CHAIN ADJUSTMENTS...........................................................................................191 MAST ADJUSTMENTS.................................................................................................191 CARRIAGE ADJUSTMENTS.............................................................................................193 TROUBLESHOOTING......................................................................................................194 INTRODUCTION.........................................................................................................195 GENERAL..........................................................................................................195 DESCRIPTION......................................................................................................195 REPAIRS..............................................................................................................195 COUNTERWEIGHT....................................................................................................196 Removal......................................................................................................196 Installation.................................................................................................196 MUFFLER..........................................................................................................197 HOOD.............................................................................................................197 Removal......................................................................................................197 Installation.................................................................................................197 OVERHEAD GUARD...................................................................................................198 Removal and Installation.....................................................................................198 RADIATOR AND COOLANG SYSTEM......................................................................................198 Removal......................................................................................................198 Installation.................................................................................................198 OPERATOR RESTRAINT SYSTEM........................................................................................198 ENGINE REMOVAL AND INSTALLATION..................................................................................199 Removal of the Engine and Transmission.......................................................................199 Installation of the Engine and Transmission..................................................................202 FUEL AND HYDRAULIC TANKS.........................................................................................204 Inspection...................................................................................................204 Repairs, Small Leaks.........................................................................................204 Repairs, Large Leaks.........................................................................................204 Cleaning.....................................................................................................204 Steam Method of Cleaning.....................................................................................204 Chemical Solution Method of Cleaning.........................................................................204 Other Methods Of Preparation For Repair......................................................................205 SAFETY LABELS....................................................................................................205 THE CARBURETOR, (MAZDA M4-121G ENGINE)...............................................................................209 DESCRIPTION......................................................................................................209 REPAIRS, CARBURETOR..............................................................................................210 Removal......................................................................................................210 Cleaning.....................................................................................................213 Inspection...................................................................................................213 Assembly.....................................................................................................213 Installation.................................................................................................215 CHECKS AND ADJUSTMENTS...........................................................................................215 Carburetor, Idle Speed And Mixture Adjustment................................................................215 Adjust The Governor..........................................................................................216 ADJUST THE THROTTLE LINKAGE......................................................................................217 SPECIFICATIONS.......................................................................................................217 TROUBLESHOOTING......................................................................................................218 INTRODUCTION ........................................................................................................220 GENERAL .........................................................................................................220 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ........................................................................220 REPAIRS .............................................................................................................221 FORKS ...........................................................................................................221 Removal .....................................................................................................221 Installation ................................................................................................222 CARRIAGES .......................................................................................................222 Removal, Standard Carriage ..................................................................................222 Removal, Side–Shift Carriage ................................................................................223 Repairs .....................................................................................................223 Installation, Standard Carriage .............................................................................223 Installation, Side–Shift Carriage ...........................................................................224 MAST ............................................................................................................225 Removal .....................................................................................................225 Disassembly, Three–Stage FFL Mast ...........................................................................231 Disassembly, Two–Stage LFL And Two–Stage FFL Masts ..........................................................225 Cleaning and Inspection .....................................................................................231 Assembly, Two–Stage LFL And Two–Stage FFL Mast ..............................................................234 Assembly, Three–Stage FFL Mast ..............................................................................235 Installation, Mast ..........................................................................................236 LIFT CYLINDERS ..................................................................................................237 Removal, Main Lift Cylinders ................................................................................237 Removal, Free–Lift Cylinder .................................................................................237 Disassembly, Lift Cylinders .................................................................................237 Assembly, Lift Cylinders ....................................................................................238 Installation, Main Lift Cylinders ...........................................................................239 Installation, Free–Lift Cylinder ............................................................................240 HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) ....................241 New Hose Installation, Two–Stage, LFL Mast ..................................................................241 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................241 New Hose Installation, Two–Stage FFL Mast ...................................................................245 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................245 New Hose Installation, Three–Stage FFL Mast .................................................................249 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................254 HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) ....256 New Hose Installation, Two–Stage LFL Mast ...................................................................257 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................257 New Hose Installation, Two–Stage FFL Mast ...................................................................260 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................260 New Hose Installation, Three–Stage, FFL Mast ................................................................264 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................269 CHECKS AND ADJUSTMENTS ..............................................................................................270 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ....................................................................270 Check The Lift Cylinders For Leaks .........................................................................270 Check The Tilt Cylinders For Leaks .........................................................................270 ADJUST THE TILT CYLINDERS ......................................................................................270 ADJUST THE LIFT CHAINS .........................................................................................271 ADJUST THE MAST ................................................................................................272 ADJUST THE CARRIAGE ............................................................................................273 TROUBLESHOOTING......................................................................................................274 INTRODUCTION.........................................................................................................275 GENERAL..........................................................................................................275 DESCRIPTION AND OPERATION........................................................................................275 Carriages....................................................................................................275 Mast Mounts..................................................................................................276 TWO-STAGE MAST, LIMITED FREE-LIFT................................................................................277 Description and Operation....................................................................................277 TWO-STAGE MAST, FULL FREE-LIFT...................................................................................279 Description..................................................................................................279 Operation....................................................................................................279 THREE-STAGE, FULL FREE-LIFT MAST.................................................................................281 Description..................................................................................................281 Operation....................................................................................................281 INTRODUCTION.........................................................................................................283 GENERAL..........................................................................................................283 DESCRIPTION......................................................................................................284 REMOVAL AND INSTALLATION OF THE ENGINE...........................................................................284 CYLINDER HEAD AND MECHANISM......................................................................................284 Cylinder Head, Removal.......................................................................................284 Cylinder Head, Disassembly...................................................................................285 Cleaning And Inspection......................................................................................286 Valve And Valve Seats........................................................................................287 Studs For The Rocker Arms....................................................................................287 Hydraulic Valve Lifters, Replacement.........................................................................287 Hydraulic Valve Lifters, Cleaning And Inspection.............................................................288 Cylinder Head, Assembly......................................................................................288 Cylinder Head, Installation..................................................................................288 Rocker Arm Cover, Installation...............................................................................289 TIMING GEAR COVER................................................................................................290 Removal......................................................................................................290 Installation.................................................................................................290 CAMSHAFT.........................................................................................................291 Removal......................................................................................................291 Inspection...................................................................................................292 Camshaft Bearings, Removal...................................................................................292 Camshaft Bearings, Installation..............................................................................292 DISTRIBUTOR......................................................................................................293 Removal......................................................................................................293 Installation.................................................................................................293 LUBRICATION SYSTEM...............................................................................................294 Oil Sump, Removal............................................................................................294 Oil Sump, Installation.......................................................................................294 Oil Pump, Removal............................................................................................294 Oil Pump, Disassembly and Repair.............................................................................294 Oil Pump, Assembly...........................................................................................295 Oil Pump, Installation.......................................................................................295 PISTON AND CONNECTING ROD ASSEMBLIES.............................................................................295 Connecting Rod Bearings, Replacement.........................................................................295 Piston And Connecting Rod Assemblies, Removal................................................................296 Disassembly..................................................................................................297 Piston, Cleaning And Inspection..............................................................................297 Cylinder Bores, Inspection And Repair........................................................................297 Piston Rings.................................................................................................298 Assembly.....................................................................................................299 Piston And Connecting Rod Assemblies, Installation...........................................................299 CRANKSHAFT.......................................................................................................300 Main Bearings, Replacement...................................................................................300 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).....................................301 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).....................301 Crankshaft, Removal..........................................................................................302 Inspection and Repair........................................................................................303 How To Check The Clearance Between The Main Bearings And Their Journals......................................303 Installation.................................................................................................304 FLYWHEEL AND FLYWHEEL HOUSING....................................................................................305 Flywheel, Removal............................................................................................305 Ring Gear, Replacement.......................................................................................306 Flywheel, Installation.......................................................................................306 COOLING SYSTEM...................................................................................................306 Coolant Pump.................................................................................................306 Fan Drive....................................................................................................307 Viscous Fan Drive............................................................................................307 ENGINE SPECIFICATIONS................................................................................................308 ENGINE DATA......................................................................................................308 CYLINDER HEAD....................................................................................................308 HYDRAULIC VALVE LIFTER...........................................................................................309 CAMSHAFT.........................................................................................................309 PISTONS..........................................................................................................309 CYLINDER BORE....................................................................................................310 CRANKSHAFT.......................................................................................................310 CONNECTING RODS..................................................................................................310 COOLING SYSTEM...................................................................................................311 LUBRICATION SYSTEM...............................................................................................311 TORQUE SPECIFICATIONS................................................................................................311 HIGH ENERGY IGNITION (HEI)...........................................................................................314 DESCRIPTION......................................................................................................314 REPAIRS..............................................................................................................316 DISTRIBUTOR......................................................................................................316 Removal......................................................................................................316 Disassembly..................................................................................................316 Assembly.....................................................................................................321 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.....................................322 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED......................................323 IGNITION COIL....................................................................................................323 Removal, Some 4 And 6 Cylinder Models........................................................................323 Installation, Some 4 And 6 Cylinder Models...................................................................324 Removal, V8, Some 4 And 6 Cylinder Models....................................................................324 Installation, V8, Some 4 And 6 Cylinder Models...............................................................325 ELECTRONIC MODULE................................................................................................326 Removal......................................................................................................326 Installation.................................................................................................326 SENSING COIL.....................................................................................................327 Removal......................................................................................................327 Installation.................................................................................................327 SPARK PLUGS......................................................................................................327 Removal......................................................................................................327 Installation.................................................................................................328 CHECKS AND ADJUSTMENTS...........................................................................................328 Visual Checks................................................................................................328 Check The High Voltage Wires.................................................................................328 Checking The Ignition Coil...................................................................................328 Coil In Distributor Cap Design...............................................................................328 Separate Coil Design.........................................................................................329 Checking The Sensing Coil....................................................................................329 Check The Electronic Module..................................................................................330 Ignition Timing Adjustment...................................................................................330 Ignition System, GM V8-366 (6-litre).........................................................................331 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).............................................331 SPECIFICATIONS.......................................................................................................331 TROUBLESHOOTING......................................................................................................332 INTRODUCTION.........................................................................................................333 GENERAL..........................................................................................................333 DESCRIPTION......................................................................................................333 REPAIRS..............................................................................................................335 REMOVAL AND DISASSEMBLY..........................................................................................335 CLEANING.........................................................................................................335 INSPECTION.......................................................................................................335 ASSEMBLY AND INSTALLATION........................................................................................336 TROUBLESHOOTING......................................................................................................337 GENERAL..........................................................................................................337 INTRODUCTION.........................................................................................................338 GENERAL..........................................................................................................338 DESCRIPTION......................................................................................................340 Hydraulic System.............................................................................................340 Gear Pump Assembly...........................................................................................340 Flow Control Valve...........................................................................................341 Relief Valve (Early Model)...................................................................................341 Relief Valve (Later Model)...................................................................................341 OPERATION........................................................................................................343 Hydraulic System.............................................................................................343 Gear Pump....................................................................................................343 Flow Control Valve...........................................................................................343 Relief Valve (Early Model)...................................................................................343 Relief Valve (Later Model)...................................................................................343 REPAIR...............................................................................................................345 GEAR PUMP ASSEMBLY...............................................................................................345 Removal and Disassembly......................................................................................345 Assembly and Installation....................................................................................346 CHECKS AND ADJUSTMENTS...............................................................................................346 CHECK AND ADJUST STEERING RELIEF PRESSURE........................................................................346 CHECK GEAR PUMP FOR CORRECT FLOW.................................................................................347 TROUBLESHOOTING......................................................................................................347 INTRODUCTION.........................................................................................................349 GENERAL..........................................................................................................349 DESCRIPTION..........................................................................................................349 GENERAL..........................................................................................................349 STEERING COLUMN GAUGES, METERS AND INDICATORS....................................................................352 LED DISPLAY PANEL................................................................................................352 Battery Discharge Indicators.................................................................................352 Brush Wear Indicators........................................................................................353 Motor Temperature Indicators.................................................................................354 "LX" SERIES DISPLAY PANEL........................................................................................355 Hourmeter Functions..........................................................................................356 Battery Indicator Function...................................................................................356 Status Code Function.........................................................................................356 "ZX" SERIES DISPLAY PANELS.......................................................................................356 Display Panel................................................................................................357 Basic Display Panels.........................................................................................357 Performance Display..........................................................................................359 Brush Wear Indicators........................................................................................362 CHECKS AND ADJUSTMENTS...............................................................................................362 GENERAL..........................................................................................................362 REPLACEMENT..........................................................................................................363 GENERAL..........................................................................................................363 METER REPLACEMENT................................................................................................363 SENDER REPLACEMENT...............................................................................................364 Fuel Level Sender............................................................................................364 Pressure And Temperature Sender..............................................................................364 I.T.W. DISPLAY PANEL.............................................................................................365 Removal......................................................................................................365 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT............................................366 Removal......................................................................................................366 Replacing Display Panel Assembly.............................................................................366 Indicator LEDs...............................................................................................366 Battery Indicators...........................................................................................366 Digital Display (Performance Disply Panel Only)..............................................................366 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)................366 Replacing Parts Of The Basic Display Panel...................................................................367 Replacing Parts Of The Performance Display Panel.............................................................369 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT................................................369 Removal And Replacement......................................................................................369 SPECIFICATIONS.......................................................................................................370 TROUBLESHOOTING......................................................................................................371 INTRODUCTION ........................................................................................................372 GENERAL .........................................................................................................372 DESCRIPTION .....................................................................................................372 FUEL SYSTEM .....................................................................................................373 Description .................................................................................................373 Operation, Fuel Injection Pump, Model VE ....................................................................375 Operation, Fuel Injection Pump, Model PE4A ..................................................................376 Pneumatic Governor For Fuel Injection Pump, Model PE4A ......................................................377 Inlet Manifold For Fuel Injection Pump, Model PE4A ..........................................................378 REPAIRS .............................................................................................................379 FUEL INJECTION PUMP (ALL MODELS) ................................................................................379 Removal .....................................................................................................379 Installation ................................................................................................379 REMOVAL AND INSTALLATION OF THE ENGINE ..........................................................................379 CYLINDER HEAD AND VALVE MECHANISM ...............................................................................379 Cylinder Head, Removal ......................................................................................379 Valve Guides, Replacement ...................................................................................380 Cylinder Head, Inspection And Repair ........................................................................381 Combustion Chamber Plugs, Inspection And Repair .............................................................381 Combustion Chamber Plugs, Installation ......................................................................381 Valves, Inspection And Repair ...............................................................................382 Valve Seat, Inspection ......................................................................................382 Valve Seat, Removal .........................................................................................383 Valve Seat, Installation ....................................................................................383 Valve Spring, Inspection ....................................................................................383 Rocker Arms, Inspection And Assembly ........................................................................383 Installation Of The Cylinder Head ...........................................................................384 TIMING GEAR CASE ................................................................................................385 Removal .....................................................................................................385 Installation ................................................................................................385 CAMSHAFT ........................................................................................................387 Removal .....................................................................................................387 Inspection ..................................................................................................387 Camshaft Bearings ...........................................................................................388 Cam Followers ...............................................................................................388 CAMSHAFT, INSTALLATION ..........................................................................................388 CRANKSHAFT AND MAIN BEARINGS ....................................................................................389 Crankshaft, Removal .........................................................................................389 Crankshaft, Inspection And Repair ...........................................................................389 Main Bearings ...............................................................................................389 Pilot Bearing ...............................................................................................390 Crankshaft, Installation ....................................................................................390 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) .................................................................392 Flywheel, Removal ...........................................................................................392 Ring Gear, Replacement ......................................................................................392 Flywheel, Installation ......................................................................................392 PISTONS AND CONNECTING RODS .....................................................................................393 Pistons And Connecting Rods, Removal ........................................................................393 Disassembly .................................................................................................393 Pistons, Inspection And Repair ..............................................................................394 Piston Rings, Inspection And Repair .........................................................................394 Piston Pins, Inspection And Repair ..........................................................................395 Connecting Rods, Inspection And Repair ......................................................................396 Pistons And Connecting Rods, Assembly And Installation ......................................................396 CYLINDER BLOCK AND CYLINDER LINERS ..............................................................................396 Cylinder Liners, Inspection .................................................................................396 Replacement Of A Cylinder Liner .............................................................................397 LUBRICATION SYSTEM ..............................................................................................398 Oil Pump, Removal And Disassembly ...........................................................................398 Oil Pump, Inspection ........................................................................................398 Oil Pump, Assembly And Installation .........................................................................399 Oil Filter ..................................................................................................399 COOLING SYSTEM ..................................................................................................400 Coolant Pump, Removal .......................................................................................400 Coolant Pump, Disassembly ...................................................................................400 Coolant Pump, Assembly And Installation .....................................................................400 Thermostat, Replacement .....................................................................................401 CHECKS AND ADJUSTMENTS ..............................................................................................401 VALVE CLEARANCE ADJUSTMENT ......................................................................................401 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ...........................................................402 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A .........................................................403 FUEL INJECTORS ..................................................................................................403 Fuel Injectors, Removal .....................................................................................404 Fuel Injectors, Inspection ..................................................................................404 Fuel Injectors, Installation ................................................................................405 DIESEL FUEL FILTERS .............................................................................................405 Filter Replacement, Models With A Water Separator ...........................................................405 Filter Replacement, Models Without A Water Separator ........................................................406 Filter For The Fuel Injection Pump, Model PE4A ..............................................................406 REMOVE AIR FROM THE FUEL SYSTEM .................................................................................406 Throttle Linkage, Adjustment ................................................................................407 Idle Speed, Adjustment ......................................................................................407 Check The Elements For The Cold Start Aid System ............................................................407 ENGINE SPECIFICATIONS ...............................................................................................407 TORQUE SPECIFICATIONS ...............................................................................................409 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................................410 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................410 LIFT CYLINDERS.......................................................................................................413 GENERAL..........................................................................................................413 DESCRIPTION......................................................................................................413 Lowering Control Valve.......................................................................................413 Cylinders (General)..........................................................................................416 Cylinders (H520-620B,H700-800A)..............................................................................418 Cylinders (H360-460B)........................................................................................419 Cylinders (Two-Speed)........................................................................................419 REPAIRS..............................................................................................................420 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...........................................................420 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.....................420 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead......................................424 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder................................422 DISASSEMBLY......................................................................................................422 ASSEMBLY.........................................................................................................424 INSTALLATION OF THE LIFT CYLINDER IN THE MAST....................................................................424 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.....................424 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.............................424 CHEVRON PACKING..................................................................................................425 LIFT CYLINDERS FOR VISTA MASTS.......................................................................................428 DESCRIPTION......................................................................................................428 Lowering Control Valve.......................................................................................430 REMOVAL..........................................................................................................431 DISASSEMBLY......................................................................................................431 ASSEMBLY.........................................................................................................431 INSTALLATION.....................................................................................................432 Main Lift Cylinders..........................................................................................432 Free-Lift Cylinders..........................................................................................432 CHECKS AND ADJUSTMENTS...............................................................................................433 CHECK FOR LEAKS IN LIFT SYSTEM...................................................................................433 TROUBLESHOOTING......................................................................................................434 SPECIFICATIONS.......................................................................................................435 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)............................................................................436 GENERAL..........................................................................................................436 DESCRIPTION......................................................................................................436 Fuel Tank....................................................................................................437 Fuel Filter And Fuel Valve Unit..............................................................................438 Vaporizer....................................................................................................438 The IMPCO CA 100 Carbureto...................................................................................440 IMPCO CA 50 Carburetor.......................................................................................442 The Governor (GM Engines Only)...............................................................................443 Governor With Electronic Controller..........................................................................444 REPAIRS..............................................................................................................445 LPG TANK.........................................................................................................445 Removal......................................................................................................445 Installation.................................................................................................446 REPLACE THE HOSES................................................................................................446 HYDROSTATIC RELIEF VALVE.........................................................................................446 Removal and Installation.....................................................................................446 FILTER UNIT......................................................................................................447 Replacement Of the Fuel Filter Element.......................................................................447 Replacement of the Diaphragm and Fuel Valve..................................................................448 VAPORIZER........................................................................................................448 Removal......................................................................................................448 Disassembly..................................................................................................448 Cleaning.....................................................................................................448 Inspection...................................................................................................448 Assembly.....................................................................................................450 Installation.................................................................................................450 CARBURETOR (IMPCO CA 100)........................................................................................452 Removal......................................................................................................452 Disassembly..................................................................................................452 Cleaning.....................................................................................................452 Assembly.....................................................................................................452 Installation.................................................................................................455 CARBURETER (IMPCO CA 50).........................................................................................454 Removal......................................................................................................454 Disassembly..................................................................................................454 Cleaning.....................................................................................................455 Inspection...................................................................................................455 Assembly (See FIGURE 26.)....................................................................................455 Installation.................................................................................................455 CHECKS AND ADJUSTMENTS...............................................................................................456 CHECK THE FILTER UNIT............................................................................................456 CHECK THE VAPORIZER..............................................................................................456 Pressure Reducer Valve.......................................................................................456 Vapor Valve..................................................................................................456 ADJUST THE CARBURETOR............................................................................................456 Idle Mixture.................................................................................................456 Idle Speed...................................................................................................456 Power Mixture................................................................................................456 ADJUST THE GOVERNOR (GM Engines Only)............................................................................457 Checks.......................................................................................................457 Main Adjusting Screw.........................................................................................457 Secondary Adjusting Screw....................................................................................457 AISAN Governor...............................................................................................458 Adjustment, AISAN Governor...................................................................................458 TROUBLESHOOTING......................................................................................................459 INTRODUCTION.........................................................................................................463 GENERAL..........................................................................................................463 DESCRIPTION......................................................................................................463 OPERATION........................................................................................................464 Lift Section.................................................................................................465 Tilt Section.................................................................................................465 Relief Valve.................................................................................................467 SOLENOID VALVE FOR AUXILIARY FUNCTION............................................................................468 Operation....................................................................................................468 REPAIRS..............................................................................................................468 MAIN CONTROL VALVE...............................................................................................468 Removal and Disassembly......................................................................................468 Cleaning and Inspection......................................................................................469 Assembly.....................................................................................................469 Installation.................................................................................................469 SOLENOID VALVE FOR AUXILIARY FUNCTION............................................................................469 Removal and Disassembly......................................................................................469 Assembly and Installation....................................................................................471 CHECKS AND ADJUSTMENTS...............................................................................................471 PRESSURE RELIEF VALVES...........................................................................................471 Primary Relief Valve.........................................................................................471 Seconday Relief Valve........................................................................................472 CONTROL LEVER ARRANGEMENT........................................................................................472 TROUBLESHOOTING......................................................................................................475 SPECIFICATIONS.......................................................................................................477 MAZDA M4-121G ENGINE.................................................................................................478 GENERAL..........................................................................................................478 DESCRIPTION......................................................................................................479 REMOVAL AND INSTALLATION OF THE ENGINE...........................................................................479 CYLINDER HEAD AND VALVE MECHANISM................................................................................479 Cylinder Head, Removal.......................................................................................479 Cylinder Head, Inspection and Repairs........................................................................480 Rocker Arm Assembly..........................................................................................480 Valve Guides.................................................................................................480 Valve Seats..................................................................................................481 Valves.......................................................................................................481 Valve Springs................................................................................................481 Cylinder Head, Installation..................................................................................481 TIMING GEAR CASE, REMOVAL........................................................................................482 TIMING GEAR CASE, INSTALLATION...................................................................................483 CAMSHAFT.........................................................................................................483 Removal......................................................................................................483 Inspection...................................................................................................484 Cam Followers, Inspection....................................................................................484 Installation.................................................................................................484 CRANKSHAFT AND MAIN BEARINGS.....................................................................................484 Crankshaft, Removal..........................................................................................484 Crankshaft, Inspection And Repair............................................................................485 Main Bearings................................................................................................486 Crankshaft, Installation.....................................................................................486 PISTONS AND CONNECTING RODS......................................................................................487 Removal......................................................................................................487 Disassembly..................................................................................................487 Pistons, Inspection And Repair...............................................................................487 Piston Rings.................................................................................................488 Piston Pin and Bushing.......................................................................................488 Connecting Rods and Bearings, Inspection.....................................................................488 Pistons and Connecting Rods, Assembly........................................................................488 Pistons and Connecting Rods, Installation....................................................................489 CYLINDER BLOCK AND CYLINDER LINERS...............................................................................489 Cylinder Block, Repairs......................................................................................489 Cylinder Liners..............................................................................................489 DISTRIBUTOR......................................................................................................490 Removal......................................................................................................490 Installation.................................................................................................490 OIL PUMP.........................................................................................................492 Removal......................................................................................................492 Repairs......................................................................................................492 Installation.................................................................................................493 GOVERNOR.........................................................................................................493 Description..................................................................................................493 Removal......................................................................................................493 Disassembly..................................................................................................494 Assembly.....................................................................................................495 Installation.................................................................................................496 COOLANT PUMP.....................................................................................................496 Removal......................................................................................................496 Disassembly and Repair.......................................................................................497 Assembly.....................................................................................................497 Installation.................................................................................................498 FLYWHEEL.........................................................................................................498 Repairs......................................................................................................498 Installation.................................................................................................498 CHECKS AND ADJUSTMENTS...............................................................................................498 ADJUST THE VALVES................................................................................................498 ADJUST THE THROTTLE LINKAGE......................................................................................499 ENGINE SPECIFICATIONS................................................................................................499 ENGINE SPECIFICATIONS............................................................................................499 Engine Data..................................................................................................499 Cooling System...............................................................................................499 Cylinder Head and Valve Mechanism............................................................................499 Camshaft.....................................................................................................501 Timing Gear..................................................................................................502 Camshaft.....................................................................................................502 Connecting Rods..............................................................................................502 Cylinder Liners..............................................................................................502 Pistons......................................................................................................502 Lubrication System...........................................................................................503 Fuel Pump....................................................................................................503 TORQUE SPECIFICATIONS............................................................................................504 TROUBLESHOOTING......................................................................................................505
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
