Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster H40 60XL A177 service manual – PDF DOWNLOAD
Original price was: $92.95.$32.95Current price is: $32.95.
Hyster H40 60XL A177 service manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster H40 60XL A177 service manual
File Details:
Hyster H40 60XL A177 service manual
Language : English
Pages : 512
Size : 16.1 MB
Downloadable : Yes
Format : PDF
HYSTER H40 60XL A177 SERVICE MANUAL – PDF DOWNLOAD:
Image Preview:
Description:
Hyster H40 60XL A177 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 H40 60XL A177 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 LIFT TRUCK WEIGHTS*........................................................................................... 35 ENGINE SPECIFICATIONS......................................................................................... 35 ENGINE ELECTRICAL SPECIFICATIONS.............................................................................. 36 HYDRAULIC SPECIFICATIONS...................................................................................... 36 CAPACITIES.................................................................................................... 37 LIFT TRUCK TRAVEL SPEEDS...................................................................................... 37 TIRE SPECIFICATIONS........................................................................................... 37 MAST SPEEDS (Early A177* Units)............................................................................... 38 MAST SPEEDS (Later A177* Units)............................................................................... 38 MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)......................................... 39 MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)....................................................... 39 TORQUE SPECIFICATIONS......................................................................................... 41 TORQUE SPECIFICATIONS......................................................................................... 42 COOLING SYSTEM................................................................................................ 44 INTRODUCTION.............................................................................................. 44 DESCRIPTION............................................................................................... 44 RADIATOR.................................................................................................. 44 RADIATOR CAP.............................................................................................. 44 THERMOSTAT................................................................................................ 44 WATER PUMP................................................................................................ 45 FAN AND FAN SHROUD........................................................................................ 45 REPAIRS....................................................................................................... 45 COOLING SYSTEM CHECKS..................................................................................... 45 Exhaust Leaks......................................................................................... 45 RADIATOR.................................................................................................. 45 Checks................................................................................................ 45 Cleaning The Radiator................................................................................. 45 Drain The Cooling System.............................................................................. 47 Fill The Cooling System............................................................................... 47 WATER PUMP................................................................................................ 47 Checks................................................................................................ 47 THERMOSTAT................................................................................................ 48 Checks................................................................................................ 48 FAN AND FAN SHROUD........................................................................................ 48 TROUBLESHOOTING............................................................................................... 49 HYDRAULIC SCHEMATIC SYMBOLS................................................................................... 50 HYDRAULIC SYSTEM SCHEMATIC - FOR UNITS WITH WARNER TRANSMISSION............................................... 52 HYDRAULIC SYSTEM SCHEMATIC - FOR UNITS WITH HYSTER T41, T42, T43 TRANSMISSIONS................................ 54 TRANSMISSION HYDRAULIC SCHEMATIC - FOR UNITS WITH WARNER TRANSMISSION......................................... 55 TRANSMISSION HYDRAULIC SCHEMATIC - FOR UNITS WITH HYSTER T41, T42, T43 TRANSMISSION........................... 56 GASOLINE/LPG ENGINE WIRING DIAGRAM (G and LPG Rating)......................................................... 58 GASOLINE/LPG (SAFETY) ENGINE WIRING DIAGRAM (GS and LPS Rating)............................................... 60 GASOLINE/LPG ENGINE CABLE DIAGRAM (G and LPG Rating).......................................................... 62 DIESEL ENGINE WIRING DIAGRAM (D Rating)....................................................................... 64 DIESEL (SAFETY) ENGINE WIRING DIAGRAM (DS Rating)............................................................. 66 DIESEL ENGINE CABLE DIAGRAM (D Rating)........................................................................ 68 ELECTRICAL DIAGRAM, INSTRUMENT PANEL.......................................................................... 69 INTRODUCTION.................................................................................................. 70 GENERAL................................................................................................... 70 DESCRIPTION............................................................................................... 70 REPAIRS....................................................................................................... 71 REMOVAL................................................................................................... 71 CLEANING.................................................................................................. 71 INSPECTION................................................................................................ 71 ASSEMBLY.................................................................................................. 71 TROUBLESHOOTING............................................................................................... 74 SPECIFICATIONS................................................................................................ 74 INTRODUCTION.................................................................................................. 75 GENERAL................................................................................................... 75 DESCRIPTION............................................................................................... 75 Starting System....................................................................................... 75 Charging System....................................................................................... 75 Vacuum Pump On Alternator (On Units With Brake Booster)............................................... 77 REPAIRS....................................................................................................... 78 STARTER................................................................................................... 78 Removal And Disassembly............................................................................... 78 Assembly And Installation............................................................................. 78 REPLACING GLOW PLUGS...................................................................................... 80 ALTERNATOR (With Vaccum Pump)............................................................................. 80 Removal And Disassembly............................................................................... 80 Cleaning.............................................................................................. 82 Assembly And Installation............................................................................. 82 ALTERNATOR (Without Vacuum Pump).......................................................................... 83 Removal And Disassembly............................................................................... 83 Cleaning.............................................................................................. 85 Assembly And Installation............................................................................. 85 REGULATOR REPLACEMENT..................................................................................... 86 CHECKS........................................................................................................ 86 GENERAL................................................................................................... 86 STARTER................................................................................................... 86 Starter Operation..................................................................................... 86 Solenoid Coil Checks.................................................................................. 87 Brush Length.......................................................................................... 87 Brush Holder.......................................................................................... 87 Armature.............................................................................................. 87 Field Windings........................................................................................ 88 Clutch And Bearings................................................................................... 88 COLD START AID............................................................................................ 88 Glow Plugs............................................................................................ 88 Resistor.............................................................................................. 88 CHARGING CIRCUIT.......................................................................................... 88 Check For Low Output.................................................................................. 88 Check Ford High Output................................................................................ 90 ALTERNATOR................................................................................................ 90 Rotor Resistance...................................................................................... 90 Diodes Circuit........................................................................................ 90 Rotor Coil............................................................................................ 91 Stator Coil........................................................................................... 91 Diode Assembly........................................................................................ 91 Brushes And Bearings.................................................................................. 92 REGULATOR (At Hydraulic Tank)............................................................................. 92 TROUBLESHOOTING............................................................................................... 93 INTRODUCTION.................................................................................................. 96 GENERAL................................................................................................... 96 DESCRIPTION............................................................................................... 96 Starting System....................................................................................... 96 Ignition System....................................................................................... 96 Charging System....................................................................................... 97 REPAIR........................................................................................................ 99 STARTER................................................................................................... 99 Removal And Disassembly............................................................................... 99 Assembly And Installation............................................................................. 99 BALLAST RESISTOR RELAY (Earlier Production)...............................................................101 DISTRIBUTOR (Earlier Production With Contact Points)......................................................101 Removal And Disassembly...............................................................................101 Assembly And Installation.............................................................................103 COIL REPLACEMENT..........................................................................................103 DISTRIBUTOR (Later Production with Electronic Ignition System)............................................103 Removal And Disassembly...............................................................................103 Assembly And Installation.............................................................................105 ALTERNATOR (All Models)...................................................................................105 Removal And Disassembly...............................................................................105 Assembly And Installation.............................................................................106 REGULATOR REPLACEMENT (Earlier Production)................................................................107 CHECKS AND ADJUSTMENTS........................................................................................108 GENERAL...................................................................................................108 STARTER...................................................................................................108 Check Operation.......................................................................................108 Check Brush Length....................................................................................109 Check Brush Holder....................................................................................109 Armature..............................................................................................109 Field Windings........................................................................................109 Clutch And Bearing....................................................................................109 BALLAST RESISTOR RELAY (Earlier Production)...............................................................109 DISTRIBUTOR...............................................................................................110 Distributor Contact Clearance.........................................................................110 SPARK PLUGS...............................................................................................111 COIL AND BALLAST RESISTOR (Earlier Production)............................................................111 ALTERNATOR................................................................................................111 Check For Low Output (Alternator With Separate Regulator).............................................111 Check For Low Output (Alternator With Integral Regulator).............................................113 Check For High Output (Alternator With Separate Regulator)............................................114 Check For High Output (Alternator With Integral Regulator)............................................114 Rotor Resistance (Alternator with Separate Regulator).................................................114 Diodes Circuit (Alternator with Separate Regulator)...................................................115 Diode Assembly (Alternator With Separate Regulator)...................................................115 Check The Diodes, Diode Trio (Alternator with Integral Regulator).....................................115 Check The Rectifier Bridge (Alternator with Integral Regulator).......................................116 Check Field Winding For The Rotor (All Alternators)...................................................116 Check Windings In The Stator (All Alternators)........................................................117 Brushes And Bearings..................................................................................117 Check The Voltage Regulator (Alternator with Separate Regulator)......................................117 Check The Voltage Regulator (Alternator with Integral Regulator)......................................118 ADJUSTMENTS...............................................................................................118 TROBLESHOOTING................................................................................................119 INTRODUCTION..................................................................................................121 GENERAL...................................................................................................121 DESCRIPTION...............................................................................................121 REPAIRS.......................................................................................................121 COUNTERWEIGHT.............................................................................................122 Removal...............................................................................................122 Installation..........................................................................................122 MUFFLER...................................................................................................123 HOOD......................................................................................................123 Removal...............................................................................................123 Installation..........................................................................................123 RADIATOR AND COOLANT SYSTEM...............................................................................123 Removal...............................................................................................123 Installation..........................................................................................123 OVERHEAD GUARD............................................................................................124 Removal And Installation..............................................................................124 OPERATOR RESTRAINT SYSTEM.................................................................................124 ENGINE REMOVAL AND INSTALLATION...........................................................................125 Removal of the Engine and Transmission................................................................125 Installation of the Engine and Transmission...........................................................129 FUEL AND HYDRAULIC TANKS..................................................................................131 Inspection............................................................................................131 Repairs, Small Leaks..................................................................................131 Repairs, Large Leaks..................................................................................131 Cleaning..............................................................................................131 Steam Method Of Cleaning..............................................................................131 Chemical Solution Method of Cleaning..................................................................132 Additional Preparations For Repair....................................................................132 SAFETY LABELS.............................................................................................132 CAB.......................................................................................................134 Cab Replacement.......................................................................................134 Window Replacement....................................................................................134 Windshield Wipers and Heater..........................................................................136 THE CARBURETOR, (MAZDA M4-121G ENGINE)........................................................................137 DESCRIPTION...............................................................................................137 REPAIRS, CARBURETOR.......................................................................................138 Removal...............................................................................................138 Cleaning..............................................................................................141 Inspection............................................................................................141 Assembly..............................................................................................141 Installation..........................................................................................143 CHECKS AND ADJUSTMENTS....................................................................................143 Carburetor, Idle Speed And Mixture Adjustment.........................................................143 Adjust The Governor...................................................................................144 ADJUST THE THROTTLE LINKAGE...............................................................................145 SPECIFICATIONS................................................................................................145 TROUBLESHOOTING...............................................................................................146 INTRODUCTION..................................................................................................148 GENERAL...................................................................................................148 DESCRIPTION...............................................................................................150 Hydraulic System......................................................................................150 Gear Pump Assembly....................................................................................150 Flow Control Valve....................................................................................151 Relief Valve (Early Model)............................................................................151 Relief Valve (Later Model)............................................................................151 OPERATION.................................................................................................153 Hydraulic System......................................................................................153 Gear Pump.............................................................................................153 Flow Control Valve....................................................................................153 Relief Valve (Early Model)............................................................................153 Relief Valve (Later Model)............................................................................153 REPAIR........................................................................................................155 GEAR PUMP ASSEMBLY........................................................................................155 Removal and Disassembly...............................................................................155 Assembly and Installation.............................................................................156 CHECKS AND ADJUSTMENTS........................................................................................156 CHECK AND ADJUST STEERING RELIEF PRESSURE.................................................................156 CHECK GEAR PUMP FOR CORRECT FLOW..........................................................................157 TROUBLESHOOTING...............................................................................................157 INTRODUCTION..................................................................................................159 NOMENCLATURE, THREADS.....................................................................................159 STRENGTH IDENTIFICATION...................................................................................160 TABLE 1. BOLTS AND SCREWS.....................................................................................160 TABLE 2. STUDS AND NUTS.......................................................................................161 TABLE 3. TORQUE NUTS..........................................................................................162 TABLE 4. TORQUE NUTS WITH NYLON INSERT........................................................................163 TABLE 5. TORQUE VALUES FOR INCH FASTENERS.....................................................................164 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...................................................................165 INTRODUCTION..................................................................................................168 GENERAL...................................................................................................168 DESCRIPTION...................................................................................................168 GENERAL...................................................................................................168 STEERING COLUMN GAUGES, METERS AND INDICATORS.............................................................171 LED DISPLAY PANEL.........................................................................................171 Battery Discharge Indicators..........................................................................171 Brush Wear Indicators.................................................................................172 Motor Temperature Indicators..........................................................................173 "LX" SERIES DISPLAY PANEL.................................................................................174 Hourmeter Functions...................................................................................175 Battery Indicator Function............................................................................175 Status Code Function..................................................................................175 "ZX" SERIES DISPLAY PANELS................................................................................175 Display Panel.........................................................................................176 Basic Display Panels..................................................................................176 Performance Display...................................................................................178 Brush Wear Indicators.................................................................................181 CHECKS AND ADJUSTMENTS........................................................................................181 GENERAL...................................................................................................181 REPLACEMENT...................................................................................................182 GENERAL...................................................................................................182 METER REPLACEMENT.........................................................................................182 SENDER REPLACEMENT........................................................................................183 Fuel Level Sender.....................................................................................183 Pressure And Temperature Sender.......................................................................183 I.T.W. DISPLAY PANEL......................................................................................184 Removal...............................................................................................184 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT.....................................185 Removal...............................................................................................185 Replacing Display Panel Assembly......................................................................185 Indicator LEDs........................................................................................185 Battery Indicators....................................................................................185 Digital Display (Performance Disply Panel Only).......................................................185 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only).........185 Replacing Parts Of The Basic Display Panel............................................................186 Replacing Parts Of The Performance Display Panel......................................................188 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT.........................................188 Removal And Replacement...............................................................................188 SPECIFICATIONS................................................................................................189 TROUBLESHOOTING...............................................................................................190 INTRODUCTION .................................................................................................191 GENERAL ..................................................................................................191 DESCRIPTION ..............................................................................................191 FUEL SYSTEM ..............................................................................................192 Description ..........................................................................................192 Operation, Fuel Injection Pump, Model VE .............................................................194 Operation, Fuel Injection Pump, Model PE4A ...........................................................195 Pneumatic Governor For Fuel Injection Pump, Model PE4A ...............................................196 Inlet Manifold For Fuel Injection Pump, Model PE4A ...................................................197 REPAIRS ......................................................................................................198 FUEL INJECTION PUMP (ALL MODELS) .........................................................................198 Removal ..............................................................................................198 Installation .........................................................................................198 REMOVAL AND INSTALLATION OF THE ENGINE ...................................................................198 CYLINDER HEAD AND VALVE MECHANISM ........................................................................198 Cylinder Head, Removal ...............................................................................198 Valve Guides, Replacement ............................................................................199 Cylinder Head, Inspection And Repair .................................................................200 Combustion Chamber Plugs, Inspection And Repair ......................................................200 Combustion Chamber Plugs, Installation ...............................................................200 Valves, Inspection And Repair ........................................................................201 Valve Seat, Inspection ...............................................................................201 Valve Seat, Removal ..................................................................................202 Valve Seat, Installation .............................................................................202 Valve Spring, Inspection .............................................................................202 Rocker Arms, Inspection And Assembly .................................................................202 Installation Of The Cylinder Head ....................................................................203 TIMING GEAR CASE .........................................................................................204 Removal ..............................................................................................204 Installation .........................................................................................204 CAMSHAFT .................................................................................................206 Removal ..............................................................................................206 Inspection ...........................................................................................206 Camshaft Bearings ....................................................................................207 Cam Followers ........................................................................................207 CAMSHAFT, INSTALLATION ...................................................................................207 CRANKSHAFT AND MAIN BEARINGS .............................................................................208 Crankshaft, Removal ..................................................................................208 Crankshaft, Inspection And Repair ....................................................................208 Main Bearings ........................................................................................208 Pilot Bearing ........................................................................................209 Crankshaft, Installation .............................................................................209 FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) ..........................................................211 Flywheel, Removal ....................................................................................211 Ring Gear, Replacement ...............................................................................211 Flywheel, Installation ...............................................................................211 PISTONS AND CONNECTING RODS ..............................................................................212 Pistons And Connecting Rods, Removal .................................................................212 Disassembly ..........................................................................................212 Pistons, Inspection And Repair .......................................................................213 Piston Rings, Inspection And Repair ..................................................................213 Piston Pins, Inspection And Repair ...................................................................214 Connecting Rods, Inspection And Repair ...............................................................215 Pistons And Connecting Rods, Assembly And Installation ...............................................215 CYLINDER BLOCK AND CYLINDER LINERS .......................................................................215 Cylinder Liners, Inspection ..........................................................................215 Replacement Of A Cylinder Liner ......................................................................216 LUBRICATION SYSTEM .......................................................................................217 Oil Pump, Removal And Disassembly ....................................................................217 Oil Pump, Inspection .................................................................................217 Oil Pump, Assembly And Installation ..................................................................218 Oil Filter ...........................................................................................218 COOLING SYSTEM ...........................................................................................219 Coolant Pump, Removal ................................................................................219 Coolant Pump, Disassembly ............................................................................219 Coolant Pump, Assembly And Installation ..............................................................219 Thermostat, Replacement ..............................................................................220 CHECKS AND ADJUSTMENTS .......................................................................................220 VALVE CLEARANCE ADJUSTMENT ...............................................................................220 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ....................................................221 CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A ..................................................222 FUEL INJECTORS ...........................................................................................222 Fuel Injectors, Removal ..............................................................................223 Fuel Injectors, Inspection ...........................................................................223 Fuel Injectors, Installation .........................................................................224 DIESEL FUEL FILTERS ......................................................................................224 Filter Replacement, Models With A Water Separator ....................................................224 Filter Replacement, Models Without A Water Separator .................................................225 Filter For The Fuel Injection Pump, Model PE4A .......................................................225 REMOVE AIR FROM THE FUEL SYSTEM ..........................................................................225 Throttle Linkage, Adjustment .........................................................................226 Idle Speed, Adjustment ...............................................................................226 Check The Elements For The Cold Start Aid System .....................................................226 ENGINE SPECIFICATIONS ........................................................................................226 TORQUE SPECIFICATIONS ........................................................................................228 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................229 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................229 LIFT CYLINDERS................................................................................................232 GENERAL...................................................................................................232 DESCRIPTION...............................................................................................232 Lowering Control Valve................................................................................232 Cylinders (General)...................................................................................235 Cylinders (H520-620B,H700-800A).......................................................................237 Cylinders (H360-460B).................................................................................238 Cylinders (Two-Speed).................................................................................238 REPAIRS.......................................................................................................239 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST....................................................239 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............239 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...............................243 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.........................241 DISASSEMBLY...............................................................................................241 ASSEMBLY..................................................................................................243 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.............................................................243 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..............243 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead......................243 CHEVRON PACKING...........................................................................................244 LIFT CYLINDERS FOR VISTA MASTS................................................................................247 DESCRIPTION...............................................................................................247 Lowering Control Valve................................................................................249 REMOVAL...................................................................................................250 DISASSEMBLY...............................................................................................250 ASSEMBLY..................................................................................................250 INSTALLATION..............................................................................................251 Main Lift Cylinders...................................................................................251 Free-Lift Cylinders...................................................................................251 CHECKS AND ADJUSTMENTS........................................................................................252 CHECK FOR LEAKS IN LIFT SYSTEM............................................................................252 TROUBLESHOOTING...............................................................................................253 SPECIFICATIONS................................................................................................254 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100).....................................................................255 GENERAL...................................................................................................255 DESCRIPTION...............................................................................................255 Fuel Tank.............................................................................................256 Fuel Filter And Fuel Valve Unit.......................................................................257 Vaporizer.............................................................................................257 The IMPCO CA 100 Carbureto............................................................................259 IMPCO CA 50 Carburetor................................................................................261 The Governor (GM Engines Only)........................................................................262 Governor With Electronic Controller...................................................................263 REPAIRS.......................................................................................................264 LPG TANK..................................................................................................264 Removal...............................................................................................264 Installation..........................................................................................265 REPLACE THE HOSES.........................................................................................265 HYDROSTATIC RELIEF VALVE..................................................................................265 Removal and Installation..............................................................................265 FILTER UNIT...............................................................................................266 Replacement Of the Fuel Filter Element................................................................266 Replacement of the Diaphragm and Fuel Valve...........................................................267 VAPORIZER.................................................................................................267 Removal...............................................................................................267 Disassembly...........................................................................................267 Cleaning..............................................................................................267 Inspection............................................................................................267 Assembly..............................................................................................269 Installation..........................................................................................269 CARBURETOR (IMPCO CA 100).................................................................................271 Removal...............................................................................................271 Disassembly...........................................................................................271 Cleaning..............................................................................................271 Assembly..............................................................................................271 Installation..........................................................................................274 CARBURETER (IMPCO CA 50)..................................................................................273 Removal...............................................................................................273 Disassembly...........................................................................................273 Cleaning..............................................................................................274 Inspection............................................................................................274 Assembly (See FIGURE 26.).............................................................................274 Installation..........................................................................................274 CHECKS AND ADJUSTMENTS........................................................................................275 CHECK THE FILTER UNIT.....................................................................................275 CHECK THE VAPORIZER.......................................................................................275 Pressure Reducer Valve................................................................................275 Vapor Valve...........................................................................................275 ADJUST THE CARBURETOR.....................................................................................275 Idle Mixture..........................................................................................275 Idle Speed............................................................................................275 Power Mixture.........................................................................................275 ADJUST THE GOVERNOR (GM Engines Only).....................................................................276 Checks................................................................................................276 Main Adjusting Screw..................................................................................276 Secondary Adjusting Screw.............................................................................276 AISAN Governor........................................................................................277 Adjustment, AISAN Governor............................................................................277 TROUBLESHOOTING...............................................................................................278 INTRODUCTION..................................................................................................282 GENERAL...................................................................................................282 DESCRIPTION...............................................................................................282 OPERATION.................................................................................................283 Lift Section..........................................................................................284 Tilt Section..........................................................................................284 Relief Valve..........................................................................................286 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................287 Operation.............................................................................................287 REPAIRS.......................................................................................................287 MAIN CONTROL VALVE........................................................................................287 Removal and Disassembly...............................................................................287 Cleaning and Inspection...............................................................................288 Assembly..............................................................................................288 Installation..........................................................................................288 SOLENOID VALVE FOR AUXILIARY FUNCTION.....................................................................288 Removal and Disassembly...............................................................................288 Assembly and Installation.............................................................................290 CHECKS AND ADJUSTMENTS........................................................................................290 PRESSURE RELIEF VALVES....................................................................................290 Primary Relief Valve..................................................................................290 Seconday Relief Valve.................................................................................291 CONTROL LEVER ARRANGEMENT.................................................................................291 TROUBLESHOOTING...............................................................................................294 SPECIFICATIONS................................................................................................296 INTRODUCTION..................................................................................................297 GENERAL...................................................................................................297 DESCRIPTION...............................................................................................297 Upright Assembly......................................................................................297 Upright Mounts........................................................................................298 Carriage..............................................................................................299 OPERATION.................................................................................................299 Standard Upright......................................................................................299 Three Stage Uprights..................................................................................299 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................302 INTRODUCTION..................................................................................................303 GENERAL...................................................................................................303 REPAIR....................................................................................................303 Forks.................................................................................................303 Forks, Adjustment.....................................................................................303 Forks, Removal And Installation.......................................................................304 Hook Fork, Removal....................................................................................304 Hook Fork, Installation...............................................................................304 CARRIAGE..................................................................................................304 Removal...............................................................................................304 Installation..........................................................................................305 MAST......................................................................................................305 Removal...............................................................................................305 Disassembly, Standard Mast............................................................................306 Disassembly, Three-Stage Mast.........................................................................306 Cleaning And Inspection...............................................................................310 Assembly..............................................................................................311 Installation..........................................................................................311 SIDE-SHIFT CARRIAGE.......................................................................................311 Removal...............................................................................................311 Repairs...............................................................................................313 Installation..........................................................................................313 CHECKS AND ADJUSTMENTS....................................................................................313 Check For Leaks In The Lift Sytem.....................................................................313 Leakage Outside the Hydraulic Lift System.............................................................313 Leakage Inside the Hydraulic Lift System..............................................................313 Check the lift cylinder for inside leakage............................................................313 Check For Leaks In The Tilt System....................................................................313 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...............................................313 LIFT CHAIN ADJUSTMENTS....................................................................................314 MAST ADJUSTMENTS..........................................................................................315 CARRIAGE ADJUSTMENT.......................................................................................316 HEADER HOSE ARRANGEMENT...................................................................................316 Three-Stage Header Hoses..............................................................................316 TROUBLESHOOTING...............................................................................................318 MAZDA M4-121G ENGINE..........................................................................................319 GENERAL...................................................................................................319 DESCRIPTION...............................................................................................320 REMOVAL AND INSTALLATION OF THE ENGINE....................................................................320 CYLINDER HEAD AND VALVE MECHANISM.........................................................................320 Cylinder Head, Removal................................................................................320 Cylinder Head, Inspection and Repairs.................................................................321 Rocker Arm Assembly...................................................................................321 Valve Guides..........................................................................................321 Valve Seats...........................................................................................322 Valves................................................................................................322 Valve Springs.........................................................................................322 Cylinder Head, Installation...........................................................................322 TIMING GEAR CASE, REMOVAL.................................................................................323 TIMING GEAR CASE, INSTALLATION............................................................................324 CAMSHAFT..................................................................................................324 Removal...............................................................................................324 Inspection............................................................................................325 Cam Followers, Inspection.............................................................................325 Installation..........................................................................................325 CRANKSHAFT AND MAIN BEARINGS..............................................................................325 Crankshaft, Removal...................................................................................325 Crankshaft, Inspection And Repair.....................................................................326 Main Bearings.........................................................................................327 Crankshaft, Installation..............................................................................327 PISTONS AND CONNECTING RODS...............................................................................328 Removal...............................................................................................328 Disassembly...........................................................................................328 Pistons, Inspection And Repair........................................................................328 Piston Rings..........................................................................................329 Piston Pin and Bushing................................................................................329 Connecting Rods and Bearings, Inspection..............................................................329 Pistons and Connecting Rods, Assembly.................................................................329 Pistons and Connecting Rods, Installation.............................................................330 CYLINDER BLOCK AND CYLINDER LINERS........................................................................330 Cylinder Block, Repairs...............................................................................330 Cylinder Liners.......................................................................................330 DISTRIBUTOR...............................................................................................331 Removal...............................................................................................331 Installation..........................................................................................331 OIL PUMP..................................................................................................333 Removal...............................................................................................333 Repairs...............................................................................................333 Installation..........................................................................................334 GOVERNOR..................................................................................................334 Description...........................................................................................334 Removal...............................................................................................334 Disassembly...........................................................................................335 Assembly..............................................................................................336 Installation..........................................................................................337 COOLANT PUMP..............................................................................................337 Removal...............................................................................................337 Disassembly and Repair................................................................................338 Assembly..............................................................................................338 Installation..........................................................................................339 FLYWHEEL..................................................................................................339 Repairs...............................................................................................339 Installation..........................................................................................339 CHECKS AND ADJUSTMENTS........................................................................................339 ADJUST THE VALVES.........................................................................................339 ADJUST THE THROTTLE LINKAGE...............................................................................340 ENGINE SPECIFICATIONS.........................................................................................340 ENGINE SPECIFICATIONS.....................................................................................340 Engine Data...........................................................................................340 Cooling System........................................................................................340 Cylinder Head and Valve Mechanism.....................................................................340 Camshaft..............................................................................................342 Timing Gear...........................................................................................343 Camshaft..............................................................................................343 Connecting Rods.......................................................................................343 Cylinder Liners.......................................................................................343 Pistons...............................................................................................343 Lubrication System....................................................................................344 Fuel Pump.............................................................................................344 TORQUE SPECIFICATIONS.....................................................................................345 TROUBLESHOOTING...............................................................................................346 PERIODIC MAINTENANCE..........................................................................................350 GENERAL...................................................................................................350 Serial Number Data....................................................................................350 HOW TO MOVE A DISABLED LIFT TRUCK.........................................................................351 How To Tow the Lift Truck.............................................................................351 HOW TO PUT A LIFT TRUCK ON BLOCKS.........................................................................351 How To Raise the Drive Tires..........................................................................351 How To Raise the Steering Tires.......................................................................352 MAINTENANCE PROCEDURES........................................................................................356 EVERY 8 HOURS OR DAILY........................................................................................356 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED................................................................356 Engine Oil............................................................................................356 Drive Belts...........................................................................................356 Cooling System........................................................................................356 Battery...............................................................................................357 Fuel System...........................................................................................359 Air Filter............................................................................................359 Hydraulic System Oil..................................................................................359 Tires and Wheels......................................................................................360 Forks.................................................................................................360 Forks, Adjustment.....................................................................................361 Forks, Removal And Installation.......................................................................361 Inspection Of Forks, Mast, and Lift Chains............................................................362 Safety Labels.........................................................................................363 Operator Restraint System.............................................................................363 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING................................................................364 Gauges, Lights, Horn, and Fuses.......................................................................364 Fuel Filter, Diesel Engine............................................................................365 How To Drain The Water From The Fuel Filter...........................................................365 Oil Level, Powershift Transmission....................................................................365 Control Levers and Pedals.............................................................................365 Lift System Operation.................................................................................365 Inching/Brake Pedal...................................................................................366 Service Brakes........................................................................................366 Parking Brake.........................................................................................366 Steering System.......................................................................................366 EVERY 250 HOURS OR TWO MONTHS.................................................................................367 ENGINE OIL AND FILTER.....................................................................................367 Mazda, GM, And Later Production Isuzu Engines.........................................................367 Earlier Production Isuzu C240 Engines.................................................................367 GOVERNOR, MAZDA ENGINE....................................................................................368 DRIVE BELTS...............................................................................................368 Mazda Engine..........................................................................................368 Isuzu, GM 4-181, And GM 4-153 Engines.................................................................368 BRAKE FLUID...............................................................................................369 HYDRAULIC TANK BREATHER, CLEAN AND CHECK..................................................................369 FORKS, CHECK FOR WEAR AND DAMAGE..........................................................................369 LIFT CHAINS...............................................................................................369 Lubrication...........................................................................................369 Check For Wear........................................................................................369 MAST, LUBRICATION.........................................................................................370 TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...............................................................370 CONTROL LEVERS AND PEDALS, LUBRICATION....................................................................371 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.......................................................................371 Idle Speed, Diesel....................................................................................371 LPG Carburetor........................................................................................372 Gasoline Carburetor...................................................................................372 EVERY 1000 HOURS OR SIX MONTHS................................................................................373 DIESEL FUEL FILTER........................................................................................373 Filter Replacement, Models Without A Water Separator..................................................374 Filter Replacement, Models With A Water Separator.....................................................374 Remove Air from the Diesel Fuel System................................................................374 DIFFERENTIAL..............................................................................................375 VALVE CLEARANCE ADJUSTMENT................................................................................375 IGNITION SYSTEM, MAZDA AND GM ENGINES.....................................................................375 PCV VALVE AND FILTER......................................................................................377 EVERY 2000 HOURS OR YEARLY....................................................................................377 HYDRAULIC SYSTEM..........................................................................................377 Replace the Hydraulic Oil and Filter..................................................................377 POWERSHIFT TRANSMISSION...................................................................................377 COOLING SYSTEM............................................................................................378 SERVICE BRAKES............................................................................................378 DIFFERENTIAL..............................................................................................378 WHEEL BEARINGS............................................................................................379 Steering Wheels, lubrication..........................................................................379 Drive Wheels, Lubrication.............................................................................379 GASOLINE FUEL FILTER, REPLACEMENT.........................................................................379 PCV VALVE, GM ENGINES.....................................................................................379 LPG FILTER, REPLACEMENT...................................................................................379 FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A............................................................379 GENERAL PROCEDURES............................................................................................380 CHECK THE HOOD LATCH......................................................................................380 LIFT CHAIN ADJUSTMENTS....................................................................................380 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..............................................................382 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...............................................................383 Check the Lift Cylinders for Leaks....................................................................383 Check the Tilt Cylinders for Leaks....................................................................383 FUEL INJECTORS............................................................................................384 WELDING REPAIRS...........................................................................................384 CHANGES TO THE OVERHEAD GUARD.............................................................................384 WHEELS AND TIRES..........................................................................................384 Solid Rubber Tires (Press-on).........................................................................384 Install The Wheels....................................................................................385 Pneumatic Tires, Remove The Wheels From The Lift Truck................................................386 Pneumatic Tires, Remove the Tire From The Wheel.......................................................386 Pneumatic Tires, Install The Wheel In The Tire........................................................387 Pneumatic Tires, Add Air To The Tires.................................................................388 Pneumatic Tires, Install the Wheels...................................................................389 Pneumatic Tires, Installation Procedures, Dual Drive Wheels...........................................389 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.........................................................390 Remove The Wheels From The Lift Truck.................................................................390 Remove The Tire From The Wheel........................................................................390 Install The Tire On The Wheel.........................................................................391 REFERENCE TABLE...............................................................................................392 INTRODUCTION..................................................................................................393 General...................................................................................................393 DESCRIPTION AND OPERATION.....................................................................................393 General...................................................................................................393 Torque Converter..........................................................................................394 Description...........................................................................................394 Operation.............................................................................................394 Clutch Assemblies.........................................................................................396 Description...........................................................................................396 Operation.............................................................................................397 Hydraulic System..........................................................................................397 General...............................................................................................397 Oil Pump and Front Cover..................................................................................398 Torque Converter Regulator............................................................................398 Oil Cooler By-Pass....................................................................................398 Control Valve.............................................................................................398 General...............................................................................................398 Differential..............................................................................................403 Oil Flow Diagrams.........................................................................................404 Neutral...............................................................................................404 Forward...............................................................................................406 Forward-Inching.......................................................................................408 Reverse...............................................................................................410 INTRODUCTION..................................................................................................412 GENERAL...................................................................................................412 DESCRIPTION AND OPERATION.....................................................................................413 GENERAL...................................................................................................413 TORQE CONVERTER...........................................................................................413 Description...........................................................................................413 Operation.............................................................................................413 CLUTCH ASSEMBLIES.........................................................................................416 Description...........................................................................................416 Operation.............................................................................................418 HYDRAULIC SYSTEM..........................................................................................418 General...............................................................................................418 CONTROL VALVE.............................................................................................418 Regulator for Clutch Pressure.........................................................................421 Inching Spool Assembly................................................................................421 Direction Spool.......................................................................................421 MONOTROL Control Valve................................................................................421 Neutral Start Switch, MONOTROL Pedal Only.............................................................422 Neutral Start Switch, Direction Control Lever Only....................................................422 Modulator Circuit.....................................................................................422 Regulator for the Toruqe Converter....................................................................423 By-Pass Valve for the Oil Cooler......................................................................423 DIFFERENTIAL..............................................................................................424 OIL FLOW DIAGRAMS.........................................................................................424 INTRODUCTION..................................................................................................433 GENERAL...................................................................................................433 REPAIRS.......................................................................................................435 REPAIRS...................................................................................................435 Torque Converter, Removal.............................................................................435 Torque Converter, Installation........................................................................435 Front Cover And Transmission Pump, Removal and Disassembly............................................436 Front Cover And Transmission Pump, Assembly and Installation..........................................436 Clutch Assemblies, Removal and Disassembly............................................................437 Clutch Assemblies, Inspection.........................................................................440 Clutch Assemblies, Assembly and Installation..........................................................441 Differential, Removal and Disassembly.................................................................444 Differential, Inspection..............................................................................446 Differential, Assembly And Installation...............................................................446 CONTROL VALVE.............................................................................................456 Control Valve, Removal and Disassembly................................................................456 Control Valve, Inspection.............................................................................456 Control Valve, Assembly and Installation..............................................................458 MONOTROL Pedal, Removal and Disassembly...............................................................460 MONOTROL Pedal, Assembly and Installation.............................................................460 CHECKS AND ADJUSTMENTS........................................................................................462 Stall Test................................................................................................462 Adjustment Of The Direction Control Linkage...............................................................463 Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1).............464 Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)..............467 Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187).......................468 Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)....................469 Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)....473 Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)............474 Check The Oil Pressures...................................................................................474 Check The Relief Valve for the Transmission Pump..........................................................474 Check The Clutch Pressure.................................................................................474 Check The Torque Converter Regulator......................................................................475 Check The Oil Pressure from the Oil Cooler................................................................475 Check The Modulator Pressure..............................................................................476 TROUBLESHOOTING...............................................................................................476 TROUBLESHOOTING, PRESSURE TESTS...............................................................................478 INTRODUCTION..................................................................................................481 General...................................................................................................481 Removal of The Transmission...........................................................................481 Installation of the Transmission......................................................................481 REPAIRS.......................................................................................................483 Torque Converter..........................................................................................483 Front Cover and Oil Pump..................................................................................483 Clutch Assemblies.........................................................................................485 Differential..............................................................................................493 Control Valve.............................................................................................502 CHECKS AND ADJUSTMENTS........................................................................................504 Stall Test................................................................................................504 Adjusting the Direction Control Linkage...................................................................505 Adjusting the Brake and Inching Pedals....................................................................506 Checking the Oil Pressures................................................................................508 SPECIFICATIONS................................................................................................510 TROUBLESHOOTING...............................................................................................510
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]
1 review for Hyster H40 60XL A177 service manual – PDF DOWNLOAD
Add a review
Sincere Vincenzo –
ease of use