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Hyster H70-H120XM Service Manual – PDF DOWNLOAD
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Description
Hyster H70-H120XM Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster H70-H120XM Service Manual – PDF DOWNLOAD
Language : English
Pages : 450
Downloadable : Yes
File Type : PDF
Size: 34.2 MB
TABLE OF CONTENTS:
Hyster H70-H120XM Service Manual – PDF DOWNLOAD
100726........................................................................................... 1 THE FRAME.................................................................................... 1 GENERAL.................................................................................. 1 DESCRIPTION.............................................................................. 1 COUNTERWEIGHT............................................................................ 1 Removal.............................................................................. 1 Installation......................................................................... 2 HOOD..................................................................................... 2 Removal ............................................................................. 2 Installation......................................................................... 2 OVERHEAD GUARD........................................................................... 3 Removal.............................................................................. 3 Inspection........................................................................... 3 Installation......................................................................... 3 OPERATOR RESTRAINT SYSTEM................................................................ 3 RADIATOR................................................................................. 4 Removal.............................................................................. 4 Installation......................................................................... 4 EXHAUST SYSTEM........................................................................... 6 Muffler Removal...................................................................... 6 Muffler Installation................................................................. 6 Exhaust pipe removal - LPG/GAS Engine................................................ 6 Exhaust pipe Installation LPG/GAS Engine............................................. 6 Exhaust pipe removal - Diesel Engine................................................. 7 Exhaust pipe Installation Diesel Engine.............................................. 8 ENGINE................................................................................... 9 Removal.............................................................................. 9 Installation......................................................................... 12 FUEL AND HYDRAULIC TANKS................................................................. 13 Inspection........................................................................... 13 Repairs, Small Leaks................................................................. 13 Repairs, Large Leaks................................................................. 13 Cleaning............................................................................. 13 Other Methods Of Preparation For Repair.............................................. 14 SAFETY LABELS............................................................................ 14 100778........................................................................................... 17 GENERAL...................................................................................... 17 REMOVAL...................................................................................... 18 INSTALLATION................................................................................. 19 SWITCH PANEL................................................................................. 19 WINDOW WIPERS................................................................................ 19 Front Wiper Assembly..................................................................... 19 Rear Wiper Assembly...................................................................... 20 DOOR HANDLE ASSEMBLY......................................................................... 22 FUSE PANEL................................................................................... 22 HEATER ASSEMBLY.............................................................................. 22 Removal.................................................................................. 22 Installation............................................................................. 23 WINDOW REPLACEMENT........................................................................... 23 OPTIONS...................................................................................... 25 Rear Strobe Lights....................................................................... 25 Heavy Duty Air Cleaner................................................................... 25 LABEL RELACEMENT............................................................................. 25 ELECTRICAL SCHEMATIC......................................................................... 25 600590........................................................................................... 28 GM 4.3 LITRE V-6............................................................................. 28 INTRODUCTION............................................................................. 28 DESCRIPTION.............................................................................. 28 ENGINE, REMOVAL AND INSTALLATION ........................................................ 29 CYLINDER HEAD............................................................................ 29 Removal And Disassembly.............................................................. 29 Cleaning And Inspection.............................................................. 29 Repairs, Valve Guides and Seats...................................................... 29 Repairs, Valves ..................................................................... 30 Repairs, Valve Seats................................................................. 30 Valve Springs........................................................................ 31 Studs For The Rocker Arms (Early Models)............................................. 32 Studs For The Rocker Arms (Late Models).............................................. 33 Assembly And Installation............................................................ 33 CYLINDER BLOCK, CLEANING AND INSPECTION.................................................. 35 PISTON BORE PREPARATION.................................................................. 35 ENGINE MOUNTS............................................................................ 35 LUBRICATION SYSTEM....................................................................... 35 Oil Pump, Removal and Disassembly.................................................... 35 Cleaning and Inspection.............................................................. 36 Oil Pump, Assembly and Installation.................................................. 36 Oil Sump, Installation............................................................... 36 TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS............................... 37 Timing Cover, Removal................................................................ 37 Installation......................................................................... 38 Timing Sprockets, Removal............................................................ 39 Timing Sprockets, Installation....................................................... 39 Camshaft, Removal.................................................................... 39 Camshaft, Inspection................................................................. 39 Camshaft, Installation............................................................... 39 Balance Shaft, Removal............................................................... 40 Balance Shaft, Installation.......................................................... 41 Hydraulic Valve Lifters, Removal..................................................... 42 Hydraulic Valve Lifters, Disassembly................................................. 42 Hydraulic Valve Lifters, Cleaning And Inspection..................................... 42 Hydraulic Valve Lifters, Assembly.................................................... 43 Hydraulic Valve Lifters, Installation................................................ 43 CRANKSHAFT............................................................................... 44 Removal.............................................................................. 44 Inspection and Repair................................................................ 44 How To Check The Clearance Between The Main Bearings And Their Journals.............. 45 Installation......................................................................... 46 PISTON AND CONNECTING ROD ASSEMBLIES..................................................... 47 Connecting Rod Bearings, Replacement................................................. 47 Piston And Connecting Rod Assemblies, Removal........................................ 48 Disassembly.......................................................................... 48 Piston, Cleaning And Inspection...................................................... 48 Cylinder Bores, Inspection And Repair................................................ 49 Piston Rings......................................................................... 50 Assembly............................................................................. 50 Piston And Connecting Rod Assemblies, Installation................................... 51 FLYWHEEL AND FLYWHEEL HOUSING............................................................ 51 Flywheel Repairs..................................................................... 51 Flywheel, Installation .............................................................. 51 Flywheel Housing..................................................................... 52 Engine Adapter....................................................................... 52 COOLANT PUMP............................................................................. 52 THERMOSTAT............................................................................... 52 FAN MOUNT, EARLY MODELS.................................................................. 52 FAN MOUNT ASSEMBLY, LATE MODELS.......................................................... 53 DRIVE BELT, INSTALLATION................................................................. 54 CHECKS AND ADJUSTMENTS....................................................................... 56 VALVE CLEARANCE ADJUSTMENT, EARLY MODELS................................................. 56 VALVE CLEARANCE ADJUSTMENT, NEW MODELS................................................... 56 CHECK THE COMPRESSION.................................................................... 56 ENGINE SPECIFICATIONS........................................................................ 57 Engine Data.............................................................................. 57 Engine Data.......................................................................... 57 Cylinder head........................................................................ 57 Hydraulic Valve Lifter............................................................... 57 Camshaft............................................................................. 57 Pistons.............................................................................. 57 Crankshaft........................................................................... 58 Connecting Rods...................................................................... 58 Connecting Rods...................................................................... 58 Balance Shaft........................................................................ 58 Cooling System....................................................................... 58 Lubrication System................................................................... 58 TORQUE SPECIFICATIONS........................................................................ 59 TROUBLESHOOTING.............................................................................. 60 600705........................................................................................... 63 PERKINS DIESEL ENGINES, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH)............................ 63 GENERAL.................................................................................. 63 General Safety Rules................................................................. 63 DESCRIPTION.............................................................................. 65 Engine Serial Number Codes........................................................... 66 Engine Data.......................................................................... 67 1004-42 (AR) ENGINE (Low Governed Speed)............................................. 67 1004-42 (AR) ENGINE (High Governed Speed)............................................ 67 1006-60 (YG) ENGINE.................................................................. 67 1006-60 (YH) ENGINE.................................................................. 67 REMOVAL AND INSTALLATION................................................................. 68 Lifting The Engine................................................................... 68 CYLINDER HEAD ASSEMBLY....................................................................... 68 VALVE COVER.............................................................................. 68 Removal.............................................................................. 68 Installation......................................................................... 69 ROCKER ARM ASSEMBLY...................................................................... 69 Removal.............................................................................. 69 Installation......................................................................... 69 Disassembly.......................................................................... 69 Inspection........................................................................... 70 Assembly............................................................................. 70 VALVE CLEARANCE ADJUSTMENTS.............................................................. 70 Four Cylinder Engines................................................................ 70 Six Cylinder Engines................................................................. 71 VALVE SPRINGS............................................................................ 71 CYLINDER HEAD ASSEMBLY................................................................... 72 Removal.............................................................................. 72 Installation......................................................................... 75 VALVES AND VALVE SPRINGS................................................................. 79 Removal.............................................................................. 79 Inspection........................................................................... 80 Installation......................................................................... 80 VALVE GUIDES............................................................................. 80 Inspection........................................................................... 80 Removal.............................................................................. 81 Installation......................................................................... 81 CYLINDER HEAD AND VALVE SEATS............................................................ 82 Inspection........................................................................... 82 Repair............................................................................... 82 Installation Of New Valve Seats...................................................... 83 PISTON AND CONNECTING ROD ASSEMBLIES......................................................... 83 ROD BEARINGS............................................................................. 84 Removal.............................................................................. 84 Installation......................................................................... 85 PISTON AND CONNECTING ROD ASSEMBLY....................................................... 85 Service Note......................................................................... 85 Removal.............................................................................. 86 Installation......................................................................... 86 PISTON RINGS............................................................................. 87 Removal.............................................................................. 87 Inspection........................................................................... 87 Installation......................................................................... 88 PISTON AND CONNECTING ROD................................................................ 89 Disassembly.......................................................................... 89 Inspection........................................................................... 90 How To Select the Correct Replacements............................................... 90 Installation......................................................................... 91 PISTON COOLING JETS...................................................................... 91 Removal.............................................................................. 91 Installation......................................................................... 91 CRANKSHAFT ASSEMBLY.......................................................................... 92 GENERAL.................................................................................. 92 CRANKSHAFT PULLEY........................................................................ 93 Removal, Engine AR................................................................... 93 Removal, Engine YG and YH............................................................ 93 Inspection........................................................................... 93 Installation, Engine AR.............................................................. 94 Installation, Engine YG and YH....................................................... 94 REAR OIL SEAL............................................................................ 95 Replacement.......................................................................... 95 MAIN BEARINGS............................................................................ 96 Removal.............................................................................. 96 Inspection........................................................................... 96 Installation......................................................................... 97 THRUST WASHERS........................................................................... 97 Check The Axial Movement Of The Crankshaft........................................... 97 Removal.............................................................................. 98 Installation......................................................................... 98 CRANKSHAFT............................................................................... 99 Removal.............................................................................. 99 Inspection........................................................................... 99 Installation......................................................................... 99 FLYWHEEL.................................................................................101 Removal..............................................................................101 Ring Gear (Replacement)..............................................................101 Installation.........................................................................101 FLYWHEEL HOUSING.........................................................................102 Removal..............................................................................102 Installation.........................................................................102 TIMING CASE AND TIMING GEARS.................................................................103 GENERAL..................................................................................103 TIMING CASE COVER........................................................................103 Removal..............................................................................103 Installation.........................................................................103 FRONT OIL SEAL...........................................................................104 Removal..............................................................................104 Installation.........................................................................104 CRANKSHAFT PULLEY WEAR SLEEVE............................................................105 Installation.........................................................................105 IDLER GEAR AND HUB.......................................................................105 Removal..............................................................................105 Installation.........................................................................106 AIR COMPRESSOR DRIVE, BENDIX.............................................................107 Disassembly..........................................................................107 Compressor Drive, Assembly...........................................................108 GEAR FOR THE FUEL INJECTION PUMP.........................................................108 Removal..............................................................................108 Installation.........................................................................109 CAMSHAFT GEAR............................................................................110 Removal..............................................................................110 Installation.........................................................................110 CRANKSHAFT GEAR..........................................................................111 Removal..............................................................................111 Installation.........................................................................111 TIMING CASE..............................................................................111 Removal..............................................................................111 Installation.........................................................................112 CAMSHAFT AND TAPPETS.....................................................................113 Removal..............................................................................113 Installation.........................................................................113 CYLINDER BLOCK ASSEMBLY......................................................................114 DESCRIPTION..............................................................................114 CYLINDER BLOCK...........................................................................114 Disassembly..........................................................................114 Inspection...........................................................................115 Assembly.............................................................................115 CYLINDER BORE (4-CYLINDER ENGINES).......................................................115 CYLINDER BORE (6-CYLINDER ENGINES).......................................................116 Inspection...........................................................................116 To Check the Condition of a Cylinder Liner...........................................116 Removal..............................................................................117 Installation (Service Liner).........................................................118 Installation (Partially Finished Liner)..............................................119 ENGINE TIMING................................................................................120 GENERAL DESCRIPTION......................................................................120 How To Set Number 1 Piston To TDC On The Compression Stroke..........................121 How To Set Number 1 Piston To TDC On The Compression Stroke (Alternate Procedure)....122 Check The Valve Timing...............................................................122 Check The Timing Of The Fuel Injection Pump..........................................123 TURBOCHARGER, ENGINE YH......................................................................124 GENERAL..................................................................................124 Removal..............................................................................124 Installation.........................................................................124 Clean The Impeller And Compressor Housing............................................125 LUBRICATION SYSTEM...........................................................................126 GENERAL..................................................................................126 OIL FILTER, REPLACEMENT..................................................................126 FILTER HEAD..............................................................................127 To Remove and to Install.............................................................127 OIL SUMP.................................................................................127 Removal..............................................................................127 Installation.........................................................................128 OIL PUMP.................................................................................128 Removal..............................................................................128 Inspection...........................................................................128 Installation.........................................................................129 RELIEF VALVE.............................................................................130 Removal..............................................................................130 Disassembly..........................................................................130 Inspection...........................................................................131 Assembly.............................................................................131 Installation.........................................................................131 IDLER GEAR SHAFT, REPLACEMENT............................................................131 Removal..............................................................................131 Removal, Alternative.................................................................132 Installation.........................................................................133 Installation, Alternative............................................................133 Installation, Alternative for 4-Cylinder Engines Only................................133 FUEL SYSTEM..................................................................................134 DESCRIPTION..............................................................................134 FUEL INJECTION PUMP......................................................................134 Removal..............................................................................134 Installation.........................................................................135 FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS..........................................136 REMOVE AIR FROM THE FUEL SYSTEM......................................................137 FUEL FILTER (REPLACEMENT)............................................................138 Canister Type....................................................................138 Quick Release Canister Type......................................................138 FUEL INJECTORS.......................................................................139 Removal..........................................................................139 Inspection.......................................................................140 Installation.....................................................................140 FUEL PUMP............................................................................141 Removal..........................................................................141 Disassembly......................................................................141 Assembly.........................................................................142 Installation.....................................................................142 Test.............................................................................143 COOLING SYSTEM...........................................................................143 GENERAL..............................................................................143 THERMOSTAT...........................................................................143 Thermostats......................................................................143 Remove...........................................................................143 Install..........................................................................143 Test.............................................................................143 COOLANT PUMP.........................................................................144 Removal..........................................................................144 Disassembly......................................................................145 Assembly.........................................................................146 Installation.....................................................................149 FAN AND FAN DRIVE....................................................................150 Removal..........................................................................150 Installation.....................................................................150 OIL COOLER (6-CYLINDER ENGINES)......................................................150 Removal..........................................................................150 Disassembly And Assembly.........................................................150 Installation.....................................................................151 By-Pass Valve, Oil Cooler........................................................151 ELECTRICAL EQUIPMENT.....................................................................151 DRIVE BELTS..........................................................................151 ALTERNATOR...........................................................................152 Removal..........................................................................152 Installation.....................................................................152 STARTER MOTOR........................................................................152 Removal..........................................................................152 Installation.....................................................................153 COLD START AID.......................................................................153 AIR COMPRESSOR, ENGINES YG AND YH........................................................153 GENERAL..............................................................................153 Air Compressor, Removal..........................................................153 Air Compressor, Installation.....................................................154 ENGINE SPECIFICATIONS....................................................................155 CYLINDER HEAD ASSEMBLY...............................................................155 Cylinder Head....................................................................155 Valve Guides.....................................................................156 Inlet Valve......................................................................156 Exhaust Valves...................................................................157 Valve Springs....................................................................157 Tappets..........................................................................157 Rocker Arm Shaft.................................................................158 Rocker Arms And Bushings.........................................................158 PISTON AND CONNECTING RODS...........................................................158 Pistons (Engine AR)..............................................................158 Pistons (Engine YG and YH).......................................................158 Piston Rings (Engine AR).........................................................158 Piston Rings (Engines YG and YH).................................................159 Piston Pins......................................................................159 Connecting Rods..................................................................159 Small End Bushings...............................................................160 Connecting Rod,Bearings, Engines AR And YG.......................................160 Connecting Rod,Bearings, Engines YH..............................................160 Piston Cooling Jets..............................................................160 CRANKSHAFT ASSEMBLY..................................................................160 Crankshaft.......................................................................160 Main Bearings....................................................................161 Crankshaft Thrust Washers........................................................161 Crankshaft Heat Treatment........................................................161 Crankshaft Overhaul..............................................................161 TIMING CASE AND DRIVE ASSEMBLY.......................................................163 Camshaft.........................................................................163 Camshaft Thrust Washer...........................................................163 Camshaft Gear....................................................................163 Gear For Fuel Injection Pump.....................................................163 Crankshaft Gear..................................................................163 Idler Gear And Hub...............................................................163 ENGINE BLOCK ASSEMBLY................................................................164 Cylinder Block (Engine AR).......................................................164 Cylinder Bore Specifications (Engine AR).........................................164 Cylinder Block (Engine YG and YH)................................................165 Cylinder LIners (Engine YG and YH)...............................................165 Cylinder Liner Specifications (Partially Finished)...............................165 TURBOCHARGER.........................................................................166 LUBRICATION SYSTEM...................................................................166 Oil Pump, Engine AR..............................................................166 Oil Pump, Engine YG and YH.......................................................166 Idler Gear for Oil Pump..........................................................166 Relief Valve.....................................................................166 Oil Filter.......................................................................167 FUEL SYSTEM..........................................................................167 Lucas Fuel Injection Pump........................................................167 Fuel Injector Codes..............................................................168 Fuel Pump, Engine AR.............................................................168 Fuel Pump, Engines YG And YH.....................................................168 Fuel Filter......................................................................169 COOLING SYSTEM.......................................................................169 Coolant Pump.....................................................................169 Thermostat.......................................................................169 Fan Drive Housing................................................................169 FLYWHEEL AND HOUSING.................................................................169 Limits for Flywheel "Run Out" and Alignment (Total Indicator Reading)............169 ELECTRICAL EQUIPMENT.................................................................169 Alternator.......................................................................169 Starter Motor....................................................................169 Cold Start Aid...................................................................169 TORQUE SPECIFICATIONS....................................................................170 SPECIAL TORQUE SPECIFICATIONS............................................................172 SPECIAL TOOLS............................................................................173 TROUBLESHOOTING..........................................................................177 List of Possible Causes..............................................................178 700740...........................................................................................180 COOLING SYSTEM...............................................................................180 INTRODUCTION.............................................................................180 DESCRIPTION..............................................................................180 RADIATOR ................................................................................180 RADIATOR CAP.............................................................................180 THERMOSTAT...............................................................................180 WATER PUMP...............................................................................181 FAN AND FAN SHROUD.......................................................................181 DRIVE SHAFT..............................................................................181 REPAIRS......................................................................................181 COOLING SYSTEM CHECKS....................................................................181 Exhaust Leaks........................................................................181 RADIATOR.................................................................................181 Checks...............................................................................181 Cleaning The Radiator................................................................181 Draining The Cooling System..........................................................183 Filling The Cooling System...........................................................183 WATER PUMP...............................................................................183 Checks...............................................................................183 THERMOSTAT...............................................................................183 Checks...............................................................................184 FAN ASSEMBLY.............................................................................184 Removal..............................................................................184 Inspection ..........................................................................184 Installation.........................................................................184 FAN BELT.................................................................................184 Removal..............................................................................184 Installation.........................................................................184 DRIVE SHAFT..............................................................................185 Removal..............................................................................185 Installation.........................................................................185 TROUBLESHOOTING..............................................................................187 900745...........................................................................................188 INTRODUCTION.................................................................................188 GENERAL..................................................................................188 DESCRIPTION AND OPERATION................................................................188 Fuel Tank............................................................................189 Fuel Filter and Fuel Valve Unit......................................................189 Vaporizer............................................................................190 Carburetor...........................................................................191 Governor.............................................................................192 2-Way Valves, Open Loop System.......................................................193 O.E.Tune Valve, Closed Loop System...................................................193 REPAIRS......................................................................................194 LPG TANK.................................................................................194 Removal..............................................................................194 Installation.........................................................................195 HYDROSTATIC RELIEF VALVE.................................................................195 Removal and Installation.............................................................195 FILTER UNIT..............................................................................195 Replacement Of The Fuel Filter Element...............................................195 Replacement Of The Diaphragm and Fuel Valve..........................................196 REPLACEMENT OF THE HOSES.................................................................197 VAPORIZER................................................................................197 Removal..............................................................................197 Vaporizer Disassembly................................................................197 Cleaning.............................................................................199 Inspection...........................................................................199 Vaporizer Assembly...................................................................199 Installation.........................................................................201 CARBURETOR...............................................................................201 Removal..............................................................................201 Disassembly..........................................................................201 Cleaning.............................................................................201 Assembly.............................................................................201 Installation.........................................................................202 GOVERNOR ASSEMBLY........................................................................202 CHECKS AND ADJUSTMENTS.......................................................................203 CHECK THE FILTER UNIT....................................................................203 CHECK THE VAPORIZER......................................................................203 Pressure Reducer Valve...............................................................203 Vapor Valve..........................................................................203 ADJUST THE CARBURETOR....................................................................203 Idle Mixture.........................................................................203 Idle Speed...........................................................................203 ADJUST THE THROTTLE LINKAGE..............................................................203 TROUBLESHOOTING..............................................................................205 900768...........................................................................................208 INTRODUCTION.................................................................................208 GENERAL..................................................................................208 DESCRIPTION..............................................................................209 OPERATION................................................................................209 REPAIRS......................................................................................209 LPG SOLENOID VALVE.......................................................................209 FUEL SELECTOR SWITCH.....................................................................209 ADJUSTMENTS..............................................................................209 TROUBLESHOOTING..............................................................................210 1300727..........................................................................................211 DESCRIPTION AND OPERATION....................................................................211 GENERAL..................................................................................211 MECHANICAL DESCRIPTION...................................................................211 Torque Converter.....................................................................211 Transmission Pump....................................................................212 Shaft Assemblies.....................................................................212 Input Shaft..........................................................................212 Forward Clutch Shafts................................................................212 Clutch Assemblies....................................................................212 Output Gear And Pinion...............................................................213 Electronic Control Unit..............................................................213 HYDRAULIC OPERATION......................................................................213 Torque Converter.....................................................................213 Seal Rings...........................................................................214 CONTROL VALVE............................................................................214 Regulator for Clutch Pressure........................................................215 Inching Spool Assembly...............................................................215 Direction Spool......................................................................215 Modulator Circuit....................................................................216 Regulator for the Torque Converter...................................................216 MONOTROL PEDAL...........................................................................217 Start Circuit, Monotrol Pedal........................................................217 DIRECTION CONTROL LEVER..................................................................218 OIL FLOW DIAGRAMS............................................................................218 Neutral..................................................................................219 Neutral..............................................................................219 Forward-Low..........................................................................223 Forward-Low-Inching..................................................................225 Reverse..............................................................................227 1300728..........................................................................................229 REPAIRS......................................................................................229 GENERAL..................................................................................229 TRANSMISSION.............................................................................229 Removal..............................................................................229 Installation.........................................................................230 CLUTCH PACKS.............................................................................231 Removal And Disassembly..............................................................231 Inspection...........................................................................233 Assembly And Installation............................................................233 DIFFERENTIAL.............................................................................237 Removal And Disassembly..............................................................237 Inspection...........................................................................238 Assembly And Installation Of Original Parts..........................................238 Assembly And Installation Of New Parts...............................................238 CONTROL VALVE............................................................................245 Removal and Disassembly..............................................................245 Inspection...........................................................................245 Assembly and Installation............................................................246 MONOTROL PEDAL...........................................................................247 Removal and Disassembly..............................................................247 Assembly and Installation............................................................247 DIRECTION CONTROL LEVER..................................................................250 Removal and Disassembly..............................................................250 Assembly and Installation............................................................250 CHECKS AND ADJUSTMENTS.......................................................................251 STALL TEST...............................................................................251 ADJUST THE INCHING/BRAKE PEDAL...........................................................251 ADJUST THE NEUTRAL START SWITCH, MONOTROL PEDAL..........................................253 TEST THE NEUTRAL START SWITCH, MONOTROL PEDAL............................................254 CHECK THE ELECTRONIC CONTROL UNIT........................................................254 CHECK THE OIL PRESSURES..................................................................255 Check The Relief Valve for the Transmission Pump, TEST PORT 1........................255 Check The Reverse Clutch Pressure, TEST PORT 2.......................................256 Check The Forward Clutch Pressure, TEST PORT 3 and 4.................................256 Check The Torque Converter Regulator, TEST PORT 5....................................256 Check The Lubrication Circuit Oil Pressure, TEST PORT 6..............................256 Check The Modulator Pressure, TEST PORT 7............................................256 TROUBLESHOOTING..............................................................................257 TROUBLESHOOTING - PRESSURE TEST..............................................................260 1300751..........................................................................................261 DESCRIPTION AND OPERATION....................................................................261 GENERAL..................................................................................261 MECHANICAL DESCRIPTION...................................................................261 Torque Converter.....................................................................261 Transmission Pump....................................................................262 Shaft Assemblies.....................................................................262 Input Shaft..........................................................................262 Forward Clutch Shaft.................................................................262 Clutch Assemblies....................................................................262 Output Gear And Pinion...............................................................262 HYDRAULIC OPERATION......................................................................263 Torque Converter.....................................................................263 Seal Rings...........................................................................264 CONTROL VALVE............................................................................264 Regulator for Clutch Pressure........................................................264 Inching Spool Assembly...............................................................264 Direction Spool......................................................................265 Modulator Circuit....................................................................266 Regulator for the Torque Converter...................................................266 MONOTROL PEDAL...........................................................................266 Start Circuit, Monotrol Pedal........................................................266 Creep Speed Switch...................................................................267 DIRECTION CONTROL LEVER..................................................................267 OIL FLOW DIAGRAMS............................................................................267 Neutral..................................................................................268 Neutral..............................................................................268 Forward..............................................................................272 Forward-Inching......................................................................274 Reverse..............................................................................276 1300752..........................................................................................278 REPAIRS......................................................................................278 GENERAL..................................................................................278 TRANSMISSION.............................................................................278 Removal..............................................................................278 Installation.........................................................................279 CLUTCH PACKS.............................................................................280 Removal and Disassembly..............................................................280 Inspection...........................................................................282 Assembly And Installation............................................................282 DIFFERENTIAL.............................................................................285 Removal And Disassembly..............................................................285 Inspection...........................................................................286 Assembly And Installation Of Original Parts..........................................286 Assembly And Installation Of New Parts...............................................287 CONTROL VALVE............................................................................295 Removal and Disassembly..............................................................295 Inspection...........................................................................295 Assembly and Installation............................................................296 MONOTROL PEDAL...........................................................................297 Removal and Disassembly..............................................................297 Assembly and Installation............................................................297 DIRECTION CONTROL LEVER..................................................................300 Removal and Disassembly..............................................................300 Assembly and Installation............................................................300 CHECKS AND ADJUSTMENTS.......................................................................301 STALL TEST...............................................................................301 ADJUST THE INCHING/BRAKE PEDAL ..........................................................301 ADJUST THE NEUTRAL START SWITCH, MONOTROL PEDAL..........................................303 TEST THE NEUTRAL START SWITCH, MONOTROL PEDAL............................................304 CHECK THE OIL PRESSURES..................................................................304 Check The Relief Valve for the Transmission Pump, TEST PORT 1........................305 Check The Reverse Clutch Pressure, TEST PORT 2.......................................305 Check The Forward Clutch Pressure, TEST PORT 3.......................................305 Check The Torque Converter Regulator, TEST PORT 4....................................305 Check The Lubrication Circuit Oil Pressure, TEST PORT 5..............................305 Check The Modulator Pressure, TEST PORT 6............................................305 TROUBLESHOOTING..............................................................................307 TROUBLESHOOTING - PRESSURE TESTS.............................................................309 1400731..........................................................................................310 INTRODUCTION.................................................................................310 GENERAL..................................................................................310 DESCRIPTION..............................................................................310 REPAIRS......................................................................................311 REMOVAL AND DISASSEMBLY..................................................................311 CLEANING AND INSPECTION..................................................................311 ASSEMBLY AND INSTALLATION................................................................312 TROUBLESHOOTING..............................................................................314 1600732..........................................................................................315 INTRODUCTION.................................................................................315 GENERAL..................................................................................315 DESCRIPTION..............................................................................315 OPERATION................................................................................315 REPAIRS......................................................................................315 STEERING WHEEL AND COLUMN ASSEMBLY.......................................................315 STEERING COLUMN ASSEMBLY.................................................................317 Removal And Disassembly..............................................................317 Assembly And Installation............................................................317 Disassembly of Steering Control Unit.................................................319 Cleaning of Steering Control Unit....................................................319 Assembly of Steering Control Unit....................................................321 CHECKS AND ADJUSTMENTS.......................................................................323 REMOVE AIR FROM THE SYSTEM...............................................................323 TROUBLESHOOTING..............................................................................324 1600733..........................................................................................325 STEERING AXLE................................................................................325 GENERAL..................................................................................325 DESCRIPTION..............................................................................325 REPAIRS......................................................................................326 STEERING AXLE............................................................................326 Removal..............................................................................326 Installation.........................................................................326 WHEELS AND HUBS..........................................................................327 Removal and Disassembly..............................................................327 Cleaning.............................................................................327 Inspection...........................................................................327 Assembly and Installation............................................................327 SPINDLES AND BEARINGS....................................................................328 Removal..............................................................................328 Cleaning.............................................................................328 Inspection...........................................................................328 Assembly and Installation............................................................328 TIE RODS.................................................................................329 Removal..............................................................................329 Cleaning.............................................................................329 Inspection...........................................................................329 Installation.........................................................................329 STEERING CYLINDER........................................................................329 Removal And Disassembly..............................................................329 Cleaning and Inspection..............................................................329 Assembly and Installation............................................................329 TROUBLESHOOTING..............................................................................331 1800734..........................................................................................332 BRAKE SYSTEM.................................................................................332 GENERAL..................................................................................332 DESCRIPTION AND OPERATION................................................................332 Brake Booster And Master Cylinder........................................................332 Service Brake Assembly...................................................................332 Parking Brake............................................................................332 REPAIRS......................................................................................333 BRAKE SHOE ASSEMBLIES....................................................................333 Removal and Disassembly..............................................................333 Cleaning and Inspection..............................................................333 Assembly and Installation............................................................335 BRAKE BOOSTER AND MASTER CYLINDER........................................................338 Removal..............................................................................338 Disassembly..........................................................................338 Cleaning and Inspection..............................................................339 Assembly.............................................................................339 Installation.........................................................................339 PARKING BRAKE............................................................................339 Removal And Disassembly..............................................................339 Assembly And Installation............................................................339 CHECKS AND ADJUSTMENTS.......................................................................340 REMOVE THE AIR FROM THE BRAKE SYSTEM.....................................................340 ADJUST THE BRAKE PEDAL...................................................................340 ADJUST THE PARKING BRAKE.................................................................340 TEST THE "PARKING BRAKE NOT APPLIED" SWITCH..............................................340 TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)......................................340 ADJUST THE BRAKE SHOES...................................................................341 TROUBLESHOOTING..............................................................................342 1900743..........................................................................................344 INTRODUCTION.................................................................................344 GENERAL..................................................................................344 DESCRIPTION AND OPERATION................................................................344 Hydraulic Pump.......................................................................345 Main Control Valve...................................................................345 Steering Control Unit................................................................345 SPECIFICATIONS...............................................................................347 TROUBLESHOOTING..............................................................................347 1900753..........................................................................................350 INTRODUCTION.................................................................................350 GENERAL..................................................................................350 DESCRIPTION..............................................................................350 OPERATION................................................................................350 REPAIRS......................................................................................351 REMOVAL..................................................................................351 DISASSEMBLY..............................................................................351 CLEANING.................................................................................352 INSPECTION...............................................................................352 ASSEMBLY.................................................................................353 INSTALLATION.............................................................................354 CHECKS AND ADJUSTMENTS.......................................................................355 CHECK THE OUTPUT OF THE PUMP.............................................................355 CHECK FOR AIR IN THE HYDRAULIC SYSTEM....................................................355 TROUBLESHOOTING..............................................................................357 4000736..........................................................................................359 VISTA ® MASTS................................................................................359 GENERAL..................................................................................359 DESCRIPTION AND OPERATION................................................................359 CARRIAGES................................................................................359 TWO-STAGE MAST WITH LIMITED FREE-LIFT....................................................359 THREE-STAGE MAST WITH FULL FREE-LIFT.....................................................360 REPAIRS......................................................................................362 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ............................................362 FORKS....................................................................................363 Forks, Removal And Installation......................................................363 CARRIAGE.................................................................................364 Removal..............................................................................364 SIDE-SHIFT CARRIAGE .....................................................................365 Removal..............................................................................365 Disassembly..........................................................................366 Assembly.............................................................................366 Installation.........................................................................367 TWO-STAGE MAST WITH LIMITED FREE-LIFT....................................................367 Removal..............................................................................367 Disassembly..........................................................................367 Cleaning and Inspection..............................................................369 Assembly.............................................................................369 Installation.........................................................................370 THREE-STAGE MAST.........................................................................370 Removal..............................................................................370 Disassembly..........................................................................370 Cleaning and Inspection..............................................................371 Assembly.............................................................................371 Installation.........................................................................372 CHECKS AND ADJUSTMENTS.......................................................................376 CHECK THE OPERATION OF THE MAST..........................................................376 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM..............................................376 Lift System..........................................................................376 Tilt System..........................................................................376 ADJUST THE TILT CYLINDER STROKE AND BACKWARD TILT ANGLE..................................377 LIFT CHAIN ADJUSTMENTS...................................................................377 MAST ADJUSTMENT..........................................................................378 CARRIAGE ADJUSTMENT......................................................................379 TROUBLESHOOTING..............................................................................381 4000741..........................................................................................383 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.................................................383 LIFT CYLINDERS...............................................................................384 GENERAL..................................................................................384 DESCRIPTION..............................................................................384 Lowering Control Valve...............................................................387 REMOVAL..................................................................................387 DISASSEMBLY..............................................................................387 ASSEMBLY.................................................................................388 INSTALLATION.............................................................................388 CHECKS AND ADJUSTMENTS.......................................................................389 CHECK FOR LEAKS IN THE LIFT SYSTEM.......................................................389 TROUBLESHOOTING..............................................................................390 8000737..........................................................................................392 PERIODIC MAINTENANCE.........................................................................392 GENERAL..................................................................................392 SERIAL NUMBER DATA.......................................................................392 HOW TO MOVE A DISABLED LIFT TRUCK........................................................392 How To Tow the Lift Truck............................................................392 HOW TO PUT A LIFT TRUCK ON BLOCKS........................................................393 How To Raise the Drive Tires.........................................................393 How To Raise the Steering Tires......................................................393 MAINTENANCE SCHEDULE.........................................................................395 MAINTENANCE PROCEDURES.......................................................................397 EVERY 8 HOURS OR DAILY.......................................................................397 HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED ..........................................397 Engine Oil...........................................................................398 Hydraulic System Oil.................................................................398 Cooling System.......................................................................398 Drive Belts..........................................................................399 Air Filter...........................................................................399 Heavy Duty Air Filter................................................................399 Fuel System..........................................................................400 Battery..............................................................................400 Tires and Wheels.....................................................................400 Forks................................................................................401 Forks, Adjustment....................................................................401 Forks, Removal And Installation......................................................401 Inspection Of Forks, Mast, and Lift Chains...........................................401 Operator Restraint System............................................................403 Safety Labels........................................................................403 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING...............................................404 Gauges, Lights, Horn, and Fuses......................................................404 Engine Oil Pressure..................................................................404 Cooling System.......................................................................404 Transmission Oil Level...............................................................404 Control Levers and Pedals............................................................405 Lift System Operation................................................................405 Inching/Brake Pedal..................................................................405 Service Brakes.......................................................................406 Parking Brake........................................................................406 Steering System......................................................................406 EVERY 350 HOURS OR TWO MONTHS................................................................407 LIFT CHAINS, LUBRICATION.................................................................407 HYDRAULIC PUMP DRIVE SHAFT...............................................................407 ENGINE OIL AND FILTER....................................................................407 DRIVE BELTS..............................................................................407 Fan Drive Belts......................................................................407 Perkins Diesel Engine....................................................................407 Alternator Drive Belt................................................................407 GM 4.3L ENGINE...........................................................................408 Serpentine Drive Belt................................................................408 HYDRAULIC TANK BREATHER, CLEAN AND CHECK.................................................409 BRAKE FLUID..............................................................................409 LIFT CHAINS, CHECK FOR WEAR..............................................................409 FORKS, CHECK FOR WEAR AND DAMAGE.........................................................409 MAST, LUBRICATION........................................................................410 CONTROL LEVERS AND PEDALS, LUBRICATION...................................................410 STEERING AXLE, LUBRICATION...............................................................410 FUEL SYSTEM, CHECKS AND ADJUSTMENTS......................................................411 LPG Carburetor.......................................................................411 Fuel Injection (Perkins Engine)......................................................411 GM V-6 Engine........................................................................411 EVERY 1000 HOURS OR SIX MONTHS...............................................................412 PCV VALVE, GM V-6........................................................................412 CRANKCASE BREATHER, GM-V6................................................................412 VALVE CLEARANCE ADJUSTMENT...............................................................412 Water Separator, Diesel Engine...........................................................412 FUEL FILTER (REPLACEMENT), DIESEL ENGINE.................................................412 REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004.42 DIESEL ENGINE ..........................413 Fuel Injection Pump With A Vent Screw................................................413 Differential And Drive Axle..........................................................413 EVERY 2000 HOURS OR YEARLY...................................................................415 THRUST SCREW FOR THE DIFFERENTIAL........................................................415 HYDRAULIC SYSTEM.........................................................................415 Replace the Hydraulic Oil and Filter.................................................415 CHANGE THE OIL AND REPLACE THE OIL FILTER................................................416 Replace the Transmission Oil And Filter..............................................416 COOLING SYSTEM...........................................................................417 WHEEL BEARINGS...........................................................................417 Steering Wheels, lubrication.........................................................417 Drive Wheels, Lubrication............................................................417 PCV VALVE, GM V-6........................................................................417 SERVICE BRAKES...........................................................................417 LPG FILTER, REPLACEMENT..................................................................418 GASOLINE FUEL FILTER, REPLACEMENT........................................................418 OPERATOR RESTRAINT SYSTEM................................................................418 GENERAL PROCEDURES...........................................................................419 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................419 LIFT CHAIN ADUSTMENTS....................................................................420 FUEL INJECTORS...........................................................................421 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM .............................................421 Check the Lift Cylinders for Leaks...................................................421 Check the Tilt Cylinders for Leaks...................................................422 WELDING REPAIRS..........................................................................422 CHANGES TO THE OVERHEAD GUARD............................................................422 WHEELS AND TIRES.........................................................................423 Remove The Wheels From The Lift Truck................................................424 Remove The Wheels From The Tire......................................................424 Install the Wheel In The Tire........................................................425 Add Air To The Tires.................................................................426 Install the Wheels...................................................................427 INSTALLATION PROCEDURES, DUAL DRIVE WHEELS...............................................427 SOLID RUBBER TIRES.......................................................................427 Remove The Tire From The Wheel.......................................................428 Install The Tire On the Wheel........................................................428 8000738..........................................................................................431 LIFT TRUCK WEIGHTS...........................................................................431 ELECTRICAL SYSTEM............................................................................431 STALL SPEEDS.................................................................................431 CAPACITIES...................................................................................431 TIRE PRESSURE................................................................................431 ENGINE SPECIFICATIONS........................................................................432 TRANSMISSION PRESSURES, SINGLE-SPEED.........................................................432 TRANSMISSION PRESSURES, TWO-SPEED............................................................433 HYDRAULIC SYSTEM.............................................................................434 MAST SPEEDS..................................................................................434 TORQUE SPECIFICATIONS........................................................................435 8000757..........................................................................................439 FIGURE 1. ELECTRICAL SCHEMATIC, PERKINS DIESEL..............................................439 FIGURE 2. ELECTRICAL SCHEMATIC, GM V-6 GASOLINE.............................................440 FIGURE 3. ELECTRICAL SCHEMATIC, GM V-6 LPG..................................................441 FIGURE 4. ELECTRICAL SCHEMATIC, GM V-6 DUAL FUEL............................................442 FIGURE 5. ELECTRICAL SCHEMATIC, OPERATOR COMPARTMENT........................................443 FIGURE 6. ELECTRICAL SCHEMATIC, TRANSMISSION................................................444 FIGURE 7. ELECTRICAL SCHEMATIC, TYPE "S" OPTION.............................................444 FIGURE 8. ELECTRICAL SCHEMATIC, LIGHT OPTIONS...............................................445 FIGURE 9. HYDRAULIC SCHEMATIC, HYDRAULIC SYSTEM.............................................446 FIGURE 11. HYDRAULIC SCHEMATIC, TWO-SPEED TRANSMISSION......................................448 FIGURE 12. OPERATOR CAB WIRING SCHEMATIC....................................................449 FIGURE 13. CAB LIGHTING SCHEMATIC...........................................................450
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