Hyster A177 (H2.00-3.00XL Europe) & A177 (H40-60XL) Repair Service Manuals
Catalog:
Model:
Complete service repair manual for Hyster A177 (H2.00-3.00XL Europe) & A177 (H40-60XL), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster A177 (H2.00-3.00XL Europe) & A177 (H40-60XL) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Hyster A177 (H2.00-3.00XL Europe) & A177 (H40-60XL) Service Manual.pdf
Total Pages: 1,121 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CAPACITIES AND SPECIFICATIONS .pdf
DIAGRAMS.pdf
ELECTRICAL WARNING DEVICES .pdf
INCH (SAE) AND METRIC FASTENERS .pdf
INSTRUMENT PANEL INDICATORS AND SENDERS .pdf
LIFT CYLINDERS .pdf
LIFT CYLINDERS_ .pdf
PERIODIC MAINTENANCE .pdf
THE BRAKE SYSTEM .pdf
THE CARBURETOR .pdf
THE COOLING SYSTEM .pdf
THE DRIVE AXLE .pdf
THE DRIVE AXLE_ .pdf
THE ELECTRICAL SYSTEM (ISUZU) .pdf
THE ELECTRICAL SYSTEM (MAZDA) .pdf
THE FRAME.pdf
THE HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY .pdf
THE ISUZU C240 ENGINE .pdf
THE LPG FUEL SYSTEM.pdf
THE MAIN CONTROL VALVE .pdf
THE MAZDA M4-121G ENGINE .pdf
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS.pdf
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS .pdf
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS _.pdf
THE STEERING AXLE .pdf
THE STEERING CONTROL UNIT .pdf
THE STEERING CONTROL UNIT_ .pdf
THE TILT CYLINDERS .pdf
UPRIGHTS - DESCRIPTION .pdf
UPRIGHTS - REPAIRS .pdf
VISTA UPRIGHTS - DESCRIPTION .pdf
VISTA UPRIGHTS - REPAIR .pdf
CAPACITIES AND SPECIFICATIONS.pdf
DIAGRAMS.pdf
ELECTRICAL WARNING DEVICES.pdf
INSTRUMENT PANEL INDICATORS AND SENDERS.pdf
LIFT CYLINDERS.pdf
MAZDA M4-121G ENGINE.pdf
METRIC AND INCH (SAE) FASTENERS.pdf
PERIODIC MAINTENANCE.pdf
THE BRAKE SYSTEM.pdf
THE CARBURETOR.pdf
THE COOLING SYSTEM.pdf
THE DRIVE AXLE.pdf
THE ELECTRICAL SYSTEM (ISUZU).pdf
THE ELECTRICAL SYSTEM (MAZDA).pdf
THE FRAME.pdf
THE HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY.pdf
THE ISUZU C240 ENGINE.pdf
THE LPG FUEL SYSTEM.pdf
THE MAIN CONTROL VALVE.pdf
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - DESCRIPTION AND OPERATION.pdf
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS.pdf
THE STEERING AXLE.pdf
THE STEERING CONTROL UNIT..pdf
THE STEERING CONTROL UNIT.pdf
THE TILT CYLINDERS.pdf
UPRIGHTS - DESCRIPTION.pdf
UPRIGHTS - REPAIRS.pdf
VISTA UPRIGHTS - DESCRIPTION.pdf
VISTA UPRIGHTS - REPAIR.pdf
A177 (H2.00-3.00XL Europe)...2
CAPACITIES AND SPECIFICATIONS ...4
LIFT TRUCK WEIGHTS*...4
ENGINE SPECIFICATIONS...4
ENGINE ELECTRICAL SPECIFICATIONS...5
HYDRAULIC SPECIFICATIONS...5
CAPACITIES...6
LIFT TRUCK TRAVEL SPEEDS...6
TIRE SPECIFICATIONS...6
MAST SPEEDS (Early A177* Units)...7
MAST SPEEDS (Later A177* Units)...7
MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)...8
MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)...8
TORQUE SPECIFICATIONS...10
TORQUE SPECIFICATIONS...11
DIAGRAMS ...13
HYDRAULIC SCHEMATIC SYMBOLS...13
HYDRAULIC SYSTEM SCHEMATIC - FOR UNITS WITH WARNER TRANSMISSION...15
HYDRAULIC SYSTEM SCHEMATIC - FOR UNITS WITH HYSTER T41, T42, T43 TRANSMISSIONS...17
TRANSMISSION HYDRAULIC SCHEMATIC - FOR UNITS WITH WARNER TRANSMISSION...18
TRANSMISSION HYDRAULIC SCHEMATIC - FOR UNITS WITH HYSTER T41, T42, T43 TRANSMISSION...19
GASOLINE/LPG ENGINE WIRING DIAGRAM (G and LPG Rating)...21
GASOLINE/LPG (SAFETY) ENGINE WIRING DIAGRAM (GS and LPS Rating)...23
GASOLINE/LPG ENGINE CABLE DIAGRAM (G and LPG Rating)...25
DIESEL ENGINE WIRING DIAGRAM (D Rating)...27
DIESEL (SAFETY) ENGINE WIRING DIAGRAM (DS Rating)...29
DIESEL ENGINE CABLE DIAGRAM (D Rating)...31
ELECTRICAL DIAGRAM, INSTRUMENT PANEL...32
ELECTRICAL WARNING DEVICES ...33
ELECTRICAL WARNING DEVICES...33
GENERAL...33
DESCRIPTION...33
Operator Controlled Horns...33
System Warning Lights, Buzzers and Bells...33
Reverse Warning Horns...34
Warning Lights...34
REPLACEMENT...35
General...35
Replacing Horns or Bells...35
Replacing Horn Relay or Buzzer...35
Replacing Warning Lights...35
Light Assemblies...36
Replacing Flashing Units...36
INCH (SAE) AND METRIC FASTENERS ...37
INTRODUCTION...37
NOMENCLATURE, THREADS...37
STRENGTH IDENTIFICATION...38
TABLE 1. BOLTS AND SCREWS...38
TABLE 2. STUDS AND NUTS...39
TABLE 3. TORQUE NUTS...40
TABLE 4. TORQUE NUTS WITH NYLON INSERT...41
TABLE 5. TORQUE VALUES FOR INCH FASTENERS...42
TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...43
INSTRUMENT PANEL INDICATORS AND SENDERS ...46
INTRODUCTION...46
GENERAL...46
DESCRIPTION...46
GENERAL...46
STEERING COLUMN GAUGES, METERS AND INDICATORS...49
LED DISPLAY PANEL...49
Battery Discharge Indicators ...49
Brush Wear Indicators...50
Motor Temperature Indicators...51
"LX" SERIES INSTRUMENT PANEL DISPLAY...52
Hourmeter Functions...53
Battery Indicator Function...53
Status Code Function...53
CHECKS AND ADJUSTMENTS...53
GENERAL...53
REPLACEMENT...54
GENERAL...54
METER REPLACEMENT...54
SENDER REPLACEMENT...55
Fuel Level Sender...55
Pressure And Temperature Sender...56
I.T.W. DISPLAY PANEL...56
Removal...56
SPECIFICATIONS...57
TROUBLESHOOTING...58
LIFT CYLINDERS ...59
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...59
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...59
LIFT CYLINDERS...62
GENERAL...62
DESCRIPTION...62
Lowering Control Valve...62
Cylinders (General)...65
Cylinders (H520-620B,H700-800A)...67
Cylinders (H360-460B)...68
Cylinders (Two-Speed)...68
REPAIRS...69
REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...69
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...69
Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...73
Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...71
DISASSEMBLY...71
ASSEMBLY...73
INSTALLATION OF THE LIFT CYLINDER IN THE MAST...73
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...73
Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead...73
CHEVRON PACKING...74
LIFT CYLINDERS FOR VISTA MASTS...77
DESCRIPTION...77
Lowering Control Valve...79
REMOVAL...80
DISASSEMBLY...80
ASSEMBLY...80
INSTALLATION...81
Main Lift Cylinders...81
Free-Lift Cylinders...81
CHECKS AND ADJUSTMENTS...82
CHECK FOR LEAKS IN LIFT SYSTEM...82
TROUBLESHOOTING...83
SPECIFICATIONS...84
LIFT CYLINDERS_ ...85
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...85
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...85
LIFT CYLINDERS...88
GENERAL...88
DESCRIPTION...88
Lowering Control Valve...88
Cylinders (General)...91
Cylinders (H520-620B,H700-800A)...93
Cylinders (H360-460B)...94
Cylinders (Two-Speed)...94
REPAIRS...95
REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...95
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...95
Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...99
Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...97
DISASSEMBLY...97
ASSEMBLY...99
INSTALLATION OF THE LIFT CYLINDER IN THE MAST...99
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...99
Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead...99
CHEVRON PACKING...100
LIFT CYLINDERS FOR VISTA MASTS...103
DESCRIPTION...103
Lowering Control Valve...105
REMOVAL...106
DISASSEMBLY...106
ASSEMBLY...106
INSTALLATION...107
Main Lift Cylinders...107
Free-Lift Cylinders...107
CHECKS AND ADJUSTMENTS...108
CHECK FOR LEAKS IN LIFT SYSTEM...108
TROUBLESHOOTING...109
SPECIFICATIONS...110
PERIODIC MAINTENANCE ...111
PERIODIC MAINTENANCE...111
GENERAL...111
Serial Number Data...111
HOW TO MOVE A DISABLED LIFT TRUCK...112
How To Tow the Lift Truck...112
HOW TO PUT A LIFT TRUCK ON BLOCKS...112
How To Raise the Drive Tires...112
How To Raise the Steering Tires...113
MAINTENANCE PROCEDURES...117
EVERY 8 HOURS OR DAILY...117
HOW TO MAKE CHECKS WITH THE ENGINE STOPPED...117
Engine Oil...117
Drive Belts...117
Cooling System...117
Battery...118
Fuel System...120
Air Filter...120
Hydraulic System Oil...120
Tires and Wheels...121
Forks...121
Forks, Adjustment...122
Forks, Removal And Installation...122
Inspection Of Forks, Mast, and Lift Chains...123
Safety Labels...124
Operator Restraint System...124
HOW TO MAKE CHECKS WITH THE ENGINE RUNNING...125
Gauges, Lights, Horn, and Fuses...125
Fuel Filter, Diesel Engine...126
How To Drain The Water From The Fuel Filter...126
Oil Level, Powershift Transmission...126
Control Levers and Pedals...126
Lift System Operation...126
Inching/Brake Pedal...127
Service Brakes...127
Parking Brake...127
Steering System...127
EVERY 250 HOURS OR TWO MONTHS...128
ENGINE OIL AND FILTER...128
Mazda, GM, And Later Production Isuzu Engines...128
Earlier Production Isuzu C240 Engines...128
GOVERNOR, MAZDA ENGINE...129
DRIVE BELTS...129
Mazda Engine...129
Isuzu, GM 4-181, And GM 4-153 Engines...129
BRAKE FLUID...130
HYDRAULIC TANK BREATHER, CLEAN AND CHECK...130
FORKS, CHECK FOR WEAR AND DAMAGE...130
LIFT CHAINS...130
Lubrication...130
Check For Wear...130
MAST, LUBRICATION...131
TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...131
CONTROL LEVERS AND PEDALS, LUBRICATION...132
FUEL SYSTEM, CHECKS AND ADJUSTMENTS...132
Idle Speed, Diesel...132
LPG Carburetor...133
Gasoline Carburetor...133
EVERY 1000 HOURS OR SIX MONTHS...134
DIESEL FUEL FILTER...134
Filter Replacement, Models Without A Water Separator...135
Filter Replacement, Models With A Water Separator...135
Remove Air from the Diesel Fuel System...135
DIFFERENTIAL...136
VALVE CLEARANCE ADJUSTMENT...136
IGNITION SYSTEM, MAZDA AND GM ENGINES...136
PCV VALVE AND FILTER...138
EVERY 2000 HOURS OR YEARLY...138
HYDRAULIC SYSTEM...138
Replace the Hydraulic Oil and Filter...138
POWERSHIFT TRANSMISSION...138
COOLING SYSTEM...139
SERVICE BRAKES...139
DIFFERENTIAL...139
WHEEL BEARINGS...140
Steering Wheels, lubrication...140
Drive Wheels, Lubrication...140
GASOLINE FUEL FILTER, REPLACEMENT...140
PCV VALVE, GM ENGINES...140
LPG FILTER, REPLACEMENT...140
FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A...140
GENERAL PROCEDURES...141
CHECK THE HOOD LATCH...141
LIFT CHAIN ADJUSTMENTS...141
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...143
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...144
Check the Lift Cylinders for Leaks...144
Check the Tilt Cylinders for Leaks...144
FUEL INJECTORS...145
WELDING REPAIRS...145
CHANGES TO THE OVERHEAD GUARD...145
WHEELS AND TIRES...145
Solid Rubber Tires (Press-on)...145
Install The Wheels...146
Pneumatic Tires, Remove The Wheels From The Lift Truck...147
Pneumatic Tires, Remove the Tire From The Wheel...147
Pneumatic Tires, Install The Wheel In The Tire...148
Pneumatic Tires, Add Air To The Tires...149
Pneumatic Tires, Install the Wheels...150
Pneumatic Tires, Installation Procedures, Dual Drive Wheels...150
SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES...151
Remove The Wheels From The Lift Truck...151
Remove The Tire From The Wheel...151
Install The Tire On The Wheel...152
REFERENCE TABLE...153
THE BRAKE SYSTEM ...154
INTRODUCTION...154
GENERAL...154
DESCRIPTION AND OPERATION...154
Service and Parking Brakes...156
REPAIRS...156
REMOVAL AND DISASSEMBLY...156
Service and Parking Brakes...156
Master Cylinder...157
CLEANING AND INSPECTION...158
ASSEMBLY AND INSTALLATION...158
Service and Parking Brakes...158
Master Cylinder...163
CHECKS AND ADJUSTMENTS...163
ADJUST THE SERVICE BRAKES...163
ADJUST THE PARKING BRAKE...164
Units with Monotrol Pedal...164
REMOVE THE AIR FROM THE BRAKE SYSTEM...165
ADJUST THE BRAKE PEDAL AND INCHING PEDAL...165
CHECK AND ADJUST THE NEUTRAL START SWITCH (Monotrol Control Only)...169
TROUBLESHOOTING...171
SPECIFICATIONS...172
THE CARBURETOR ...173
THE CARBURETOR, (MAZDA M4-121G ENGINE)...173
DESCRIPTION...173
REPAIRS, CARBURETOR...174
Removal...174
Cleaning...177
Inspection...177
Assembly...177
Installation...179
CHECKS AND ADJUSTMENTS...179
Carburetor, Idle Speed And Mixture Adjustment...179
Adjust The Governor...180
ADJUST THE THROTTLE LINKAGE...181
SPECIFICATIONS...181
TROUBLESHOOTING...182
THE COOLING SYSTEM ...184
COOLING SYSTEM...184
INTRODUCTION...184
DESCRIPTION...184
RADIATOR...184
RADIATOR CAP...184
THERMOSTAT...184
WATER PUMP...185
FAN AND FAN SHROUD ...185
REPAIRS...185
COOLING SYSTEM CHECKS...185
Exhaust Leaks...185
RADIATOR...185
Checks...185
Cleaning The Radiator...185
Drain The Cooling System...187
Fill The Cooling System...187
WATER PUMP...187
Checks...187
THERMOSTAT...188
Checks...188
FAN AND FAN SHROUD ...188
TROUBLESHOOTING...189
THE DRIVE AXLE ...190
INTRODUCTION...190
GENERAL...190
DESCRIPTION...190
REPAIRS...191
REMOVAL...191
CLEANING...191
INSPECTION...191
ASSEMBLY...191
TROUBLESHOOTING...194
SPECIFICATIONS...194
THE DRIVE AXLE_ ...195
INTRODUCTION...195
DESCRIPTION...195
GENERAL...195
REPAIRS...196
STEERING AXLE...196
Removal...196
Installation...197
STEERING CYLINDER...197
Removal...197
Service...198
Installation...198
HUBS...198
Removal...198
Installation...199
SPINDLES...199
Removal...199
Installation...200
CHECKS AND ADJUSTMENTS...200
REMOVE THE AIR FROM THE STEERING SYSTEM...200
SET THE PRESSURE RELIEF VALVE...200
S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...200
H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION...200
H2.00-3.00J (H40-60J) With Powershift Transmission...200
TROUBLESHOOTING...202
THE ELECTRICAL SYSTEM (ISUZU) ...203
INTRODUCTION...203
GENERAL...203
DESCRIPTION...203
Starting System...203
Charging System...203
Vacuum Pump On Alternator (On Units With Brake Booster)...205
REPAIRS...206
STARTER...206
Removal And Disassembly...206
Assembly And Installation...206
REPLACING GLOW PLUGS...208
ALTERNATOR (With Vaccum Pump)...208
Removal And Disassembly...208
Cleaning...210
Assembly And Installation...210
ALTERNATOR (Without Vacuum Pump)...211
Removal And Disassembly...211
Cleaning...213
Assembly And Installation...213
REGULATOR REPLACEMENT...214
CHECKS...214
GENERAL...214
STARTER...214
Starter Operation...214
Solenoid Coil Checks...215
Brush Length...215
Brush Holder...215
Armature...215
Field Windings...216
Clutch And Bearings...216
COLD START AID...216
Glow Plugs...216
Resistor...216
CHARGING CIRCUIT...216
Check For Low Output...216
Check Ford High Output...218
ALTERNATOR...218
Rotor Resistance...218
Diodes Circuit...218
Rotor Coil...219
Stator Coil...219
Diode Assembly...219
Brushes And Bearings...220
REGULATOR (At Hydraulic Tank)...220
TROUBLESHOOTING...221
THE ELECTRICAL SYSTEM (MAZDA) ...224
INTRODUCTION...224
GENERAL...224
DESCRIPTION...224
Starting System...224
Ignition System...224
Charging System...225
REPAIR...227
STARTER...227
Removal And Disassembly...227
Assembly And Installation...227
BALLAST RESISTOR RELAY (Earlier Production)...229
DISTRIBUTOR (Earlier Production With Contact Points)...229
Removal And Disassembly...229
Assembly And Installation...231
COIL REPLACEMENT...231
DISTRIBUTOR (Later Production with Electronic Ignition System)...231
Removal And Disassembly...231
Assembly And Installation...233
ALTERNATOR (All Models)...233
Removal And Disassembly...233
Assembly And Installation...234
REGULATOR REPLACEMENT (Earlier Production)...235
CHECKS AND ADJUSTMENTS...236
GENERAL...236
STARTER...236
Check Operation...236
Check Brush Length...237
Check Brush Holder...237
Armature...237
Field Windings...237
Clutch And Bearing...237
BALLAST RESISTOR RELAY (Earlier Production)...237
DISTRIBUTOR...238
Distributor Contact Clearance...238
SPARK PLUGS...239
COIL AND BALLAST RESISTOR (Earlier Production)...239
ALTERNATOR...239
Check For Low Output (Alternator With Separate Regulator)...239
Check For Low Output (Alternator With Integral Regulator)...241
Check For High Output (Alternator With Separate Regulator)...242
Check For High Output (Alternator With Integral Regulator)...242
Rotor Resistance (Alternator with Separate Regulator)...242
Diodes Circuit (Alternator with Separate Regulator)...243
Diode Assembly (Alternator With Separate Regulator)...243
Check The Diodes, Diode Trio (Alternator with Integral Regulator)...243
Check The Rectifier Bridge (Alternator with Integral Regulator)...244
Check Field Winding For The Rotor (All Alternators)...244
Check Windings In The Stator (All Alternators)...245
Brushes And Bearings...245
Check The Voltage Regulator (Alternator with Separate Regulator)...245
Check The Voltage Regulator (Alternator with Integral Regulator)...246
ADJUSTMENTS...246
TROBLESHOOTING...247
THE FRAME...249
INTRODUCTION...249
GENERAL...249
DESCRIPTION...249
REPAIRS...249
COUNTERWEIGHT...250
Removal...250
Installation...250
MUFFLER...251
HOOD...251
Removal...251
Installation...251
RADIATOR AND COOLANT SYSTEM...251
Removal...251
Installation...251
OVERHEAD GUARD...252
Removal And Installation...252
OPERATOR RESTRAINT SYSTEM...252
ENGINE REMOVAL AND INSTALLATION...253
Removal of the Engine and Transmission...253
Installation of the Engine and Transmission...257
FUEL AND HYDRAULIC TANKS...259
Inspection...259
Repairs, Small Leaks...259
Repairs, Large Leaks...259
Cleaning...259
Steam Method Of Cleaning...259
Chemical Solution Method of Cleaning...260
Additional Preparations For Repair...260
SAFETY LABELS...260
CAB...262
Cab Replacement...262
Window Replacement...262
Windshield Wipers and Heater...264
THE HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY ...265
INTRODUCTION...265
GENERAL...265
DESCRIPTION...267
Hydraulic System...267
Gear Pump Assembly...267
Flow Control Valve...268
Relief Valve (Early Model)...268
Relief Valve (Later Model)...268
OPERATION...270
Hydraulic System...270
Gear Pump...270
Flow Control Valve...270
Relief Valve (Early Model)...270
Relief Valve (Later Model)...270
REPAIR...272
GEAR PUMP ASSEMBLY...272
Removal and Disassembly...272
Assembly and Installation...273
CHECKS AND ADJUSTMENTS...273
CHECK AND ADJUST STEERING RELIEF PRESSURE...273
CHECK GEAR PUMP FOR CORRECT FLOW...274
TROUBLESHOOTING...274
THE ISUZU C240 ENGINE ...276
INTRODUCTION ...276
GENERAL ...276
DESCRIPTION ...276
FUEL SYSTEM ...277
Description ...277
Operation, Fuel Injection Pump, Model VE ...279
Operation, Fuel Injection Pump, Model PE4A ...280
Pneumatic Governor For Fuel Injection Pump, Model PE4A ...281
Inlet Manifold For Fuel Injection Pump, Model PE4A ...282
REPAIRS ...283
FUEL INJECTION PUMP (ALL MODELS) ...283
Removal ...283
Installation ...283
REMOVAL AND INSTALLATION OF THE ENGINE ...283
CYLINDER HEAD AND VALVE MECHANISM ...283
Cylinder Head, Removal ...283
Valve Guides, Replacement ...284
Cylinder Head, Inspection And Repair ...285
Combustion Chamber Plugs, Inspection And Repair ...285
Combustion Chamber Plugs, Installation ...285
Valves, Inspection And Repair ...286
Valve Seat, Inspection ...286
Valve Seat, Removal ...287
Valve Seat, Installation ...287
Valve Spring, Inspection ...287
Rocker Arms, Inspection And Assembly ...287
Installation Of The Cylinder Head ...288
TIMING GEAR CASE ...289
Removal ...289
Installation ...289
CAMSHAFT ...291
Removal ...291
Inspection ...291
Camshaft Bearings ...292
Cam Followers ...292
CAMSHAFT, INSTALLATION ...292
CRANKSHAFT AND MAIN BEARINGS ...293
Crankshaft, Removal ...293
Crankshaft, Inspection And Repair ...293
Main Bearings ...293
Pilot Bearing ...294
Crankshaft, Installation ...294
FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) ...296
Flywheel, Removal ...296
Ring Gear, Replacement ...296
Flywheel, Installation ...296
PISTONS AND CONNECTING RODS ...297
Pistons And Connecting Rods, Removal ...297
Disassembly ...297
Pistons, Inspection And Repair ...298
Piston Rings, Inspection And Repair ...298
Piston Pins, Inspection And Repair ...299
Connecting Rods, Inspection And Repair ...300
Pistons And Connecting Rods, Assembly And Installation ...300
CYLINDER BLOCK AND CYLINDER LINERS ...300
Cylinder Liners, Inspection ...300
Replacement Of A Cylinder Liner ...301
LUBRICATION SYSTEM ...302
Oil Pump, Removal And Disassembly ...302
Oil Pump, Inspection ...302
Oil Pump, Assembly And Installation ...303
Oil Filter ...303
COOLING SYSTEM ...304
Coolant Pump, Removal ...304
Coolant Pump, Disassembly ...304
Coolant Pump, Assembly And Installation ...304
Thermostat, Replacement ...305
CHECKS AND ADJUSTMENTS ...305
VALVE CLEARANCE ADJUSTMENT ...305
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ...306
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A ...307
FUEL INJECTORS ...307
Fuel Injectors, Removal ...308
Fuel Injectors, Inspection ...308
Fuel Injectors, Installation ...309
DIESEL FUEL FILTERS ...309
Filter Replacement, Models With A Water Separator ...309
Filter Replacement, Models Without A Water Separator ...310
Filter For The Fuel Injection Pump, Model PE4A ...310
REMOVE AIR FROM THE FUEL SYSTEM ...310
Throttle Linkage, Adjustment ...311
Idle Speed, Adjustment ...311
Check The Elements For The Cold Start Aid System ...311
ENGINE SPECIFICATIONS ...311
TORQUE SPECIFICATIONS ...313
THE LPG FUEL SYSTEM...314
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)...314
GENERAL...314
DESCRIPTION...314
Fuel Tank...315
Fuel Filter And Fuel Valve Unit...316
Vaporizer...316
The IMPCO CA 100 Carbureto...318
IMPCO CA 50 Carburetor...320
The Governor (GM Engines Only)...321
Governor With Electronic Controller...322
REPAIRS...323
LPG TANK...323
Removal...323
Installation...324
REPLACE THE HOSES...324
HYDROSTATIC RELIEF VALVE...324
Removal and Installation...324
FILTER UNIT...325
Replacement Of the Fuel Filter Element...325
Replacement of the Diaphragm and Fuel Valve...326
VAPORIZER...326
Removal...326
Disassembly...326
Cleaning...326
Inspection...326
Assembly...328
Installation...328
CARBURETOR (IMPCO CA 100)...330
Removal...330
Disassembly...330
Cleaning...330
Assembly...330
Installation...333
CARBURETER (IMPCO CA 50)...332
Removal...332
Disassembly...332
Cleaning...333
Inspection...333
Assembly (See FIGURE 26.)...333
Installation...333
CHECKS AND ADJUSTMENTS...334
CHECK THE FILTER UNIT...334
CHECK THE VAPORIZER...334
Pressure Reducer Valve...334
Vapor Valve...334
ADJUST THE CARBURETOR...334
Idle Mixture...334
Idle Speed...334
Power Mixture...334
ADJUST THE GOVERNOR (GM Engines Only)...335
Checks...335
Main Adjusting Screw...335
Secondary Adjusting Screw...335
AISAN Governor...336
Adjustment, AISAN Governor...336
TROUBLESHOOTING...337
THE MAIN CONTROL VALVE ...341
INTRODUCTION...341
GENERAL...341
DESCRIPTION...341
OPERATION...342
Lift Section...343
Tilt Section...343
Relief Valve...345
SOLENOID VALVE FOR AUXILIARY FUNCTION...346
Operation...346
REPAIRS...346
MAIN CONTROL VALVE...346
Removal and Disassembly...346
Cleaning and Inspection...347
Assembly...347
Installation...347
SOLENOID VALVE FOR AUXILIARY FUNCTION...347
Removal and Disassembly...347
Assembly and Installation...349
CHECKS AND ADJUSTMENTS...349
PRESSURE RELIEF VALVES...349
Primary Relief Valve...349
Seconday Relief Valve...350
CONTROL LEVER ARRANGEMENT...350
TROUBLESHOOTING...353
SPECIFICATIONS...355
THE MAZDA M4-121G ENGINE ...356
MAZDA M4-121G ENGINE...356
GENERAL...356
DESCRIPTION...357
REMOVAL AND INSTALLATION OF THE ENGINE...357
CYLINDER HEAD AND VALVE MECHANISM...357
Cylinder Head, Removal...357
Cylinder Head, Inspection and Repairs...358
Rocker Arm Assembly...358
Valve Guides...358
Valve Seats...359
Valves...359
Valve Springs...359
Cylinder Head, Installation...359
TIMING GEAR CASE, REMOVAL...360
TIMING GEAR CASE, INSTALLATION...361
CAMSHAFT...361
Removal...361
Inspection...362
Cam Followers, Inspection...362
Installation...362
CRANKSHAFT AND MAIN BEARINGS...362
Crankshaft, Removal...362
Crankshaft, Inspection And Repair...363
Main Bearings...364
Crankshaft, Installation...364
PISTONS AND CONNECTING RODS...365
Removal...365
Disassembly...365
Pistons, Inspection And Repair...365
Piston Rings...366
Piston Pin and Bushing...366
Connecting Rods and Bearings, Inspection...366
Pistons and Connecting Rods, Assembly...366
Pistons and Connecting Rods, Installation...367
CYLINDER BLOCK AND CYLINDER LINERS...367
Cylinder Block, Repairs...367
Cylinder Liners...367
DISTRIBUTOR...368
Removal...368
Installation...368
OIL PUMP...370
Removal...370
Repairs...370
Installation...371
GOVERNOR...371
Description...371
Removal...371
Disassembly...372
Assembly...373
Installation...374
COOLANT PUMP...374
Removal...374
Disassembly and Repair...375
Assembly...375
Installation...376
FLYWHEEL...376
Repairs...376
Installation...376
CHECKS AND ADJUSTMENTS...376
ADJUST THE VALVES...376
ADJUST THE THROTTLE LINKAGE...377
ENGINE SPECIFICATIONS...377
ENGINE SPECIFICATIONS...377
Engine Data...377
Cooling System...377
Cylinder Head and Valve Mechanism...377
Camshaft...379
Timing Gear...380
Camshaft...380
Connecting Rods...380
Cylinder Liners...380
Pistons...380
Lubrication System...381
Fuel Pump...381
TORQUE SPECIFICATIONS...382
TROUBLESHOOTING...383
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS ...387
INTRODUCTION...387
General...387
DESCRIPTION AND OPERATION...387
General...387
Torque Converter...388
Description...388
Operation...388
Clutch Assemblies...390
Description...390
Operation...391
Hydraulic System...391
General...391
Oil Pump and Front Cover...392
Torque Converter Regulator...392
Oil Cooler By-Pass...392
Control Valve...392
General...392
Differential...397
Oil Flow Diagrams...398
Neutral...398
Forward...400
Forward-Inching...402
Reverse...404
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS _...406
INTRODUCTION...406
GENERAL...406
DESCRIPTION AND OPERATION...407
GENERAL...407
TORQE CONVERTER...407
Description...407
Operation...407
CLUTCH ASSEMBLIES...410
Description...410
Operation...412
HYDRAULIC SYSTEM...412
General...412
CONTROL VALVE...412
Regulator for Clutch Pressure...415
Inching Spool Assembly...415
Direction Spool...415
MONOTROL Control Valve...415
Neutral Start Switch, MONOTROL Pedal Only...416
Neutral Start Switch, Direction Control Lever Only...416
Modulator Circuit...416
Regulator for the Toruqe Converter...417
By-Pass Valve for the Oil Cooler...417
DIFFERENTIAL...418
OIL FLOW DIAGRAMS...418
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS...427
INTRODUCTION...427
GENERAL...427
REPAIRS...429
REPAIRS...429
Torque Converter, Removal...429
Torque Converter, Installation...429
Front Cover And Transmission Pump, Removal and Disassembly...430
Front Cover And Transmission Pump, Assembly and Installation...430
Clutch Assemblies, Removal and Disassembly...431
Clutch Assemblies, Inspection...434
Clutch Assemblies, Assembly and Installation...435
Differential, Removal and Disassembly...438
Differential, Inspection...440
Differential, Assembly And Installation...440
CONTROL VALVE...450
Control Valve, Removal and Disassembly...450
Control Valve, Inspection...450
Control Valve, Assembly and Installation...452
MONOTROL Pedal, Removal and Disassembly...454
MONOTROL Pedal, Assembly and Installation...454
CHECKS AND ADJUSTMENTS...456
Stall Test...456
Adjustment Of The Direction Control Linkage...457
Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1)...458
Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)...461
Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)...462
Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)...463
Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)...467
Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)...468
Check The Oil Pressures...468
Check The Relief Valve for the Transmission Pump...468
Check The Clutch Pressure...468
Check The Torque Converter Regulator...469
Check The Oil Pressure from the Oil Cooler...469
Check The Modulator Pressure...470
TROUBLESHOOTING...470
TROUBLESHOOTING, PRESSURE TESTS...472
THE STEERING AXLE ...475
INTRODUCTION...475
DESCRIPTION...475
GENERAL...475
REPAIRS...476
STEERING AXLE...476
Removal...476
Installation...477
STEERING CYLINDER...477
Removal...477
Service...478
Installation...478
HUBS...478
Removal...478
Installation...479
SPINDLES...479
Removal...479
Installation...480
CHECKS AND ADJUSTMENTS...480
REMOVE THE AIR FROM THE STEERING SYSTEM...480
SET THE PRESSURE RELIEF VALVE...480
S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...480
H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION...480
H2.00-3.00J (H40-60J) With Powershift Transmission...480
TROUBLESHOOTING...482
THE STEERING CONTROL UNIT ...483
INTRODUCTION...483
GENERAL...483
DESCRIPTION...483
OPERATION...483
REPAIRS...483
STEERING WHEEL AND COLUMN ASSEMBLY...483
TYPE "A" STEERING COLUMN ASSEMBLY...485
Removal And Disassembly...485
Assembly And Installation...485
TYPE "A" STEERING COLUMN...486
TYPE "A" STEERING COLUMN...487
TYPE "B" STEERING COLUMN...488
Removal And Disassembly...488
Assembly And Installation...488
TYPE "B" STEERING COLUMN...489
Disassembly of Steering Control Unit...490
Cleaning of Steering Control Unit...490
Assembly of Steering Control Unit...492
CHECKS AND ADJUSTMENTS...495
REMOVE AIR FROM THE SYSTEM...495
TROUBLESHOOTING...496
THE STEERING CONTROL UNIT_ ...497
INTRODUCTION...497
General...497
Description and Operation...497
REPAIRS...500
Removal...500
Disassembly...501
Inspection...505
Assembly...508
Installation...517
CHECKS AND ADJUSTMENTS...517
Adjusting the Rotary Spool...517
Removing the Air from the System...518
Checking the Steering Hydraulic System...519
TROUBLESHOOTING...527
THE TILT CYLINDERS ...530
INTRODUCTION...533
GENERAL...533
DESCRIPTION...533
REPAIRS...533
REMOVAL...533
DISASSEMBLY...533
CLEANING...533
ASSEMBLY...533
Tilt Cylinders for the XM and XMS Models...533
Tilt Cylinders with O-Ring or Single Lip Seals...535
Tilt Cylinders for H700-800A and Early Model H700-920B...535
INSTALLATION...535
Tilt Cylinders with Chevron Packing...535
CHECKS AND ADJUSTMENTS...539
CHECK THE TILT CYLINDERS FOR LEAKS...539
ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...539
TROUBLESHOOTING...542
UPRIGHTS - DESCRIPTION ...545
INTRODUCTION...545
GENERAL...545
DESCRIPTION...545
Upright Assembly...545
Upright Mounts...546
Carriage...547
OPERATION...547
Standard Upright...547
Three Stage Uprights...547
UPRIGHTS - REPAIRS ...550
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...550
INTRODUCTION...551
GENERAL...551
REPAIR...551
Forks...551
Forks, Adjustment...551
Forks, Removal And Installation...552
Hook Fork, Removal...552
Hook Fork, Installation...552
CARRIAGE...552
Removal...552
Installation...553
MAST...553
Removal...553
Disassembly, Standard Mast...554
Disassembly, Three-Stage Mast...554
Cleaning And Inspection...558
Assembly...559
Installation...559
SIDE-SHIFT CARRIAGE...559
Removal...559
Repairs...561
Installation...561
CHECKS AND ADJUSTMENTS...561
Check For Leaks In The Lift Sytem...561
Leakage Outside the Hydraulic Lift System...561
Leakage Inside the Hydraulic Lift System...561
Check the lift cylinder for inside leakage...561
Check For Leaks In The Tilt System...561
ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...561
LIFT CHAIN ADJUSTMENTS...562
MAST ADJUSTMENTS...563
CARRIAGE ADJUSTMENT...564
HEADER HOSE ARRANGEMENT...564
Three-Stage Header Hoses...564
TROUBLESHOOTING...566
VISTA UPRIGHTS - DESCRIPTION ...567
INTRODUCTION...567
GENERAL...567
VISTA TWO-STAGE MASTS...569
DESCRIPTION...569
OPERATION...572
VISTA THREE-STAGE MASTS...572
DESCRIPTION...572
OPERATION...574
SEQUENCE VALVE...576
VISTA UPRIGHTS - REPAIR ...579
INTRODUCTION...579
GENERAL...579
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...579
REPAIRS...580
FORKS...580
Removal...580
CARRIAGE...580
Removal (Two-Stage and Later Production Three-Stage Carriages)...580
Removal (Carriages with Removable Stop Block)...581
Installation (Two-Stage and Later Production Three-Stage Carriages)...582
Installation (Carriages With Removable Stop Block)...582
TWO-STAGE MASTS...584
REMOVAL...584
DISASSEMBLY...585
CLEANING AND INSPECTION...586
ASSEMBLY...587
INSTALLATION...588
THREE-STAGE MASTS...588
REMOVAL...588
DISASSEMBLY...588
CLEANING AND INSPECTION...590
ASSEMBLY...590
INSTALLATION...591
LIFT AND TILT CYLINDERS...592
SIDE SHIFT CARRIAGE...592
Removal...592
Repairs...592
Installation...592
SEQUENCE VALVE...593
Removal and Disassembly...596
Cleaning...596
Assembly and Installation...596
CHECKS AND ADJUSTMENTS...597
CHECKING FOR LEAKS IN THE LIFT SYSTEM...597
ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...597
LIFTING CHAIN ADJUSTMENTS...598
MAST ADJUSTMENTS...599
CARRIAGE ADJUSTMENT...600
HEADER HOSE ROLLER ADJUSTMENT, 2-STAGE...601
TROUBLESHOOTING...602
TORQUE SPECIFICATIONS...603
VISTA MASTS...604
A177 (H40-60XL)...605
CAPACITIES AND SPECIFICATIONS...606
LIFT TRUCK WEIGHTS*...606
ENGINE SPECIFICATIONS...606
ENGINE ELECTRICAL SPECIFICATIONS...607
HYDRAULIC SPECIFICATIONS...607
CAPACITIES...608
LIFT TRUCK TRAVEL SPEEDS...608
TIRE SPECIFICATIONS...608
MAST SPEEDS (Early A177* Units)...609
MAST SPEEDS (Later A177* Units)...609
MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)...610
MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)...610
TORQUE SPECIFICATIONS...612
TORQUE SPECIFICATIONS...613
DIAGRAMS...615
HYDRAULIC SCHEMATIC SYMBOLS...615
HYDRAULIC SYSTEM SCHEMATIC - FOR UNITS WITH WARNER TRANSMISSION...617
HYDRAULIC SYSTEM SCHEMATIC - FOR UNITS WITH HYSTER T41, T42, T43 TRANSMISSIONS...619
TRANSMISSION HYDRAULIC SCHEMATIC - FOR UNITS WITH WARNER TRANSMISSION...620
TRANSMISSION HYDRAULIC SCHEMATIC - FOR UNITS WITH HYSTER T41, T42, T43 TRANSMISSION...621
GASOLINE/LPG ENGINE WIRING DIAGRAM (G and LPG Rating)...623
GASOLINE/LPG (SAFETY) ENGINE WIRING DIAGRAM (GS and LPS Rating)...625
GASOLINE/LPG ENGINE CABLE DIAGRAM (G and LPG Rating)...627
DIESEL ENGINE WIRING DIAGRAM (D Rating)...629
DIESEL (SAFETY) ENGINE WIRING DIAGRAM (DS Rating)...631
DIESEL ENGINE CABLE DIAGRAM (D Rating)...633
ELECTRICAL DIAGRAM, INSTRUMENT PANEL...634
ELECTRICAL WARNING DEVICES...635
ELECTRICAL WARNING DEVICES...635
GENERAL...635
DESCRIPTION...635
Operator Controlled Horns...635
System Warning Lights, Buzzers and Bells...635
Reverse Warning Horns...636
Warning Lights...636
REPLACEMENT...637
General...637
Replacing Horns or Bells...637
Replacing Horn Relay or Buzzer...637
Replacing Warning Lights...637
Light Assemblies...638
Replacing Flashing Units...638
INSTRUMENT PANEL INDICATORS AND SENDERS...639
INTRODUCTION...639
GENERAL...639
DESCRIPTION...639
GENERAL...639
STEERING COLUMN GAUGES, METERS AND INDICATORS...642
LED DISPLAY PANEL...642
Battery Discharge Indicators...642
Brush Wear Indicators...643
Motor Temperature Indicators...644
"LX" SERIES DISPLAY PANEL...645
Hourmeter Functions...646
Battery Indicator Function...646
Status Code Function...646
"ZX" SERIES DISPLAY PANELS...646
Display Panel...647
Basic Display Panels...647
Performance Display...649
Brush Wear Indicators...652
CHECKS AND ADJUSTMENTS...652
GENERAL...652
REPLACEMENT...653
GENERAL...653
METER REPLACEMENT...653
SENDER REPLACEMENT...654
Fuel Level Sender...654
Pressure And Temperature Sender...654
I.T.W. DISPLAY PANEL...655
Removal...655
DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT...656
Removal...656
Replacing Display Panel Assembly...656
Indicator LEDs...656
Battery Indicators...656
Digital Display (Performance Disply Panel Only)...656
Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)...656
Replacing Parts Of The Basic Display Panel...657
Replacing Parts Of The Performance Display Panel...659
DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT...659
Removal And Replacement...659
SPECIFICATIONS...660
TROUBLESHOOTING...661
LIFT CYLINDERS...662
Safety Procedures When Working Near Mast...664
General...669
Description...669
Lowering Control Valve...669
Cylinders (General)...672
Cylinders (H520-620B, H700-800A)...672
Retainer, Install...672
Cylinders (H360-460B)...674
Cylinders (Two-Speed)...677
Lift Cylinder Repair...678
Lift Cylinder Removal Without Removing Mast...678
Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast...678
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...679
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder...680
Disasemble...680
Assemble...680
Lift Cylinder Installation in Mast...682
Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast...682
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...682
Chevron-Style Packing...682
Chevron-Style Packing Installation on Piston...683
Chevron-Style Packing Installation in Packing Gland...685
Lift Cylinders for Vista Masts...686
Description...686
Lowering Control Valve...686
Remove...688
Disassemble...689
Assemble...690
Install...691
Main Lift Cylinders...691
Free-Lift Cylinder...691
Lift System Leak Check...691
Specifications...692
Troubleshooting...693
MAZDA M4-121G ENGINE...696
MAZDA M4-121G ENGINE...696
GENERAL...696
DESCRIPTION...697
REMOVAL AND INSTALLATION OF THE ENGINE...697
CYLINDER HEAD AND VALVE MECHANISM...697
Cylinder Head, Removal...697
Cylinder Head, Inspection and Repairs...698
Rocker Arm Assembly...698
Valve Guides...698
Valve Seats...699
Valves...699
Valve Springs...699
Cylinder Head, Installation...699
TIMING GEAR CASE, REMOVAL...700
TIMING GEAR CASE, INSTALLATION...701
CAMSHAFT...701
Removal...701
Inspection...702
Cam Followers, Inspection...702
Installation...702
CRANKSHAFT AND MAIN BEARINGS...702
Crankshaft, Removal...702
Crankshaft, Inspection And Repair...703
Main Bearings...704
Crankshaft, Installation...704
PISTONS AND CONNECTING RODS...705
Removal...705
Disassembly...705
Pistons, Inspection And Repair...705
Piston Rings...706
Piston Pin and Bushing...706
Connecting Rods and Bearings, Inspection...706
Pistons and Connecting Rods, Assembly...706
Pistons and Connecting Rods, Installation...707
CYLINDER BLOCK AND CYLINDER LINERS...707
Cylinder Block, Repairs...707
Cylinder Liners...707
DISTRIBUTOR...708
Removal...708
Installation...708
OIL PUMP...710
Removal...710
Repairs...710
Installation...711
GOVERNOR...711
Description...711
Removal...711
Disassembly...712
Assembly...713
Installation...714
COOLANT PUMP...714
Removal...714
Disassembly and Repair...715
Assembly...715
Installation...716
FLYWHEEL...716
Repairs...716
Installation...716
CHECKS AND ADJUSTMENTS...716
ADJUST THE VALVES...716
ADJUST THE THROTTLE LINKAGE...717
ENGINE SPECIFICATIONS...717
ENGINE SPECIFICATIONS...717
Engine Data...717
Cooling System...717
Cylinder Head and Valve Mechanism...717
Camshaft...719
Timing Gear...720
Camshaft...720
Connecting Rods...720
Cylinder Liners...720
Pistons...720
Lubrication System...721
Fuel Pump...721
TORQUE SPECIFICATIONS...722
TROUBLESHOOTING...723
METRIC AND INCH (SAE) FASTENERS...727
General...729
Nomenclature, Threads...729
Strength Identification...730
Fastener Torque Tables...734
Conversion Table...736
PERIODIC MAINTENANCE...738
PERIODIC MAINTENANCE...738
GENERAL...738
Serial Number Data...738
HOW TO MOVE A DISABLED LIFT TRUCK...739
How To Tow the Lift Truck...739
HOW TO PUT A LIFT TRUCK ON BLOCKS...739
How To Raise the Drive Tires...739
How To Raise the Steering Tires...740
MAINTENANCE PROCEDURES...744
EVERY 8 HOURS OR DAILY...744
HOW TO MAKE CHECKS WITH THE ENGINE STOPPED...744
Engine Oil...744
Drive Belts...744
Cooling System...744
Battery...745
Fuel System...747
Air Filter...747
Hydraulic System Oil...747
Tires and Wheels...748
Forks...748
Forks, Adjustment...749
Forks, Removal And Installation...749
Inspection Of Forks, Mast, and Lift Chains...750
Safety Labels...751
Operator Restraint System...751
HOW TO MAKE CHECKS WITH THE ENGINE RUNNING...752
Gauges, Lights, Horn, and Fuses...752
Fuel Filter, Diesel Engine...753
How To Drain The Water From The Fuel Filter...753
Oil Level, Powershift Transmission...753
Control Levers and Pedals...753
Lift System Operation...753
Inching/Brake Pedal...754
Service Brakes...754
Parking Brake...754
Steering System...754
EVERY 250 HOURS OR TWO MONTHS...755
ENGINE OIL AND FILTER...755
Mazda, GM, And Later Production Isuzu Engines...755
Earlier Production Isuzu C240 Engines...755
GOVERNOR, MAZDA ENGINE...756
DRIVE BELTS...756
Mazda Engine...756
Isuzu, GM 4-181, And GM 4-153 Engines...756
BRAKE FLUID...757
HYDRAULIC TANK BREATHER, CLEAN AND CHECK...757
FORKS, CHECK FOR WEAR AND DAMAGE...757
LIFT CHAINS...757
Lubrication...757
Check For Wear...757
MAST, LUBRICATION...758
TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...758
CONTROL LEVERS AND PEDALS, LUBRICATION...759
FUEL SYSTEM, CHECKS AND ADJUSTMENTS...759
Idle Speed, Diesel...759
LPG Carburetor...760
Gasoline Carburetor...760
EVERY 1000 HOURS OR SIX MONTHS...761
DIESEL FUEL FILTER...761
Filter Replacement, Models Without A Water Separator...762
Filter Replacement, Models With A Water Separator...762
Remove Air from the Diesel Fuel System...762
DIFFERENTIAL...763
VALVE CLEARANCE ADJUSTMENT...763
IGNITION SYSTEM, MAZDA AND GM ENGINES...763
PCV VALVE AND FILTER...765
EVERY 2000 HOURS OR YEARLY...765
HYDRAULIC SYSTEM...765
Replace the Hydraulic Oil and Filter...765
POWERSHIFT TRANSMISSION...765
COOLING SYSTEM...766
SERVICE BRAKES...766
DIFFERENTIAL...766
WHEEL BEARINGS...767
Steering Wheels, lubrication...767
Drive Wheels, Lubrication...767
GASOLINE FUEL FILTER, REPLACEMENT...767
PCV VALVE, GM ENGINES...767
LPG FILTER, REPLACEMENT...767
FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A...767
GENERAL PROCEDURES...768
CHECK THE HOOD LATCH...768
LIFT CHAIN ADJUSTMENTS...768
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...770
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...771
Check the Lift Cylinders for Leaks...771
Check the Tilt Cylinders for Leaks...771
FUEL INJECTORS...772
WELDING REPAIRS...772
CHANGES TO THE OVERHEAD GUARD...772
WHEELS AND TIRES...772
Solid Rubber Tires (Press-on)...772
Install The Wheels...773
Pneumatic Tires, Remove The Wheels From The Lift Truck...774
Pneumatic Tires, Remove the Tire From The Wheel...774
Pneumatic Tires, Install The Wheel In The Tire...775
Pneumatic Tires, Add Air To The Tires...776
Pneumatic Tires, Install the Wheels...777
Pneumatic Tires, Installation Procedures, Dual Drive Wheels...777
SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES...778
Remove The Wheels From The Lift Truck...778
Remove The Tire From The Wheel...778
Install The Tire On The Wheel...779
REFERENCE TABLE...780
THE BRAKE SYSTEM...781
INTRODUCTION...781
GENERAL...781
DESCRIPTION AND OPERATION...781
Service and Parking Brakes...783
REPAIRS...783
REMOVAL AND DISASSEMBLY...783
Service and Parking Brakes...783
Master Cylinder...784
CLEANING AND INSPECTION...785
ASSEMBLY AND INSTALLATION...785
Service and Parking Brakes...785
Master Cylinder...790
CHECKS AND ADJUSTMENTS...790
ADJUST THE SERVICE BRAKES...790
ADJUST THE PARKING BRAKE...791
Units with Monotrol Pedal...791
REMOVE THE AIR FROM THE BRAKE SYSTEM...792
ADJUST THE BRAKE PEDAL AND INCHING PEDAL...792
CHECK AND ADJUST THE NEUTRAL START SWITCH (Monotrol Control Only)...796
TROUBLESHOOTING...798
SPECIFICATIONS...799
THE CARBURETOR...800
THE CARBURETOR, (MAZDA M4-121G ENGINE)...800
DESCRIPTION...800
REPAIRS, CARBURETOR...801
Removal...801
Cleaning...804
Inspection...804
Assembly...804
Installation...806
CHECKS AND ADJUSTMENTS...806
Carburetor, Idle Speed And Mixture Adjustment...806
Adjust The Governor...807
ADJUST THE THROTTLE LINKAGE...808
SPECIFICATIONS...808
TROUBLESHOOTING...809
THE COOLING SYSTEM...811
General...813
Description...814
Radiator...814
Radiator Cap...814
Thermostat...814
Water Pump...815
Fan and Fan Shroud...815
Cooling System Checks...815
Radiator...815
Thermostat...815
Water Pump...816
Exhaust Leaks...816
Fan and Fan Shroud...816
Radiator Cleaning...816
Drain...816
Clean...816
Fill...817
Troubleshooting...818
THE DRIVE AXLE...820
INTRODUCTION...820
GENERAL...820
DESCRIPTION...820
REPAIRS...821
REMOVAL...821
CLEANING...821
INSPECTION...821
ASSEMBLY...821
TROUBLESHOOTING...824
SPECIFICATIONS...824
THE ELECTRICAL SYSTEM (ISUZU)...825
INTRODUCTION...825
GENERAL...825
DESCRIPTION...825
Starting System...825
Charging System...825
Vacuum Pump On Alternator (On Units With Brake Booster)...827
REPAIRS...828
STARTER...828
Removal And Disassembly...828
Assembly And Installation...828
REPLACING GLOW PLUGS...830
ALTERNATOR (With Vaccum Pump)...830
Removal And Disassembly...830
Cleaning...832
Assembly And Installation...832
ALTERNATOR (Without Vacuum Pump)...833
Removal And Disassembly...833
Cleaning...835
Assembly And Installation...835
REGULATOR REPLACEMENT...836
CHECKS...836
GENERAL...836
STARTER...836
Starter Operation...836
Solenoid Coil Checks...837
Brush Length...837
Brush Holder...837
Armature...837
Field Windings...838
Clutch And Bearings...838
COLD START AID...838
Glow Plugs...838
Resistor...838
CHARGING CIRCUIT...838
Check For Low Output...838
Check Ford High Output...840
ALTERNATOR...840
Rotor Resistance...840
Diodes Circuit...840
Rotor Coil...841
Stator Coil...841
Diode Assembly...841
Brushes And Bearings...842
REGULATOR (At Hydraulic Tank)...842
TROUBLESHOOTING...843
THE ELECTRICAL SYSTEM (MAZDA)...846
INTRODUCTION...846
GENERAL...846
DESCRIPTION...846
Starting System...846
Ignition System...846
Charging System...847
REPAIR...849
STARTER...849
Removal And Disassembly...849
Assembly And Installation...849
BALLAST RESISTOR RELAY (Earlier Production)...851
DISTRIBUTOR (Earlier Production With Contact Points)...851
Removal And Disassembly...851
Assembly And Installation...853
COIL REPLACEMENT...853
DISTRIBUTOR (Later Production with Electronic Ignition System)...853
Removal And Disassembly...853
Assembly And Installation...855
ALTERNATOR (All Models)...855
Removal And Disassembly...855
Assembly And Installation...856
REGULATOR REPLACEMENT (Earlier Production)...857
CHECKS AND ADJUSTMENTS...858
GENERAL...858
STARTER...858
Check Operation...858
Check Brush Length...859
Check Brush Holder...859
Armature...859
Field Windings...859
Clutch And Bearing...859
BALLAST RESISTOR RELAY (Earlier Production)...859
DISTRIBUTOR...860
Distributor Contact Clearance...860
SPARK PLUGS...861
COIL AND BALLAST RESISTOR (Earlier Production)...861
ALTERNATOR...861
Check For Low Output (Alternator With Separate Regulator)...861
Check For Low Output (Alternator With Integral Regulator)...863
Check For High Output (Alternator With Separate Regulator)...864
Check For High Output (Alternator With Integral Regulator)...864
Rotor Resistance (Alternator with Separate Regulator)...864
Diodes Circuit (Alternator with Separate Regulator)...865
Diode Assembly (Alternator With Separate Regulator)...865
Check The Diodes, Diode Trio (Alternator with Integral Regulator)...865
Check The Rectifier Bridge (Alternator with Integral Regulator)...866
Check Field Winding For The Rotor (All Alternators)...866
Check Windings In The Stator (All Alternators)...867
Brushes And Bearings...867
Check The Voltage Regulator (Alternator with Separate Regulator)...867
Check The Voltage Regulator (Alternator with Integral Regulator)...868
ADJUSTMENTS...868
TROBLESHOOTING...869
THE FRAME...871
INTRODUCTION...871
GENERAL...871
DESCRIPTION...871
REPAIRS...871
COUNTERWEIGHT...872
Removal...872
Installation...872
MUFFLER...873
HOOD...873
Removal...873
Installation...873
RADIATOR AND COOLANT SYSTEM...873
Removal...873
Installation...873
OVERHEAD GUARD...874
Removal And Installation...874
OPERATOR RESTRAINT SYSTEM...874
ENGINE REMOVAL AND INSTALLATION...875
Removal of the Engine and Transmission...875
Installation of the Engine and Transmission...879
FUEL AND HYDRAULIC TANKS...881
Inspection...881
Repairs, Small Leaks...881
Repairs, Large Leaks...881
Cleaning...881
Steam Method Of Cleaning...881
Chemical Solution Method of Cleaning...882
Additional Preparations For Repair...882
SAFETY LABELS...882
CAB...884
Cab Replacement...884
Window Replacement...884
Windshield Wipers and Heater...886
THE HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY...887
INTRODUCTION...887
GENERAL...887
DESCRIPTION...889
Hydraulic System...889
Gear Pump Assembly...889
Flow Control Valve...890
Relief Valve (Early Model)...890
Relief Valve (Later Model)...890
OPERATION...892
Hydraulic System...892
Gear Pump...892
Flow Control Valve...892
Relief Valve (Early Model)...892
Relief Valve (Later Model)...892
REPAIR...894
GEAR PUMP ASSEMBLY...894
Removal and Disassembly...894
Assembly and Installation...895
CHECKS AND ADJUSTMENTS...895
CHECK AND ADJUST STEERING RELIEF PRESSURE...895
CHECK GEAR PUMP FOR CORRECT FLOW...896
TROUBLESHOOTING...896
THE ISUZU C240 ENGINE...898
INTRODUCTION ...898
GENERAL ...898
DESCRIPTION ...898
FUEL SYSTEM ...899
Description ...899
Operation, Fuel Injection Pump, Model VE ...901
Operation, Fuel Injection Pump, Model PE4A ...902
Pneumatic Governor For Fuel Injection Pump, Model PE4A ...903
Inlet Manifold For Fuel Injection Pump, Model PE4A ...904
REPAIRS ...905
FUEL INJECTION PUMP (ALL MODELS) ...905
Removal ...905
Installation ...905
REMOVAL AND INSTALLATION OF THE ENGINE ...905
CYLINDER HEAD AND VALVE MECHANISM ...905
Cylinder Head, Removal ...905
Valve Guides, Replacement ...906
Cylinder Head, Inspection And Repair ...907
Combustion Chamber Plugs, Inspection And Repair ...907
Combustion Chamber Plugs, Installation ...907
Valves, Inspection And Repair ...908
Valve Seat, Inspection ...908
Valve Seat, Removal ...909
Valve Seat, Installation ...909
Valve Spring, Inspection ...909
Rocker Arms, Inspection And Assembly ...909
Installation Of The Cylinder Head ...910
TIMING GEAR CASE ...911
Removal ...911
Installation ...911
CAMSHAFT ...913
Removal ...913
Inspection ...913
Camshaft Bearings ...914
Cam Followers ...914
CAMSHAFT, INSTALLATION ...914
CRANKSHAFT AND MAIN BEARINGS ...915
Crankshaft, Removal ...915
Crankshaft, Inspection And Repair ...915
Main Bearings ...915
Pilot Bearing ...916
Crankshaft, Installation ...916
FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) ...918
Flywheel, Removal ...918
Ring Gear, Replacement ...918
Flywheel, Installation ...918
PISTONS AND CONNECTING RODS ...919
Pistons And Connecting Rods, Removal ...919
Disassembly ...919
Pistons, Inspection And Repair ...920
Piston Rings, Inspection And Repair ...920
Piston Pins, Inspection And Repair ...921
Connecting Rods, Inspection And Repair ...922
Pistons And Connecting Rods, Assembly And Installation ...922
CYLINDER BLOCK AND CYLINDER LINERS ...922
Cylinder Liners, Inspection ...922
Replacement Of A Cylinder Liner ...923
LUBRICATION SYSTEM ...924
Oil Pump, Removal And Disassembly ...924
Oil Pump, Inspection ...924
Oil Pump, Assembly And Installation ...925
Oil Filter ...925
COOLING SYSTEM ...926
Coolant Pump, Removal ...926
Coolant Pump, Disassembly ...926
Coolant Pump, Assembly And Installation ...926
Thermostat, Replacement ...927
CHECKS AND ADJUSTMENTS ...927
VALVE CLEARANCE ADJUSTMENT ...927
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ...928
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A ...929
FUEL INJECTORS ...929
Fuel Injectors, Removal ...930
Fuel Injectors, Inspection ...930
Fuel Injectors, Installation ...931
DIESEL FUEL FILTERS ...931
Filter Replacement, Models With A Water Separator ...931
Filter Replacement, Models Without A Water Separator ...932
Filter For The Fuel Injection Pump, Model PE4A ...932
REMOVE AIR FROM THE FUEL SYSTEM ...932
Throttle Linkage, Adjustment ...933
Idle Speed, Adjustment ...933
Check The Elements For The Cold Start Aid System ...933
ENGINE SPECIFICATIONS ...933
TORQUE SPECIFICATIONS ...935
THE LPG FUEL SYSTEM...936
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)...936
GENERAL...936
DESCRIPTION...936
Fuel Tank...937
Fuel Filter And Fuel Valve Unit...938
Vaporizer...938
The IMPCO CA 100 Carbureto...940
IMPCO CA 50 Carburetor...942
The Governor (GM Engines Only)...943
Governor With Electronic Controller...944
REPAIRS...945
LPG TANK...945
Removal...945
Installation...946
REPLACE THE HOSES...946
HYDROSTATIC RELIEF VALVE...946
Removal and Installation...946
FILTER UNIT...947
Replacement Of the Fuel Filter Element...947
Replacement of the Diaphragm and Fuel Valve...948
VAPORIZER...948
Removal...948
Disassembly...948
Cleaning...948
Inspection...948
Assembly...950
Installation...950
CARBURETOR (IMPCO CA 100)...952
Removal...952
Disassembly...952
Cleaning...952
Assembly...952
Installation...955
CARBURETER (IMPCO CA 50)...954
Removal...954
Disassembly...954
Cleaning...955
Inspection...955
Assembly (See FIGURE 26.)...955
Installation...955
CHECKS AND ADJUSTMENTS...956
CHECK THE FILTER UNIT...956
CHECK THE VAPORIZER...956
Pressure Reducer Valve...956
Vapor Valve...956
ADJUST THE CARBURETOR...956
Idle Mixture...956
Idle Speed...956
Power Mixture...956
ADJUST THE GOVERNOR (GM Engines Only)...957
Checks...957
Main Adjusting Screw...957
Secondary Adjusting Screw...957
AISAN Governor...958
Adjustment, AISAN Governor...958
TROUBLESHOOTING...959
THE MAIN CONTROL VALVE...963
INTRODUCTION...963
GENERAL...963
DESCRIPTION...963
OPERATION...964
Lift Section...965
Tilt Section...965
Relief Valve...967
SOLENOID VALVE FOR AUXILIARY FUNCTION...968
Operation...968
REPAIRS...968
MAIN CONTROL VALVE...968
Removal and Disassembly...968
Cleaning and Inspection...969
Assembly...969
Installation...969
SOLENOID VALVE FOR AUXILIARY FUNCTION...969
Removal and Disassembly...969
Assembly and Installation...971
CHECKS AND ADJUSTMENTS...971
PRESSURE RELIEF VALVES...971
Primary Relief Valve...971
Seconday Relief Valve...972
CONTROL LEVER ARRANGEMENT...972
TROUBLESHOOTING...975
SPECIFICATIONS...977
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - DESCRIPTION AND OPERATION...978
...978
...979
...980
...981
...982
...983
...984
...985
...986
...987
...988
...989
...990
...991
...992
...993
...994
...995
...996
...997
...998
...999
...1000
...1001
...1002
...1003
...1004
...1005
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS...1006
...1006
...1007
...1008
...1009
...1010
...1011
...1012
...1013
...1014
...1015
...1016
...1017
...1018
...1019
...1020
...1021
...1022
...1023
...1024
...1025
...1026
...1027
...1028
...1029
...1030
...1031
...1032
...1033
...1034
...1035
...1036
...1037
...1038
...1039
...1040
...1041
...1042
...1043
...1044
...1045
...1046
...1047
...1048
...1049
...1050
...1051
...1052
...1053
...1054
...1055
...1056
...1057
THE STEERING AXLE...1058
INTRODUCTION...1058
DESCRIPTION...1058
GENERAL...1058
REPAIRS...1059
STEERING AXLE...1059
Removal...1059
Installation...1060
STEERING CYLINDER...1060
Removal...1060
Service...1061
Installation...1061
HUBS...1061
Removal...1061
Installation...1062
SPINDLES...1062
Removal...1062
Installation...1063
CHECKS AND ADJUSTMENTS...1063
REMOVE THE AIR FROM THE STEERING SYSTEM...1063
SET THE PRESSURE RELIEF VALVE...1063
S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...1063
H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION...1063
H2.00-3.00J (H40-60J) With Powershift Transmission...1063
TROUBLESHOOTING...1065
THE STEERING CONTROL UNIT...1066
INTRODUCTION...1066
General...1066
Description and Operation...1066
REPAIRS...1069
Removal...1069
Disassembly...1070
Inspection...1074
Assembly...1077
Installation...1086
CHECKS AND ADJUSTMENTS...1086
Adjusting the Rotary Spool...1086
Removing the Air from the System...1087
Checking the Steering Hydraulic System...1088
TROUBLESHOOTING...1096
THE STEERING CONTROL UNIT...1099
INTRODUCTION...1099
GENERAL...1099
DESCRIPTION...1099
OPERATION...1099
REPAIRS...1099
STEERING WHEEL AND COLUMN ASSEMBLY...1099
TYPE "A" STEERING COLUMN ASSEMBLY...1101
Removal And Disassembly...1101
Assembly And Installation...1101
TYPE "A" STEERING COLUMN...1102
TYPE "A" STEERING COLUMN...1103
TYPE "B" STEERING COLUMN...1104
Removal And Disassembly...1104
Assembly And Installation...1104
TYPE "B" STEERING COLUMN...1105
Disassembly of Steering Control Unit...1106
Cleaning of Steering Control Unit...1106
Assembly of Steering Control Unit...1108
CHECKS AND ADJUSTMENTS...1111
REMOVE AIR FROM THE SYSTEM...1111
TROUBLESHOOTING...1112
THE TILT CYLINDERS...1113
General...1115
Description...1115
Tilt Cylinder...1115
Remove...1115
Disassemble...1115
Clean...1115
Assemble...1115
Tilt Cylinders with O-Ring or Single-Lip Seals...1115
Tilt Cylinders for XM and XMS Models...1117
Tilt Cylinders for H700-800A and Early Model H700-920B...1118
Install...1119
Tilt Cylinders Using Chevron Packing...1120
Install...1121
Tilt Cylinder Leak Check...1123
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...1124
Torque Specifications...1124
Piston Rod Nut...1124
Retainer...1126
Troubleshooting...1127
UPRIGHTS - DESCRIPTION...1130
INTRODUCTION...1130
GENERAL...1130
DESCRIPTION...1130
Upright Assembly...1130
Upright Mounts...1131
Carriage...1132
OPERATION...1132
Standard Upright...1132
Three Stage Uprights...1132
UPRIGHTS - REPAIRS...1135
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...1135
INTRODUCTION...1136
GENERAL...1136
REPAIR...1136
Forks...1136
Forks, Adjustment...1136
Forks, Removal And Installation...1137
Hook Fork, Removal...1137
Hook Fork, Installation...1137
CARRIAGE...1137
Removal...1137
Installation...1138
MAST...1138
Removal...1138
Disassembly, Standard Mast...1139
Disassembly, Three-Stage Mast...1139
Cleaning And Inspection...1143
Assembly...1144
Installation...1144
SIDE-SHIFT CARRIAGE...1144
Removal...1144
Repairs...1146
Installation...1146
CHECKS AND ADJUSTMENTS...1146
Check For Leaks In The Lift Sytem...1146
Leakage Outside the Hydraulic Lift System...1146
Leakage Inside the Hydraulic Lift System...1146
Check the lift cylinder for inside leakage...1146
Check For Leaks In The Tilt System...1146
ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...1146
LIFT CHAIN ADJUSTMENTS...1147
MAST ADJUSTMENTS...1148
CARRIAGE ADJUSTMENT...1149
HEADER HOSE ARRANGEMENT...1149
Three-Stage Header Hoses...1149
TROUBLESHOOTING...1151
VISTA UPRIGHTS - DESCRIPTION...1152
INTRODUCTION...1152
GENERAL...1152
VISTA TWO-STAGE MASTS...1154
DESCRIPTION...1154
OPERATION...1157
VISTA THREE-STAGE MASTS...1157
DESCRIPTION...1157
OPERATION...1159
SEQUENCE VALVE...1161
VISTA UPRIGHTS - REPAIR...1164
Hyster A177 (H2.00-3.00XL Europe) & A177 (H40-60XL) Repair Service Manuals
