Hyster B177 (H2.00-3.00XL Europe & H40-60XL) Repair Service Manuals
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Complete service repair manual for Hyster B177 (H2.00-3.00XL Europe & H40-60XL), with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
Hyster B177 (H2.00-3.00XL Europe & 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 B177 (H2.00-3.00XL Europe & H40-60XL) Service Manual.pdf
Total Pages: 1,111 pages
File Format: PDF
Language: English
B177 (H2.00-3.00XL Europe)...2
100137...3
INTRODUCTION...3
GENERAL...3
DESCRIPTION...3
REPAIRS...3
COUNTERWEIGHT...4
Removal...4
Installation...4
MUFFLER...5
HOOD...5
Removal...5
Installation...5
RADIATOR AND COOLANT SYSTEM...5
Removal...5
Installation...5
OVERHEAD GUARD...6
Removal And Installation...6
OPERATOR RESTRAINT SYSTEM...6
ENGINE REMOVAL AND INSTALLATION...7
Removal of the Engine and Transmission...7
Installation of the Engine and Transmission...11
FUEL AND HYDRAULIC TANKS...13
Inspection...13
Repairs, Small Leaks...13
Repairs, Large Leaks...13
Cleaning...13
Steam Method Of Cleaning...13
Chemical Solution Method of Cleaning...14
Additional Preparations For Repair...14
SAFETY LABELS...14
CAB...16
Cab Replacement...16
Window Replacement...16
Windshield Wipers and Heater...18
1300255...19
INTRODUCTION...19
GENERAL...19
DESCRIPTION AND OPERATION...20
GENERAL...20
TORQE CONVERTER...20
Description...20
Operation...20
CLUTCH ASSEMBLIES...23
Description...23
Operation...25
HYDRAULIC SYSTEM...25
General...25
CONTROL VALVE...25
Regulator for Clutch Pressure...28
Inching Spool Assembly...28
Direction Spool...28
MONOTROL Control Valve...28
Neutral Start Switch, MONOTROL Pedal Only...29
Neutral Start Switch, Direction Control Lever Only...29
Modulator Circuit...29
Regulator for the Toruqe Converter...30
By-Pass Valve for the Oil Cooler...30
DIFFERENTIAL...31
OIL FLOW DIAGRAMS...31
1300256...40
INTRODUCTION...40
GENERAL...40
REPAIRS...42
REPAIRS...42
Torque Converter, Removal...42
Torque Converter, Installation...42
Front Cover And Transmission Pump, Removal and Disassembly...43
Front Cover And Transmission Pump, Assembly and Installation...43
Clutch Assemblies, Removal and Disassembly...44
Clutch Assemblies, Inspection...47
Clutch Assemblies, Assembly and Installation...48
Differential, Removal and Disassembly...51
Differential, Inspection...53
Differential, Assembly And Installation...53
CONTROL VALVE...63
Control Valve, Removal and Disassembly...63
Control Valve, Inspection...63
Control Valve, Assembly and Installation...65
MONOTROL Pedal, Removal and Disassembly...67
MONOTROL Pedal, Assembly and Installation...67
CHECKS AND ADJUSTMENTS...69
Stall Test...69
Adjustment Of The Direction Control Linkage...70
Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1)...71
Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)...74
Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)...75
Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)...76
Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)...80
Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)...81
Check The Oil Pressures...81
Check The Relief Valve for the Transmission Pump...81
Check The Clutch Pressure...81
Check The Torque Converter Regulator...82
Check The Oil Pressure from the Oil Cooler...82
Check The Modulator Pressure...83
TROUBLESHOOTING...83
TROUBLESHOOTING, PRESSURE TESTS...85
140085...88
INTRODUCTION...88
GENERAL...88
DESCRIPTION...88
REPAIRS...89
REMOVAL...89
CLEANING...89
INSPECTION...89
ASSEMBLY...89
TROUBLESHOOTING...92
SPECIFICATIONS...92
160010...93
INTRODUCTION...93
DESCRIPTION...93
GENERAL...93
REPAIRS...94
STEERING AXLE...94
Removal...94
Installation...95
STEERING CYLINDER...95
Removal...95
Service...96
Installation...96
HUBS...96
Removal...96
Installation...97
SPINDLES...97
Removal...97
Installation...98
CHECKS AND ADJUSTMENTS...98
REMOVE THE AIR FROM THE STEERING SYSTEM...98
SET THE PRESSURE RELIEF VALVE...98
S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...98
H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION...98
H2.00-3.00J (H40-60J) With Powershift Transmission...98
TROUBLESHOOTING...100
1600459...101
THE STEERING SYSTEM...101
GENERAL...101
DESCRIPTION...101
Hydraulic Pump Assembly...102
Flow Control Valve...103
Relief Valve...103
OPERATION...103
Steering System...103
Hydraulic Pump...104
Flow Control Valve...104
Relief Valve...104
STEERING WHEEL AND COLUMN ASSEMBLY...105
Removal (Serial Code C177 And C187)...105
Installation (Serial Code C177 And C187)...105
Removal (Serial Code B177 And B187)...108
Installation (Serial Code B177 And B187)...108
STEERING CONTROL UNIT...109
Description...109
Operation, Control Valve Section...109
Operation, Metering Section...110
CHECKS AND ADJUSTMENTS...110
Remove Air From The Steering System...110
Check And Adjust Steering Relief Pressure...110
Check Hydraulic Pump For Correct Flow...110
TROUBLESHOOTING...111
1800458...112
INTRODUCTION...112
GENERAL...112
SERVICE BRAKES AND PARKING BRAKE...112
DESCRIPTION AND OPERATION...112
Service Brakes...112
Parking Brake...113
REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES...113
Parking Brake...115
CLEANING...116
INSPECTION...116
ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES...116
Adjustments...119
Parking Brake Installation...120
Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes...120
REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES...122
Parking Brake...124
CLEANING...125
INSPECTION...125
ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES...125
Adjustments...127
Parking brake...128
Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes...128
MASTER CYLINDER...129
Removal...129
Repair...129
Installation...129
Cleaning And Inspection...131
MASTER CYLINDER WITH BRAKE BOOSTER...133
Operation...133
Repair...133
CHECKS AND ADJUSTMENTS...135
ADJUST THE SERVICE BRAKES...135
TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)...135
REMOVE THE AIR FROM THE BRAKE SYSTEM...136
ADJUST THE INCHING/BRAKE PEDAL...136
ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL)...141
TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)...141
Test 1...141
Test 2...142
TORQUE SPECIFICATIONS...142
TROUBLESHOOTING...142
1900130...145
INTRODUCTION...145
GENERAL...145
DESCRIPTION...147
Hydraulic System...147
Gear Pump Assembly...147
Flow Control Valve...148
Relief Valve (Early Model)...148
Relief Valve (Later Model)...148
OPERATION...150
Hydraulic System...150
Gear Pump...150
Flow Control Valve...150
Relief Valve (Early Model)...150
Relief Valve (Later Model)...150
REPAIR...152
GEAR PUMP ASSEMBLY...152
Removal and Disassembly...152
Assembly and Installation...153
CHECKS AND ADJUSTMENTS...153
CHECK AND ADJUST STEERING RELIEF PRESSURE...153
CHECK GEAR PUMP FOR CORRECT FLOW...154
TROUBLESHOOTING...154
200077...156
INTRODUCTION...156
GENERAL...156
DESCRIPTION...156
OPERATION...157
Lift Section...158
Tilt Section...158
Relief Valve...160
SOLENOID VALVE FOR AUXILIARY FUNCTION...161
Operation...161
REPAIRS...161
MAIN CONTROL VALVE...161
Removal and Disassembly...161
Cleaning and Inspection...162
Assembly...162
Installation...162
SOLENOID VALVE FOR AUXILIARY FUNCTION...162
Removal and Disassembly...162
Assembly and Installation...164
CHECKS AND ADJUSTMENTS...164
PRESSURE RELIEF VALVES...164
Primary Relief Valve...164
Seconday Relief Valve...165
CONTROL LEVER ARRANGEMENT...165
TROUBLESHOOTING...168
SPECIFICATIONS...170
2100103...171
INTRODUCTION...174
GENERAL...174
DESCRIPTION...174
REPAIRS...174
REMOVAL...174
DISASSEMBLY...174
CLEANING...174
ASSEMBLY...174
Tilt Cylinders for the XM and XMS Models...174
Tilt Cylinders with O-Ring or Single Lip Seals...176
Tilt Cylinders for H700-800A and Early Model H700-920B...176
INSTALLATION...176
Tilt Cylinders with Chevron Packing...176
CHECKS AND ADJUSTMENTS...180
CHECK THE TILT CYLINDERS FOR LEAKS...180
ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...180
TROUBLESHOOTING...183
2200106...186
INTRODUCTION...186
GENERAL...186
DESCRIPTION AND OPERATION...186
REPAIRS...188
REMOVAL...188
DISSASEMBLY...188
CLEANING...189
ASSEMBLY...189
INSTALLATION...189
CHECKS AND ADJUSTMENTS...190
GENERAL...190
TROUBLESHOOTING...192
2200132...194
INTRODUCTION...194
GENERAL...194
DESCRIPTION...194
Starting System...194
Ignition System...194
Charging System...195
REPAIR...197
STARTER...197
Removal And Disassembly...197
Assembly And Installation...197
BALLAST RESISTOR RELAY (Earlier Production)...199
DISTRIBUTOR (Earlier Production With Contact Points)...199
Removal And Disassembly...199
Assembly And Installation...201
COIL REPLACEMENT...201
DISTRIBUTOR (Later Production with Electronic Ignition System)...201
Removal And Disassembly...201
Assembly And Installation...203
ALTERNATOR (All Models)...203
Removal And Disassembly...203
Assembly And Installation...204
REGULATOR REPLACEMENT (Earlier Production)...205
CHECKS AND ADJUSTMENTS...206
GENERAL...206
STARTER...206
Check Operation...206
Check Brush Length...207
Check Brush Holder...207
Armature...207
Field Windings...207
Clutch And Bearing...207
BALLAST RESISTOR RELAY (Earlier Production)...207
DISTRIBUTOR...208
Distributor Contact Clearance...208
SPARK PLUGS...209
COIL AND BALLAST RESISTOR (Earlier Production)...209
ALTERNATOR...209
Check For Low Output (Alternator With Separate Regulator)...209
Check For Low Output (Alternator With Integral Regulator)...211
Check For High Output (Alternator With Separate Regulator)...212
Check For High Output (Alternator With Integral Regulator)...212
Rotor Resistance (Alternator with Separate Regulator)...212
Diodes Circuit (Alternator with Separate Regulator)...213
Diode Assembly (Alternator With Separate Regulator)...213
Check The Diodes, Diode Trio (Alternator with Integral Regulator)...213
Check The Rectifier Bridge (Alternator with Integral Regulator)...214
Check Field Winding For The Rotor (All Alternators)...214
Check Windings In The Stator (All Alternators)...215
Brushes And Bearings...215
Check The Voltage Regulator (Alternator with Separate Regulator)...215
Check The Voltage Regulator (Alternator with Integral Regulator)...216
ADJUSTMENTS...216
TROBLESHOOTING...217
2200134...219
INTRODUCTION...219
GENERAL...219
DESCRIPTION...219
Starting System...219
Charging System...219
Vacuum Pump On Alternator (On Units With Brake Booster)...221
REPAIRS...222
STARTER...222
Removal And Disassembly...222
Assembly And Installation...222
REPLACING GLOW PLUGS...224
ALTERNATOR (With Vaccum Pump)...224
Removal And Disassembly...224
Cleaning...226
Assembly And Installation...226
ALTERNATOR (Without Vacuum Pump)...227
Removal And Disassembly...227
Cleaning...229
Assembly And Installation...229
REGULATOR REPLACEMENT...230
CHECKS...230
GENERAL...230
STARTER...230
Starter Operation...230
Solenoid Coil Checks...231
Brush Length...231
Brush Holder...231
Armature...231
Field Windings...232
Clutch And Bearings...232
COLD START AID...232
Glow Plugs...232
Resistor...232
CHARGING CIRCUIT...232
Check For Low Output...232
Check Ford High Output...234
ALTERNATOR...234
Rotor Resistance...234
Diodes Circuit...234
Rotor Coil...235
Stator Coil...235
Diode Assembly...235
Brushes And Bearings...236
REGULATOR (At Hydraulic Tank)...236
TROUBLESHOOTING...237
2200143...240
INTRODUCTION...240
GENERAL...240
DESCRIPTION...240
GENERAL...240
STEERING COLUMN GAUGES, METERS AND INDICATORS...243
LED DISPLAY PANEL...243
Battery Discharge Indicators ...243
Brush Wear Indicators...244
Motor Temperature Indicators...245
"LX" SERIES INSTRUMENT PANEL DISPLAY...246
Hourmeter Functions...247
Battery Indicator Function...247
Status Code Function...247
CHECKS AND ADJUSTMENTS...247
GENERAL...247
REPLACEMENT...248
GENERAL...248
METER REPLACEMENT...248
SENDER REPLACEMENT...249
Fuel Level Sender...249
Pressure And Temperature Sender...250
I.T.W. DISPLAY PANEL...250
Removal...250
SPECIFICATIONS...251
TROUBLESHOOTING...252
2200144...253
ELECTRICAL WARNING DEVICES...253
GENERAL...253
DESCRIPTION...253
Operator Controlled Horns...253
System Warning Lights, Buzzers and Bells...253
Reverse Warning Horns...254
Warning Lights...254
REPLACEMENT...255
General...255
Replacing Horns or Bells...255
Replacing Horn Relay or Buzzer...255
Replacing Warning Lights...255
Light Assemblies...256
Replacing Flashing Units...256
22002...257
INTRODUCTION...257
GENERAL...257
DESCRIPTION...257
REPAIRS...259
GENERAL...259
REMOVAL AND DISASSEMBLY (Type A)...259
CLEANING...259
ASSEMBLY (Type A)...260
REMOVAL AND DISAASSEMBLY (Type B)...262
CLEANING...264
ASSEMBLY (Type B)...264
INSTALLATION (Type A and Type B)...265
CHECKS AND ADJUSTMENTS...265
GENERAL...265
CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)...266
CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)...267
CHECK THE CIRCUIT FOR THE BRUSHES...269
Delco Alternators...269
Motorola Alternators...269
CHECK THE DIODES...269
CHECK THE DIODE BRIDGE...269
Delco and Leece–Neville Alternators...269
Motorola Alternators...269
CHECK THE FIELD WINDING FOR THE ROTOR...270
CHECK THE WINDINGS IN THE STATOR...270
CHECK THE VOLTAGE REGULATOR...271
TROUBLESHOOTING...271
4000135...272
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...272
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...272
LIFT CYLINDERS...275
GENERAL...275
DESCRIPTION...275
Lowering Control Valve...275
Cylinders (General)...278
Cylinders (H520-620B,H700-800A)...280
Cylinders (H360-460B)...281
Cylinders (Two-Speed)...281
REPAIRS...282
REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...282
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...282
Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...286
Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...284
DISASSEMBLY...284
ASSEMBLY...286
INSTALLATION OF THE LIFT CYLINDER IN THE MAST...286
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...286
Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead...286
CHEVRON PACKING...287
LIFT CYLINDERS FOR VISTA MASTS...290
DESCRIPTION...290
Lowering Control Valve...292
REMOVAL...293
DISASSEMBLY...293
ASSEMBLY...293
INSTALLATION...294
Main Lift Cylinders...294
Free-Lift Cylinders...294
CHECKS AND ADJUSTMENTS...295
CHECK FOR LEAKS IN LIFT SYSTEM...295
TROUBLESHOOTING...296
SPECIFICATIONS...297
4000222...298
INTRODUCTION...298
GENERAL...298
MAST WELDMENTS...298
CARRIAGE...298
MAST MOUNTS...299
VISTA® TWO-STAGE MAST...300
DESCRIPTION AND OPERATION...300
VISTA® FREE-LIFT MAST...302
DESCRIPTION...302
OPERATION...302
VISTA® THREE-STAGE MAST...304
DESCRIPTION...304
OPERATION...304
VISTA® FOUR-STAGE MAST...305
DESCRIPTION...305
OPERATION...306
4000223...308
VISTA MAST, REPAIR...308
GENERAL...308
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...308
FORKS...309
Forks, Removal And Installation...309
CARRIAGE...310
Removal...310
Installation...311
MASTS...311
Removal...311
Disassembly...312
Cleaning and Inspection...317
Assembly...317
Installation...321
SIDE-SHIFT CARRIAGE (EARLIER DESIGN)...322
Removal...322
Repairs...322
Installation...322
SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)...323
Removal...323
Repairs...323
Installation...324
CHECKS AND ADJUSTMENTS...325
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...325
ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...326
LIFT CHAIN ADJUSTMENTS...327
MAST ADJUSTMENTS...327
CARRIAGE ADJUSTMENT...329
HEADER HOSE ARRANGEMENTS...329
Two-Stage Header Hose...330
Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts...330
TROUBLESHOOTING...335
60066...336
MAZDA M4-121G ENGINE...336
GENERAL...336
DESCRIPTION...337
REMOVAL AND INSTALLATION OF THE ENGINE...337
CYLINDER HEAD AND VALVE MECHANISM...337
Cylinder Head, Removal...337
Cylinder Head, Inspection and Repairs...338
Rocker Arm Assembly...338
Valve Guides...338
Valve Seats...339
Valves...339
Valve Springs...339
Cylinder Head, Installation...339
TIMING GEAR CASE, REMOVAL...340
TIMING GEAR CASE, INSTALLATION...341
CAMSHAFT...341
Removal...341
Inspection...342
Cam Followers, Inspection...342
Installation...342
CRANKSHAFT AND MAIN BEARINGS...342
Crankshaft, Removal...342
Crankshaft, Inspection And Repair...343
Main Bearings...344
Crankshaft, Installation...344
PISTONS AND CONNECTING RODS...345
Removal...345
Disassembly...345
Pistons, Inspection And Repair...345
Piston Rings...346
Piston Pin and Bushing...346
Connecting Rods and Bearings, Inspection...346
Pistons and Connecting Rods, Assembly...346
Pistons and Connecting Rods, Installation...347
CYLINDER BLOCK AND CYLINDER LINERS...347
Cylinder Block, Repairs...347
Cylinder Liners...347
DISTRIBUTOR...348
Removal...348
Installation...348
OIL PUMP...350
Removal...350
Repairs...350
Installation...351
GOVERNOR...351
Description...351
Removal...351
Disassembly...352
Assembly...353
Installation...354
COOLANT PUMP...354
Removal...354
Disassembly and Repair...355
Assembly...355
Installation...356
FLYWHEEL...356
Repairs...356
Installation...356
CHECKS AND ADJUSTMENTS...356
ADJUST THE VALVES...356
ADJUST THE THROTTLE LINKAGE...357
ENGINE SPECIFICATIONS...357
ENGINE SPECIFICATIONS...357
Engine Data...357
Cooling System...357
Cylinder Head and Valve Mechanism...357
Camshaft...359
Timing Gear...360
Camshaft...360
Connecting Rods...360
Cylinder Liners...360
Pistons...360
Lubrication System...361
Fuel Pump...361
TORQUE SPECIFICATIONS...362
TROUBLESHOOTING...363
60070...367
INTRODUCTION ...367
GENERAL ...367
DESCRIPTION ...367
FUEL SYSTEM ...368
Description ...368
Operation, Fuel Injection Pump, Model VE ...370
Operation, Fuel Injection Pump, Model PE4A ...371
Pneumatic Governor For Fuel Injection Pump, Model PE4A ...372
Inlet Manifold For Fuel Injection Pump, Model PE4A ...373
REPAIRS ...374
FUEL INJECTION PUMP (ALL MODELS) ...374
Removal ...374
Installation ...374
REMOVAL AND INSTALLATION OF THE ENGINE ...374
CYLINDER HEAD AND VALVE MECHANISM ...374
Cylinder Head, Removal ...374
Valve Guides, Replacement ...375
Cylinder Head, Inspection And Repair ...376
Combustion Chamber Plugs, Inspection And Repair ...376
Combustion Chamber Plugs, Installation ...376
Valves, Inspection And Repair ...377
Valve Seat, Inspection ...377
Valve Seat, Removal ...378
Valve Seat, Installation ...378
Valve Spring, Inspection ...378
Rocker Arms, Inspection And Assembly ...378
Installation Of The Cylinder Head ...379
TIMING GEAR CASE ...380
Removal ...380
Installation ...380
CAMSHAFT ...382
Removal ...382
Inspection ...382
Camshaft Bearings ...383
Cam Followers ...383
CAMSHAFT, INSTALLATION ...383
CRANKSHAFT AND MAIN BEARINGS ...384
Crankshaft, Removal ...384
Crankshaft, Inspection And Repair ...384
Main Bearings ...384
Pilot Bearing ...385
Crankshaft, Installation ...385
FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) ...387
Flywheel, Removal ...387
Ring Gear, Replacement ...387
Flywheel, Installation ...387
PISTONS AND CONNECTING RODS ...388
Pistons And Connecting Rods, Removal ...388
Disassembly ...388
Pistons, Inspection And Repair ...389
Piston Rings, Inspection And Repair ...389
Piston Pins, Inspection And Repair ...390
Connecting Rods, Inspection And Repair ...391
Pistons And Connecting Rods, Assembly And Installation ...391
CYLINDER BLOCK AND CYLINDER LINERS ...391
Cylinder Liners, Inspection ...391
Replacement Of A Cylinder Liner ...392
LUBRICATION SYSTEM ...393
Oil Pump, Removal And Disassembly ...393
Oil Pump, Inspection ...393
Oil Pump, Assembly And Installation ...394
Oil Filter ...394
COOLING SYSTEM ...395
Coolant Pump, Removal ...395
Coolant Pump, Disassembly ...395
Coolant Pump, Assembly And Installation ...395
Thermostat, Replacement ...396
CHECKS AND ADJUSTMENTS ...396
VALVE CLEARANCE ADJUSTMENT ...396
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ...397
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A ...398
FUEL INJECTORS ...398
Fuel Injectors, Removal ...399
Fuel Injectors, Inspection ...399
Fuel Injectors, Installation ...400
DIESEL FUEL FILTERS ...400
Filter Replacement, Models With A Water Separator ...400
Filter Replacement, Models Without A Water Separator ...401
Filter For The Fuel Injection Pump, Model PE4A ...401
REMOVE AIR FROM THE FUEL SYSTEM ...401
Throttle Linkage, Adjustment ...402
Idle Speed, Adjustment ...402
Check The Elements For The Cold Start Aid System ...402
ENGINE SPECIFICATIONS ...402
TORQUE SPECIFICATIONS ...404
700626...405
COOLING SYSTEM...405
INTRODUCTION...405
DESCRIPTION...405
RADIATOR...405
RADIATOR CAP...405
THERMOSTAT...405
WATER PUMP...406
FAN AND FAN SHROUD ...406
REPAIRS...406
COOLING SYSTEM CHECKS...406
Exhaust Leaks...406
RADIATOR...406
Checks...406
Cleaning The Radiator...406
Drain The Cooling System...408
Fill The Cooling System...408
WATER PUMP...408
Checks...408
THERMOSTAT...409
Checks...409
FAN AND FAN SHROUD ...409
TROUBLESHOOTING...410
8000231...411
INTRODUCTION...411
NOMENCLATURE, THREADS...411
STRENGTH IDENTIFICATION...412
TABLE 1. BOLTS AND SCREWS...412
TABLE 2. STUDS AND NUTS...413
TABLE 3. TORQUE NUTS...414
TABLE 4. TORQUE NUTS WITH NYLON INSERT...415
TABLE 5. TORQUE VALUES FOR INCH FASTENERS...416
TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...417
8000259...420
PERIODIC MAINTENANCE...420
GENERAL...420
Serial Number Data...420
HOW TO MOVE A DISABLED LIFT TRUCK...421
How To Tow the Lift Truck...421
HOW TO PUT A LIFT TRUCK ON BLOCKS...421
How To Raise the Drive Tires...421
How To Raise the Steering Tires...422
MAINTENANCE PROCEDURES...426
EVERY 8 HOURS OR DAILY...426
HOW TO MAKE CHECKS WITH THE ENGINE STOPPED...426
Engine Oil...426
Drive Belts...426
Cooling System...426
Battery...427
Fuel System...429
Air Filter...429
Hydraulic System Oil...429
Tires and Wheels...430
Forks...430
Forks, Adjustment...431
Forks, Removal And Installation...431
Inspection Of Forks, Mast, and Lift Chains...432
Safety Labels...433
Operator Restraint System...433
HOW TO MAKE CHECKS WITH THE ENGINE RUNNING...434
Gauges, Lights, Horn, and Fuses...434
Fuel Filter, Diesel Engine...435
How To Drain The Water From The Fuel Filter...435
Oil Level, Powershift Transmission...435
Control Levers and Pedals...435
Lift System Operation...435
Inching/Brake Pedal...436
Service Brakes...436
Parking Brake...436
Steering System...436
EVERY 250 HOURS OR TWO MONTHS...437
ENGINE OIL AND FILTER...437
Mazda, GM, And Later Production Isuzu Engines...437
Earlier Production Isuzu C240 Engines...437
GOVERNOR, MAZDA ENGINE...438
DRIVE BELTS...438
Mazda Engine...438
Isuzu, GM 4-181, And GM 4-153 Engines...438
BRAKE FLUID...439
HYDRAULIC TANK BREATHER, CLEAN AND CHECK...439
FORKS, CHECK FOR WEAR AND DAMAGE...439
LIFT CHAINS...439
Lubrication...439
Check For Wear...439
MAST, LUBRICATION...440
TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...440
CONTROL LEVERS AND PEDALS, LUBRICATION...441
FUEL SYSTEM, CHECKS AND ADJUSTMENTS...441
Idle Speed, Diesel...441
LPG Carburetor...442
Gasoline Carburetor...442
EVERY 1000 HOURS OR SIX MONTHS...443
DIESEL FUEL FILTER...443
Filter Replacement, Models Without A Water Separator...444
Filter Replacement, Models With A Water Separator...444
Remove Air from the Diesel Fuel System...444
DIFFERENTIAL...445
VALVE CLEARANCE ADJUSTMENT...445
IGNITION SYSTEM, MAZDA AND GM ENGINES...445
PCV VALVE AND FILTER...447
EVERY 2000 HOURS OR YEARLY...447
HYDRAULIC SYSTEM...447
Replace the Hydraulic Oil and Filter...447
POWERSHIFT TRANSMISSION...447
COOLING SYSTEM...448
SERVICE BRAKES...448
DIFFERENTIAL...448
WHEEL BEARINGS...449
Steering Wheels, lubrication...449
Drive Wheels, Lubrication...449
GASOLINE FUEL FILTER, REPLACEMENT...449
PCV VALVE, GM ENGINES...449
LPG FILTER, REPLACEMENT...449
FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A...449
GENERAL PROCEDURES...450
CHECK THE HOOD LATCH...450
LIFT CHAIN ADJUSTMENTS...450
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...452
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...453
Check the Lift Cylinders for Leaks...453
Check the Tilt Cylinders for Leaks...453
FUEL INJECTORS...454
WELDING REPAIRS...454
CHANGES TO THE OVERHEAD GUARD...454
WHEELS AND TIRES...454
Solid Rubber Tires (Press-on)...454
Install The Wheels...455
Pneumatic Tires, Remove The Wheels From The Lift Truck...456
Pneumatic Tires, Remove the Tire From The Wheel...456
Pneumatic Tires, Install The Wheel In The Tire...457
Pneumatic Tires, Add Air To The Tires...458
Pneumatic Tires, Install the Wheels...459
Pneumatic Tires, Installation Procedures, Dual Drive Wheels...459
SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES...460
Remove The Wheels From The Lift Truck...460
Remove The Tire From The Wheel...460
Install The Tire On The Wheel...461
REFERENCE TABLE...462
8000461...463
FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC...464
FIGURE 2. TRANSMISSION SCHEMATIC...465
FIGURE 3. INSTRUMENT PANEL ELECTRICAL DIAGRAM...466
FIGURE 4. MAZDA ENGINE, GASOLINE/LPG WIRING SCHEMATIC...468
FIGURE 5. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)...470
FIGURE 6. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)...472
FIGURE 7. DIESEL ENGINE WIRING SCHEMATIC...474
FIGURE 8. DIESEL ENGINE CABLE DIAGRAM (D Rating)...476
FIGURE 9. DIESEL (SAFETY) ENGINE CABLE DIAGRAM (DS RATING)...478
FIGURE 10. GM ENGINE, GASOLINE/LPG WIRING DIAGRAM (GS and LPS Rating)...480
FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)...482
FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)...484
800048...489
LIFT TRUCK WEIGHTS*...489
ENGINE SPECIFICATIONS...489
ENGINE ELECTRICAL SPECIFICATIONS...490
HYDRAULIC SPECIFICATIONS...490
CAPACITIES...491
LIFT TRUCK TRAVEL SPEEDS...491
TIRE SPECIFICATIONS...491
MAST SPEEDS (Early A177* Units)...492
MAST SPEEDS (Later A177* Units)...492
MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)...493
MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)...493
TORQUE SPECIFICATIONS...495
TORQUE SPECIFICATIONS...496
900129...498
THE CARBURETOR, (MAZDA M4-121G ENGINE)...498
DESCRIPTION...498
REPAIRS, CARBURETOR...499
Removal...499
Cleaning...502
Inspection...502
Assembly...502
Installation...504
CHECKS AND ADJUSTMENTS...504
Carburetor, Idle Speed And Mixture Adjustment...504
Adjust The Governor...505
ADJUST THE THROTTLE LINKAGE...506
SPECIFICATIONS...506
TROUBLESHOOTING...507
90015...509
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)...509
GENERAL...509
DESCRIPTION...509
Fuel Tank...510
Fuel Filter And Fuel Valve Unit...511
Vaporizer...511
The IMPCO CA 100 Carbureto...513
IMPCO CA 50 Carburetor...515
The Governor (GM Engines Only)...516
Governor With Electronic Controller...517
REPAIRS...518
LPG TANK...518
Removal...518
Installation...519
REPLACE THE HOSES...519
HYDROSTATIC RELIEF VALVE...519
Removal and Installation...519
FILTER UNIT...520
Replacement Of the Fuel Filter Element...520
Replacement of the Diaphragm and Fuel Valve...521
VAPORIZER...521
Removal...521
Disassembly...521
Cleaning...521
Inspection...521
Assembly...523
Installation...523
CARBURETOR (IMPCO CA 100)...525
Removal...525
Disassembly...525
Cleaning...525
Assembly...525
Installation...528
CARBURETER (IMPCO CA 50)...527
Removal...527
Disassembly...527
Cleaning...528
Inspection...528
Assembly (See FIGURE 26.)...528
Installation...528
CHECKS AND ADJUSTMENTS...529
CHECK THE FILTER UNIT...529
CHECK THE VAPORIZER...529
Pressure Reducer Valve...529
Vapor Valve...529
ADJUST THE CARBURETOR...529
Idle Mixture...529
Idle Speed...529
Power Mixture...529
ADJUST THE GOVERNOR (GM Engines Only)...530
Checks...530
Main Adjusting Screw...530
Secondary Adjusting Screw...530
AISAN Governor...531
Adjustment, AISAN Governor...531
TROUBLESHOOTING...532
B177 (H40-60XL)...536
100137...537
INTRODUCTION...537
GENERAL...537
DESCRIPTION...537
REPAIRS...537
COUNTERWEIGHT...538
Removal...538
Installation...538
MUFFLER...539
HOOD...539
Removal...539
Installation...539
RADIATOR AND COOLANT SYSTEM...539
Removal...539
Installation...539
OVERHEAD GUARD...540
Removal And Installation...540
OPERATOR RESTRAINT SYSTEM...540
ENGINE REMOVAL AND INSTALLATION...541
Removal of the Engine and Transmission...541
Installation of the Engine and Transmission...545
FUEL AND HYDRAULIC TANKS...547
Inspection...547
Repairs, Small Leaks...547
Repairs, Large Leaks...547
Cleaning...547
Steam Method Of Cleaning...547
Chemical Solution Method of Cleaning...548
Additional Preparations For Repair...548
SAFETY LABELS...548
CAB...550
Cab Replacement...550
Window Replacement...550
Windshield Wipers and Heater...552
1300255...553
...553
...554
...555
...556
...557
...558
...559
...560
...561
...562
...563
...564
...565
...566
...567
...568
...569
...570
...571
...572
...573
...574
...575
...576
...577
...578
...579
...580
1300256...581
...581
...582
...583
...584
...585
...586
...587
...588
...589
...590
...591
...592
...593
...594
...595
...596
...597
...598
...599
...600
...601
...602
...603
...604
...605
...606
...607
...608
...609
...610
...611
...612
...613
...614
...615
...616
...617
...618
...619
...620
...621
...622
...623
...624
...625
...626
...627
...628
...629
...630
...631
...632
140085...633
INTRODUCTION...633
GENERAL...633
DESCRIPTION...633
REPAIRS...634
REMOVAL...634
CLEANING...634
INSPECTION...634
ASSEMBLY...634
TROUBLESHOOTING...637
SPECIFICATIONS...637
160010...638
INTRODUCTION...638
DESCRIPTION...638
GENERAL...638
REPAIRS...639
STEERING AXLE...639
Removal...639
Installation...640
STEERING CYLINDER...640
Removal...640
Service...641
Installation...641
HUBS...641
Removal...641
Installation...642
SPINDLES...642
Removal...642
Installation...643
CHECKS AND ADJUSTMENTS...643
REMOVE THE AIR FROM THE STEERING SYSTEM...643
SET THE PRESSURE RELIEF VALVE...643
S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)...643
H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION...643
H2.00-3.00J (H40-60J) With Powershift Transmission...643
TROUBLESHOOTING...645
1600459...646
THE STEERING SYSTEM...646
GENERAL...646
DESCRIPTION...646
Hydraulic Pump Assembly...647
Flow Control Valve...648
Relief Valve...648
OPERATION...648
Steering System...648
Hydraulic Pump...649
Flow Control Valve...649
Relief Valve...649
STEERING WHEEL AND COLUMN ASSEMBLY...650
Removal (Serial Code C177 And C187)...650
Installation (Serial Code C177 And C187)...650
Removal (Serial Code B177 And B187)...653
Installation (Serial Code B177 And B187)...653
STEERING CONTROL UNIT...654
Description...654
Operation, Control Valve Section...654
Operation, Metering Section...655
CHECKS AND ADJUSTMENTS...655
Remove Air From The Steering System...655
Check And Adjust Steering Relief Pressure...655
Check Hydraulic Pump For Correct Flow...655
TROUBLESHOOTING...656
1800458...657
INTRODUCTION...657
GENERAL...657
SERVICE BRAKES AND PARKING BRAKE...657
DESCRIPTION AND OPERATION...657
Service Brakes...657
Parking Brake...658
REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES...658
Parking Brake...660
CLEANING...661
INSPECTION...661
ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES...661
Adjustments...664
Parking Brake Installation...665
Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes...665
REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES...667
Parking Brake...669
CLEANING...670
INSPECTION...670
ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES...670
Adjustments...672
Parking brake...673
Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes...673
MASTER CYLINDER...674
Removal...674
Repair...674
Installation...674
Cleaning And Inspection...676
MASTER CYLINDER WITH BRAKE BOOSTER...678
Operation...678
Repair...678
CHECKS AND ADJUSTMENTS...680
ADJUST THE SERVICE BRAKES...680
TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)...680
REMOVE THE AIR FROM THE BRAKE SYSTEM...681
ADJUST THE INCHING/BRAKE PEDAL...681
ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL)...686
TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)...686
Test 1...686
Test 2...687
TORQUE SPECIFICATIONS...687
TROUBLESHOOTING...687
1900130...690
INTRODUCTION...690
GENERAL...690
DESCRIPTION...692
Hydraulic System...692
Gear Pump Assembly...692
Flow Control Valve...693
Relief Valve (Early Model)...693
Relief Valve (Later Model)...693
OPERATION...695
Hydraulic System...695
Gear Pump...695
Flow Control Valve...695
Relief Valve (Early Model)...695
Relief Valve (Later Model)...695
REPAIR...697
GEAR PUMP ASSEMBLY...697
Removal and Disassembly...697
Assembly and Installation...698
CHECKS AND ADJUSTMENTS...698
CHECK AND ADJUST STEERING RELIEF PRESSURE...698
CHECK GEAR PUMP FOR CORRECT FLOW...699
TROUBLESHOOTING...699
200077...701
INTRODUCTION...701
GENERAL...701
DESCRIPTION...701
OPERATION...702
Lift Section...703
Tilt Section...703
Relief Valve...705
SOLENOID VALVE FOR AUXILIARY FUNCTION...706
Operation...706
REPAIRS...706
MAIN CONTROL VALVE...706
Removal and Disassembly...706
Cleaning and Inspection...707
Assembly...707
Installation...707
SOLENOID VALVE FOR AUXILIARY FUNCTION...707
Removal and Disassembly...707
Assembly and Installation...709
CHECKS AND ADJUSTMENTS...709
PRESSURE RELIEF VALVES...709
Primary Relief Valve...709
Seconday Relief Valve...710
CONTROL LEVER ARRANGEMENT...710
TROUBLESHOOTING...713
SPECIFICATIONS...715
2100103...716
General...718
Description...718
Tilt Cylinder...718
Remove...718
Disassemble...718
Clean...718
Assemble...718
Tilt Cylinders with O-Ring or Single-Lip Seals...718
Tilt Cylinders for XM and XMS Models...720
Tilt Cylinders for H700-800A and Early Model H700-920B...721
Install...722
Tilt Cylinders Using Chevron Packing...723
Install...724
Tilt Cylinder Leak Check...726
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...727
Torque Specifications...727
Piston Rod Nut...727
Retainer...729
Troubleshooting...730
2200106...733
General...735
Description and Operation...735
Starter Repair...737
Remove...737
Disassemble...737
Clean...738
Assemble...738
Install...739
General Checks and Adjustments...739
Troubleshooting...742
2200132...746
INTRODUCTION...746
GENERAL...746
DESCRIPTION...746
Starting System...746
Ignition System...746
Charging System...747
REPAIR...749
STARTER...749
Removal And Disassembly...749
Assembly And Installation...749
BALLAST RESISTOR RELAY (Earlier Production)...751
DISTRIBUTOR (Earlier Production With Contact Points)...751
Removal And Disassembly...751
Assembly And Installation...753
COIL REPLACEMENT...753
DISTRIBUTOR (Later Production with Electronic Ignition System)...753
Removal And Disassembly...753
Assembly And Installation...755
ALTERNATOR (All Models)...755
Removal And Disassembly...755
Assembly And Installation...756
REGULATOR REPLACEMENT (Earlier Production)...757
CHECKS AND ADJUSTMENTS...758
GENERAL...758
STARTER...758
Check Operation...758
Check Brush Length...759
Check Brush Holder...759
Armature...759
Field Windings...759
Clutch And Bearing...759
BALLAST RESISTOR RELAY (Earlier Production)...759
DISTRIBUTOR...760
Distributor Contact Clearance...760
SPARK PLUGS...761
COIL AND BALLAST RESISTOR (Earlier Production)...761
ALTERNATOR...761
Check For Low Output (Alternator With Separate Regulator)...761
Check For Low Output (Alternator With Integral Regulator)...763
Check For High Output (Alternator With Separate Regulator)...764
Check For High Output (Alternator With Integral Regulator)...764
Rotor Resistance (Alternator with Separate Regulator)...764
Diodes Circuit (Alternator with Separate Regulator)...765
Diode Assembly (Alternator With Separate Regulator)...765
Check The Diodes, Diode Trio (Alternator with Integral Regulator)...765
Check The Rectifier Bridge (Alternator with Integral Regulator)...766
Check Field Winding For The Rotor (All Alternators)...766
Check Windings In The Stator (All Alternators)...767
Brushes And Bearings...767
Check The Voltage Regulator (Alternator with Separate Regulator)...767
Check The Voltage Regulator (Alternator with Integral Regulator)...768
ADJUSTMENTS...768
TROBLESHOOTING...769
2200134...771
INTRODUCTION...771
GENERAL...771
DESCRIPTION...771
Starting System...771
Charging System...771
Vacuum Pump On Alternator (On Units With Brake Booster)...773
REPAIRS...774
STARTER...774
Removal And Disassembly...774
Assembly And Installation...774
REPLACING GLOW PLUGS...776
ALTERNATOR (With Vaccum Pump)...776
Removal And Disassembly...776
Cleaning...778
Assembly And Installation...778
ALTERNATOR (Without Vacuum Pump)...779
Removal And Disassembly...779
Cleaning...781
Assembly And Installation...781
REGULATOR REPLACEMENT...782
CHECKS...782
GENERAL...782
STARTER...782
Starter Operation...782
Solenoid Coil Checks...783
Brush Length...783
Brush Holder...783
Armature...783
Field Windings...784
Clutch And Bearings...784
COLD START AID...784
Glow Plugs...784
Resistor...784
CHARGING CIRCUIT...784
Check For Low Output...784
Check Ford High Output...786
ALTERNATOR...786
Rotor Resistance...786
Diodes Circuit...786
Rotor Coil...787
Stator Coil...787
Diode Assembly...787
Brushes And Bearings...788
REGULATOR (At Hydraulic Tank)...788
TROUBLESHOOTING...789
2200143...792
INTRODUCTION...792
GENERAL...792
DESCRIPTION...792
GENERAL...792
STEERING COLUMN GAUGES, METERS AND INDICATORS...795
LED DISPLAY PANEL...795
Battery Discharge Indicators...795
Brush Wear Indicators...796
Motor Temperature Indicators...797
"LX" SERIES DISPLAY PANEL...798
Hourmeter Functions...799
Battery Indicator Function...799
Status Code Function...799
"ZX" SERIES DISPLAY PANELS...799
Display Panel...800
Basic Display Panels...800
Performance Display...802
Brush Wear Indicators...805
CHECKS AND ADJUSTMENTS...805
GENERAL...805
REPLACEMENT...806
GENERAL...806
METER REPLACEMENT...806
SENDER REPLACEMENT...807
Fuel Level Sender...807
Pressure And Temperature Sender...807
I.T.W. DISPLAY PANEL...808
Removal...808
DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT...809
Removal...809
Replacing Display Panel Assembly...809
Indicator LEDs...809
Battery Indicators...809
Digital Display (Performance Disply Panel Only)...809
Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)...809
Replacing Parts Of The Basic Display Panel...810
Replacing Parts Of The Performance Display Panel...812
DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT...812
Removal And Replacement...812
SPECIFICATIONS...813
TROUBLESHOOTING...814
2200144...815
ELECTRICAL WARNING DEVICES...815
GENERAL...815
DESCRIPTION...815
Operator Controlled Horns...815
System Warning Lights, Buzzers and Bells...815
Reverse Warning Horns...816
Warning Lights...816
REPLACEMENT...817
General...817
Replacing Horns or Bells...817
Replacing Horn Relay or Buzzer...817
Replacing Warning Lights...817
Light Assemblies...818
Replacing Flashing Units...818
22002...819
General...821
Description...821
Alternator Repair...823
Alternator Type A...823
Remove and Disassemble...823
Clean...824
Assemble...824
Install...825
Alternator Type B...828
Remove and Disassemble...828
Clean...828
Assemble...829
Install...830
General Check and Adjustment...831
Low Output Check (Type A or Type B)...831
High Output Check (Type A or Type B)...833
Brushes Circuit Check...834
Delco Alternators...834
Motorola Alternators...835
Diodes Check...836
Diodes Bridge Check...836
Delco and Leece-Neville Alternators...836
Motorola Alternators...836
Rotor Field Winding Check...837
Stator Windings Check...838
Voltage Regulator Check...838
Troubleshooting...839
4000135...841
Safety Procedures When Working Near Mast...843
General...848
Description...848
Lowering Control Valve...848
Cylinders (General)...851
Cylinders (H520-620B, H700-800A)...851
Retainer, Install...851
Cylinders (H360-460B)...853
Cylinders (Two-Speed)...856
Lift Cylinder Repair...857
Lift Cylinder Removal Without Removing Mast...857
Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast...857
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...858
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder...859
Disasemble...859
Assemble...859
Lift Cylinder Installation in Mast...861
Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast...861
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...861
Chevron-Style Packing...861
Chevron-Style Packing Installation on Piston...862
Chevron-Style Packing Installation in Packing Gland...864
Lift Cylinders for Vista Masts...865
Description...865
Lowering Control Valve...865
Remove...867
Disassemble...868
Assemble...869
Install...870
Main Lift Cylinders...870
Free-Lift Cylinder...870
Lift System Leak Check...870
Specifications...871
Troubleshooting...872
4000222...875
INTRODUCTION...875
GENERAL...875
MAST WELDMENTS...875
CARRIAGE...875
MAST MOUNTS...876
VISTA® TWO-STAGE MAST...877
DESCRIPTION AND OPERATION...877
VISTA® FREE-LIFT MAST...879
DESCRIPTION...879
OPERATION...879
VISTA® THREE-STAGE MAST...881
DESCRIPTION...881
OPERATION...881
VISTA® FOUR-STAGE MAST...882
DESCRIPTION...882
OPERATION...883
4000223...885
VISTA MAST, REPAIR...885
GENERAL...885
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...885
FORKS...886
Forks, Removal And Installation...886
CARRIAGE...887
Removal...887
Installation...888
MASTS...888
Removal...888
Disassembly...889
Cleaning and Inspection...894
Assembly...894
Installation...898
SIDE-SHIFT CARRIAGE (EARLIER DESIGN)...899
Removal...899
Repairs...899
Installation...899
SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)...900
Removal...900
Repairs...900
Installation...901
CHECKS AND ADJUSTMENTS...902
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...902
ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...903
LIFT CHAIN ADJUSTMENTS...904
MAST ADJUSTMENTS...904
CARRIAGE ADJUSTMENT...906
HEADER HOSE ARRANGEMENTS...906
Two-Stage Header Hose...907
Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts...907
TROUBLESHOOTING...912
60066...913
MAZDA M4-121G ENGINE...913
GENERAL...913
DESCRIPTION...914
REMOVAL AND INSTALLATION OF THE ENGINE...914
CYLINDER HEAD AND VALVE MECHANISM...914
Cylinder Head, Removal...914
Cylinder Head, Inspection and Repairs...915
Rocker Arm Assembly...915
Valve Guides...915
Valve Seats...916
Valves...916
Valve Springs...916
Cylinder Head, Installation...916
TIMING GEAR CASE, REMOVAL...917
TIMING GEAR CASE, INSTALLATION...918
CAMSHAFT...918
Removal...918
Inspection...919
Cam Followers, Inspection...919
Installation...919
CRANKSHAFT AND MAIN BEARINGS...919
Crankshaft, Removal...919
Crankshaft, Inspection And Repair...920
Main Bearings...921
Crankshaft, Installation...921
PISTONS AND CONNECTING RODS...922
Removal...922
Disassembly...922
Pistons, Inspection And Repair...922
Piston Rings...923
Piston Pin and Bushing...923
Connecting Rods and Bearings, Inspection...923
Pistons and Connecting Rods, Assembly...923
Pistons and Connecting Rods, Installation...924
CYLINDER BLOCK AND CYLINDER LINERS...924
Cylinder Block, Repairs...924
Cylinder Liners...924
DISTRIBUTOR...925
Removal...925
Installation...925
OIL PUMP...927
Removal...927
Repairs...927
Installation...928
GOVERNOR...928
Description...928
Removal...928
Disassembly...929
Assembly...930
Installation...931
COOLANT PUMP...931
Removal...931
Disassembly and Repair...932
Assembly...932
Installation...933
FLYWHEEL...933
Repairs...933
Installation...933
CHECKS AND ADJUSTMENTS...933
ADJUST THE VALVES...933
ADJUST THE THROTTLE LINKAGE...934
ENGINE SPECIFICATIONS...934
ENGINE SPECIFICATIONS...934
Engine Data...934
Cooling System...934
Cylinder Head and Valve Mechanism...934
Camshaft...936
Timing Gear...937
Camshaft...937
Connecting Rods...937
Cylinder Liners...937
Pistons...937
Lubrication System...938
Fuel Pump...938
TORQUE SPECIFICATIONS...939
TROUBLESHOOTING...940
60070...944
INTRODUCTION ...944
GENERAL ...944
DESCRIPTION ...944
FUEL SYSTEM ...945
Description ...945
Operation, Fuel Injection Pump, Model VE ...947
Operation, Fuel Injection Pump, Model PE4A ...948
Pneumatic Governor For Fuel Injection Pump, Model PE4A ...949
Inlet Manifold For Fuel Injection Pump, Model PE4A ...950
REPAIRS ...951
FUEL INJECTION PUMP (ALL MODELS) ...951
Removal ...951
Installation ...951
REMOVAL AND INSTALLATION OF THE ENGINE ...951
CYLINDER HEAD AND VALVE MECHANISM ...951
Cylinder Head, Removal ...951
Valve Guides, Replacement ...952
Cylinder Head, Inspection And Repair ...953
Combustion Chamber Plugs, Inspection And Repair ...953
Combustion Chamber Plugs, Installation ...953
Valves, Inspection And Repair ...954
Valve Seat, Inspection ...954
Valve Seat, Removal ...955
Valve Seat, Installation ...955
Valve Spring, Inspection ...955
Rocker Arms, Inspection And Assembly ...955
Installation Of The Cylinder Head ...956
TIMING GEAR CASE ...957
Removal ...957
Installation ...957
CAMSHAFT ...959
Removal ...959
Inspection ...959
Camshaft Bearings ...960
Cam Followers ...960
CAMSHAFT, INSTALLATION ...960
CRANKSHAFT AND MAIN BEARINGS ...961
Crankshaft, Removal ...961
Crankshaft, Inspection And Repair ...961
Main Bearings ...961
Pilot Bearing ...962
Crankshaft, Installation ...962
FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) ...964
Flywheel, Removal ...964
Ring Gear, Replacement ...964
Flywheel, Installation ...964
PISTONS AND CONNECTING RODS ...965
Pistons And Connecting Rods, Removal ...965
Disassembly ...965
Pistons, Inspection And Repair ...966
Piston Rings, Inspection And Repair ...966
Piston Pins, Inspection And Repair ...967
Connecting Rods, Inspection And Repair ...968
Pistons And Connecting Rods, Assembly And Installation ...968
CYLINDER BLOCK AND CYLINDER LINERS ...968
Cylinder Liners, Inspection ...968
Replacement Of A Cylinder Liner ...969
LUBRICATION SYSTEM ...970
Oil Pump, Removal And Disassembly ...970
Oil Pump, Inspection ...970
Oil Pump, Assembly And Installation ...971
Oil Filter ...971
COOLING SYSTEM ...972
Coolant Pump, Removal ...972
Coolant Pump, Disassembly ...972
Coolant Pump, Assembly And Installation ...972
Thermostat, Replacement ...973
CHECKS AND ADJUSTMENTS ...973
VALVE CLEARANCE ADJUSTMENT ...973
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE ...974
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A ...975
FUEL INJECTORS ...975
Fuel Injectors, Removal ...976
Fuel Injectors, Inspection ...976
Fuel Injectors, Installation ...977
DIESEL FUEL FILTERS ...977
Filter Replacement, Models With A Water Separator ...977
Filter Replacement, Models Without A Water Separator ...978
Filter For The Fuel Injection Pump, Model PE4A ...978
REMOVE AIR FROM THE FUEL SYSTEM ...978
Throttle Linkage, Adjustment ...979
Idle Speed, Adjustment ...979
Check The Elements For The Cold Start Aid System ...979
ENGINE SPECIFICATIONS ...979
TORQUE SPECIFICATIONS ...981
700626...982
General...984
Description...985
Radiator...985
Radiator Cap...985
Thermostat...985
Water Pump...986
Fan and Fan Shroud...986
Cooling System Checks...986
Radiator...986
Thermostat...986
Water Pump...987
Exhaust Leaks...987
Fan and Fan Shroud...987
Radiator Cleaning...987
Drain...987
Clean...987
Fill...988
Troubleshooting...989
8000231...991
General...993
Nomenclature, Threads...993
Strength Identification...994
Fastener Torque Tables...998
Conversion Table...1000
8000259...1002
PERIODIC MAINTENANCE...1002
GENERAL...1002
Serial Number Data...1002
HOW TO MOVE A DISABLED LIFT TRUCK...1003
How To Tow the Lift Truck...1003
HOW TO PUT A LIFT TRUCK ON BLOCKS...1003
How To Raise the Drive Tires...1003
How To Raise the Steering Tires...1004
MAINTENANCE PROCEDURES...1008
EVERY 8 HOURS OR DAILY...1008
HOW TO MAKE CHECKS WITH THE ENGINE STOPPED...1008
Engine Oil...1008
Drive Belts...1008
Cooling System...1008
Battery...1009
Fuel System...1011
Air Filter...1011
Hydraulic System Oil...1011
Tires and Wheels...1012
Forks...1012
Forks, Adjustment...1013
Forks, Removal And Installation...1013
Inspection Of Forks, Mast, and Lift Chains...1014
Safety Labels...1015
Operator Restraint System...1015
HOW TO MAKE CHECKS WITH THE ENGINE RUNNING...1016
Gauges, Lights, Horn, and Fuses...1016
Fuel Filter, Diesel Engine...1017
How To Drain The Water From The Fuel Filter...1017
Oil Level, Powershift Transmission...1017
Control Levers and Pedals...1017
Lift System Operation...1017
Inching/Brake Pedal...1018
Service Brakes...1018
Parking Brake...1018
Steering System...1018
EVERY 250 HOURS OR TWO MONTHS...1019
ENGINE OIL AND FILTER...1019
Mazda, GM, And Later Production Isuzu Engines...1019
Earlier Production Isuzu C240 Engines...1019
GOVERNOR, MAZDA ENGINE...1020
DRIVE BELTS...1020
Mazda Engine...1020
Isuzu, GM 4-181, And GM 4-153 Engines...1020
BRAKE FLUID...1021
HYDRAULIC TANK BREATHER, CLEAN AND CHECK...1021
FORKS, CHECK FOR WEAR AND DAMAGE...1021
LIFT CHAINS...1021
Lubrication...1021
Check For Wear...1021
MAST, LUBRICATION...1022
TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE...1022
CONTROL LEVERS AND PEDALS, LUBRICATION...1023
FUEL SYSTEM, CHECKS AND ADJUSTMENTS...1023
Idle Speed, Diesel...1023
LPG Carburetor...1024
Gasoline Carburetor...1024
EVERY 1000 HOURS OR SIX MONTHS...1025
DIESEL FUEL FILTER...1025
Filter Replacement, Models Without A Water Separator...1026
Filter Replacement, Models With A Water Separator...1026
Remove Air from the Diesel Fuel System...1026
DIFFERENTIAL...1027
VALVE CLEARANCE ADJUSTMENT...1027
IGNITION SYSTEM, MAZDA AND GM ENGINES...1027
PCV VALVE AND FILTER...1029
EVERY 2000 HOURS OR YEARLY...1029
HYDRAULIC SYSTEM...1029
Replace the Hydraulic Oil and Filter...1029
POWERSHIFT TRANSMISSION...1029
COOLING SYSTEM...1030
SERVICE BRAKES...1030
DIFFERENTIAL...1030
WHEEL BEARINGS...1031
Steering Wheels, lubrication...1031
Drive Wheels, Lubrication...1031
GASOLINE FUEL FILTER, REPLACEMENT...1031
PCV VALVE, GM ENGINES...1031
LPG FILTER, REPLACEMENT...1031
FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A...1031
GENERAL PROCEDURES...1032
CHECK THE HOOD LATCH...1032
LIFT CHAIN ADJUSTMENTS...1032
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...1034
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...1035
Check the Lift Cylinders for Leaks...1035
Check the Tilt Cylinders for Leaks...1035
FUEL INJECTORS...1036
WELDING REPAIRS...1036
CHANGES TO THE OVERHEAD GUARD...1036
WHEELS AND TIRES...1036
Solid Rubber Tires (Press-on)...1036
Install The Wheels...1037
Pneumatic Tires, Remove The Wheels From The Lift Truck...1038
Pneumatic Tires, Remove the Tire From The Wheel...1038
Pneumatic Tires, Install The Wheel In The Tire...1039
Pneumatic Tires, Add Air To The Tires...1040
Pneumatic Tires, Install the Wheels...1041
Pneumatic Tires, Installation Procedures, Dual Drive Wheels...1041
SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES...1042
Remove The Wheels From The Lift Truck...1042
Remove The Tire From The Wheel...1042
Install The Tire On The Wheel...1043
REFERENCE TABLE...1044
8000461...1045
FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC...1046
FIGURE 2. TRANSMISSION SCHEMATIC...1047
FIGURE 3. INSTRUMENT PANEL ELECTRICAL DIAGRAM...1048
FIGURE 4. MAZDA ENGINE, GASOLINE/LPG WIRING SCHEMATIC...1050
FIGURE 5. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)...1052
FIGURE 6. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)...1054
FIGURE 7. DIESEL ENGINE WIRING SCHEMATIC...1056
FIGURE 8. DIESEL ENGINE CABLE DIAGRAM (D Rating)...1058
FIGURE 9. DIESEL (SAFETY) ENGINE CABLE DIAGRAM (DS RATING)...1060
FIGURE 10. GM ENGINE, GASOLINE/LPG WIRING DIAGRAM (GS and LPS Rating)...1062
FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)...1064
FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)...1066
800048...1071
LIFT TRUCK WEIGHTS*...1071
ENGINE SPECIFICATIONS...1071
ENGINE ELECTRICAL SPECIFICATIONS...1072
HYDRAULIC SPECIFICATIONS...1072
CAPACITIES...1073
LIFT TRUCK TRAVEL SPEEDS...1073
TIRE SPECIFICATIONS...1073
MAST SPEEDS (Early A177* Units)...1074
MAST SPEEDS (Later A177* Units)...1074
MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)...1075
MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)...1075
TORQUE SPECIFICATIONS...1077
TORQUE SPECIFICATIONS...1078
900129...1080
THE CARBURETOR, (MAZDA M4-121G ENGINE)...1080
DESCRIPTION...1080
REPAIRS, CARBURETOR...1081
Removal...1081
Cleaning...1084
Inspection...1084
Assembly...1084
Installation...1086
CHECKS AND ADJUSTMENTS...1086
Carburetor, Idle Speed And Mixture Adjustment...1086
Adjust The Governor...1087
ADJUST THE THROTTLE LINKAGE...1088
SPECIFICATIONS...1088
TROUBLESHOOTING...1089
90015...1091
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)...1091
GENERAL...1091
DESCRIPTION...1091
Fuel Tank...1092
Fuel Filter And Fuel Valve Unit...1093
Vaporizer...1093
The IMPCO CA 100 Carbureto...1095
IMPCO CA 50 Carburetor...1097
The Governor (GM Engines Only)...1098
Governor With Electronic Controller...1099
REPAIRS...1100
LPG TANK...1100
Removal...1100
Installation...1101
REPLACE THE HOSES...1101
HYDROSTATIC RELIEF VALVE...1101
Removal and Installation...1101
FILTER UNIT...1102
Replacement Of the Fuel Filter Element...1102
Replacement of the Diaphragm and Fuel Valve...1103
VAPORIZER...1103
Removal...1103
Disassembly...1103
Cleaning...1103
Inspection...1103
Assembly...1105
Installation...1105
CARBURETOR (IMPCO CA 100)...1107
Removal...1107
Disassembly...1107
Cleaning...1107
Assembly...1107
Installation...1110
CARBURETER (IMPCO CA 50)...1109
Removal...1109
Disassembly...1109
Cleaning...1110
Inspection...1110
Assembly (See FIGURE 26.)...1110
Installation...1110
CHECKS AND ADJUSTMENTS...1111
CHECK THE FILTER UNIT...1111
CHECK THE VAPORIZER...1111
Pressure Reducer Valve...1111
Vapor Valve...1111
ADJUST THE CARBURETOR...1111
Idle Mixture...1111
Idle Speed...1111
Power Mixture...1111
ADJUST THE GOVERNOR (GM Engines Only)...1112
Checks...1112
Main Adjusting Screw...1112
Secondary Adjusting Screw...1112
AISAN Governor...1113
Adjustment, AISAN Governor...1113
TROUBLESHOOTING...1114
Hyster B177 (H2.00-3.00XL Europe & H40-60XL) Repair Service Manuals
