Hyster D001 (S25-35XM S40XMS) Service Manual - PDF DOWNLOAD

DRIVE AXLE H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

PART NO. 897556

1400 SRM 542

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Drive Axle

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

Drive Axle Repair...............................................................................................................................................

Remove and Disassemble ..............................................................................................................................

Clean and Inspect ..........................................................................................................................................

Assemble and Install .....................................................................................................................................

Torque Specifications .........................................................................................................................................

Troubleshooting..................................................................................................................................................

1 2 2 2 3 3 5 5

This section is for the following models: H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

©2004 HYSTER COMPANY

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"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1400 SRM 542

General

General This section has the description and repair procedures for the drive axle, wheel bearings, and the mounts for the axle housing. See Figure 1.

Information for the differential and ring and pinion gears is in section Single-Speed Powershift Transmission 1300 SRM 543.

Figure 1. Drive Axle Parts

1

Drive Axle Repair

1400 SRM 542 Legend for Figure 1

1.

2.

3.

4.

5.

6.

7.

8.

9.

AXLE HOUSING CAPSCREW STUD AXLE SHAFT WHEEL NUT WHEEL STUD BRAKE ASSEMBLY NUT WASHER

10.

11.

12.

13.

14.

15.

16.

17.

18.

HUB/BRAKE DRUM OUTER SEAL INNER SEAL BEARING LOCKPLATE BREATHER LEVEL PLUG DRAIN PLUG PLUG

19. WASHER (S25-35XM, S40XMS ONLY) 20. CAPSCREW (S25-35XM, S40XMS ONLY) 21. OIL SEAL 22. HUB (CUSHION TIRES) 23. TIRE/WHEEL (CUSHION TIRES)

Description The drive axle is mounted directly to the frame and is held in place by two caps. These caps are fastened to the frame of the lift truck by capscrews. See Figure 1.

The differential housing can move a small amount in the axle mounts. The outer ends of the axle housing are the mounts for the wheel bearings. The wheel bearings are tapered-roller bearings with the cups pressed into the hub/brake drum. The lock nut on the end of the spindle holds and adjusts the wheel

bearings. The axle shafts are fastened to the hubs by capscrews. The back plate and brake assembly are fastened to the axle housing. The axle housing is also the mounting for the mast.

The outer wheel bearing is lubricated with gear oil from the differential housing. The inner wheel bearing is lubricated with wheel bearing grease.

Drive Axle Repair REMOVE AND DISASSEMBLE WARNING When putting the lift truck on blocks, make sure surface is solid, even, and level. Any blocks used to support lift truck must be solid and one piece.

1. Put blocks on each side (front and back) of steering tires to prevent movement of lift truck.

2. Raise lift truck and put blocks under frame so that drive wheels just touch floor. Put blocks under counterweight for stability.

3. Remove mast assembly as described in Mast Repairs 4000 SRM 522.

4. Drain oil from differential.

WARNING On machines with pneumatic tires, completely remove air from tires before removing them from lift truck. Air pressure in tires can cause tire and rim parts to explode, which can cause serious injury or death. Never loosen nuts that

2

hold together inner and outer wheel halves when there is air pressure in tire.

5. Remove wheels. Remove capscrews that hold axle shafts to brake drums. Remove axle shafts.

See Figure 1.

6. Bend lock plate and remove the lock nut from spindle. Remove washer and bearing cone. Slide hub/brake drum from spindle. If assembly cannot be removed easily, loosen brake shoes. Put a screwdriver through hole in back plate to turn adjuster wheel and loosen brake shoes. Pull actuator away from adjuster wheel while adjuster wheel is turned up.

7. Disconnect brake lines to wheel cylinders. Disconnect parking brake cables at parking brake lever. Loosen cable clamps for parking brake cables.

8. Put blocks under transmission housing. The blocks must reach from floor to bottom of transmission. This will prevent any movement of the transmission after the mounting caps are removed.

1400 SRM 542

WARNING The axle housing is heavy. A lifting device must be used to move the axle housing.

9. Support center of axle housing with a transmission-type jack that has a minimum capacity of 115 kg (250 lb). The jack must have four wheels and a flat platform that will properly support the axle housing. Remove capscrews that hold axle housing to transmission housing. Remove capscrews that hold mounting caps to frame.

10. Separate axle housing from transmission. Pull axle housing out from lift truck.

Drive Axle Repair 3. Install new grease seals in hub. Install outer seal with lip toward outer bearing. Install inner bearing and seal. Put wheel bearing grease in bearing that is between seals.

4. Install hub/brake drum assembly on axle housing.

5. Install outer bearing cone on axle housing. Install washer and lock plate. Install lock nut.

Tighten lock nut while rotating hub. Loosen lock nut until hub turns freely. Tighten lock nut to 3.4 N•m (2.5 lbf ft) or until first alignment position. Bend lock plate over lock nut. See Figure 2 and Figure 3.

11. Disassemble brake assembly as described in Brake System 1800 SRM 540. Remove back plate from mounts for axle housing.

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s safety precautions.

1. Clean all parts of drive axle with solvent.

2. Inspect bearings and seals for damage. Spindles must turn freely in mounts. Splines for axle shafts must not be damaged. Replace any damaged parts.

ASSEMBLE AND INSTALL 1. Attach back plate to axle housing. See Figure 1.

Apply Loctite to mounting studs and tighten nuts to 102 N•m (75 lbf ft). Assemble brake assembly onto back plate as described in Brake System 1800 SRM 540.

WARNING The axle housing is heavy. A lifting device must be used to move the axle housing.

2. Put sealant on mounting surface of axle housing. Use jack described in Step 9 in Remove and Disassemble section in this manual to install axle housing on transmission and frame. Tighten capscrews that attach transmission to axle housing. Attach mounting caps and tighten mounting hardware to 72 N•m (53 lbf ft).

Figure 2. Lock Plate Installation 6. Connect brake lines to wheel cylinders. Connect parking brake cables to parking brake lever. Attach cable clamps for parking brake cables.

7. Adjust clearance of brake shoes as described in Brake System 1800 SRM 540.

8. Install the hub bolt and hub nut. Tighten the hub nut to 124 N•m (91.4 lbf ft).

On the H1.50-1.75XM and 9. Install wheels.

(H25-35XM and H40XMS) models, H2.00XMS wheel nuts to 196 to 216 N•m (144.5 tighten lbf ft).

On the S25-35XM and S40XMS to 159.3 tighten capscrews for wheels to 129 N•m models, (95 lbf ft).

10. Put sealant on flange of axle shaft. Install axle shafts and capscrews. Tighten capscrews to 66 N•m (49 lbf ft).

3

Drive Axle Repair

1400 SRM 542

Figure 3. Hub Assembly

4

1400 SRM 542

Troubleshooting Legend for Figure 3

A. S25-35XM, S40XMS B. H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

OUTER SEAL INNER SEAL HUB/BRAKE DRUM AXLE SHAFT DIFFERENTIAL HOUSING NUT

11. Install and tighten drain plug. Fill differential housing with SAE 90 EP gear oil through fill hole. Install plug. Remove air from brake system as described in Brake System 1800 SRM 540.

LOCK PLATE WASHER BEARING CUP AND CONE WHEEL NUT HUB BOLT HUB NUT

12. Install mast as described in Mast Repairs 4000 SRM 522.

Torque Specifications Wheel Nuts, H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS) 196 to 216 N•m (144.5 to 159.3 lbf ft)

Back Plate to Axle Housing Nuts 102 N•m (75 lbf ft) Axle Shaft Capscrews 66 N•m (49 lbf ft)

Wheel Capscrews, S25-35XM, S40XMS 129 N•m (95 lbf ft)

Hub Nut 124 N•m (91.4 lbf ft)

Troubleshooting PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The lift truck will not move.

An axle shaft is broken.

Install new axle shaft.

The drive axle has leaks.

The drain plug or fill plug has damaged threads, is loose, or is missing.

Repair threads, tighten plug, or install new plug as needed.

The O-rings or seals are damaged.

Install new O-rings and seals.

The drive axle housing is cracked.

Install new drive axle housing.

The bearings are damaged.

Install new parts.

The brake assembly is damaged.

Repair brake assembly.

The oil level is low.

Fill as required. Check for leaks.

The axle mounting capscrews are loose.

Tighten capscrews to the specified torque.

The drive axle makes noise.

5

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

6

TECHNICAL PUBLICATIONS 1400 SRM 542

12/03 (2/01)(12/94)(9/93) Printed in U.S.A.

SINGLE-SPEED POWERSHIFT TRANSMISSION DESCRIPTION, OPERATION, AND REPAIRS H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

PART NO. 897557

1300 SRM 543

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Single-Speed Powershift Transmission

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Torque Converter Description and Operation ..................................................................................................

Description .....................................................................................................................................................

Operation .......................................................................................................................................................

Clutch Assemblies Description and Operation ................................................................................................

Description .....................................................................................................................................................

Operation .......................................................................................................................................................

Hydraulic System Operation.............................................................................................................................

Control Valve Operation ....................................................................................................................................

Regulator for Clutch Pressure ......................................................................................................................

Inching Spool Assembly ................................................................................................................................

Direction Spool...............................................................................................................................................

Modulator Circuit ..........................................................................................................................................

Regulator for the Torque Converter..............................................................................................................

MONOTROL® Pedal Operation ........................................................................................................................

Direction Control Lever Operation ...................................................................................................................

Differential Operation .......................................................................................................................................

Torque Converter and Transmission Pump Repair..........................................................................................

Remove and Disassemble ..............................................................................................................................

Inspect ............................................................................................................................................................

Assemble and Install .....................................................................................................................................

Clutch Assemblies Repair..................................................................................................................................

Remove and Disassemble ..............................................................................................................................

Inspect ............................................................................................................................................................

Assemble and Install .....................................................................................................................................

Differential Repair .............................................................................................................................................

Remove and Disassemble ..............................................................................................................................

Inspect ............................................................................................................................................................

Assemble and Install .....................................................................................................................................

New Ring and Pinion Assembly, Install...................................................................................................

Pinion Assembly, Install ...........................................................................................................................

Differential and Ring Gear Assembly, Assemble.....................................................................................

Control Valve Repair..........................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble, Earlier Models.........................................................................................................................

Disassemble, Later Models ...........................................................................................................................

Inspect ............................................................................................................................................................

Assemble, Earlier Models..............................................................................................................................

Assemble, Later Models ................................................................................................................................

Install .............................................................................................................................................................

MONOTROL® Pedal Repair ..............................................................................................................................

Remove and Disassemble ..............................................................................................................................

Assemble and Install .....................................................................................................................................

Direction Control Lever Repair.........................................................................................................................

Remove and Disassemble ..............................................................................................................................

Assemble and Install .....................................................................................................................................

Torque Converter Stall Test ..............................................................................................................................

Transmission Pressure Tests.............................................................................................................................

Transmission Pump Pressure Check, Test Port No. 1.................................................................................

Torque Converter Inlet Pressure Check, Test Port No. 2............................................................................

Clutch Pressure Check, Test Port No. 3.......................................................................................................

©2003 HYSTER COMPANY

1 2 2 2 4 4 5 6 8 8 8 8 8 8 9 9 9 9 9 10 10 11 11 14 14 15 15 15 15 16 19 20 21 21 21 22 22 22 23 23 24 24 24 27 27 27 28 29 30 30 30

i

Table of Contents

Single-Speed Powershift Transmission

TABLE OF CONTENTS (Continued) Inching/Brake Pedal Adjustment......................................................................................................................

Troubleshooting..................................................................................................................................................

This section is for the following models: H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

ii

30 30

1300 SRM 543

General

General The single-speed powershift transmission has forward and reverse clutch assemblies, a torque converter, transmission pump, control valve, and differential assembly. See Figure 1.

The transmission is a constant mesh type in that the gears are in contact with each other at all times. The clutch assemblies are actuated by hydraulic pressure and released by the force of a spring.

NOTE: EARLIER MODEL TRANSMISSION IS SHOWN. LATER MODEL IS SIMILAR. 1. TORQUE CONVERTER HOUSING 2. TRANSMISSION HOUSING 3. DIFFERENTIAL ASSEMBLY

4. CONTROL VALVE 5. SOLENOID VALVE 6. DIPSTICK Figure 1. Transmission

1

Torque Converter Description and Operation

1300 SRM 543

Torque Converter Description and Operation DESCRIPTION The torque converter hydraulically connects the engine to the transmission. There is no direct mechanical connection between the engine and the transmission. See Figure 2.

the stator clutch permits the stator to rotate as a unit with the impeller and turbine.

1. FORCE 2. OUTER RACE (LOCKED)

3. TOOTH LOCKED 4. INNER RACE (FIXED)

Figure 3. Stator (One-Way) Clutch Locked

NOTE: EARLIER MODEL TORQUE CONVERTER IS SHOWN. LATER MODEL IS SIMILAR. 1.

2.

3.

4.

DRIVE PLATE FLYWHEEL ACCESS COVER HOUSING

5. TORQUE CONVERTER 6. OIL PUMP 7. INPUT SHAFT

Figure 2. Torque Converter Arrangement The torque converter has an impeller, a turbine, and a stator with a stator clutch. The impeller is fastened to the flywheel and has a set of curved blades. The turbine also has blades, and is connected to the input shaft of the transmission by splines. The stator is between the turbine and the impeller. The stator clutch is a one-way clutch that permits the stator to turn freely in the direction of engine rotation, but locks to prevent rotation in the opposite direction from engine rotation. See Figure 3 and Figure 4. When the turbine is rotating at the same speed as the impeller,

2

1.

2.

3.

4.

FREE ROTATION OUTER RACE TOOTH UNLOCKED INNER RACE (FIXED)

Figure 4. Stator (One-Way) Clutch Unlocked

OPERATION The torque converter has two main functions. It operates as a fluid clutch to smoothly transfer power from the engine to the transmission. The torque converter will multiply the torque from the engine.

When the engine works against a load, the torque converter can multiply the torque from the engine and send more torque to the transmission. The maximum torque multiplication is available just before the torque converter stalls. If the need for torque multiplication is not required, the torque converter operates as a fluid clutch.

1300 SRM 543

Torque Converter Description and Operation

The impeller has a set of curved blades that accelerates the oil from the center of the impeller when the impeller turns. The volume of the impeller decreases toward the outer circumference. This decreasing volume increases the speed and energy of the oil as it leaves impeller and flows into the outer circumference of the turbine. The force from the high-speed oil hitting the blades in the turbine transfers most of the energy to the turbine and causes it to move in the direction of the engine rotation. The oil then flows from the outer circumference toward the center of the turbine. See Figure 5. The turbine blades change the direction of the oil flow so the oil leaving the center of the turbine is going in the direction opposite of engine rotation. This oil now has a lower velocity because it has given most of its energy to rotate the turbine.

The stator is between the turbine and impeller in the center of the torque converter. When the oil hits the stator blades, the stator clutch prevents the stator from turning in the direction opposite of engine rotation.

The blades of the stator change the direction of the oil so the oil enters the impeller in the direction of engine rotation. The energy that remains in the oil flow as it leaves the stator is added to the new energy being added to the impeller by the engine. This use of energy, controlled by the stator, permits the torque converter to multiply the torque of the engine.

Resistance to the flow of oil in the turbine, because of centrifugal force, increases as the speed of the turbine increases. This resistance decreases the energy and amount of oil flow to the impeller from the stator. When the flow to the impeller decreases, the additional force added to the impeller decreases. Less torque is generated when less torque is needed.

When the lift truck is traveling at a constant speed on level ground, the turbine and impeller rotate at approximately the same speed. See Figure 6. The centrifugal force of the oil is the same for both the impeller and turbine. The oil does not flow through the stator and torque is not multiplied. The rotating oil hits the back of the stator blades and turns the stator in the direction of engine rotation. The stator clutch permits the stator to turn with engine rotation. The impeller, turbine, stator, and oil rotate as a unit when torque multiplication is not required.

A. VORTEX FLOW

B. ROTARY FLOW

Figure 5. Types of Flow When the lift truck begins to travel up a ramp, the resistance to turning the turbine increases. The centrifugal force of the oil in the turbine decreases.

When the speed of the turbine is less than the speed of the impeller, the stator locks in place. Torque is multiplied only when the stator is held by the stator clutch. The oil flows from the impeller, through the turbine and stator, and enters the impeller to multiply the torque. The torque converter again increases the torque when more torque is needed.

3

Clutch Assemblies Description and Operation

1300 SRM 543

Figure 6. Lift Truck at Constant Speed (No Torque Multiplication)

Clutch Assemblies Description and Operation DESCRIPTION The transmission has two clutch assemblies, a forward clutch and a reverse clutch. See Figure 7. The forward and reverse clutch housings are on the input shaft. The input shaft is connected to the turbine of the torque converter. The forward and reverse hubs are always engaged with the output gear and the reverse shaft. Hydraulic pressure is used to apply one of the clutches so power is transmitted from the engine through the transmission to the drive wheels.

Each clutch assembly has a housing, piston, friction discs, and separator plates. The friction discs and separator plates are installed in the housing in a sequence. Each friction disc is next to a separator plate. (The separator plate that is next to the piston has a concave shape.) The separator plates have a smooth metal surface. The friction discs have a friction material on the surface. The hub in each clutch assembly engages with the inner splines of the friction discs. The splines in the outer circumference of

4

the separator plates engage the splines in the clutch housing. A pressure plate holds the friction discs and separator plates in the housing. A large return spring keeps the piston retracted against the housing. There is enough clearance in the clutch assembly to permit the friction discs to rotate when a clutch is not applied. When hydraulic pressure is applied to the piston, the friction discs and separator plates are pressed together and the clutch assembly rotates as a single unit. The hydraulic pressure for the clutches is 1075 to 1370 kPa (156 to 199 psi) measured at the test port for the clutch regulator.

An orifice in each clutch piston permits a small continuous oil flow from the pressure chamber in the clutch. This orifice makes sure the clutch will completely release. The orifice also makes sure oil does not stay in the pressure chamber of the clutch because of centrifugal force after the clutch is released.

1300 SRM 543

Clutch Assemblies Description and Operation

NOTE: ON LATER MODELS, SPACERS AND THRUST WASHERS ARE NEEDLE BEARINGS. 1. SNAP RING 2. BEARING 3. BEARING RETAINER (EARLIER MODELS ONLY) 4. SPACER 5. REVERSE HUB

6.

7.

8.

9.

10.

11.

THRUST WASHER SNAP RING RETAINER SPRING RETAINER PRESSURE PLATE

12.

13.

14.

15.

16.

FRICTION DISC SEPARATOR PLATE PISTON SEAL RING FORWARD HUB

Figure 7. Clutch Assembly The input shaft in the transmission has oil passages that connect the clutch assemblies to the control valve. There are also oil passages in the transmission housing and the clutch assemblies for the lubrication and cooling of the clutch assemblies.

Seal rings on one end of the input shaft seal the oil passages so oil can flow from the passages in the transmission housing to the passages in the input shaft.

OPERATION When the engine is running, the input shaft is turning in the direction of engine rotation. See Figure 8.

When the forward clutch is engaged, the power from

the engine is sent from the input shaft and forward clutch assembly to the output pinion. The flow of power is from the input shaft through the applied clutch to the forward hub. The gear on the forward hub is engaged with the output gear on the pinion of the differential.

When the reverse clutch is applied, the forward clutch is released. The flow of power is from the input shaft and reverse clutch hub to the reverse gear and shaft. The reverse gear and shaft transfers the power to the output gear and pinion. The pinion will rotate in the opposite direction as it did when the forward clutch was applied.

5

Hydraulic System Operation

1300 SRM 543

A. REVERSE

B. FORWARD

1.

2.

3.

4.

5.

6.

7.

8.

INPUT SHAFT REVERSE CLUTCH AND HUB FORWARD CLUTCH AND HUB REVERSE GEAR

REVERSE SHAFT OUTPUT GEAR PINION RING GEAR

Figure 8. Clutch Operation

Hydraulic System Operation The powershift transmission has a hydraulic system for control and lubrication of the transmission. The oil pump for the transmission is driven by the torque converter. See Figure 2. The transmission pump turns with the torque converter when the engine is running. The oil supply for the system is kept in the sump of the transmission. A screen in the suction line to the transmission pump prevents large particles from entering the hydraulic system of the

6

transmission. The oil flows through the screen in the sump, through the transmission pump, by the relief valve, and then through the filter. See Figure 9 or Figure 10. The pressure, which is controlled by the relief valve for the transmission pump, is 1170 to 1470 kPa (170 to 213 psi). From the filter, the oil flows through passages in the transmission housing to the control valve.

1300 SRM 543

1. STRAINER 2. PUMP 3. CLUTCH PRESSURE REGULATOR

Hydraulic System Operation

4. TORQUE CONVERTER REGULATOR 5. TORQUE CONVERTER 6. OIL COOLER 7. OIL FILTER

8. CLUTCH 9. DIRECTION SPOOL (SOLENOID VALVE) 10. MODULATOR SPOOL 11. INCHING SPOOL

Figure 9. Hydraulic Schematic (Earlier Models) Legend for Figure 10 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

STRAINER PUMP CLUTCH PRESSURE REGULATOR TORQUE CONVERTER REGULATOR TORQUE CONVERTER OIL COOLER OIL FILTER CLUTCH DIRECTION SPOOL (SOLENOID VALVE) ACCUMULATOR INCHING SPOOL CHECK PORT

Figure 10. Hydraulic Schematic (Later Models)

7

Control Valve Operation

1300 SRM 543

Control Valve Operation The control valve is installed on the top of the transmission. The inching spool, modulator circuit, regulator for clutch pressure, and regulator for the torque converter are part of the control valve. The position of the inching spool is controlled by the inching/brake pedal. See Figure 20.

A solenoid valve is installed at the side of the control valve. The solenoid valve is actuated by the shift lever. The solenoid valve controls the position of the direction spool.

REGULATOR FOR CLUTCH PRESSURE The regulator for clutch pressure controls the oil pressure for applying the clutches to engage the transmission. The control pressure of the regulator is 1075 to 1370 kPa (156 to 199 psi). Oil that flows to the regulator for clutch pressure flows to the torque converter circuit and oil lubrication circuit. See Figure 20.

DIRECTION SPOOL The direction spool is inside the solenoid valve and controls the oil flow from the inching spool to the direction clutches. The direction spool has three positions: FORWARD, NEUTRAL, and REVERSE. When the direction spool is in its FORWARD position, oil flow and pressure is sent to apply the forward clutch. When the direction spool is in its REVERSE position, oil flow and pressure is sent to apply the reverse clutch. When the direction spool is in its NEUTRAL position, oil pressure to both of the clutches is reduced to approximately zero. When the direction spool is moved to control a direction of travel, oil flows to and from the clutch assemblies and also to the modulator circuit. See Figure 20.

Electric switches in the direction control lever energize and de-energize the solenoid valve. When the direction solenoid is energized, the direction spool changes position to change the flow of oil.

INCHING SPOOL ASSEMBLY

MODULATOR CIRCUIT

Inching is the slow movement of a lift truck while a high engine speed is used for faster operation of the hydraulic system. The inching function is normally used for fine movements of the lift truck when handling a load. Operation of the inching pedal decreases the oil pressure to a clutch so the clutch is not completely applied. See Figure 20.

A modulator circuit is used to control the rate of application of the clutches. When the direction spool is moved to select a direction of travel, the modulator circuit controls the application of the clutch during a 1.50 to 2.0-second period. The modulator circuit controls the pressure increase to apply the clutch smoothly. This delay and smooth application of pressure reduces the shock and stress to the drive train when engaging the transmission or changing directions. See Figure 20.

The inching spool assembly has an inching spool, an inching spool plunger, and two springs. Oil flows to the inching spool from the transmission pump. The inching spool controls the oil flow and pressure to the direction spool (solenoid valve). When the inching function is not used, the oil flows through the inching spool to the direction spool. Operation of the inching function causes a restriction of the oil flow to the direction spool and the clutch. This operation decreases the oil pressure to the direction spool (and clutch) as the inching spool plunger is extended.

When the inching spool plunger is completely extended, the oil pressure to the direction spool (and clutch) is approximately zero. The clutch is then released and the transmission is in NEUTRAL.

8

REGULATOR FOR THE TORQUE CONVERTER When the engine speed is low, the oil flows to the torque converter through an orifice in the bore in the clutch pressure regulator. The pressure regulator for the torque converter stays closed until the pressure to the torque converter increases to 296 to 685 kPa (43 to 99 psi). When the pressure regulator for the torque converter opens, the oil that does not go to the torque converter flows directly to the passage to cool and lubricate of the parts of the transmission. The oil that flows to the torque converter goes through the oil cooler before entering the passage to cool and lubricate the clutches. See Figure 20.

1300 SRM 543

Torque Converter and Transmission Pump Repair

MONOTROL® Pedal Operation The MONOTROL pedal controls the speed of the engine and the operation of the solenoid valve for direction control. The pedal pad is held to the pedal frame by a pivot shaft. The pedal pad rotates on the shaft and is held in the forward or reverse position by magnets in the pedal frame. There are two switches in the MONOTROL pedal assembly. When the MONOTROL pedal is in the forward position,

both pedal switch buttons are actuated. Battery power flows through both pedal switches to energize the solenoid valve and move the direction spool for forward travel. When the MONOTROL pedal is in the reverse position, both pedal switch buttons are released. Battery power flows through both pedal switches to energize the solenoid valve and move the direction spool for reverse travel. See Figure 23.

Direction Control Lever Operation The direction control lever is used to control the operation of the direction spool (solenoid valve). If the lift truck has a direction control lever, an accelerator pedal is used to control the speed of the engine. The movement of the control lever actuates four switches.

In the NEUTRAL position, all of the switches are closed. The lever must be in this position to start

the engine. Moving the lever to the FORWARD position opens the forward switch and closes the reverse switch. This action shifts the direction spool for forward travel. Moving the lever to the REVERSE position opens the reverse switch and closes the forward switch. This action shifts the direction spool for reverse travel. See Figure 28.

Differential Operation The ring and pinion gears transfer power to the axle shafts at right angles to the transmission. The ring and pinion is also a gear reduction which increases the torque to the drive wheels. The differential assembly permits the two drive wheels to turn at different speeds when the lift truck is turning a corner.

The ring and pinion gears are held in position in the transmission case by the differential housing. The housing for the drive axle is fastened to the differential housing. The output gear for the transmission is installed on the pinion shaft. The output gear is in constant mesh with the gears of the forward clutch hub and the reverse shaft.

Torque Converter and Transmission Pump Repair NOTE: The procedure for removal of the transmission is found in the section Frame 100 SRM 545.

1. Remove access cover from top of torque converter housing. See Figure 11.

NOTE: The torque converter cannot be repaired.

2. Remove capscrews that hold drive plate to flywheel.

REMOVE AND DISASSEMBLE CAUTION Be careful to not damage any parts of the torque converter or transmission when the transmission is separated from the engine.

Keep the transmission and engine in alignment until they are completely separated, so the parts of the transmission are not damaged.

Use a crane or lifting device to separate the transmission from the engine.

3. Remove capscrews that hold torque converter housing to engine. Remove starter. Carefully separate transmission from engine. Make sure torque converter stays with transmission.

4. Remove torque converter from transmission.

5. Remove transmission pump from housing. See Figure 12. Disassemble pump as follows:

9

Torque Converter and Transmission Pump Repair a. Remove eight capscrews that hold pump to torque converter housing. Remove two cover capscrews from pump. b. Install two pump mounting capscrews in cover holes. Tighten two capscrews to push pump from housing. c. Remove gears from pump. Remove seal and O-ring from pump.

INSPECT 1. Inspect pump gears for wear or damage.

2. Check all parts that have splines for damage to splines. Check for notches worn in splines.

3. Inspect bushing in pump body for wear or damage.

1300 SRM 543 4. Inspect surface of seal on torque converter for wear or damage.

ASSEMBLE AND INSTALL 1. Apply silicone gasket material to mounting surface of transmission housing. Install torque converter housing on transmission housing. Be sure to align holes in torque converter housing with holes in bearing carrier. When holes are aligned, install housings together. See Figure 11 and Figure 12.

2. Use thread-locking adhesive and install socket head capscrews for bearing retainer. See Figure 14. Tighten capscrews to 10 N•m (7 lbf ft).

Install capscrews that hold housings together and tighten them to 41 N•m (30 lbf ft).

NOTE: EARLIER MODEL HOUSING IS SHOWN. LATER MODEL IS SIMILAR. 1.

2.

3.

4.

ENGINE CRANKSHAFT FLYWHEEL DRIVE PLATE TORQUE CONVERTER

5. OIL PUMP 6. ACCESS COVER 7. TORQUE CONVERTER HOUSING Figure 11. Torque Converter and Housing

10

1300 SRM 543

Clutch Assemblies Repair

3. Assemble transmission pump as follows: a. Lubricate all parts of pump with clean transmission oil. b. Install new oil seal in pump body. c. Install gears and stator shaft on pump body.

Make sure side of drive gear with grooves is toward torque converter. Use gasket sealant on both sides of washers and install two capscrews. Tighten capscrews to 9 to 16 N•m (7 to 12 lbf ft). d. Install new O-ring on pump body.

4. Install pump on housing. Use thread locking adhesive and install capscrews. Tighten capscrews to 20 N•m (15 lbf ft). Check that drive gear rotates freely in body.

5. Install torque converter, making sure notches align with gear in oil pump.

1. O-RING 2. BODY 3. SEAL

4. STATOR 5. BUSHING

Figure 12. Transmission Pump

Clutch Assemblies Repair REMOVE AND DISASSEMBLE 1. Remove torque converter housing.

2. Remove snap ring, bearing, spacer, and reverse gear from reverse shaft. See Figure 13.

3. Remove input shaft and clutch assembly from transmission. See Figure 14.

4. Remove seal rings from both ends of input shaft.

5. Remove snap ring for ball bearing. Use puller to remove bearing carrier and ball bearing.

retainer down. See Figure 15. Remove snap ring for retainer. Remove retainer, spring, and piston. Pull piston from clutch housing. Remove seal from circumference of piston and O-ring from shaft.

WARNING The spring for piston is compressed. Make sure spring and spring retainer cannot cause injury when snap ring is removed.

6. Remove spacer and reverse clutch hub.

NOTE: Some service people make a special bracket so the spring and retainer can be compressed and held with a press to remove snap ring.

7. Remove retaining ring and pressure plate from reverse clutch. Remove friction discs and separator plates.

9. Remove snap ring for ball bearing for forward clutch. Use puller to remove forward clutch hub, spacer, and ball bearing.

8. Remove piston only if there is a problem with piston or seals. Use two punches to push spring

10. Remove remaining clutch parts as described in Step 7 and Step 8.

11

Clutch Assemblies Repair

1.

2.

3.

4.

5.

6.

CLUTCH ASSEMBLY TRANSMISSION HOUSING BEARING CAP RING GEAR PINION BEARING

1300 SRM 543

7.

8.

9.

10.

11.

12.

SHIMS SEAL OUTPUT GEAR WASHER NUT LOCKWASHER

13.

14.

15.

16.

17.

18.

Figure 13. Transmission Arrangement

12

LOCK NUT SNAP RING RETAINER REVERSE SHAFT REVERSE GEAR SPACER

1300 SRM 543

Clutch Assemblies Repair

Figure 14. Clutch Assemblies

13

Clutch Assemblies Repair

1300 SRM 543 Legend for Figure 14

1.

2.

3.

4.

5.

6.

SEAL RING SNAP RING BEARING SPACER FORWARD HUB THRUST WASHER

7.

8.

9.

10.

11.

12.

RETAINER SPRING RETAINING RING PRESSURE PLATE FRICTION DISC SEPARATOR PLATE

INSPECT 1. Inspect gears for clutch assemblies and differential gears for wear or damage.

2. Check all parts that have splines for damage to splines. Check for notches worn in splines.

3. Inspect friction discs for burned lining or bent surfaces. Check for small holes in lining. Replace friction discs if one-half depth of oil grooves are worn away or discs are damaged. Discard friction disc that has thickness less than 1.70 mm (0.067 in.).

4. Check separator plates. Plates must not be bent, have damaged surfaces, or have large blue areas from too much heat.

5. Inspect bearings for wear or damage.

6. Inspect piston for damage. Make sure sealing surfaces are good. Make sure orifice is clean.

13.

14.

15.

16.

17.

PISTON PISTON SEAL CLUTCH HOUSING BEARING RETAINER REVERSE HUB

7. Check for grooves or other damage on machined surfaces of shaft. Check seal rings for damage and wear. Check seal ring surfaces in housing for damage.

ASSEMBLE AND INSTALL NOTE: Lubricate all parts of clutch assemblies with clean transmission oil. See Figure 13 and Figure 14.

1. Use the following procedures for either forward or reverse clutch: a. Install seals on piston and on shaft. Install piston in housing.

WARNING The spring for the clutch must be compressed.

Make sure the spring and spring retainer cannot cause injury when the snap ring is installed.

NOTE: Some service people make a special bracket so the spring and retainer can be compressed and held with a press to install snap ring. b. Install piston spring and retainer. See Figure 15. Use two punches to push spring retainer down. Install snap ring for retainer.

NOTE: There is one separator plate with concave shape in each clutch assembly. c. Install friction discs and separator plates in alternate sequence. Start with separator plate with concave shape. See Figure 7.

Make sure concave side is away from piston, then install remaining friction discs and separator plates. Install pressure plate and retaining ring.

1. PUNCH 2. SNAP RING

3. SPRING RETAINER 4. PISTON

Figure 15. Piston Return Spring

14

d. Install thrust washer and clutch hub. Make sure inner chamfer on thrust washer is toward clutch pack.

1300 SRM 543

Differential Repair

2. On forward clutch, install thrust washer and ball bearing on shaft. Make sure inner chamfer on thrust washer is toward clutch pack. Install snap ring. Install seal rings on shaft.

3. On reverse clutch, install thrust washer so that inner chamfer on thrust washer is toward clutch pack. Apply Loctite 242 in area of bearing carrier for bearing. Install bearing, making sure adhesive does not get into bearing. After adhesive is

dry, install bearing on shaft. Install snap ring and seal ring.

4. Lubricate seal rings and install clutch assembly in housing. See Figure 13 and Figure 14.

5. Install reverse gear, spacer, bearing, and snap ring on reverse shaft.

Differential Repair REMOVE AND DISASSEMBLE 1. Disassemble only parts of differential that must be repaired. If ring gear and pinion are not to be replaced, check contact pattern before disassembly. Pattern and gear clearance are used as references for assembly. See Assemble and Install procedure.

2. Before removing differential assembly, measure outside diameter of case as shown in Figure 16.

This dimension is necessary when assembling parts.

5. Remove outer bearing cup and shims. Make note of shim arrangement. If pinion will not be replaced, shim arrangement will be approximately same when differential is assembled again. Remove inner bearing cup and oil seal.

6. Disassemble differential as needed to make repairs. Remove ring gear from differential case.

Remove roll pin and shaft. Remove differential pinions, side gears, and thrust washers. See Figure 17.

7. If necessary, remove reverse shaft from housing.

Remove capscrews for bearing retainer, then remove shaft assembly. Remove snap ring and bearing from shaft.

INSPECT 1. Check pinion and ring gear for wear. Inspect side gears and differential pinions for worn teeth. Inspect shaft for wear where gears turn. Shaft and holes for shaft in differential case must fit tightly.

2. Check all bearings for wear and damage. Replace worn or damaged parts.

ASSEMBLE AND INSTALL Figure 16. Differential Case Measurement 3. Make note of positions of adjusting nuts for ring gear. Remove bearing caps, adjusting nuts, and differential assembly.

4. Remove nuts and lockwasher from pinion shaft.

Remove output gear. Push pinion shaft from bearings.

NOTE: When a ring gear and pinion are worn or damaged, they must be replaced as a set. Always check that the gears are a matched set.

NOTE: The pinion variation number is on the end of pinion. The number is used to adjust the depth of the pinion in the housing (for example, +0.01 or 0.02). The pinion variation number is indicated in hundredths of millimeters. This procedure is described in the following paragraphs.

15

Differential Repair

1.

2.

3.

4.

5.

1300 SRM 543

THRUST WASHER SIDE GEAR DIFFERENTIAL PINION ADJUSTING NUT BEARING ASSEMBLY

6.

7.

8.

9.

10.

SHAFT DIFFERENTIAL CASE ROLL PIN RING GEAR PINION

Figure 17. Differential Assembly

New Ring and Pinion Assembly, Install 1. The pinion and ring gear are made in sets. See Figure 17. Both ring gear and pinion must have same numbers. When pinion bearings are replaced or ring gear and pinion are replaced, shim arrangement must be adjusted for new parts.

Most service people do not have equipment used by manufacturer to find shim arrangement before differential is assembled. Service people must often make more than one adjustment before clearances are correct. Differential must be disassembled for adjustment and assembled again for checks. Adjustments are correct when gear clearance and contact pattern between pinion and ring gear are correct and preload on pinion bearings is correct.

2. Look at pinion variation number on pinion that is being replaced.

16

Dimension on end of pinion is variation from standard Gauge Distance. Gauge Distance is distance from center of ring gear to bearing shoulder behind pinion. See Figure 18. Shims must be added or removed between outer bearing cup and housing to adjust for manufacturing tolerances.

3. Look at number on pinion that was removed.

Subtract variation number that is on new pinion. Remainder is amount of shim thickness that must be adjusted from shim set on pinion that was removed. For examples, see Table 1. In examples 3 and 4, negative number indicates that shims must be removed. Examples 1 and 2 show that shims must be added to original shim set.

Use this shim set as reference. Final adjustment of shim set is done according to contact pattern on ring gear teeth. See Ring and Pinion Tooth Contact Adjustment.

1300 SRM 543

1.

2.

3.

4.

5.

6.

7.

Differential Repair

BALL BEARING LOCK NUT LOCKWASHER NUT WASHER OUTPUT GEAR BEARING ASSEMBLY

8.

9.

10.

11.

12.

13.

14.

OIL SEAL SHIMS CASE PINION BEARING CAP RING GEAR GAUGE DISTANCE = 127 mm (5 in.)

Figure 18. Ring Gear and Pinion Arrangement Table 1. Pinion Assembly Shims Adjustment Examples Number on OLD PINION minus number on NEW PINION SHIMS to be REMOVED FROM or ADDED TO OLD SET Examples Number on OLD PINION minus number on NEW PINION SHIMS to be REMOVED FROM or ADDED TO OLD SET

1 +0.31 (+0.26)

2 +0.31 ( 0.26)

+0.05 mm Add

+0.57 mm Add

3

4

+0.26 (+0.31)

0.26 (+0.31)

0.05 mm Remove

0.57 mm Remove

17

Differential Repair

1300 SRM 543 Table 2. Ring and Pinion Tooth Contact Adjustment

1. Apply a colored dye or grease to approximately 12 of the ring gear teeth.

2. Rotate ring gear forward and backward so that the 12 gear teeth go past the drive six times to get to the contact patterns. Repeat if needed to get a clearer pattern.

3. Check the tooth contact pattern on the ring gear.

Make sure that the pattern is checked on the side of the tooth where the pinion applies the force.

Correct Tooth Contact The contact area is the center between the top and bottom of the tooth. The contact area is toward the inner circumference of the ring gear.

NOTE: Normal pattern during adjustment shown.

The contact area is the center between the top and the bottom of the tooth. The contact area will be almost the full length of the tooth.

NOTE: Wear pattern from operation shown.

18

1300 SRM 543

Differential Repair

Table 2. Ring and Pinion Tooth Contact Adjustment (Continued) Incorrect Tooth Contact The pinion is too far away from the center of the gear. Add shims to move pinion toward ring gear.

Check that the clearance is correct. Some movement of ring gear away from pinion may be necessary.

The pinion is too close to the center of the ring gear.

Remove shims to move pinion away from the ring gear. Check that the clearance is correct. Some movement of the ring gear toward the pinion may be necessary.

NOTE: If removed, reverse shaft must be installed before output gear is installed. Install bearing retainer, bearing, and snap ring on reverse shaft.

Install reverse shaft and bearing in housing. Use thread-locking adhesive and install capscrews for bearing retainer. Tighten capscrews to 20 N•m (15 lbf ft).

Pinion Assembly, Install 1. Install oil seal in housing. Install inner bearing cup in housing. Install shims and outer bearing cup. See Figure 18.

2. Install pinion in transmission housing. Install inner bearing cone on pinion. Install output gear.

19

Differential Repair

1300 SRM 543

3. Install and tighten pinion nut. Measure gauge distance and add or remove shims until measurement is within 126.9 to 127.1 mm (4.996 to 5.004 in.).

nuts. Tighten one adjusting nut four notches more than zero clearance to put preload on bearings. Correct rotating torque of differential assembly is 2.9 to 3.4 N•m (25.7 to 30.1 lbf in).

4. When measurement in Step 3 is correct, adjust preload on pinion bearings. Tighten nut on pinion shaft until rotating torque is 5.4 to 5.9 N•m (47.8 to 52.2 lbf in). When preload is correct, install lockwasher and lock nut. Lubricate lockwasher with grease before installation. Bend tabs on lockwasher to keep nuts in position.

9. Check clearance between ring gear and pinion.

Ring gear and pinion must have clearance of 0.18 to 0.23 mm (0.007 to 0.009 in.). See Figure 19.

Move ring gear toward pinion to decrease clearance. Move ring gear away from pinion to increase clearance. Loosen one adjusting nut same amount as other adjusting nut is tightened to adjust clearance between ring gear and pinion.

When clearance is correct, apply thread locking adhesive to capscrews for bearing caps. Tighten capscrews to 263 to 314 N•m (194 to 232 lbf ft).

Differential and Ring Gear Assembly, Assemble WARNING Hot parts. Wear protective clothing and gloves to prevent burns.

1. If ring gear was removed from differential case, put ring gear in hot water that is 82 to 105 C (180 to 221 F) for approximately 10 minutes. Remove ring gear from water and put it on differential case. Do not use press or hammer to install ring gear. Tighten special capscrews to 152 to 167 N•m (112 to 123 lbf ft).

2. Lubricate and install side gears and thrust washer in differential case.

3. Install differential pinions and shaft. Install roll pin that holds shaft in case.

4. Install bearing cones on differential case.

5. Apply axle lubricant on inner diameter of bearing cups and on both bearing cones that are installed on differential. Do not permit lubricant on outer diameter of bearing cups or bearing bores of differential housing.

10. Check pattern on teeth of ring gear by applying grease to teeth. Put pry bar between ring gear and housing to keep ring gear from turning freely. Turn pinion shaft. Compare pattern on ring gear teeth with patterns shown in Ring and Pinion Tooth Contact Adjustment. Adjust gear clearances as necessary. Adjustment of pinion to move contact pattern also normally requires adjustment of ring gear clearance as described in Step 9.

11. Measure outside diameter of case as shown in Figure 16. Compare dimension with measurement made during disassembly. They will be approximately the same. Inside diameter of support in axle housing for case is 254.0 to 254.1 mm (9.99 to 10.00 in.).

12. When all adjustments are complete, install cotter pins for adjusting nuts.

6. Install differential assembly into transmission housing. Install bearing cups, adjusting nuts and bearing caps.

7. Install capscrews for bearing caps and tighten them to approximately 68 N•m (50 lbf ft). Use your hand to tighten each adjusting nut against bearing cup.

8. Tighten adjusting nuts to remove clearance between adjusting nuts and bearings. Make sure there is clearance between ring gear and pinion. Loosen adjusting nut only until there is zero clearance between bearings and adjusting

20

Figure 19. Ring Gear and Pinion Clearance Check

1300 SRM 543

Control Valve Repair

Control Valve Repair REMOVE

DISASSEMBLE, EARLIER MODELS

1. Clean area around control valve.

WARNING

2. Disconnect inching spool from crank. Disconnect wires from solenoid valve.

3. Remove capscrews that hold control valve to transmission. Remove control valve. Put cover on top of transmission to keep dirt from inside of transmission.

4. Remove solenoid valve from control valve. Disassemble solenoid valve as necessary. Only O-rings and solenoid coil can be replaced. See Figure 22.

5. Remove the stop for the modulator. Remove the modulator and springs.

There are compressed springs in control valve.

Carefully remove the covers so compressed springs do not cause injury.

1. Remove cover. Remove inching spool assembly.

Remove clutch pressure regulator, torque converter regulator, and springs. Keep springs with regulators. See Figure 20.

2. Remove spring seat for modulator. Remove modulator and springs.

3. Remove pin from inching spool. Remove spring seat, spring, and plunger.

6. Remove the pin from the inching spool. Remove the spring seat, spring and plunger.

1. VALVE BODY 2. CLUTCH PRESSURE REGULATOR 3. TORQUE CONVERTER REGULATOR

4.

5.

6.

7.

8.

SPRING GASKET COVER OIL SEAL INCHING SPOOL

9.

10.

11.

12.

13.

PLUNGER SPRING SEAT PIN STOP MODULATOR SPOOL

Figure 20. Control Valve (Earlier Models)

21

Control Valve Repair

1300 SRM 543

DISASSEMBLE, LATER MODELS WARNING There are compressed springs in control valve. Carefully remove covers so compressed springs do not cause injury.

1. Remove cover. Remove clutch pressure regulator, springs, and stopper. Keep springs with regulator. See Figure 21.

3. Remove pin from inching spool. Remove stopper, springs, and piston.

INSPECT 1. Make sure there are no scratches or damage on spools or in bores.

2. Check that springs are not bent or damaged.

3. Make sure spools move freely in their bores.

2. Remove inching spool assembly.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

VALVE BODY INCHING SPOOL PISTON SPRING PIN STOP SPRING CHECK PORT PLUG BOLT SPRING

SPRING STOP PISTON OIL SEAL COVER COVER GASKET STOP SNAP RING GASKET

Figure 21. Control Valve (Later Models)

ASSEMBLE, EARLIER MODELS NOTE: Lubricate parts of control valve with clean transmission oil during assembly.

22

1. Install modulator spool and springs in control valve. Install stop with new gasket. Tighten capscrews to 12 to 15 N•m (9 to 11 lbf ft). See Figure 20.

1300 SRM 543

Control Valve Repair

2. Install new seal in cover. Install plunger on inching spool. Install spring, spring seat, and pin.

3. Install torque converter regulator, clutch pressure regulator, and springs. Install inching spool and spring. Install new gasket and cover. Be careful not to damage oil seal. Tighten capscrews to 12 to 15 N•m (9 to 11 lbf ft).

2. Install clutch pressure regulator piston, springs, and stopper. Install inching spool assembly, spring, and new oil seal.

3. Install new gasket on cover. Install cover and tighten capscrews to 12 to 15 N•m (9 to 11 lbf ft).

INSTALL 1. Assemble solenoid valve as shown in Figure 22.

Use new O-rings and install solenoid valve.

ASSEMBLE, LATER MODELS NOTE: Lubricate parts of control valve with clean transmission oil during assembly.

1. Install piston on inching spool. Install spring, stopper, and pin. See Figure 21.

2. Use new gasket and install control valve on transmission. Tighten capscrews for control valve 31 N•m (23 lbf ft). Connect wires at solenoid valve.

3. Connect inching spool to crank.

1.

2.

3.

4.

VALVE BODY O-RING COVER SOLENOID COIL

5. TUBE 6. PLUG 7. PLUG Figure 22. Solenoid Valve

23

MONOTROL® Pedal Repair

1300 SRM 543

MONOTROL® Pedal Repair REMOVE AND DISASSEMBLE 1. Disconnect wires at transmission. Remove capscrew that holds pedal to bracket, then remove pedal. See Figure 23.

2. Remove straps that hold wires to pedal. Loosen setscrews in pedal pad 3 to 4 turns and remove pivot pin. Remove pedal pad and spring.

3. Remove retainer for wires. Loosen screws for switches, then remove switches and wires.

4. If necessary, remove lock nuts for magnets, then remove magnets from pedal frame. Make sure screws are tight in magnets. Use thread-locking compound on screws if they are loose in magnets.

ASSEMBLE AND INSTALL NOTE: These sealed switches can only be repaired as an assembly.

1. Install switches and wires in pedal pad. See Figure 23. Align surface of switches with machined surface of mount in pedal pad. Switches must be even with or below alignment surface as shown in Figure 24. Install retainer for wires.

2. Put wires through hole in pedal frame. Install spring and pedal pad on pedal frame. Install pivot pin. Apply thread-locking compound to setscrews. Install and tighten setscrews. Use straps to hold wires to pedal frame.

1.

2.

3.

4.

PEDAL PAD PEDAL FRAME MAGNET PIVOT SHAFT

5. SPRING 6. MAGNET PLATE 7. SWITCH

Figure 23. MONOTROL Pedal

3. Do following procedure to check and adjust pedal assembly. See Figure 25: a. Put pedal assembly in vise. Use dial indicator to measure movement of pedal pad. b. Push reverse side of pedal. Put dial indicator on Reverse side of pedal pad as shown.

Loosen lock nut and rotate screw for magnet counterclockwise until it stops. Set dial indicator to zero. Rotate screw for magnet clockwise until gauge needle moves 0.25 mm (0.01 in.) from zero. This adjustment makes sure magnet is in contact with plate in pedal pad.

1.

2.

3.

4.

PEDAL PAD SWITCH SURFACE OF MOUNT SURFACE OF SWITCH Figure 24. MONOTROL Pedal Switches

24

MONOTROL® Pedal Repair

1300 SRM 543

A. FORWARD

B. REVERSE

1. LOCK NUT 2. MAGNET

3. PLATE 4. DIAL INDICATOR

5. PEDAL FRAME 6. PEDAL PAD

Figure 25. MONOTROL Pedal Adjustment Rotate screw for magnet counterclockwise until gauge needle indicates zero. Rotate screw for magnet clockwise until gauge needle indicates 0.05 mm (0.002 in.) movement.

Tighten lock nut to 5.2 N•m (46 lbf in) without changing adjustment. c. Push on forward side of pedal. Put dial indicator on forward side of pedal pad as shown.

Loosen lock nut and rotate screw for magnet counterclockwise until it stops. Set dial indicator to zero. Rotate screw for magnet clockwise until gauge needle moves 0.25 mm (0.01 in.) from zero. This adjustment makes sure magnet is in contact with plate in pedal pad.

Rotate screw for magnet counterclockwise until gauge needle indicates zero. Rotate screw for magnet clockwise until gauge needle indicates 0.05 mm (0.002 in.) movement.

Tighten lock nut to 5.2 N•m (46 lbf in) without changing adjustment. d. Use ohmmeter to check operation of switches. When forward side of pedal is depressed, there must be complete circuit between red (battery) and black (forward solenoid) wires. When reverse side of pedal

is depressed, there must be complete circuit between red (battery) and yellow (reverse solenoid) wires. e. Push on forward side of pedal. Put dial indicator on forward side of pedal pad as shown.

Connect ohmmeter between red and black wires. Check that there is complete circuit between wires. Push on reverse side of pedal.

Pedal must move 1.00 mm (0.039 in.) minimum from FORWARD position before circuit is disconnected.

NOTE: It is important that magnets have correct strength for correct operation of MONOTROL pedal.

4. Test strength of magnets as follows. See Figure 26: a. Put pedal assembly in vise. Use spring scale to change pedal from FORWARD and REVERSE positions as shown in Figure 26. b. When pushing on spring scale, it must take 13.3 to 31.1 N (3.0 to 7.0 lbf) to change from FORWARD to REVERSE and REVERSE to FORWARD positions. If force is not within specifications, replace magnet(s).

25

MONOTROL® Pedal Repair

1300 SRM 543 5. With pad located in either FORWARD or REVERSE, check to ensure minimum of 2.0 mm (0.079 in.) total pad travel when changed to opposite position. If 2.0 mm (0.079 in.) is not obtained, do adjustment again. If 2.0 mm (0.079 in.) is still not obtained, replace pedal pad.

6. Install capscrew, washers, tube, and nut that hold pedal assembly to bracket. Connect link between pedal and crank as shown in Figure 27.

1. PEDAL PAD

2. SPRING SCALE

7. Install pedal return springs. Make sure throttle cable is connected to correct position as shown in Figure 27.

Figure 26. MONOTROL Pedal Magnets Check

NOTE: A = ALL UNITS, B = GASOLINE/LPG UNITS, C = DIESEL UNITS. PEDAL HEIGHT: GASOLINE = 46.3 mm (1.8 in.), LPG = 32.3 mm (1.27 in.), DIESEL = 41.3 mm (1.6 in.).

1. PEDAL PAD 2. PEDAL FRAME 3. LINK

4. PEDAL STOP 5. CRANK 6. PEDAL HEIGHT Figure 27. MONOTROL Pedal

26

1300 SRM 543

Direction Control Lever Repair

Direction Control Lever Repair REMOVE AND DISASSEMBLE

wheel. Tighten nut for steering wheel to 40 to 54 N•m (30 to 40 lbf ft).

1. Remove steering wheel.

2. Remove back cover from steering column. equipped, remove turn signal switch.

If

3. Disconnect wires at switches for transmission lever. Make sure wires have identification marks for correct installation.

4. Remove capscrews that hold bracket for control lever to steering housing. Remove control lever assembly and switches. See Figure 28.

5. Disassemble control lever assembly as necessary.

ASSEMBLE AND INSTALL 1. Assemble control lever assembly as shown in Figure 28. Tighten nuts that hold control lever to crank to 6.3 N•m (56 lbf in). Make sure spring washers are between cranks and actuator plate.

Tighten nuts for cranks to 7.9 N•m (70 lbf in).

Install detent plungers until they touch crank, then loosen one turn. Fill detent areas with multipurpose grease.

2. Install four switches on switch plate as shown in Figure 29.

3. Use four capscrews and install control lever assembly and switches on steering housing.

4. Connect wires to switches as shown in Figure 29.

5. Start lift truck and operate direction control lever in forward and reverse to make sure lever operates correctly.

1.

2.

3.

4.

5.

6.

MOUNT ACTUATOR PLATE DETENT CRANK CRANK LEVER BOLT

7.

8.

9.

10.

11.

LOCK NUT DETENT PLUNGER SHOULDER BOLT NUT SPRING WASHER

Figure 28. Direction Control Lever

6. If equipped, install turn signal switch. Install back cover on steering housing. Install steering

27

Torque Converter Stall Test

1300 SRM 543

NOTE: COLOR CODES: Y = WHITE, W = GREEN, X = RED, CB = LIGHT GREEN, CC = ORANGE/BLACK. 1.

2.

3.

4.

CONTROL LEVER ASSEMBLY DIRECTION INDICATOR SWITCH PLATE REVERSE CONTROL SWITCH

5. NEUTRAL START SWITCH 6. FORWARD CONTROL SWITCH 7. WIRING HARNESS

8. CONNECTOR TO COWL WIRING HARNESS

Figure 29. Direction Control Lever

Torque Converter Stall Test The stall test checks the condition of the engine, transmission clutches, and the stator clutch in the torque converter. If the engine is not operating correctly, the stall speed will be lower than the stall speed shown in the specification. If the stator clutch does not hold, the oil in the torque converter flows into the impeller in the direction opposite of the engine rotation. This reverse flow of oil prevents the engine from reaching the correct rpm. If the engine speed is greater than the stall speed shown in the specification, the transmission clutches are not holding or the wheels are turning. The transmission clutches will not hold if the clutch pressure is not great enough or the clutches are worn.

Do a stall test to check the operation of the transmission clutches. The engine and hydraulic oil must be at operating temperature. Put a capacity load on the forks to prevent the wheels from turning. (Do not apply the inching/brake pedal or the parking

28

brake. These controls will release the clutches in the transmission.) Connect a tachometer to the engine. Put the lift truck against an object that cannot move. Start the engine, put the transmission in FORWARD, and slowly push the accelerator pedal to full throttle. See Table 3 for stall speeds.

CAUTION Do not hold the throttle open for more than 15 seconds at a time. Operate the engine at idle speed for 2 minutes between tests.

Release the accelerator immediately if the engine speed increases to the speed limit of the governor.

NOTE: Make sure the governor is adjusted correctly.

NOTE: The wheels must not turn during the stall speed test.

1300 SRM 543

Transmission Pressure Tests

• If the stall speed is 50 to 200 rpm below the specification, the engine is not operating at full power.

Check the ignition timing, air filter, fuel system, and compression.

• If the engine speed is 250 to 500 rpm below the specification, the stator clutch has a defect. The torque converter must be replaced as a unit. If the governor is not adjusted correctly, the results will be wrong.

• If the stall speed is greater than the specification, the engaged clutch is not holding or the converter is damaged. Put the transmission in REVERSE to test the other clutch assembly. If the engine rpm is greater than the specification in either direction, do the pressure checks to check for the possible cause.

Table 3. Stall Speeds Engine

Speed

Mazda M4-1.5G Gasoline LPG

1456 to 1656 rpm 1404 to 1604 rpm

Mazda M4-2.0G Gasoline LPG

1482 to 1682 rpm 1435 to 1635 rpm

Mazda M4-2.5D

1679 to 1879 rpm

Transmission Pressure Tests NOTE: See Troubleshooting for causes of pressures that do not meet specifications.

Table 4. Pressure Test Ports (Continued)

See Table 4. These test ports are normally used to check the operation of the transmission. Install three 0 to 2000 kPa (0 to 290 psi) pressure gauges in the test ports shown in Table 4. The regulators in this transmission are adjustable. The pressure tests are for troubleshooting. Before checking the oil pressures, do the following: 1. Operate lift truck until engine and transmission are at normal operating temperatures. Connect tachometer to engine. When engine is at normal operating temperature, make sure engine will operate at governor speed limit.

2. Start engine and tilt mast backward. Put blocks under outer mast channels. Tilt mast forward to raise drive wheels from ground.

Table 4. Pressure Test Ports Item

Specification

Test Port No. 1 Pump Pressure

1170 to 1470 kPa (170 to 213 psi)

LATER MODEL CONTROL VALVE

Test Port No. 2 Torque Converter Inlet

296 to 685 kPa (43 to 99 psi)

Test Port No. 3 Clutch Pressure

1075 to 1370 kPa (156 to 199 psi)

3. All oil pressures are checked while engine is operating at 2000 rpm. Operating temperature of transmission oil is 65 to 70 C (149 to 158 F).

29

Troubleshooting

1300 SRM 543

TRANSMISSION PUMP PRESSURE CHECK, TEST PORT NO. 1 Apply parking brake. Put shift lever in NEUTRAL. If pressure from transmission is not 1170 to 1470 kPa (170 to 213 psi), see Troubleshooting.

TORQUE CONVERTER INLET PRESSURE CHECK, TEST PORT NO. 2 Apply parking brake. Put shift lever in NEUTRAL. If pressure from transmission is not 296 to 685 kPa (43 to 99 psi), see Troubleshooting.

CLUTCH PRESSURE CHECK, TEST PORT NO. 3 1. Put transmission in FORWARD. If pressure is not 1075 to 1370 kPa (156 to 199 psi), see Troubleshooting.

2. Run engine at 2000 rpm and push inching pedal down. Clutch pressure must decrease to approximately zero when inching pedal is fully pushed down.

3. Put transmission in REVERSE. If pressure is not 1075 to 1370 kPa (156 to 199 psi), see Troubleshooting.

4. Run engine at 2000 rpm and push inching pedal down. Clutch pressure must decrease to approximately zero when inching pedal is fully pushed down.

The difference in the forward and reverse clutch pressures cannot be more than 100 kPa (15 psi).

A larger difference in clutch pressures indicates a problem.

Inching/Brake Pedal Adjustment The following adjustment procedure gives a small amount of transmission "inching" as the brakes are applied (called inching/brake "overlap"). This overlap makes the inching function smooth on small grades. As the inching/brake pedal is pushed in, inching/brake overlap occurs. The brakes start to apply and the transmission clutch packs begin to disengage.

Check and adjust the inching/brake pedal if the control valve was removed for repairs. See the section Brake System 1800 SRM 540 for the correct procedure.

Troubleshooting PROBLEM Engine will not start.

30

POSSIBLE CAUSE

PROCEDURE OR ACTION

The parking brake is not applied or the transmission is not in NEUTRAL.

Apply parking brake and put transmission control lever in NEUTRAL.

The parking brake is applied but the switch in the parking brake lever is not operating correctly.

Check and adjust switch. Install new switch.

The neutral start switches at the direction control lever are not connected, out of adjustment, or have damage.

Check connections and adjust switches. Install new switches or parts as necessary.

1300 SRM 543

PROBLEM Transmission is too hot.

There are bubbles in the oil fill tube.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Operator slipping clutches. Excessive inching and trying to push or move loads greater than capacity.

Train the operator. Evaluate application. Handle only loads within rated capacity.

Oil level is not correct.

Check oil level.

Check for leaks.

Clutch does not engage completely.

Install new parts as required.

Clutch pressure is too low.

Check and adjust pressure(s). Repair or install new pressure regulator valve(s). Repair or install new charge pump.

Worn or wrong friction discs or separator plates.

Install new discs and plates.

Engine coolant level low. Radiator core dirty. Cooling system pressure not to specification.

Check and fill cooling system. Clean radiator core. Check system pressure. Install new radiator cap.

Oil cooler in radiator has a restriction.

Flush oil cooler. If problem not corrected, install new oil cooler or radiator.

The torque converter is worn or has damage.

Perform stall test. Repair or install new torque converter.

Clutch discs are bent, release springs are weak, or clutch is not fully releasing.

Repair and install new parts. Overhaul transmission.

Charge pump is worn or damaged.

Repair or install new charge pump.

Clutch assembly will not disengage completely because orifice in piston has a restriction.

Remove restriction. Clean system.

Fill with correct clean oil.

Air leak on the suction side of the transmission charge pump.

Repair leak. Install new parts as required.

Oil level is not correct.

Check and adjust oil to the correct level.

Water in the oil.

Check oil supply and storage. Oil cooler has damage. Install new oil cooler or radiator. Drain system and fill with clean oil.

Fill as required.

31

Troubleshooting

PROBLEM There are bubbles in the oil fill tube. (Cont.)

Lift truck will not move in either direction. Engine is running, direction control lever is in position for travel, and parking brake is released.

32

1300 SRM 543

POSSIBLE CAUSE

PROCEDURE OR ACTION

Oil is too hot.

See Problem "Transmission is too hot."

The torque converter is damaged.

Perform stall test. Repair or install new torque converter.

Switches at direction control lever have damage or are not connected.

Check wiring and adjust switches.

Install new switches.

Transmission oil level is too low.

Check and fill to correct level. Check for leaks.

Axle shaft(s) or transmission/differential is damaged.

Repair or install new parts.

Brakes are not released.

Check operation of parking and service brakes. Repair as required.

Forward and reverse solenoids do not operate.

Check switches at control lever.

Check wiring to solenoids. Check solenoids. Install new parts as required.

Transmission pump is damaged.

Check pressures at the control valve.

Install new pump.

Pressure regulator(s) is in the open position.

Check operation of pressure regulators. Repair or install new parts.

Direction spool will not move.

Check operation of directional spool.

Repair or install new spool.

Torque converter is disconnected from the flywheel.

Check torque converter mounting hardware. Repair as required.

Tube to direction spool is damaged or disconnected.

Check tube. Connect or install new tube.

Control valve gasket is damaged.

Remove control valve and check gasket. Install new gasket.

Control valve is damaged.

Check operation of control valve. Install new control valve.

1300 SRM 543

Troubleshooting

PROBLEM

POSSIBLE CAUSE

Lift truck moves in one direction only.

Inching operation smooth.

is

not

PROCEDURE OR ACTION

Worn or broken seal rings on the clutch assembly that do not engage.

Check clutch pressure to both clutches. If clutch pressure is low to one of the clutches, disassemble transmission and overhaul the clutch.

Clutch parts are damaged.

Check clutch pressure. Check operation of control valve.

Clutch for the direction selected is not engaged.

Check pressure for clutch that is not operating at control valve.

Clutch for opposite direction is not releasing.

Make sure directional spool in control valve is operating correctly. Check to make sure clutch pressure goes to zero when opposite direction is selected.

Control valve gasket is damaged.

Remove control valve and check gasket. Install new gasket.

Control valve is damaged.

Check operation of control valve. Install new control valve.

Brakes are not correctly adjusted.

Adjust brakes.

Inching spool or plunger does not move freely.

Repair or install new parts.

Broken spring(s) for inching spool or plunger.

Install new springs.

Clutch piston does not move freely.

Repair or install new parts.

Control valve has leaks.

Repair or install new control valve.

Clutch discs are bent or burned.

Repair or install new clutch discs.

Inching linkage is not adjusted correctly.

Adjust linkage.

33

Troubleshooting

PROBLEM Clutches do not engage.

(Clutch operating pressures are not correct.)

All pressures are too low.

34

1300 SRM 543

POSSIBLE CAUSE

PROCEDURE OR ACTION

Transmission pump is damaged.

Check pressures at the control valve.

Install new pump.

Control valve gasket is damaged.

Remove control valve. gasket.

Clutch piston does not move.

Check the operation of the modulator valve to determine if the piston moves. Disassemble transmission and repair clutch piston.

Clutch piston seal has a leak.

Check for correct pressure. Disassemble transmission and install new clutch piston seal.

Modulator valve has a leak.

Check operation of modulator valve.

Repair modulator valve. Install new control valve.

Direction spool does not move freely.

Check operation of direction spool.

Repair or install new control valve.

Friction discs are bent or damaged.

Repair and install new parts. Overhaul transmission.

Regulator valves are damaged.

Check pressures. Repair or install new regulator valves.

O-ring on clutch shaft is damaged.

Check clutch pressure. Disassemble transmission and install new O-ring on clutch shaft.

O-rings for solenoid valve stems in the control valve are damaged.

Check operation of solenoid valves.

Install new O-rings or new solenoid valve.

Parts in the control valve are damaged.

Check operation and pressures of control valve. Repair or install new control valve.

Oil level is not correct.

Check oil level.

Check for leaks.

Pressure at the relief valve for the transmission pump is not correct.

See next Problem "Pressure at the relief valve for the transmission pump is not correct."

Worn transmission oil pump.

Install new pump.

Install new

Fill as required.

1300 SRM 543

PROBLEM All pressures are too low.

(Cont.)

Pressure at the relief valve for the transmission pump is not correct.

Clutch pressure is not correct.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Pressure regulators are stuck open.

Check operation of regulator valves.

Install new parts as required.

Leaks inside the transmission.

Check operation of each spool in control valve.

Oil level is not correct.

Check oil level.

Check for leaks.

Worn transmission oil pump.

Install new pump.

Oil filter has a restriction.

Install new filter.

Spring for pump relief valve is damaged. Spool does not move.

Check, clean, and install new parts as required.

The pressure for the relief valve of the transmission pump is not correct.

Check and adjust torque converter relief pressure.

Clutch regulator is not operating correctly or has damage.

Check, clean, and install new parts as required.

Linkage for the inching spool is not adjusted correctly.

Check and adjust linkage for inching spool.

Inching spool and/or direction spool are not operating correctly.

Check, clean, repair, and install new parts as required.

Forward and reverse solenoids do not operate correctly.

Check switches at control lever.

Check wiring to solenoids. Check solenoids. Install new parts as required.

Seals for clutch piston leak.

Verify that clutch piston seals are leaking by checking pressure during operation of modulator valve. Disassemble transmission and install new piston seals.

Fill as required.

35

Troubleshooting

PROBLEM Pressure at the torque converter check port is not correct.

36

1300 SRM 543

POSSIBLE CAUSE

PROCEDURE OR ACTION

The pressure for the relief valve of the transmission pump is not correct.

Check and adjust the pressure relief valve for the transmission pump.

Spring or spool for the torque converter regulator is damaged.

Check, clean, and install new parts as required. Adjust the torque converter pressure.

There is a leak or restriction in the circuit for the torque converter.

Check, clean, repair, and install new parts as required.

The oil cooler circuit has a leak or restriction.

Check, clean, repair, and install new parts as required.

TECHNICAL PUBLICATIONS 1300 SRM 543

12/03 (2/01)(11/94)(11/93)(10/93) Printed in U.S.A.

CAPACITIES AND SPECIFICATIONS H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

PART NO. 897590

8000 SRM 546

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Capacities and Specifications

Table of Contents

TABLE OF CONTENTS Engine Specifications.........................................................................................................................................

Electrical System ...............................................................................................................................................

Hydraulic System...............................................................................................................................................

Lift Truck Weights .............................................................................................................................................

Torque Converter Stall Speeds..........................................................................................................................

Tire Pressure ......................................................................................................................................................

Capacities ...........................................................................................................................................................

Mast Speeds .......................................................................................................................................................

Mazda M4-1.5G Engine Mast Speeds...........................................................................................................

Mazda M4-2.0G Engine Mast Speeds...........................................................................................................

Mazda M4-2.5D Engine Mast Speeds...........................................................................................................

Transmission Oil Pressures...............................................................................................................................

Torque Specifications .........................................................................................................................................

Brake System.................................................................................................................................................

Drive Axle ......................................................................................................................................................

Engine - Mazda M4-1.5G...............................................................................................................................

Engine - Mazda M4-2.0G...............................................................................................................................

Engine - Mazda M4-2.5D...............................................................................................................................

Frame .............................................................................................................................................................

Mast................................................................................................................................................................

Steering System.............................................................................................................................................

Transmission and Differential ......................................................................................................................

1 1 2 2 2 3 3 4 4 4 5 5 6 6 6 6 6 7 8 8 8 8

This section is for the following models: H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

©2002 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 546

Electrical System

Engine Specifications Item

Mazda M4-1.5G*

Mazda M4-2.0G

Mazda M4-2.5D

4

4

4

1-3-4-2

1-3-4-2

1-3-4-2

Bore and Stroke

77 mm × 80 mm (3.03 in. × 3.15 in.)

86 mm × 86 mm (3.39 in. × 3.39 in.)

88.9 mm × 101.6 mm (3.50 in. × 4.00 in.)

Displacement

1489 cm 3 (90.8 in. 3 )

1998 cm 3 (121.9 in. 3 )

2522 cm 3 (153.9 in. 3 )

9.0:1

8.6:1

21:1

1180 kPa (171 psi) @ 300 rpm

1131 kPa (164 psi) @ 270 rpm

2944 kPa (427 psi) @ 200 rpm

226 to 362 kPa (33 to 53 psi) @ 2400 rpm

226 to 362 kPa (33 to 53 psi) @ 2400 rpm

390 kPa (57 psi) minimum @ 1000 rpm

0.25 mm (0.010 in.)

Intake 0.3 mm (0.12 in.)

Exhaust

0.3 mm (0.012 in.) Intake and Exhaust (Cold)

0.45 mm (0.018 in.)

Intake and Exhaust (Cold)

725 ±25 rpm

725 ±25 rpm

775 ±25 rpm

2500 to 2900 rpm

2600 to 2700 rpm

2100 to 2200 rpm

82 to 95 C (180 to 203 F)

82 C (180 F)

75 to 78 C (167 to 172 F)

103 kPa (15 psi)

103 kPa (15 psi)

103 kPa (15 psi)

Fuel Injector Pressure

--

--

13.4 to 13.9 MPa (1944 to 2016 psi)

Fuel Injection Timing

--

--

0 /TDC Static

No. of Cylinders Firing Order

Compression Ratio Compression Pressure Oil Pressure Valve Clearance (Intake/Exhaust)

Idle Speed Governed Speed @ No Load Thermostat Range Cooling System Pressure

*Available in the Far East only.

Electrical System Item All Models

Mazda M4-1.5G*

Mazda M4-2.0G

Mazda M4-2.5D

12 volts, negative ground

12 volts, negative ground

12 volts, negative ground

35 amps

35 amps

40 amps

0 /TDC 10 BTDC

0 /TDC 8 BTDC

ND W14 EXR-U

ND War EXR-U

--

0.8 mm (0.031 in.)

0.8 mm (0.031 in.)

--

Alternator Output

--

Ignition Timing Gasoline LPG Spark Plugs Spark Plug Clearance

*Available in the Far East only.

1

Torque Converter Stall Speeds

8000 SRM 546

Hydraulic System Item

Specification

Hydraulic Pump Type Priority Flow Gasoline/LPG Diesel

Gear 45.8 liter/min (12.1 gal/min) 66.6 liter/min (17.6 gal/min)

Relief Pressures Steering (At Control Valve) Primary (At Control Valve) Secondary (At Control Valve)

5.4 to 5.9 MPa (783 to 856 psi) 17.7 to 18.2 MPa (2567 to 2640 psi) 15.7 to 16.2 MPa (2277 to 2350 psi)

All pressures with oil at 55 to 65 C (130 to 150 F) and engine at 2000 rpm.

Lift Truck Weights Model

kg

lb

H25XM

1870

4125

H1.50XM (H30XM)

2030

4475

H1.75XM (H35XM)

2205

4860

H2.00XMS (H40XMS)

2385

5260

S25XM

1885

4155

S30XM

2060

4545

S35XM

2245

4590

S40XMS

2440

5380

NOTE: Weight is for complete truck without mast.

Torque Converter Stall Speeds Engine

Speed

Mazda M4-1.5G* Gasoline LPG

1456 to 1656 rpm 1404 to 1604 rpm

Mazda M4-2.0G Gasoline LPG

1482 to 1682 rpm 1435 to 1635 rpm

Mazda M4-2.5D

1679 to 1879 rpm

*Available in the Far East only.

2

8000 SRM 546

Capacities

Tire Pressure Bias Ply Tires Tire Size

kPa

psi

5.00 × 8, 8 ply

700

100

5.00 × 8, 10 ply

900

130

6.50 × 10, 10 ply

790

115

6.50 × 10, 12 ply

900

130

Capacities Item Engine Oil (with filter) Mazda M4-1.5G* Mazda M4-2.0G Mazda M4-2.5D

Quantity 3.7 liter (3.9 qt) 4.3 liter (4.5 qt) 7.9 liter (8.3 qt)

Cooling System Mazda M4-1.5G* Mazda M4-2.0G H25-40XM S25-40XM Mazda M4-2.5D

12.0 liter (3.2 gal) 10.8 liter (2.9 gal) 13.8 liter (3.6 gal)

Hydraulic System H25-40XM S25-40XM

30 liter (7.9 gal) 19.7 liter (5.20 gal)

9.1 liter (2.4 gal)

Transmission H25-40XM S25-40XM

9.2 liter (9.7 qt) 7.5 liter (7.9 qt)

Differential

2.5 liter (2.6 qt)

Fuel Tank H25-40XM S25-40XM

30 liter (7.9 gal) 26 liter (6.9 gal)

Brake Fluid

0.3 liter (0.6 pt)

*Available in the Far East only.

3

Mast Speeds

8000 SRM 546

Mast Speeds MAZDA M4-1.5G ENGINE MAST SPEEDS Unit

Lifting No Load m/sec

Lowering Rated Load

ft/min

m/sec

ft/min

No Load m/sec

Rated Load

ft/min

m/sec

ft/min

0.45

89

0.54

106

0.38

75

0.50

98

77

0.51

100

Two-Stage Limited Free-Lift H1.50-1.75XM

.54

106

0.51

100

Two-Stage Full Free-Lift H1.50-1.75XM

.49

96

0.47

93

Three-Stage Full Free-Lift H1.50-1.75XM

0.51

100

0.49

96

0.39

NOTE: Available in the Far East only.

MAZDA M4-2.0G ENGINE MAST SPEEDS Unit

Lifting No Load m/sec

Lowering Rated Load

ft/min

m/sec

ft/min

No Load m/sec

Rated Load

ft/min

m/sec

ft/min

Two-Stage Limited Free-Lift H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS)

0.55

108

0.52

102

0.45

89

0.54

106

S25-35XM, S40XMS

0.55

108

0.53

104

0.47

93

0.51

100

Two-Stage Full Free-Lift H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS)

0.50

98

0.48

94

0.38

75

0.50

98

S25-35XM, S40XMS

0.50

98

0.475

94

0.37

73

0.46

91

Three-Stage Full Free-Lift H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS)

0.52

103

0.49

96

0.39

77

0.51

100

S25-35XM, S40XMS

0.51

100

0.49

96

0.41

81

0.48

94

4

8000 SRM 546

Transmission Oil Pressures

MAZDA M4-2.5D ENGINE MAST SPEEDS Unit

Lifting No Load m/sec

Lowering Rated Load

ft/min

m/sec

No Load

ft/min

m/sec

Rated Load

ft/min

m/sec

ft/min

0.45

89

0.54

106

0.38

75

0.50

98

77

0.51

100

Two-Stage Limited Free-Lift H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS)

0.65

128

0.64

126

Two-Stage Full Free-Lift H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS)

0.60

118

0.58

114

Three-Stage Full Free-Lift H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS)

0.62

122

0.60

118

0.39

Transmission Oil Pressures Item

Specification

Test Port No. 1 (Pump Pressure)

1170 to 1470 kPa (170 to 213 psi)

Test Port No. 2 (Torque Converter Inlet)

296 to 685 kPa (43 to 99 psi)

Test Port No. 3 (Clutch Pressure)

1075 to 1370 kPa (156 to 199 psi)

LATER MODEL CONTROL VALVE

5

Torque Specifications

8000 SRM 546

Torque Specifications BRAKE SYSTEM Axle Shaft Capscrews 66 N•m (49 lbf ft) Back Plate to Axle Mount Capscrews 102 N•m (75 lbf ft) Wheel Nuts (Pneumatic) 204 to 225 N•m (150 to 166 lbf ft) Wheel Nuts (Cushion) 128.5 N•m (94.8 lbf ft) Wheel Stud Assembly Nuts 127 N•m (94 lbf ft)

DRIVE AXLE Axle Mounts to Frame Capscrews 72 N•m (53 lbf ft) Axle Shaft Capscrews 66 N•m (49 lbf ft) Back Plate to Axle Mount Capscrews 102 N•m (75 lbf ft) Wheel Nuts (Pneumatic) 204 to 225 N•m (150 to 166 lbf ft) Wheel Nuts (Cushion) 128.5 N•m (94.8 lbf ft)

ENGINE - MAZDA M4-1.5G Camshaft Nut 69 to 79 N•m (51 to 58 lbf ft) Connecting Rod Cap Nuts 30 to 34 N•m (22 to 25 lbf in) Crankshaft Pulley 156 to 165 N•m (115 to 122 lbf ft) Cylinder Head 85 to 91 N•m (63 to 67 lbf ft) Engine Mount to Engine 41 to 49 N•m (30 to 36 lbf ft) Exhaust Manifold 19 to 26 N•m (14 to 19 lbf ft) Flywheel 71 N•m (52 lbf ft)

6

Flywheel Housing 41 N•m (30 lbf ft) Front Cover 19 to 26 N•m (14 to 19 lbf in) Intake Manifold 19 to 26 N•m (14 to 19 lbf ft) Main Bearing Cap 65 to 69 N•m (48 to 51 lbf ft) Oil Pan 7 to 9 N•m (5 to 7 lbf ft) Oil Pump Shaft 30 to 34 N•m (22 to 25 lbf ft) Spark Plugs 15 to 23 N•m (11 to 17 lbf ft) Starter 41 N•m (30 lbf ft) Thermostat Cover 12 to 18 N•m (9 to 13 lbf ft) Valve Cover 19 to 30 N•m (14 to 22 lbf ft) Water Pump 19 to 26 N•m (14 to 19 lbf ft)

ENGINE - MAZDA M4-2.0G Camshaft Pulley Lock Bolt 48 to 66 N•m (35 to 49 lbf ft) Cooling Fan 8 to 11 N•m (6 to 8 lbf ft) Connecting Rod Cap 51 to 56 N•m (38 to 41 lbf ft) Crankshaft Pulley 30 to 33 N•m (22 to 24 lbf ft) Cylinder Head (Cold) 81 to 88 N•m (60 to 65 lbf ft) Engine Mount to Engine 41 to 49 N•m (30 to 36 lbf ft) Engine Mount Capscrew 66 N•m (49 lbf ft)

8000 SRM 546

Torque Specifications

Exhaust Manifold 22 to 29 N•m (16 to 21 lbf ft)

Camshaft Thrust Plate 16 to 24 N•m (12 to 18 lbf ft)

Flywheel 96 to 103 N•m (71 to 76 lbf ft)

Cooling Fan 16 to 24 N•m (12 to 18 lbf ft)

Intake Manifold 19 to 31 N•m (14 to 23 lbf ft)

Connecting Rod Cap 82 to 90 N•m (60 to 66 lbf ft)

Main Bearing Cap 84 to 90 N•m (62 to 66 lbf ft)

Crankshaft Pulley 343 to 392 N•m (253 to 289 lbf ft)

Oil Pan 7 to 12 N•m (5 to 9 lbf ft)

Cylinder Head 118 to 125 N•m (87 to 92 lbf ft)

Oil Pump M8 Capscrews 19 to 26 N•m (14 to 19 lbf ft) M10 Capscrews 38 to 53 N•m (28 to 39 lbf ft)

Engine Mount to Engine 41 to 49 N•m (30 to 36 lbf ft)

Rocker Cover 30 to 40 N•m (22 to 30 lbf ft) Rocker Shaft Assembly 18 to 27 N•m (13 to 20 lbf ft) Spark Plugs 15 to 23 N•m (11 to 17 lbf ft) Starter 66 to 79 N•m (49 to 58 lbf ft) Thermostat Cover 12 to 18 N•m (9 to 13 lbf ft) Timing Belt Cover Upper Capscrews 8 to 12 N•m (6 to 9 lbf ft) Lower Capscrews 7 to 8 N•m (5 to 6 lbf ft) Timing Belt Tension Lock Bolt 20 to 35 N•m (15 to 26 lbf ft) Torque Converter Housing Adapter M8 Capscrews 21 to 25 N•m (15 to 18 lbf ft) M14 Capscrews 118 to 142 N•m (87 to 105 lbf ft) Torque Converter Housing M10 Capscrews 41 N•m (30 lbf ft) M12 Capscrews 71 N•m (52 lbf ft) Water Pump 19 to 26 N•m (14 to 19 lbf ft)

ENGINE - MAZDA M4-2.5D Camshaft Gear 64 to 95 N•m (47 to 70 lbf ft)

Exhaust Manifold 18 to 22 N•m (13 to 16 lbf ft) Flywheel 206 to 225 N•m (152 to 166 lbf ft) Glow Plug 10 to 15 N•m (7 to 11 lbf ft) Injection Pump Drive Gear 40 to 70 N•m (30 to 52 lbf ft) Intake Manifold 16 to 24 N•m (12 to 18 lbf ft) Main Bearing Cap 110 to 117 N•m (81 to 86 lbf ft) Oil Pan 16 to 24 N•m (12 to 18 lbf ft) Rear Oil Seal 15 to 20 N•m (11 to 15 lbf ft) Rocker Cover 2.7 to 4.1 N•m (24 to 36 lbf in) Rocker Shaft Assembly 118 to 125 N•m (87 to 92 lbf ft) Starter 66 to 79 N•m (49 to 58 lbf ft) Timing Gear Cover 16 to 24 N•m (12 to 18 lbf ft) Torque Converter Housing Adapter 43 to 51 N•m (32 to 38 lbf ft)

7

Torque Specifications Torque Converter Housing 41 N•m (30 lbf ft) Water Pump 16 to 24 N•m (12 to 18 lbf ft)

FRAME Counterweight Capscrews 621 to 746 N•m (458 to 550 lbf ft)

MAST Lift Cylinder Mount Bolts 53 N•m (40 lbf ft) Mast Pivot Capscrews 90 N•m (66 lbf ft)

STEERING SYSTEM Axle Mount Capscrews 41 to 49 N•m (30 to 36 lbf ft) Steering Cylinder Capscrews 294 to 353 N•m (217 to 260 lbf ft) Wheel Bearings (While rotating the wheel) Pneumatic 200 N•m (148 lbf ft) Initial Pneumatic 34 N•m (25 lbf ft) Final Cushion 200 N•m (148 lbf ft) Initial Cushion 3 to 5 N•m (2 to 4 lbf ft) Final Wheel Nuts (Pneumatic Only) 114 to 136 N•m (84 to 100 lbf ft)

8000 SRM 546

TRANSMISSION AND DIFFERENTIAL Control Valve Capscrews Pneumatic 31 N•m (23 lbf ft) Cushion 61 N•m (45 lbf ft) Torque Converter Drive Plate Capscrews 41 N•m (30 lbf ft) Torque Converter Housing Adapter to Engine M4-1.5G Engine (Pneumatic Only) 43 to 51 N•m (32 to 38 lbf ft) M4-2.0G Engine M8 Capscrews (Pneumatic Only) 21 to 25 N•m (16 to 18 lbf ft) M14 Capscrews (Pneumatic Only) 118 to 142 N•m (87 to 105 lbf ft) Cushion Only 96 to 103 N•m (71 to 76 lbf ft) M4-2.5D Engine (Pneumatic Only) 43 to 51 N•m (32 to 38 lbf ft) Torque Converter Housing to Adapter Plate M10 Capscrews 41 N•m (30 lbf ft) M12 Capscrews 71 N•m (52 lbf ft) Transmission Housing to Torque Converter Housing Capscrews 41 N•m (30 lbf ft) Transmission Pump Pneumatic 20 N•m (15 lbf ft) Cushion 21 N•m (15 lbf ft) Differential Bearing Caps 263 to 314 N•m (194 to 232 lbf ft) Ring Gear Capscrews 152 to 167 N•m (112 to 123 lbf ft)

8

TECHNICAL PUBLICATIONS 8000 SRM 546

2/01 (1/95)(10/93) Printed in U.S.A.

*$62/,1( )8(/ 6<67(0 H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

PART NO. 897591

900 SRM 547

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Gasoline Fuel System

Table of Contents

TABLE OF CONTENTS Description .........................................................................................................................................................

Governor.........................................................................................................................................................

Carburetor Repair..............................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Clean ..............................................................................................................................................................

Inspect ............................................................................................................................................................

Assemble ........................................................................................................................................................

Install .............................................................................................................................................................

Carburetor Checks and Adjustments ...............................................................................................................

Idle Speed and Mixture, Adjust ....................................................................................................................

Throttle Linkage, Adjust ...............................................................................................................................

Governor Checks and Adjustments ..................................................................................................................

Troubleshooting..................................................................................................................................................

1 1 2 2 4 6 6 7 10 10 10 10 12 13

This section is for the following models: H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

©2002 HYSTER COMPANY

i

··THE QUALITY KEE PE Rs••

HYSTER APPROVED PARTS

900 SRM 547

Description

Description The fuel tank is part of the frame weldment. See Figure 1. Gasoline flows from the fuel tank through a filter to the fuel pump. The fuel pump is operated by a cam on the engine. The fuel pump sends the gasoline to the carburetor. The carburetor makes sure the correct air-to-fuel mixture goes to the combustion chambers during the different operating conditions of the engine.

new hoses are installed, make sure the correct hoses are installed.

The carburetor has a single venturi. A choke cable from the instrument panel controls the choke plate and the fast idle cam. A fuel solenoid valve quickly stops fuel to the engine when the ignition switch is turned to the OFF position.

NOTE: Parts are not available for repairing the fuel pump. If the fuel pump needs repair, install a new fuel pump.

GOVERNOR The governor keeps the engine speed at the specification limit under all load conditions when the throttle plate in the carburetor is fully open. The governor measures the air pressure above and below the carburetor throttle plate. A piston adjusts the governor throttle plate as needed to control the maximum engine speed. A leaf spring and a coil spring are used to control the tension of the governor throttle plate. The adjustment screw changes the number of coils used by the coil spring. The adjustment wheel changes the tension of the coil spring.

NOTE: Parts are not available for repairing the governor. If the governor needs repair, install a new governor. If a new governor is installed, adjust the governor as described in Governor Checks and Adjustments.

NOTE: The vacuum hoses installed on the governor are made of special high-temperature material. If

1.

2.

3.

4.

5.

CARBURETOR GOVERNOR FUEL PUMP FILTER CAP, FUEL TANK

6. FUEL TANK (PART OF FRAME) 7. FLOAT, FUEL LEVEL SENDER

Figure 1. Gasoline Fuel System

1

Carburetor Repair

900 SRM 547

Carburetor Repair REMOVE WARNING Keep all fire and sparks away from the area used for removal and disassembly. Disconnect the negative cable at the battery to prevent electrical sparks.

NOTE: Use tags for identification and location of vacuum hoses and engine coolant hoses before removal of carburetor and governor.

1. Disconnect air filter hose and vacuum hoses at air inlet tube on carburetor.

2

2. Disconnect fuel line at carburetor. Put cap on open fuel line.

3. Disconnect throttle cable at carburetor. Disconnect solenoid wire at connector.

4. Disconnect vacuum hoses at governor.

5. Disconnect engine coolant lines at carburetor and governor.

6. Remove two nuts from studs that fasten carburetor and governor to inlet manifold. Remove carburetor and governor from inlet manifold. See Figure 2.

900 SRM 547

Carburetor Repair

Figure 2. Carburetor Parts

3

Carburetor Repair

900 SRM 547 Legend for Figure 2

1.

2.

3.

4.

5.

6.

7.

AIR HORN FLOAT BOWL HOUSING THROTTLE BODY ASSEMBLY ACCELERATOR PUMP LEVER CONNECTING ROD CHOKE PLATE ACCELERATOR PUMP SPRING 8. ACCELERATOR PUMP ASSEMBLY

SOLENOID SHUTOFF VALVE POWER VALVE ACCELERATOR WEIGHT FLOAT FLOAT VALVE MAIN JET FUEL JET FOR SLOW SPEED SMALL AIR JET FOR SLOW SPEED 17. AIR JET FOR MAIN NOZZLE 9.

10.

11.

12.

13.

14.

15.

16.

18. THROTTLE ADJUSTMENT SCREW 19. IDLE ADJUSTMENT SCREW 20. THROTTLE PLATE 21. SPRING

DISASSEMBLE Disassemble carburetor as follows: STEP 1.

Remove fuel shutoff solenoid.

Remove pins and clips and disconnect connecting rod from accelerator pump.

Remove screws that fasten air horn to float bowl housing.

1. SOLENOID 2. CONNECTING ROD

4

3. SCREW

900 SRM 547

Carburetor Repair

STEP 2.

Remove mounting spring and accelerator pump from air horn.

Remove pin that holds float. Remove float.

Remove float valve seat, needle valve, spring, and spring seat.

1. MOUNTING SPRING 2. ACCELERATOR PUMP 3. PIN 4. FLOAT

5.

6.

7.

8.

VALVE SEAT NEEDLE VALVE SPRING SPRING SEAT

STEP 3.

Remove screws. Separate float bowl housing from throttle body assembly.

1. SCREW

5

Carburetor Repair

900 SRM 547

STEP 4.

Remove following components from float bowl housing: Check Valve Power Valve Main Jet Fuel Jet for Slow Speed Small Air Jet for Slow Speed Air Jet for Main Nozzle Plug

1.

2.

3.

4.

CLEAN WARNING The solvent for cleaning carburetors is flammable.

Carefully follow the instructions of the manufacturer.

Dirt or water inside or outside the carburetor is often the cause of carburetor problems. It is important that the parts of the carburetor be clean before assembly.

CHECK VALVE POWER VALVE MAIN JET FUEL JET FOR SLOW SPEED

5. SMALL AIR JET FOR SLOW SPEED 6. AIR JET FOR MAIN NOZZLE 7. PLUG

away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION Do not use a wire brush to clean any parts of the carburetor. Do not use a drill or wire to clean the jets or passages of the carburetor.

2. Use compressed air to clean jets and passages of carburetor.

1. Clean metal carburetor parts with carburetor cleaning solvent. See Figure 2. Do not use cleaning solvent to clean float, solenoid valve, and parts that are not metal (seals and gaskets).

3. Use a clean cloth to clean parts that cannot be cleaned in solvent.

Be careful when cleaning plastic and nylon parts on carburetor. Follow instructions of cleaning solvent manufacturer for cleaning plastic parts.

Inspect all carburetor parts for correct operation, wear, or damage. Install new parts as necessary.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure the path of the compressed air is

6

INSPECT

1. Inspect carburetor body for cracks, distortion, or other damage. Inspect each gasket surface for damage.

2. Inspect choke plate, shaft, and linkage for wear and damage. Check for rough edges on choke plate. Make sure shaft for choke plate rotates

900 SRM 547 freely in air horn. Inspect choke return springs for distortion and damage.

3. Inspect throttle plate, shaft, and linkage for wear or damage. Check for rough edges on throttle plate. Make sure shaft for throttle plate rotates freely in throttle body. Inspect throttle bushings and return springs for wear.

Carburetor Repair 9. Check fuel shut-off solenoid. See Figure 3. Touch body of solenoid to negative terminal of 12-volt battery. Touch connector to positive terminal of battery. Solenoid shaft should retract into body of solenoid.

4. Inspect accelerator pump and return spring for wear. Make sure passage in power valve is open.

5. Make sure carburetor jets are clean.

6. Inspect float and inlet valve for wear. Make sure needle moves freely in seat.

7. Inspect carburetor screws and nuts for damaged threads.

8. Inspect hoses for damage and good seal at ports.

Figure 3. Fuel Shutoff Solenoid

ASSEMBLE NOTE: Install new gaskets during the assembly of the carburetor.

Assemble carburetor as follows: STEP 1.

Install following components into float bowl housing: Check Valve Power Valve Main Jet Fuel Jet for Slow Speed Small Air Jet for Slow Speed Air Jet for Main Nozzle Plug

1.

2.

3.

4.

CHECK VALVE POWER VALVE MAIN JET FUEL JET FOR SLOW SPEED

5. SMALL AIR JET FOR SLOW SPEED 6. AIR JET FOR MAIN NOZZLE 7. PLUG

7

Carburetor Repair

900 SRM 547

STEP 2.

Install float bowl housing on throttle body assembly.

Install screws.

Install idle mixture screw and spring in throttle body.

1. SCREW STEP 3.

Install float valve seat, spring, needle valve, and spring seat.

Install accelerator pump into air horn. mounting spring.

Install

Install float and pin that holds float.

1. MOUNTING SPRING 2. ACCELERATOR PUMP 3. PIN 4. FLOAT

8

5.

6.

7.

8.

VALVE SEAT NEEDLE VALVE SPRING SPRING SEAT

900 SRM 547

Carburetor Repair

STEP 4.

Check float level as shown. Adjust valve seat against needle valve to get correct float level.

STEP 5.

Install air horn on float bowl housing. Install screws.

Install connecting rod to connect accelerator pump to lever. Install pins and clips.

Install fuel shutoff solenoid.

1. SOLENOID 2. CONNECTING ROD

3. SCREW

STEP 6.

Choke plate is connected to throttle valve through link. When choke cable is pulled, choke plate closes, and throttle valve is opened approximately 24 degrees so that engine can start.

Hold choke plate closed and measure dimension A. Correct measurement is 1.0 mm (0.039 in.). Bend link to adjust dimension A.

9

Carburetor Checks and Adjustments

900 SRM 547

INSTALL

3. Connect engine coolant hoses to governor.

NOTE: The vacuum and engine coolant hoses installed on the carburetor and governor are made of special high-temperature material. If any of the hoses are replaced, make sure the correct hoses are installed.

4. Connect wire for solenoid shutoff valve.

1. Install gasket and governor on engine manifold studs. Install gasket and carburetor on governor.

Install and tighten nuts on studs.

5. Connect throttle cable to carburetor.

6. Install air inlet adapter on carburetor. Connect inlet adapter to air filter hose. Connect vacuum hose to idle control actuator. Make sure delay valve is installed so that arrow on valve body points toward idle control actuator.

2. Connect vacuum hoses to carburetor and governor.

Carburetor Checks and Adjustments IDLE SPEED AND MIXTURE, ADJUST NOTE: The engine must be at the normal operating temperature.

1. Stop engine and apply parking brake.

2. Check that choke plate is fully open. Connect tachometer to engine.

3. Put transmission in NEUTRAL. Start engine.

4. Turn idle mixture screw until it is against its seat. See Figure 4. Loosen screw 1-1/2 to 2 turns. Loosen idle speed screw until engines runs roughly.

5. Adjust idle mixture screw until engine runs smoothly. Adjust idle speed screw until idle speed is 700 to 750 rpm.

6. Repeat Step 4 and Step 5 until engine runs smoothly at idle speed.

7. Use exhaust gas analyzer to check that CO level is below 4.5%.

8. Stop engine. See Figure 5. Adjust idle control actuator so there is 1 to 2 mm (0.04 to 0.08 in.) between bottom of rod and throttle lever.

1. IDLE SPEED SCREW 2. IDLE MIXTURE SCREW 3. VACUUM HOSE CONNECTION Figure 4. Carburetor Adjustments, Idle Speed and Air/Fuel Mixture

THROTTLE LINKAGE, ADJUST NOTE: Whenever the throttle linkage is disassembled, the throttle cable must be adjusted.

1. Connect throttle cable at pedal. Tighten jam nut at pedal bracket . See Figure 6.

10

900 SRM 547

Carburetor Checks and Adjustments 2. Adjust idle speed of engine by turning idle adjustment screw on carburetor. Correct idle speed is 700 to 750 rpm.

3. Adjust pedal stop until pedal height is 46.3 mm (1.82 in.).

4. Connect cable at carburetor. Adjust length of cable housing so that cable is not loose. With engine running at correct idle speed, change position of cable housing with nuts at bracket.

5. Check that engine speed with throttle wide open and no load is as follows: Mazda M4-1.5G engine - 2500 to 2900 rpm Mazda M4-2.0G engine - 2600 to 2700 rpm Use adjustment screw on carburetor to set engine speed at wide open throttle.

1. IDLE CONTROL ACTUATOR

2. ADJUSTMENT NUTS

Figure 5. Carburetor Adjustments, Idle Control Actuator

NOTE: MONOTROL®PEDAL SHOWN. NOTE: LINKAGE CONNECTIONS: A = ALL UNITS, B = GASOLINE/LPG UNITS, C = DIESEL UNITS 1. PEDAL PAD 2. PEDAL FRAME

3. LINK 4. PEDAL STOP

5. CRANK 6. PEDAL HEIGHT

7. PEDAL BRACKET

11

Governor Checks and Adjustments

900 SRM 547

8. THROTTLE CABLE Figure 6. Throttle Arrangement Linkage

Governor Checks and Adjustments The governor does not normally need adjustment. If adjustment is necessary, do not turn the adjustment screws more than 1/4 turn at a time. If the adjustment screws are turned more than this, the governor can be difficult to adjust.

Before making any adjustments to the governor, check the following: • Make sure the mechanical, electrical, and fuel systems are operating correctly.

• Make sure the tachometer will work with the ignition system.

• Make sure the air filter is clean and connected to the carburetor.

1. Apply parking brake. Run engine at operating temperature.

2. Remove lock wire from lock screw. Loosen lock screw. See Figure 7.

1. ADJUSTMENT WHEEL 2. ADJUSTMENT SCREW

3. LOCK SCREW 4. SPRING

Figure 7. Governor Adjustment Components 3. With no load, run engine at full open throttle to obtain maximum engine speed. See Figure 8.

12

To adjust maximum no load engine speed, hold adjustment screw and turn adjustment wheel.

Turn adjustment wheel clockwise to increase engine speed or counterclockwise to decrease engine speed. Set maximum no load engine speed as follows: Mazda M4-1.5G engine - 2500 to 2900 rpm Mazda M4-2.0G engine - 2600 to 2700 rpm 4. When maximum no load engine speed is set, tighten lock screw.

5. Run engine with throttle fully open, then pull TILT FORWARD lever to increase load on engine.

The governor setting is correct when the engine runs smoothly (without speed changes) and the difference in speed between the load and no load conditions is within the limits of the specifications.

• If engine speed changes, loosen lock screw and turn adjustment screw 1/4 turn clockwise. Set maximum no load engine speed by turning adjustment wheel counterclockwise. Repeat this procedure until engine speed is steady.

• If engine speed difference between load and no load conditions is greater than specification, turn adjustment wheel 1/4 turn clockwise. Set maximum no load engine speed by turning adjustment screw counterclockwise. Repeat this procedure until engine runs correctly.

6. When governor adjustment is correct, tighten lock screw. Install lock wire between lock screw and adjustment screw.

900 SRM 547

Troubleshooting

Figure 8. Governor Adjustments

Troubleshooting PROBLEM The engine will not start or is difficult to start.

POSSIBLE CAUSE

PROCEDURE OR ACTION

The fuel solenoid valve is not operating correctly.

Install new fuel solenoid valve.

The screen at the fuel inlet valve has a restriction.

Clean screen.

The inlet valve needle does not move.

Check, clean, or install new parts as required.

13

Troubleshooting

PROBLEM

900 SRM 547

POSSIBLE CAUSE

PROCEDURE OR ACTION

The engine will not start or is difficult to start. (Cont.)

Choke plate does not move correctly.

Repair choke plate or overhaul carburetor.

The engine speed is faster than the specified governor limit.

The adjustment of the governor is not correct.

Adjust governor.

The governor is not operating correctly.

Install new governor.

Ice is on the throttle plate at 0 to 5 C (32 to 41 F) air temperature.

Heat inlet air. Operate in warmer and drier air.

The vacuum hose has restrictions.

Remove restriction or install new hose.

The fuel solenoid valve is not operating correctly.

Install new fuel solenoid valve.

The choke system does not operate correctly.

Check, clean, and repair choke system.

The adjustment for the float mechanism is not correct.

Check and adjust float level.

The fuel inlet screen has restrictions.

Clean screen.

The throttle assembly is worn or bent.

Repair throttle assembly. Overhaul carburetor. Install new carburetor.

The fast idle speed is too slow.

Adjust fast idle speed.

The idle speed is too slow.

Adjust idle speed.

The adjustment for the idle mixture is not correct.

Adjust idle mixture.

The PCV system is not operating correctly.

Check and clean PCV system. Install new PCV valve.

The air filter has restrictions.

Check air restriction indicator. Clean or install new filter element.

The air jets have restrictions.

Clean or install new air jets.

Ice is on the throttle plate at 0 to 5 C (32 to 41 F) air temperature.

Heat inlet air. Operate in warmer and drier air.

The engine does not run smoothly at idle.

14

900 SRM 547

PROBLEM The smoke from the exhaust is black.

The engine does not accelerate smoothly.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

The air filter has restrictions.

Check air restriction indicator. Clean or install new filter element.

The engine inlet valve(s) will not close or has damage.

Adjust valves. Grind valves. Install new valve springs.

The carburetor float adjustment is not correct (fuel level is too high).

Check and adjust float level.

The float has damage.

Install new float. Check and adjust float level.

The choke plate does not move.

Repair choke plate or overhaul carburetor.

The coolant hose has a restriction.

Remove restriction. Install new hose.

The choke linkage is not connected.

Connect and adjust choke linkage.

The coolant temperature sensor is not operating correctly.

Replace the coolant temperature sensor.

The fuel pressure is too low.

Check fuel pressure. Install new fuel pump.

The air filter has a restriction.

Check air restriction indicator. Clean or install new filter element.

The adjustment of the carburetor float mechanism is not correct.

Adjust float level.

The fuel inlet screen has a restriction.

Clean screen.

The main jet has a restriction.

Clean or install new main jet.

The operation of the throttle valve is not correct.

Repair throttle assembly. Overhaul carburetor. Install new carburetor.

The operation of the fuel solenoid valve is not correct.

Install new fuel solenoid valve.

The operation of the power piston is not correct.

Check, clean, or install new power piston. Overhaul carburetor.

The operation of the power valve is not correct.

Check, clean, or install new power valve. Overhaul carburetor.

The accelerator pump is not operating correctly.

Repair, clean, or install new accelerator pump.

15

Troubleshooting

PROBLEM The engine does not accelerate smoothly. (Cont.)

The engine does not run smoothly at idle with light load or hot conditions.

16

900 SRM 547

POSSIBLE CAUSE

PROCEDURE OR ACTION

The inlet check valve has a restriction or is damaged.

Check, clean, or install new parts as required.

The outlet check valve has a restriction or is damaged.

Check, clean, or install new parts as required.

The idle compensator valve does not open when hot.

Repair or install new idle compensator valve.

The idle speed diaphragm has leaks.

Install new diaphragm.

The delay valve is not operating correctly.

Install new delay valve.

The delay valve is not installed correctly.

Install delay valve correctly.

The vacuum hose to the idle speed diaphragm has leaks.

Check vacuum hose. hose.

Install new

TECHNICAL PUBLICATIONS 900 SRM 547

2/01 (12/94)(11/93) Printed in U.S.A.

INSTRUMENT CLUSTER J2.00-3.20XM (J40-60XM) [A216]; N30-40XMR2, N25XMDR2 [B470]; N50XMA2 [B471]; S1.25-2.00XM (S25-40XM) [C010, D010]; H1.25-2.00XM/XMS (H25-40XM/XMS) [D001, E001]; E1.50-2.00XMS (E25-40XMS) [D114]; S2.00-3.25XM (S45-65XM) [D187]; E2.00-3.20XM (E45-65XM) [F108]; N30XMDR2, N45XMR2 [F138]; H2.00-3.20XM (H40-65XM) [H177]

PART NO. 897495

2200 SRM 514

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Instrument Cluster

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

Display Panels on Steering Column, Internal Combustion ........................................................................

Display Panels on Steering Column, Electric Lift Trucks...........................................................................

Standard Display Panel ............................................................................................................................

Enhanced Display Panel ...........................................................................................................................

Curtis 1215 Display Panel ............................................................................................................................

Description and Features..........................................................................................................................

Operation ...................................................................................................................................................

Cluster-Type Display Panel (Internal Combustion) Replacement ..................................................................

Remove and Disassemble ..............................................................................................................................

Assemble and Install .....................................................................................................................................

Cluster Display Panel (Electric Lift Truck) Replacement ...............................................................................

Display Panel Assembly, Replace .................................................................................................................

LED Indicators ..............................................................................................................................................

Battery Indicators..........................................................................................................................................

Digital Display (Enhanced Display Panel Only)..........................................................................................

Status Code or Performance Level Switches and LED indicators (Enhanced Display Panel Only) ........

Standard Display Panel Parts, Replace .......................................................................................................

Enhanced Display Panel Parts, Replace ......................................................................................................

Curtis 1215 Display Panel Replacement ..........................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

1 1 1 6 6 7 11 11 11 12 12 15 17 17 17 18 18 18 18 19 19 19 19

This section is for the following models: J2.00-3.20XM (J40-60XM) [A216]; N30-40XMR2, N25XMDR2 [B470]; N50XMA2 [B471]; S1.25-2.00XM (S25-40XM) [C010, D010]; H1.25-2.00XM/XMS (H25-40XM/XMS) [D001, E001]; E1.50-2.00XMS (E25-40XMS) [D114]; S2.00-3.25XM (S45-65XM) [D187]; E2.00-3.20XM (E45-65XM) [F108]; N30XMDR2, N45XMR2 [F138]; H2.00-3.20XM (H40-65XM) [H177]

©2004 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

2200 SRM 514

Description

General This section has the description and the repair procedures for the instrument clusters used on the XM model lift trucks. Senders that have signals for some of the meters and indicators are described in the section Instrument Panel Indicators and Senders 2200 SRM 143.

Description DISPLAY PANELS ON STEERING COLUMN, INTERNAL COMBUSTION The instrument cluster is installed around the steering column housing. See Figure 1 and Figure 5. The

instrument cluster has a series of gauges and indicator lights that help let the operator know about the condition of the lift truck and its systems. A list of the gauges and indicator lights and their operation is shown in Table 1.

Figure 1. Instrument Cluster, Internal Combustion Trucks Table 1. Instrument Cluster, Internal Combustion Item No. 1

Item Fuel Gauge

Function This gauge indicates the amount of fuel in the gasoline or diesel fuel tank. The sending unit for the fuel gauge is in the fuel tank. If the fuel gauge does not work, check the wiring or replace the sending unit or gauge. To check the wiring, see the service manual section for Diagrams.

1

Description

2200 SRM 514

Table 1. Instrument Cluster, Internal Combustion (Continued) Item No. 2

Item Coolant Temperature Gauge

Function

CAUTION Do not continue to operate the lift truck when the gauge indicates that the engine is too hot (needle in the red zone).

This gauge indicates engine coolant temperature when the key is in the ON position. During normal operation, the gauge needle will be in the green area. The sending unit for the coolant temperature gauge is in the cylinder head. If the temperature gauge does not work, check the wiring or replace the sending unit or gauge. To check the wiring, see the service manual section for Diagrams.

3

Hourmeter

The hourmeter operates when the key is in the ON position. Periodic Maintenance recommendations are based on these hours.

4

Left-Hand Turn Indicator (Optional)

The light is on when the turn indicator lever is in the left turn position.

5

Warning Light, Alternator

CAUTION Do not continue to operate the lift truck if the red light is ON at engine speeds above idle.

The light will be ON when the key is in the ON position and the engine is not running and must go OFF when the engine is running. If the light does not function correctly, check the alternator as described in the section for the Electrical System 2200 SRM 560. To check the wiring, see the service manual section for Diagrams.

6

Warning Light, Transmission Oil Temperature

CAUTION Do not continue to operate the lift truck if the red light is ON. The red light is ON when the key is in the START position and must go OFF when the engine is running. The sending unit for the temperature light is at the bottom of the transmission housing, on the front side. If the temperature light does not work, check the wiring or replace the sending unit or light. To check the wiring, see the service manual section for Diagrams.

2

2200 SRM 514

Description

Table 1. Instrument Cluster, Internal Combustion (Continued) Item No. 7

Item Warning Light, Engine Oil Pressure

Function

CAUTION Stop the engine immediately if the red light is ON while the engine is running.

The red light is ON when the key is in the ON position and the engine is not running and must go OFF when the engine is running. The sending unit for the warning light is in the engine block.

If the warning light does not work, check the wiring or replace the sending unit or light. To check the wiring, see the service manual section for Diagrams.

8

Warning Light, Brake Fluid Level

CAUTION Do not continue to operate the lift truck if the light is ON during operation.

The red light is ON when the key is in the START position and must go OFF when the engine is running. If the light is ON when the engine is running, the brake fluid level in the reservoir is low. There is a float in the master cylinder that actuates the warning light. If the light does not work, check the wiring or the master cylinder or replace the light. To check the master cylinder, see the service manual section for the Brake System. To check the wiring, see the service manual section for Diagrams.

9

Warning Light, Coolant Level in the Radiator

CAUTION Do not continue to operate the lift truck if the light is ON during operation.

The red light is ON when the key is in the START position and must go OFF when the engine is running. If the light flashes when the engine is running, the level of the coolant in the radiator is too low. The sending unit for the warning light is in the top of the radiator. If the warning light does not work, check the wiring or replace the sending unit or light. To check the wiring, see the service manual section for Diagrams.

3

Description

2200 SRM 514

Table 1. Instrument Cluster, Internal Combustion (Continued) Item No. 9

10

Item Coolant Level/Hot Warning Light Used ONLY On Later Model H/S2.00-3.20XM (H/S40-65XM) Trucks

Warning Light, Fasten Seat Belt

Function

CAUTION Do not continue to operate the lift truck if the light is ON during operation.

The red light is ON when the key is in the START position and must go OFF when the engine is running. If the light flashes when the engine is running, the level of the coolant in the radiator is too low. The sending unit for the warning light is in the top of the radiator. If the warning light does not work, check the wiring or replace the sending unit or light.

The light will also come on when the coolant temperature reaches 121 C (250 F).

To check the wiring, see the service manual section for Diagrams.

WARNING Always fasten the seat belt when operating the lift truck.

The red light is ON for 10 seconds any time the key is put in the ON position. This warning light is activated by a switch in the seat. If the light does not work correctly, check the switch or wiring or replace the circuit board. To check the wiring, see the service manual section for Diagrams.

4

11

Warning Light, Water in Fuel Filter (Diesel Only)

The red light is ON when the key is in the START position and must go OFF when the engine is running. If the light is ON when the engine is running, there is water in the fuel filter.

The sending unit for the warning light is in the fuel filter. If the warning light does not work, check the wiring or replace the sending unit or light. To check the wiring, see the service manual section for Diagrams.

12

Indicator Light, Cold Start (Diesel Only)

The red light is ON when the key is in the ON position and the glow plugs are activated. The length of time that the light is ON (glow plugs activated) is determined by the temperature of the engine. When the light goes out, the engine can be started. When the starter is cranking, the light will come ON again until the starter is off and the engine is running.

2200 SRM 514

Description

Table 1. Instrument Cluster, Internal Combustion (Continued) Item No.

Item

Function

13

Malfunction Indicator Lamp (Only on units with GM 3.0L engine or low emissions exhaust system)

The light will be ON when the key is in the ON position and the engine is not running. This light will illuminate when the ECM computer senses a fault in the operation of the engine. If the engine will start, the operation of the engine will not be correct until the fault is corrected. If this light is ON when the engine is running, a trained service person must make repairs and adjustments. See the Electronic Engine Control section for your lift truck model.

14

Indicator Light, Low LPG Fuel Level

The red light is ON when the key is in the START position and must go OFF when the engine is running. If the light is ON when the engine is running, the fuel level in the tank is low. The sending unit for the light is in the fuel line at the fuel filter. If the warning light does not work, check the wiring or replace the sending unit or light. To check the wiring, see the service manual section for Diagrams.

15

Indicator Light, Air Filter Restriction

The red light is ON when the key is in the START position and must go OFF when the engine is running. If the light is ON when the engine is running, the air cleaner has a restriction and needs cleaning. The sending unit for the light is in the canister for the air filter. If the light does not work, check the wiring or replace the sending unit or light. To check the wiring, see the service manual section for Diagrams.

16

Right-Hand Turn Indicator (Optional)

The light is on when the turn indicator lever is in the right turn position.

17

Engine Oil Pressure Gauge

CAUTION Do not continue to operate the lift truck when the gauge indicates low oil pressure (needle in the red area).

This gauge indicates the pressure of the oil in the engine. During normal operation, the gauge needle will be in the green area. The sending unit for the gauge is in the engine block. If the gauge does not work, check the wiring or replace the sending unit or gauge. To check the wiring, see the service manual section for Diagrams.

5

Description

2200 SRM 514

Table 1. Instrument Cluster, Internal Combustion (Continued) Item No. 18

Item

Function

Voltmeter

CAUTION Do not continue to operate the lift truck when the gauge indicates in the yellow or red areas of the gauge.

This gauge indicates the output of the alternator.

During normal operation the gauge needle will be in the green area. If the gauge does not work correctly, check the alternator as described in the Electrical System 2200 SRM 560. See the service manual section for Diagrams to check the wiring.

19

Key Switch

The key switch has three positions: No. 1 Position: OFF position. De-energizes all electric circuits except for the horn.

No. 2 Position: ON position. Energizes all electric circuits except the starter circuit. The key switch will be in this position during normal operation.

No. 3 Position: START position. Energizes the starter motor for starting the engine. A spring returns the key to position No. 2 (ON position) when the key is released.

NOTE: There is a mechanical lockout that prevents the key switch from being returned to the START position without first being returned to the OFF position.

DISPLAY PANELS ON STEERING COLUMN, ELECTRIC LIFT TRUCKS There are two display panels available on electric lift trucks: • A standard display panel gives the operator basic information about the operation of the lift truck.

• An enhanced display panel also includes diagnostic capabilities, more indicators, and performance settings.

Standard Display Panel When the key is first moved to the ON position, a start program will cause each LED indicator (LightEmitting Diode) to illuminate to show that the LED is functioning. See Figure 2.

This display panel has the following components:

6

1. Hourmeter. The hourmeter display shows the operating time of 0000 to 9999 hours. The time for the traction circuit is shown for four seconds after the lift truck has been operating and the key is moved to the OFF position.

2. Battery Indicator. This battery indicator has a green, yellow, and red band to indicate the voltage of the battery. The battery must have a current draw (load) to check the battery charge.

Hold the tilt or rotate lever in the BACKWARD position and look at the indicator. If the needle is in the red band, charge the battery. Operating the lift truck when the battery needs charging can decrease battery life. Continued operation with a discharged battery can damage the battery, motors, or the contactors. See the section Battery Indicators 2260 SRM 138 for a more complete description of the operation and the adjustment and repair procedures.

2200 SRM 514

Description

Standard Display 18-Pin Connector

1.

2.

3.

4.

Pin

Function

1-11 12 13 14

No Connection Battery Negative ( ) Parking Brake Switch Brake Fluid Switch

Pin 15 16 17 18

HOURMETER BATTERY INDICATOR WARNING LED, PARKING BRAKE INDICATOR WARNING LED, BRAKE FLUID RESERVOIR IS LOW

Function Hyd. Contactor Coil Seat Switch Key Switch (IGN) Battery Positive (+) from Fuse 6 5.

6.

7.

8.

WARNING LED, FASTEN SEAT BELT RED/BRN "IGN" TERMINAL BRN "BAT" TERMINAL KEY SWITCH LEADS

Figure 2. Standard Display Panel and Plug Connector, Electric Trucks 3. Warning LED, parking brake indicator. The red LED is ON when the parking brake is applied and the seat switch is closed, and goes OFF when the parking brake is released.

A buzzer is ON for 8 to 10 seconds if the parking brake is NOT applied and the seat switch opens or the key is moved to the OFF position.

4. Warning LED, brake fluid reservoir is low.

The red LED is ON for 1 second when the key switch is moved to the START position and must go OFF during operation. If the warning LED is ON during operation, the brake fluid level in the reservoir is too low.

5. Warning LED, fasten seat belt. The red LED is ON for 8 to 10 seconds after the key switch is moved to the ON position.

Enhanced Display Panel When the key is moved to the ON position, a start program will cause each warning and LED indicator to illuminate to show that the indicator is functioning. See Figure 3.

This display panel has the following functions: 1. Battery Charge Indicator with Lift Interrupt. This battery charge indicator shows the battery charge with an LED bar graph. There are four green bars, four orange bars, and two red bars. When the battery is discharged during operation, the LED bar that is illuminated decreases sequentially from the top green bar through the orange bars to the red bars. When the battery is discharged to approximately 70 to 75%, the red LED bars are illuminated and the lift interrupt function will not permit operation of the hydraulic motor. The battery must be

7

Description charged or a charged battery must be installed before lift truck operation can continue. The top green bar will be illuminated when the battery is more than 90% charged.

The controller also checks the battery voltage each time a battery is connected. The traction control will prevent lift truck operation if the battery voltage is not correct as set by traction function 15. A status code of 16 (voltage too high) or 15 (voltage too low) will indicate on the digital display. The battery can have a voltage that is too high or too low. A battery with the correct voltage can also be deeply discharged from use or other reasons and have a voltage that is less than the minimum of the voltage range.

Batteries that have different ampere-hour ratings or are of different ages can sometimes be used in the same lift truck. It can be necessary to adjust traction function 14 of the EV-100ZX motor controller so that the weakest battery is not damaged. Follow the procedure for adjusting traction function 14 in one of the following service manual sections: EV-100ZX™ SCR Motor Controller 2200 SRM 557 or EV-T100™ Transistor Motor Controller 2200 SRM 581.

2. Digital Display. This four-digit LED display is blank when the lift truck is operating correctly.

The status codes and the hourmeter values are shown on this display. When the status code Indicator is illuminated, the status code is shown.

When the hourmeter and either the hydraulic motor or traction motor indicators are illuminated, the operating hours are shown. When a problem occurs, the status code will be shown with a dash ( ) in the left digit position together with three numbers. The warning LED for the service interval will also be illuminated when a problem occurs.

When it is time for periodic maintenance, the warning LED for the service interval will be illuminated and a status code -99 will be indicated.

The traction motor or hydraulic motor indicator will also be illuminated to show which system needs maintenance. The register in the controller card must be reset by the service person before the service interval LED will go OFF. The digital display for the hourmeter shows the operating time of 0000 to 9999 hours. The time for the traction circuit is shown for 4 seconds after the lift truck has been operating and the key

8

2200 SRM 514 is moved to the OFF position. The LED indicators for the traction motor and for the hourmeter will also be illuminated during this time. If there is an SCR control card for the hydraulic pump motor, the operating time of the pump motor will then be shown on the digital display for another 4 seconds. The LED indicators for the hydraulic motor and for the hourmeter will also be illuminated during this last 4 seconds.

3. Warning LED, Fasten Seat Belt. The red LED is ON for 8 to 10 seconds after the key switch is moved to the ON position.

4. Warning LED, Brake Fluid Reservoir Is Low. The red LED is ON for 1 second when the key switch is moved to the START position and must go OFF during operation. If the warning LED is ON during operation, the brake fluid level in the reservoir is too low.

5. Warning LED, Parking Brake Indicator.

The red LED is ON when the parking brake is applied and goes OFF when the parking brake is released.

A buzzer is ON for 8 to 10 seconds if the parking brake is NOT applied and the seat switch opens or the key is moved to the OFF position.

6. LED Indicator, Steering Pump Motor. This LED will illuminate with another warning LED if the brushes in the steering pump motor are too worn. If the brush wear sensor is activated in the motor, the warning LED for brush wear will go ON and the LED indicator for the steering pump motor will show that this motor has the problem.

7. Warning LED, Motor Brushes are Worn.

When the sensor for brush wear closes, this warning LED and the LED indicator for the motor that has the problem will both illuminate.

The indicator will stay ON until the key is moved to the OFF position.

8. LED Indicator, Traction Motor. This LED will illuminate with another warning LED if the traction motor is too hot or the brushes are too worn. For example, if the brush wear sensor is activated in the motor, the warning LED for brush wear will go ON and the LED indicator for the traction motor will show that this motor has the problem.

2200 SRM 514

Description

Enhanced Display 18-Pin Connector Pin 1 2 3 4 5 6 7 8 9 10

Function Traction Card PY 5 Pump Card PY 5 No Connection Traction Card PY 14 Traction Card PY 13 Pump Card PY 14 Pump Card PY 13 No Connection Traction Card PY 4 Pump Card PY 4

Pin 11 12 13 14 15 16 17 18

Function Brush Wear Indicator & Temperature Jumper* * Parking Brake Switch Brake Fluid Switch No Connection No Connection Key Switch (IGN) No Connection

*Pin 11 to 12 jumper (in wire harness). Brush Wear Indicator (BWI) and temperature LEDs disabled if cut.

1. BATTERY CHARGE INDICATOR WITH LIFT INTERRUPT 2. DIGITAL DISPLAY 3. WARNING LED, FASTEN SEAT BELT 4. WARNING LED, BRAKE FLUID RESERVOIR IS LOW 5. WARNING LED, PARKING BRAKE INDICATOR 6. LED INDICATOR, STEERING PUMP MOTOR 7. WARNING LED, MOTOR BRUSHES ARE WORN (TRACTION, HYDRAULIC, OR STEERING) 8. LED INDICATOR, TRACTION MOTOR

9. LED INDICATOR, HYDRAULIC MOTOR 10. WARNING LED, MOTOR TEMPERATURE OVER LIMIT (TRACTION OR HYDRAULIC) 11. WARNING LED, SERVICE INTERVAL 12. LED INDICATOR, HOURMETER 13. PUSH BUTTON, DISPLAY STATUS CODES 14. PUSH BUTTON, SET PERFORMANCE LEVEL 15. PERFORMANCE LEVEL INDICATORS (4 LEDS) 16. RED/BRN "IGN" TERMINAL 17. BRN "BAT" TERMINAL 18. KEY SWITCH LEADS

Figure 3. Enhanced Display Panel and Plug Connector, Electric Trucks 9. LED Indicator, Hydraulic Motor. This LED will illuminate with another warning LED if the hydraulic pump motor is too hot or the brushes are too worn. For example, if the temperature

over limit switch closes in the motor, the warning LED for the motor temperature over limit will go ON and the LED indicator for the hydraulic motor will show that this motor has the problem.

9

Description 10. Warning LED, Motor Temperature Over Limit. The traction motor and the hydraulic pump motor have thermal switches inside the motors. When the temperature increases to the limit, the thermal switch closes and the warning LED on the display panel illuminates. The LED indicator for the traction motor indicator or for the hydraulic motor will show which motor has the problem. The maximum travel speed will also be decreased to speed limit 1.

11. Warning LED, Service Interval. When it is time for periodic maintenance, the warning LED, service interval indicator will be illuminated and a status code -99 will be indicated. The register in the controller card must be reset by the service person before this warning LED will go OFF. The warning LED will also be illuminated when a problem occurs.

12. LED Indicator, Hourmeter. This LED will illuminate with another indicator when hours of operation are shown on the digital display. Refer to the previous Digital Display for the complete description of operation.

13. Push Button, Status Codes. With the key in the OFF position, this push button will cause the status codes for the problems to be shown on the digital display. When the button is held down for 1 or 2 seconds, the LED indicator for the traction motor will illuminate. The status codes in memory for the detected problems will be displayed, starting with the most recent problem. The system will go through 16 traction codes, then automatically go through 16 pump motor codes. If the button is pushed again, the display will start from the beginning again. The hourmeter time and the battery charge at the time of the problem will not be shown. A handset or a personal computer (PC) must be used to show this additional information. A handset or a PC must be used to clear the status code from the register.

For the correct procedures for using the handset or PC, see EV-100ZX™ SCR Motor Controller 2200 SRM 557 or EV-T100™ Transistor Motor Controller 2200 SRM 581.

If the button is pushed briefly, released, then held down for 1 or 2 seconds, the LED indicator for the hydraulic motor will illuminate. The status codes in memory for the detected problems will be displayed, starting with the most recent problem. If the button is pushed twice to start the sequence again, the display will start from

10

2200 SRM 514 the beginning. The hourmeter time at the time of the problem will not be shown. A handset or a PC must be used to show this additional information. A handset or a PC must be used to clear the status code from the register. For the correct procedures for using the handset or PC, see EV-100ZX™ SCR Motor Controller 2200 SRM 557 or EV-T100™ Transistor Motor Controller 2200 SRM 581.

14. Push Button, Set Lift Truck Performance.

The lift truck can be set to any one of four performance levels by the operator. If the customer does not want this function available to the operator, a service person can set all four levels to the same setting. Each time the operator pushes the yellow button, the performance level will increase by one step. After the maximum (rabbit) level, the performance levels will begin at the lowest (turtle) level again. The four performance levels set by the manufacturer are: a. Lowest performance for handling fragile loads and lowest rate of consumption of battery energy. b. Medium travel and lift speed and some increase in consumption of battery energy. c. Higher performance with higher consumption of battery energy. d. Highest level of lift truck performance with maximum consumption of battery energy.

A service person can adjust the performance settings with either a PC or the handset (functions 48 through 62). For the correct procedures for using the handset or PC, see EV-100ZX™ SCR Motor Controller 2200 SRM 557 or EV-T100™ Transistor Motor Controller 2200 SRM 581.

The four performance levels can be set to any level up to the maximum limits. Two or more adjacent performance levels can be set to the same limits. The performance levels must be set at the same or in ascending order (from turtle to rabbit). The register interlocks will not permit a higher performance level setting toward the turtle than the adjacent registers toward the rabbit.

The lower performance level is always to the left (turtle).

15. LED Indicators, Performance Level. These four LEDs show which performance level has been selected. The LEDs illuminate in sequence from low performance (turtle) to maximum performance (rabbit).

2200 SRM 514 Status Code Memory. The control cards for the traction motor controller and hydraulic pump motor each have memory registers in which the last 16 status codes can be stored. Each status code is stored with the hourmeter time at the time of the problem. Traction cards with Battery Discharge Indicator (BDI) can also show the battery charge at the time of the problem. The status code for the last problem will be indicated on the digital display. If the key is moved to the OFF position, the status code will be removed from the digital display. The push button for the status codes can be used to show these status codes on the digital display.

CURTIS 1215 DISPLAY PANEL Description and Features NOTE: See the section Battery Indicators 2260 SRM 138 for a more complete description of the operation and the adjustment and repair procedures.

This display panel is a rectangular display unit that operates with the main interface board and the traction motor controller. See Figure 4. The panel is located in the front cover over the battery compartment of the N30-45XMR, N25-30XMDR, and N50XMA lift trucks. It is used exclusively with the Curtis 1215 traction motor controller. For additional information, see the section Traction Motor Controller and Handset 2200 SRM 608.

1.

2.

3.

4.

5.

6.

BATTERY CHARGE INDICATOR MESSAGE DISPLAY SELECTABLE FUNCTION HOURMETERS SELECTABLE FUNCTION DRIVE MODES HYDRAULIC FUNCTION INDICATORS LOW-BATTERY LIFT INTERRUPT INDICATOR

Description Two different versions of the display panel are available, depending on ambient temperature.

Standard models

25 to 70 C ( 13 to 158 F)

Freezer models

40 to 70 C ( 40 to 158 F)

Operation 1. The battery indicator has a 10-bar multicolor diode (LED) to indicate battery charge status.

The bars are green, yellow, and red. As power is used, the LEDs will turn off, starting with green, then yellow, then red. The red LED second from the bottom will flash, indicating a nearly discharged battery. The bottom red LED will alternately flash with the LO-Battery LED indicator (a crossed battery symbol), indicating a discharged battery. The lift function will be disallowed at this point. Continued operation with a discharged battery can damage the battery, motor, or the contactors. See Figure 4.

2. The message center is a 16-character, dot matrix, liquid crystal display (LCD) with green backlighting. The 16-character, alphanumeric display shows the hourmeter readings, lift truck performance status, and warning or fault conditions. When a warning message is received, the warning/fault indicator will blink as a yellow light. When a fault message is received, the warning/fault indicator will blink as a red light.

3. The instrument display hourmeter switch is controlled by the operator and is used for on-demand display of hourmeter information. The hourmeter data can be displayed at any time by pressing the hourmeter switch. The switch is marked with an hourglass symbol. Press once to display truck hours to 1/10 of an hour. Press twice to display drive motor hours. Press three times to display the lift motor hours. Press four times to return to the normal display mode. After 30 seconds, the display will return to the normal display mode, which indicates the current operational status of the truck.

4. The drive mode display allows the operator to select the level of traction motor controller performance most suited to the application. Operation of the drive mode switch will cause the green

Figure 4. Curtis 1215 Display Panel

11

Cluster-Type Display Panel (Internal Combustion) Replacement indicators and corresponding drive modes to increase from Turtle to Mid to Rabbit. The following describes these modes as programmed from the factory: • Turtle mode provides slower acceleration, reduced top speed, and maximized energy efficiency. It is also a valuable setting when training new operators.

• Mid mode reduces acceleration with full travel speed.

• Rabbit mode provides maximum acceleration and travel speed. When the key switch is turned to OFF, the selected drive mode is retained. When the battery is disconnected, the drive mode returns to the Rabbit mode.

The rates of acceleration and travel speeds are programmable and can be adjusted by a qualified

2200 SRM 514

service technician. See the section Traction Motor Controller and Handset 2200 SRM 608 for additional information. Refer to Programming Traction Motor Controller.

5. The LED function selection lights display the selected hydraulic function. Status messages will be displayed for lift, tilt, reach, and sideshift.

The function selection lights will display the current hydraulic function, independent of the present LCD display.

The instrument display is powered when the key switch is ON. The instrument panel contains an internal backup battery that is capable of memory retention of the battery indicator and hourmeter readings when the battery is disconnected.

Cluster-Type Display Panel (Internal Combustion) Replacement REMOVE AND DISASSEMBLE CAUTION To prevent damage to electrical components, disconnect negative battery cable before removing covers.

1. Remove steering control unit as described in the following sections: • Steering Housing and Control Unit 1600 SRM 512 for S/H2.00-3.20XM (S/H40-65XM) • Steering Housing and Control Unit 1600 SRM 720 for S/H1.25-1.75XM, S/H2.00XMS (S/H25-35XM, S/H40XMS) NOTE: Newer instrument cluster panels have turn signals that are red. The turn signals on older model cluster panels are green.

2. For older model instrument cluster panels, disconnect the two wiring harnesses at the instrument cluster. See Figure 5, Figure 7, and Figure 8. For newer model instrument cluster panels, disconnect the 24-pin and 6-pin pig tail connections and the ground wire at the steering column. See Figure 6 and Figure 8.

3. Remove screws that hold instrument cluster to steering housing.

12

1. INSTRUMENT CLUSTER 2. WIRING HARNESS (24-PIN CONNECTOR) 3. WIRING HARNESS (6-PIN CONNECTOR) Figure 5. Instrument Cluster Mounting (Older Model Cluster Panels)

2200 SRM 514

Cluster-Type Display Panel (Internal Combustion) Replacement

NOTE: Newer instrument clusters are non-repairable and must be replaced with a new unit. If the ignition switch fails, it is replaceable and can be installed without replacing the instrument cluster.

4. Remove screws that hold cover to housing. For older instrument clusters, replace parts in cluster as necessary. Parts in cluster cannot be repaired.

Legend for Figure 6 (Continued) 24-PIN CONNECTOR FUNCTIONS 1

Malfunction Indicator (GM Gas Only)

2

Cluster Ground

3

Diesel Fuel Filter

4

Low Brake Fluid Level

5

Low Fuel Level (LPG)

6

Glow Plug

7

Engine Oil Pressure

8

Transmission Oil Temperature

9

Air Filter Restriction

10

Low Coolant Level

11

Charging Circuit

12

Left Turn Signal

13

Engine Oil Pressure Gauge

14

Right Turn Signal

15

Fuel Gauge

16

Coolant Temperature

17

Not Used

18

Not Used

19

Reversed

20

Forward

21

Not Used

22

Not Used

23

Parking Brake

24

Seat Switch 6-PIN CONNECTOR FUNCTIONS

1.

2.

3.

4.

5.

6.

WIRING HARNESS (24-PIN CONNECTOR) WIRING HARNESS (6-PIN CONNECTOR) GROUND WIRE RING TERMINAL MOUNTING SCREWS INSTRUMENT CLUSTER STEERING COLUMN

Figure 6. Instrument Cluster Mounting (Newer Model Cluster Panels)

1

Ignition

2

Accessory

3

Not Used

4

Starter

5

Battery

6

Battery

13

Cluster-Type Display Panel (Internal Combustion) Replacement

2200 SRM 514

Figure 7. Instrument Cluster, Internal Combustion Engine Trucks (Older Model Cluster Panels)

14

2200 SRM 514

Cluster-Type Display Panel (Internal Combustion) Replacement Legend for Figure 7

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

COVER FOAM GASKET BULB CIRCUIT BOARD INDICATOR STRIP BULB HOUSING GASKET HOURMETER ENGINE OIL PRESSURE GAUGE VOLTMETER

ASSEMBLE AND INSTALL NOTE: Newer instrument clusters are non-repairable and must be replaced with a new unit. If the ignition switch fails, it is replaceable and can be installed without replacing the instrument cluster.

1. Install parts in instrument cluster that were removed or replaced as shown in Figure 7. Make sure seal is installed between housing and cover.

2. Install instrument cluster on steering housing.

Install and tighten four capscrews. On older model cluster panels, connect the two wiring harnesses at the instrument cluster. See Figure 5 and Figure 8. For newer model cluster

11.

12.

13.

14.

15.

16.

17.

18.

19.

CIRCUIT BOARD (RIGHT-HAND) FUEL GAUGE WATER TEMPERATURE GAUGE CIRCUIT BOARD (LEFT-HAND) ALARM SEAL HOUSING SCREW KEY SWITCH panels, connect the 24-pin and 6-pin pig tail connections and the ground wire to the steering column. See Figure 6 and Figure 8.

3. Install steering control unit and cover as described in the following sections: • Steering Housing and Control Unit 1600 SRM 512 for S/H2.00-3.20XM (S/H40-65XM) • Steering Housing and Control Unit 1600 SRM 720 for S/H1.25-1.75XM, S/H2.00XMS (S/H25-35XM, S/H40XMS) 4. Connect battery. Check that gauges and indicators operate as described.

15

Cluster-Type Display Panel (Internal Combustion) Replacement

2200 SRM 514

Figure 8. Instrument Cluster Schematic, Internal Combustion Engine Trucks

16

2200 SRM 514

Cluster Display Panel (Electric Lift Truck) Replacement

Cluster Display Panel (Electric Lift Truck) Replacement Each of the two display panel assemblies, standard and enhanced, can be replaced as a unit.

assembly. See Standard Display Panel Parts, Replace.

NOTE: Most parts of the standard display panel can be replaced. However, the LED indicators cannot be replaced separately. The LEDs are part of the circuit board assembly. The major replaceable parts of this display panel are: • Key switch • Housing, top cover, and O-ring seal • Housing and light filter for LED warning lights • Battery indicator • Hourmeter and gasket • Buzzer and circuit board • Jumper harness and the wires to the key switch

The LED indicators of the enhanced display panel cannot be replaced. If these LED indicators are faulty, replace display panel. See Display Panel Assembly, Replace.

NOTE: The only replaceable parts of the enhanced display panel are the O-ring seal, key switch, wires to the key switch, and the housing that fastens to the steering column. All other parts of the panel must be replaced as a single unit. See Display Panel Assembly, Replace.

DISPLAY PANEL ASSEMBLY, REPLACE Follow this procedure to replace the standard or enhanced display panel as an assembly.

1. Disconnect battery and remove key.

2. Remove front steering column cover with display panel assembly attached. Carefully disconnect 18-pin connector, key switch wires, and two-pin connector (on standard panel only) from inside column cover.

3. Remove four screws that fasten display panel to column cover.

4. Install replacement display panel assembly to cover of steering column and tighten screws. Install connectors and key switch wires. On standard panel, set DIP switches near connector for panel to voltage of lift truck. See Figure 9. Move DIP switch for correct voltage to up position and all others to down position. Install column cover on steering column.

LED INDICATORS The LED indicators of the standard display panel are part of the circuit board and must be replaced as an

ON = UP as shown 36V SW#1 ON, Others 48V SW#2 ON, Others 72V SW#3 ON, Others 80V SW#4 ON, Others

OFF OFF OFF OFF

NOTE: SET DIP SWITCHES TO TRUCK VOLTAGE. IF TRUCK VOLTAGE IS NOT KNOWN, SET 36/48V (US) TRUCKS TO 48V AND 72/80V (EUR) TRUCKS TO 80V. 1. DISPLAY PANEL 2. STEERING COLUMN

3. ELECTRICAL CONNECTOR 4. DIP SWITCHES

Figure 9. Dip Switches

17

Cluster Display Panel (Electric Lift Truck) Replacement

BATTERY INDICATORS There are two types of battery indicators for these trucks. One type is a meter movement with colored bands showing the battery charge (standard display panel). The other type is a Light-Emitting Diode (LED) display with LEDs of different colors showing battery charge (enhanced display panel).

The battery indicator is replaced as one of the components of the display panel. See procedure under Standard Display Panel Parts, Replace. The battery indicator of the enhanced display panel cannot be replaced as a separate component. The indicator must be replaced as part of the enhanced display panel.

See Display Panel Assembly, Replace.

To adjust these battery indicators, see the section Battery Indicators 2260 SRM 138.

DIGITAL DISPLAY (ENHANCED DISPLAY PANEL ONLY) The digital display of the enhanced display panel cannot be replaced as a separate component. The display must be replaced as part of the enhanced display panel. See Display Panel Assembly, Replace.

STATUS CODE OR PERFORMANCE LEVEL SWITCHES AND LED INDICATORS (ENHANCED DISPLAY PANEL ONLY) These switches of the enhanced display panel cannot be replaced as separate components. The switches must be replaced as part of the enhanced display panel. See Display Panel Assembly, Replace.

STANDARD DISPLAY PANEL PARTS, REPLACE The parts of the standard display panel can be replaced with the display panel on the steering column.

If the assembly housing will be replaced, remove the complete assembly from the steering column as described in Display Panel Assembly, Replace.

NOTE: The following is a complete disassembly procedure. Do ONLY those steps necessary to replace the part you want replaced.

2200 SRM 514 circuit board inside the housing. Carefully lift top cover up off housing and LED indicators without damaging O-ring gasket. The gasket for the LED indicators can stick to the LED housing as the top cover is removed. Do not lose or damage gasket. Disconnect three-wire connector for hourmeter.

3. If the housing or filter for the indicators will be replaced, remove screws that fasten LED housing to cover. If the hourmeter or hourmeter gasket will be replaced, remove screws that fasten it to top cover. Install replacement parts to top cover. Make sure that hourmeter is installed so that it can be read after cover is installed.

4. Remove nut that fastens key switch in housing.

See Figure 2. Remove key switch. Make a note of which wires are on which terminals and disconnect wires. Install wires on the same terminals of replacement switch.

5. Align notch in shaft housing of key switch with tab in housing of display panel. Install replacement switch. Tighten nut and connect wires.

NOTE: It is not necessary to do Step 6 if only the meter movement of the battery indicator will be replaced on the existing circuit board. Carefully lift meter movement up off pins of circuit board without bending pins. See Figure 2. Carefully install replacement meter movement on pins. Make sure pins are correctly aligned on back of meter before pushing meter on pins.

6. If the battery indicator circuit board for the hourmeter or the buzzer will be replaced, remove screws that fasten circuit board to housing. Disconnect connector from circuit board. Remove buzzer from bottom of circuit board. Make sure to install fiber washer when installing replacement buzzer on replacement circuit board. If necessary, carefully lift meter movement up off pins of circuit board without bending pins. See Figure 2. Carefully install replacement meter movement on pins of replacement circuit board.

Make sure pins are correctly aligned on back of meter before pushing meter on pins. Connect electrical connector to circuit board and install circuit board assembly in housing.

1. Disconnect battery and remove key.

2. Remove eight screws that fasten top cover to panel housing. Screws are at bottom of housing.

See Figure 2. The hourmeter is fastened to the top cover with the electrical connector on the

18

7. If the LED indicator assembly will be replaced, first remove 18-pin connector. It is necessary to remove the front steering column cover with the display panel assembly attached for access

2200 SRM 514

Curtis 1215 Display Panel Replacement

to the connector. After removing screws that fasten front cover, carefully disconnect connector. It can be necessary to disconnect key switch wires (Step 4) and two-wire connector for enough clearance to disconnect 18-pin connector. Remove two screws that fasten LED assembly to housing. Install replacement LED assembly. Carefully connect all connectors and wires. Install front steering column cover with display panel assembly attached. Install LED gasket over LED indicators.

8. If necessary, install new O-ring gasket. Carefully install O-ring gasket in groove of top cover.

Carefully install top cover assembly over LED indicators and assembly housing without damaging either LED gasket or O-ring gasket. Make

sure O-ring gasket is still correctly aligned with cover and housing before installing screws. Install eight screws that fasten top cover to panel housing and tighten them in a cross pattern.

ENHANCED DISPLAY PANEL PARTS, REPLACE The only replaceable parts of the enhanced display panel are the O-ring seal, key switch, wires to the key switch, and the housing that fastens to the steering column. All other parts of the panel must be replaced as a single unit. See Display Panel Assembly, Replace and Figure 3.

Curtis 1215 Display Panel Replacement REMOVE The Curtis 1215 Display Panel is located in the front cover over the battery compartment. The display panel cannot be repaired and must be replaced if it is faulty.

1. Move lift truck to a safe, level area. Turn key switch to OFF and remove key. Put a DO NOT OPERATE tag on the multifunction control handle. Put blocks under drive wheels to keep lift truck from moving. Refer to How to Put Lift Truck on Blocks in the section Periodic Maintenance.

WARNING Disconnect battery and separate connector before opening compartment cover or inspecting or repairing electrical system. If a tool causes a short circuit, the high-current flow from the battery can cause an injury or parts damage.

2. Disconnect and separate battery connector.

3. Remove hydraulic tank dipstick.

4. Remove socket head capscrews retaining battery compartment cover. Remove battery compartment cover.

5. Disconnect two plugs X-4 and X-6 from rear of display assembly.

6. Remove two nuts and brackets that fasten display assembly to instrument panel. See Figure 10. Remove display assembly.

1. MOUNT BRACKET

2. MOUNT NUT

Figure 10. Curtis 1215 Mount

INSTALL 1. Adjust pots on rear of dash display assembly.

2. Connect two plugs X-4 and X-6 to rear of dash display.

3. Position display assembly in instrument panel.

Install nuts and brackets to rear of display to fasten display assembly to instrument panel.

4. Install battery cover.

5. Reinstall hydraulic tank dipstick.

6. Remove blocks from under drive wheels. Remove DO NOT OPERATE tag. Connect battery and install key.

19

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

20

TECHNICAL PUBLICATIONS 2200 SRM 514

1/04 (8/03)(5/01)(9/96)(11/95)(11/94)(10/93)(4/93) Printed in U.S.A.

LPG FUEL SYSTEM AISAN CLOSED-LOOP S/H1.50-2.00XMS (S/H25-40XMS) [D010, E001]; S/H2.00-3.20XM (S/H40-65XM) [D187, H177]

PART NO. 1495954

900 SRM 948

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

LPG Fuel System

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description and Operation ................................................................................................................................

Fuel Tank .......................................................................................................................................................

Oxygen Sensor ...............................................................................................................................................

Regulator........................................................................................................................................................

Start Mode .................................................................................................................................................

Idle Mode ...................................................................................................................................................

Run Mode...................................................................................................................................................

Resonator .......................................................................................................................................................

Carburetor......................................................................................................................................................

Start Mode .................................................................................................................................................

Idle Mode ...................................................................................................................................................

Run Mode...................................................................................................................................................

Governor ....................................................................................................................................................

Hoses Replacement ............................................................................................................................................

LPG Tank Repair ...............................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Relief Valve Repair.............................................................................................................................................

Remove and Install........................................................................................................................................

Carburetor Repair..............................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Clean ..............................................................................................................................................................

Assemble ........................................................................................................................................................

Install .............................................................................................................................................................

Fuel Injector Repair ...........................................................................................................................................

Remove ...........................................................................................................................................................

Clean and Inspect ..........................................................................................................................................

Install .............................................................................................................................................................

Governor Repair.................................................................................................................................................

Remove ...........................................................................................................................................................

Inspect ............................................................................................................................................................

Install .............................................................................................................................................................

Regulator Repair................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Oxygen Sensor Repair .......................................................................................................................................

Remove and Install........................................................................................................................................

Vacuum Switches Repair ...................................................................................................................................

Remove and Install........................................................................................................................................

Inspect ............................................................................................................................................................

Resistor Repair...................................................................................................................................................

Remove and Install........................................................................................................................................

Inspect ............................................................................................................................................................

Carburetor and New Regulator Adjustment ....................................................................................................

Idle Speed and Fuel Mixture ........................................................................................................................

Idle Control Adjustment................................................................................................................................

Governor Checks and Adjustments ..................................................................................................................

Checks ............................................................................................................................................................

Adjustments ...................................................................................................................................................

©2006 HYSTER COMPANY

1 1 1 1 1 4 7 7 7 7 7 8 8 9 9 10 10 10 11 11 11 11 11 12 12 13 13 13 13 13 14 14 14 14 14 14 14 15 15 15 15 15 15 15 15 16 16 16 17 17 18

i

Table of Contents

LPG Fuel System

TABLE OF CONTENTS (Continued) Throttle Linkage Adjustment............................................................................................................................

MONOTROL Pedal Check.................................................................................................................................

Check Engine Light ...........................................................................................................................................

Inspect Warning Lamp ..................................................................................................................................

Check Feedback Operation ...........................................................................................................................

Check VAC1 and VAC2 Signals ....................................................................................................................

Check Resistor ...............................................................................................................................................

Check Fuel Injector .......................................................................................................................................

Check Oxygen Sensor ....................................................................................................................................

Check Vacuum Switch 1 ................................................................................................................................

Check Vacuum Switch 2 ................................................................................................................................

After Completing Checks ..............................................................................................................................

Troubleshooting..................................................................................................................................................

This section is for the following models: S/H1.50-2.00XMS (S/H25-40XMS) [D010, E001]; S/H2.00-3.20XM (S/H40-65XM) [D187, H177]

ii

18 20 20 20 20 20 20 21 21 21 21 21 22

900 SRM 948

Description and Operation

General This section has the description, operation, and repair procedures for the parts of the LPG fuel system used on the Mazda 2.0 liter, Mazda 2.2 liter, and GM 3.0L Engines.

Description and Operation The LPG fuel system has a fuel tank and valve, hydrostatic relief valve, regulator, carburetor, solenoid valve, makeup fuel injector, fuel pressure sensor and indicator lamp, and governor. The LPG arrangement is shown in Figure 1 and Figure 2.

FUEL TANK NOTE: Some LPG tanks have an auxiliary fill fitting instead of a plug.

The fuel tank is the reservoir for the LPG system.

See Figure 3. The fuel tank keeps the fuel in the liquid condition. The pressure of the fuel is 900 to 1100 kPa (130 to 160 psi) with 100% propane when the tank is full and at an ambient temperature of 27 C (81 F). The tank has a pressure relief valve that is set at 3310 kPa (480 psi). The inlet tube for the pressure relief valve is in the vapor area at the top of the tank.

OXYGEN SENSOR The closed-loop system incorporates an oxygen sensor in the exhaust pipe. The sensor constantly makes comparisons between the oxygen content inside the exhaust manifold and the air outside the engine. If a rich or lean air/fuel mixture is sensed in the exhaust, the sensor provides a signal to the engine control unit (ECU). The ECU will then make an adjustment to the mixture ratio by turning the makeup fuel injector on or off.

REGULATOR The function of the regulator is to change the liquid fuel to a vapor (gas) and to control the pressure of the vapor. See Figure 4,Figure 5 and Figure 6. The LPG fuel changes from a liquid to a vapor inside the primary pressure-reduction chamber. This conversion process cools the vapor, which in turn cools the surrounding parts of the regulator. Engine coolant is circulated through the regulator and, by convection, transfers the cold out of the chamber. Regardless of the ambient temperature, the engine coolant is always warmer than the vapor after expansion, thereby providing the warming function. This warming function of the engine coolant prevents the regulator from being too cold to operate.

The regulator consists of four chambers: Chamber A - Start of the vaporization process.

Chamber B - Primary pressure-reduction chamber where primary vaporization occurs and the pressure is reduced. Also provides low-pressure vapor for the fuel injector.

Chamber C - Secondary pressure-reduction chamber where the vapor pressure is reduced to zero (atmospheric).

Chamber D - Provides fuel during engine start and idle.

The regulator has three operating modes: start mode, idle mode, and run mode. These modes are described in detail in the following sections.

The basic operations of the regulator and the carburetor are similar to the Aisan open-loop LPG system.

1

Description and Operation

1.

2.

3.

4.

5.

6.

7.

LPG TANK SHUTOFF VALVE RELIEF VALVE LIQUID LPG HOSE LPG VAPOR HOSE REGULATOR/FILTER COOLING SYSTEM HOSES

900 SRM 948

8.

9.

10.

11.

12.

13.

14.

VACUUM/BALANCE LINE LPG CARBURETOR RESONATOR AIR FILTER DISCHARGE ELBOW AIR INTAKE HOSE ORIFICE FITTING FUEL INJECTOR

Figure 1. Aisan Closed-Loop LPG System

2

900 SRM 948

1.

2.

3.

4.

5.

6.

7.

8.

Description and Operation

LPG TANK SHUTOFF VALVE RELIEF VALVE LIQUID LPG HOSE LPG VAPOR HOSE REGULATOR/FILTER COOLING SYSTEM HOSES VACUUM/BALANCE LINE

9.

10.

11.

12.

13.

14.

15.

LPG CARBURETOR RESONATOR AIR FILTER DISCHARGE ELBOW AIR INTAKE HOSE ORIFICE FITTING FUEL INJECTOR FUEL FILTER (SLOW)

Figure 2. Aisan Closed Loop LPG System, EPA Compliant Engine

3

Description and Operation

900 SRM 948 constant pressure in chamber B. A very small portion of the fuel is bled off into chamber D, where the idle mixture adjusting screw controls the amount of fuel that is allowed to flow out to the carburetor to start ignition.

When the throttle valve is opened slightly, the demand for fuel at the carburetor causes a slight vacuum at the output port of the regulator. This vacuum causes the diaphragm in chamber C to depress. This opens the inlet valve between chambers B and C, allowing fuel to flow from chamber B to chamber C. This allows large amounts of fuel to flow to the carburetor for complete combustion.

1.

2.

3.

4.

5.

6.

7.

8.

SHUTOFF VALVE QUICK-DISCONNECT FITTING FUEL GAUGE PLUG LIQUID LEVEL INDICATOR RELIEF VALVE ALIGNMENT PIN TANK RELIEF VALVE Figure 3. LPG Tank

Start Mode When the ignition switch is turned to the START position and the engine begins to crank, both the main solenoid valve and the idle bypass solenoid valve are activated, allowing the LPG to flow from the fuel tank through the fuel filter to chamber A. See Figure 5 and Figure 6. The fuel pressure opens the inlet valve between chambers A and B, and the fuel enters the primary pressure reduction chamber (chamber B).

When the pressure in chamber B reaches 24.5 to 34.5 kPa (7.2 to 10.2 inHg), the diaphragm expands outward and closes the inlet valve, maintaining a

4

1.

2.

3.

4.

5.

6.

7.

8.

9.

IDLE BYPASS SOLENOID VALVE FUEL OUTLET MAIN SOLENOID VALVE CHAMBER A COOLANT PORTS RESONATOR PORT CHAMBER C CHAMBER B FUEL FILTER CHAMBER Figure 4. Regulator

900 SRM 948

Description and Operation

A. LPG INPUT FROM FUEL TANK B. LPG OUTPUT TO CARBURETOR

C. LPG OUTPUT TO FUEL INJECTOR

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

IDLE MIXTURE ADJUSTING SCREW* CHAMBER D IDLE BYPASS SOLENOID DIAPHRAGM* FUEL FILTER MAIN SOLENOID CHAMBER B CHAMBER A

INLET VALVE* RESONATOR PORT CHAMBER C DIAPHRAGM* INLET VALVE* VACUUM CHAMBER 1 VACUUM CHAMBER 2

*THE IDLE MIXTURE ADJUSTING SCREW ON THIS REGULATOR CANNOT BE ADJUSTED. ITEMS 4, 9, 12, AND 13 ARE NOT SERVICEABLE PARTS. Figure 5. Inside the Regulator

5

Description and Operation

900 SRM 948

A. LPG INPUT FROM FUEL TANK B. LPG OUTPUT TO CARBURETOR

C. LPG OUTPUT TO FUEL FILTER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

CHAMBER D IDLE BY-PASS SOLENOID DIAPHRAGM FUEL FILTER MAIN SOLENOID CHAMBER B CHAMBER A

1ST VALVE RESONATOR CONNECTION CHAMBER C DIAPHRAGM 2ND VALVE CHAMBER 1 CHAMBER 2

Figure 6. Inside the Regulator (EPA Compliant Engine)

6

900 SRM 948

Idle Mode In the idle mode, the demand for fuel at the carburetor is low and the vacuum is absent at the fuel outlet port. This causes the diaphragm in chamber C to relax and close the inlet valve between chambers B and C. See Figure 5 and Figure 6. Pressure in chamber B builds up to 24.5 to 34.5 kPa (7.2 to 10.2 inHg), causing the diaphragm in chamber B to expand and close off the fuel supply. A balance is reached between the amount of vaporizing (liquid) through chamber A and the amount of vapor escaping past the idle mixture adjusting screw in chamber D.

Description and Operation the intake system does not flow in a constant stream, but rather in small pulses generated during the intake stroke of the pistons. Without the resonator and orifice, these pulses could be generated at a frequency that is a natural harmonic of the diaphragm.

This would cause the diaphragm to vibrate uncontrollably and force the engine mixture to be either very rich or lean under certain operating conditions.

The idle mixture adjusting screw is set for a lean mixture at the factory. The fuel injector supplies additional fuel to the carburetor at idle. The ECU controls the fuel injector by using inputs from the oxygen sensor and vacuum switch 1.

Run Mode In the run mode, the throttle valve on the carburetor is opened, creating a vacuum at the fuel outlet port. This causes the diaphragm in chamber C to expand and open the inlet valve between chambers B and C. See Figure 5 and Figure 6. This causes the pressure to drop in chamber B and relaxes the diaphragm in chamber B. This opens the inlet valve between chambers A and B. Fuel is supplied to the carburetor through chamber C, the idle bypass valve, and chamber D. Figure 7. Resonator

RESONATOR The resonator is connected by vacuum hoses to a special orifice fitting on the air filter discharge elbow (see Figure 1 and Figure 7) and to the resonator port of the regulator (see Figure 4). The resonator port connects to vacuum chamber 2 (see Figure 5 and Figure 6).

As the air filter clogs, the intake vacuum increases for any relative throttle position. This increased vacuum has a similar increase in the vacuum of chambers C and 2. By increasing the vacuum of chambers C and 2 by the same level as the intake restriction, a balance is maintained and the relative position of the diaphragms remains unchanged. This maintains a constant fuel mixture regardless of the air filter restriction. See Figure 5 and Figure 6.

The special orifice fitting and the resonator act as vacuum dampeners. The air being drawn through

CARBURETOR Like the regulator, the carburetor has three operating modes: start mode, idle mode, and run mode.

These modes are described in detail in the following sections.

Start Mode Before any fuel is provided to the carburetor, the ignition switch must be turned to the ON position and the engine must be cranked without pressing the accelerator. See Figure 8. The ECU level control unit on the engine wiring harness senses that the engine is in start mode and provides an electrical signal to energize the main solenoid, the idle bypass solenoid, and the fuel injector. Fuel then flows from the regulator to the carburetor.

7

Description and Operation

900 SRM 948

A. AIR B. LPG

C. VACUUM FROM MANIFOLD D. TO INTAKE MANIFOLD

1. POWER DIAPHRAGM 2. POWER VALVE 3. THROTTLE VALVE

4. IDLE AIR BYPASS ADJUSTING SCREW 5. FUEL INJECTOR 6. TAMPER-PROOF PLUG Figure 8. Carburetor, Start Mode

The fuel flows past the orifice and into the main chamber of the carburetor, where it mixes with the air coming from the air cleaner. Because the throttle valve is closed, the air/fuel mixture flows past the idle air bypass adjusting screw, through the bypass port, to the intake manifold, and into the cylinder.

The fuel injector supplies fuel to the base of the carburetor. The fuel injector is controlled by the ECU. The engine is in closed-loop mode once the oxygen sensor is hot.

Idle Mode Engine idle is set by adjusting the airflow at the carburetor with the idle air bypass adjusting screw. See Figure 8. The idle mixture is set at the factory and cannot be adjusted. The engine idle is operating in open-loop mode until the oxygen sensor is heated.

8

Run Mode When the accelerator is pressed, the throttle valve opens, creating a slight vacuum at the output of the regulator and causing fuel to flow at a greater rate.

See Figure 9. Under heavy load, the vacuum in the intake manifold decreases. Decreasing the vacuum on the manifold side of the power diaphragm opens the power valve. The open power valve richens the fuel mixture. The oxygen sensor senses the richer fuel mixture and the ECU turns off the fuel injector.

The engine is running in open-loop mode when the power valve is open. The opening and closing of the power valve according to the vacuum in the intake manifold provides optimum fuel supply to the carburetor (depending on engine load).

900 SRM 948

Hoses Replacement

A. AIR B. LPG

C. VACUUM FROM MANIFOLD D. TO INTAKE MANIFOLD

1. POWER DIAPHRAGM 2. POWER VALVE 3. THROTTLE VALVE

4. IDLE AIR BYPASS ADJUSTING SCREW 5. FUEL INJECTOR 6. TAMPER-PROOF PLUG Figure 9. Carburetor, Run Mode

Governor The governor is installed between the carburetor and the intake manifold. The governor helps control the maximum speed of the engine.

Hoses Replacement The hoses installed on LPG systems are specially made. Hoses that are made for use with hydraulic oil will be damaged by LPG. When replacing the LPG hoses, be sure to use only HYSTER APPROVED LPG hoses.

When replacing the hose to the quick-disconnect fitting, make sure that it is the same length as the hose it replaces. A hose that is the wrong length allows the tank to be installed in an incorrect position.

9

LPG Tank Repair

900 SRM 948

LPG Tank Repair REMOVE WARNING Before disconnecting any part of the LPG fuel system, close shutoff valve on fuel tank. Run engine until fuel lines are empty and engine stops. If engine will not run, close shutoff valve on fuel tank and release fuel slowly in a nonhazardous area.

LPG can cause an explosion even when tanks are empty. When replacing tanks, do not weld, cause sparks, or permit flammable material on or near tanks. Do not change tanks when engine is running. Tanks must be filled by authorized personnel. Follow all safety rules. Do not remove any parts from tank.

Frost on surface of tank, valves, or fittings and the odor of LPG fuel indicates a leak. Inspect LPG system and repair a leak immediately. An LPG fuel leak creates an explosion hazard and a fire hazard. Do not attempt to start engine if there is a leak in LPG fuel system.

Do not use any LPG tank that is damaged.

Damaged tanks must be removed from service.

Do not store LPG tanks near heat or an open flame. For complete instructions on the storage of LPG fuels, refer to ANSI/NFPA 58 & 505.

WARNING LPG is very cold. Always wear gloves to protect your hands from LPG and the cold metal of the tank. Do not permit LPG to contact skin.

WARNING LPG tanks are heavy. The weight of an LPG tank can exceed the maximum recommended weight for safe lifting by an individual. Get assistance when lifting or lowering an LPG tank.

Use correct lifting procedures.

1. Move lift truck to area where tanks are changed.

2. Turn shutoff valve clockwise until valve is completely closed. See Figure 10.

3. Run engine until it stops. Then turn key to OFF position.

10

NOTE: SOME LPG TANKS HAVE AN AUXILIARY FILL FITTING INSTEAD OF A PLUG FOR ITEM 4.

1. SHUTOFF VALVE 2. QUICK-DISCONNECT FITTING 3. FUEL GAUGE 4. PLUG 5. LIQUID LEVEL INDICATOR

6. RELIEF VALVE 7. ALIGNMENT PIN 8. TANK RELIEF VALVE 9. TANK LATCH 10. MOUNTING BRACKET

Figure 10. LPG Tank 4. Disconnect quick-disconnect fitting.

5. Release tank latch and remove tank from bracket.

INSTALL 1. Before the tank is installed on the lift truck, check operation of fuel gauge. See Figure 10.

Look at fuel gauge and move tank. The needle of the gauge must move when the fuel moves. If the needle does not move, a new tank must be installed.

WARNING Make sure that alignment pin extends through correct hole in rim of LPG tank. The hose or fittings can be damaged if the LPG tank is not installed in the correct position. A damaged hose or fitting can release LPG fuel and cause an explosion hazard and fire hazard.

2. Install LPG tank in its bracket so that alignment pin is in correct hole in bracket. Close latches.

3. Connect quick-disconnect fitting to shutoff valve on tank. Use your hand to tighten fitting.

900 SRM 948

Carburetor Repair

4. Turn shutoff valve counterclockwise to open valve.

6. The shutoff valve on the tank must be closed when the truck is not being used.

5. Inspect fuel system for leaks when shutoff valve is open. Frost on surface of tank, valves, or fittings, or a strong odor of LPG indicates a leak.

Relief Valve Repair REMOVE AND INSTALL

1. Close shutoff valve on tank. See Figure 1.

WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near LPG system. Close fuel valve on tank. Disconnect negative battery cable to prevent sparks.

2. Slowly loosen hose fitting for relief valve. Let fuel drain from fitting before removing relief valve.

3. The valve cannot be repaired. If the valve is damaged, install new valve. After installation, open shutoff valve slowly and inspect system for leaks.

Carburetor Repair REMOVE WARNING Before disconnecting any part of the LPG fuel system, close shutoff valve on fuel tank. Run engine until fuel lines are empty and engine stops. If engine will not run, close shutoff valve on fuel tank and release fuel slowly in a nonhazardous area.

1. Turn shutoff valve clockwise until valve is completely closed. See Figure 1.

2. Run engine until it stops. Then turn key to OFF position.

3. Disconnect hose from air cleaner at bonnet.

4. Disconnect both fuel inlet hoses (large hose to carburetor and smaller hose to fuel injector).

5. Disconnect hose to idle control actuator.

8. Disconnect throttle cable at carburetor. Remove carburetor from governor.

DISASSEMBLE NOTE: Note the position of the diaphragm prior to removal to aid in the installation.

1. Disassemble power valve actuator by removing three screws, cover, spring, and diaphragm from carburetor. See Figure 11.

2. Remove idle air bypass adjusting screw and spring from carburetor.

3. Remove two screws and idle control actuator from carburetor.

4. Remove nut, lockwasher, throttle cable link, and lever from carburetor.

5. If damaged, remove adjusting screw and spring from lever.

6. Disconnect regulator hose.

7. Disconnect power valve hose.

11

Carburetor Repair

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

900 SRM 948

IDLE AIR BYPASS ADJUSTING SCREW SPRING DIAPHRAGM SPRING COVER SCREW NUT LOCKWASHER THROTTLE CABLE LINK IDLE CONTROL ACTUATOR

11.

12.

13.

14.

15.

16.

17.

18.

19.

SCREW IDLE-UP ADJUSTING SCREW SPRING LEVER VALVE VACUUM HOSE VACUUM HOSE FUEL INJECTOR BOLT

Figure 11. Carburetor Parts

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow recommendations of manufacturer.

Make sure that all of carburetor parts are clean before assembly. Wash all parts (except diaphragm) in solvent. Make sure that air passages in metering valve are clean.

12

ASSEMBLE 1. If removed, install spring and adjusting screw in lever. See Figure 11.

2. Install lever, throttle cable link, lockwasher, and nut on carburetor. Tighten nut to 9 to 12 N•m (80 to 106 lbf in).

3. Install idle control actuator and two screws on carburetor. Tighten screws to 3.4 to 4.4 N•m (30 to 39 lbf in).

900 SRM 948

Fuel Injector Repair

4. Install seal, fuel injector, and two screws on carburetor.

5. Install idle air bypass adjusting screw into carburetor until screw is seated. Unscrew idle air bypass adjusting screw the number of turns specified for the engine in the lift truck. See Table 1.

Table 1. Adjusting Screw Engine Number of Loosening Turns

2.0

2.2

GM

1

1

1

6. Using two screws, install idle-up diaphragm on carburetor.

7. Install diaphragm (as noted during removal), spring, cover, and three screws. Tighten screws to 1.5 to 2.0 N•m (13 to 18 lbf in).

INSTALL 1. Install new gasket on governor. See Figure 1.

Install carburetor on governor.

2. Connect power valve hose.

3. Connect hose from carburetor (spark advance port) to distributor.

4. Connect hose to idle control actuator.

5. Connect both fuel inlet hoses (large hose to carburetor and smaller hose to fuel injector).

6. Connect hose from air cleaner to bonnet.

7. Connect throttle cable at carburetor. Check and adjust throttle linkage as described in Throttle Linkage Adjustment.

Fuel Injector Repair REMOVE 1. Turn shutoff valve clockwise until valve is completely closed. See Figure 11.

2. Run engine until it stops, then turn key to OFF position.

3. Disconnect hose from fuel injector.

4. Remove two mounting screws. Remove fuel injector and seal from carburetor.

CLEAN AND INSPECT 1. Use a clean cloth to remove any carbon deposits around nozzle.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION Do not insert wire more than 2.0 mm (0.08 in.) into fuel injector nozzle. Otherwise, internal parts of fuel injector may be damaged.

2. Use a 1.2 mm (0.05 in.) diameter piece of steel wire to clean out inside of nozzle. Insert and pull out wire approximately 10 times while adding 343 to 490 kPa (50 to 71 psi) of pressure through fuel supply port.

3. Use an ohmmeter to check fuel injector coil for continuity. The coil resistance should be 3.5 to 4.5 .

4. Apply 12 VDC to both connector terminals of fuel injector. A clicking sound should be heard.

INSTALL 1. Insert seal and fuel injector into carburetor.

2. Install two mounting screws. Tighten screws to 6.4 to 7.9 N•m (57 to 70 lbf in).

3. Connect hose to fuel injector.

13

Regulator Repair

900 SRM 948

Governor Repair REMOVE 1. Disconnect vacuum hose from governor.

2. Remove governor from intake manifold.

3. Remove and discard gasket.

INSPECT Inspect governor assembly and all hoses for any damage. Replace any damaged components.

INSTALL

manifold and governor. Gasket material left on either surface will affect performance of lift truck.

NOTE: The vacuum hoses installed on the carburetor and governor are made of special high-temperature material. If any of the hoses are replaced, make sure that HYSTER APPROVED hoses are installed.

1. Install new gasket on intake manifold.

2. Install governor on intake manifold.

3. Connect vacuum hose to governor.

CAUTION Make sure that all gasket material has been cleaned from mating surfaces of intake

Regulator Repair REMOVE WARNING LPG can cause an explosion. Do not permit any sparks or flames in work area.

1. Close shutoff valve on tank. Run engine until it stops. See Figure 1 and Figure 4.

INSTALL 1. Connect balance line to regulator. Install regulator and capscrews on mount.

2. Connect both LPG vapor hoses to regulator.

3. Connect liquid LPG hose to regulator.

4. Connect cooling system hoses to regulator.

2. Disconnect electrical connectors from main solenoid valve and idle bypass solenoid valve respectively.

3. Put drain pan under drain valve for radiator.

Open drain valve so that coolant drains into pan.

4. Disconnect cooling system hoses from regulator.

5. Disconnect liquid LPG hose from regulator.

6. Disconnect both LPG vapor hoses from regulator.

7. Disconnect balance line from regulator. Remove capscrews and regulator from mount.

14

5. Close drain valve and fill cooling system with proper amount and mixture of coolant. See the Periodic Maintenance manual for your lift truck.

6. Connect fitting from LPG tank to regulator assembly. Connect electrical connectors from main solenoid valve and idle bypass solenoid valve respectively.

7. Connect hose to carburetor. Open shutoff valve on tank. Start engine.

900 SRM 948

Resistor Repair

Oxygen Sensor Repair REMOVE AND INSTALL 1. Disconnect electrical connector. Remove oxygen sensor from exhaust pipe.

2. Before installing the sensor, coat sensor sparingly with an antiseize compound, then install sensor. Tighten sensor to 39 N•m (29 lbf ft).

Vacuum Switches Repair NOTE: Vacuum switch 1 has a white body with a gray top. Vacuum switch 2 has a white body with a white top. This procedure is used for both switches.

switch 2 should open at 29.0 to 33.3 kPa ( 8.5 to 9.8 inHg).

3. Release vacuum. Switch contacts should open.

REMOVE AND INSTALL 1. Disconnect vacuum hose.

2. Disconnect electrical connector from vacuum switch. See Figure 12.

3. Remove mounting clamp and capscrew. Remove vacuum switch.

4. Install switch in reverse order.

INSPECT 1. Connect an ohmmeter to vacuum switch.

2. Apply vacuum to switch. The contacts of vacuum switch 1 should close at 16.0 to 20.0 kPa ( 4.7 to 5.9 inHg). The contacts of vacuum

1. VACUUM SWITCH 1 (IDLE) 2. VACUUM SWITCH 2 (WIDE-OPEN THROTTLE) 3. CARBURETOR Figure 12. Vacuum Switches

Resistor Repair REMOVE AND INSTALL

INSPECT

Disconnect electrical connector, then remove mounting screw and resistor. Install resistor in reverse order.

Use an ohmmeter to check resistor for continuity.

The coil resistance should be 5.4 to 6.6 .

15

Carburetor and New Regulator Adjustment

900 SRM 948

Carburetor and New Regulator Adjustment IDLE SPEED AND FUEL MIXTURE WARNING LPG can cause an explosion. Do not permit any sparks or open flames in work area.

1. Warm engine, transmission, and hydraulic system to normal operating temperatures. Make sure that idle control actuator is not in contact with idle-up adjusting screw.

NOTE: For EPA Compliant engines go to Step 10.

9. Install tamper-proof plug in idle mixture adjusting screw port on regulator. The idle mixture adjusting screw can no longer be adjusted.

10. On EPA Compliant engines, install tamper-proof plug in fuel filter assembly. The idle mixture adjusting screw can no longer be adjusted.

2. Check idle speed and engine timing. The timing should be 8 BTDC @ 800 ±25 rpm GM 3.0L Engine, 9 BTDC @ 800 ±25 rpm S/H2.00-3.20XM (S/H40-65XM), and 8 BTDC @ 725±25 rpm S/H1.50-2.00XM (S/H25-40XM).

3. If idle speed is not within specifications, adjust idle air bypass adjusting screw on carburetor.

See Figure 13 and Figure 14.

NOTE: The following steps are for adjusting the fuel mixture on a new replacement regulator that has not been tamper-proofed. Do not perform this adjustment on an old regulator. A CO% meter will be required.

4. Disconnect electrical connector from fuel injector.

5. Attach exhaust gas analyzer to raw gas emissions port on exhaust pipe.

6. Adjust idle speed to 725 rpm S/H1.50-2.00XM (S/H25-40XM) or 800 rpm S/H2.00-3.20XM (S/H40-65XM). If the reading on the CO% meter is not between 0.06 and 0.13, replace regulator.

7. On a new replacement regulator, adjust idle mixture adjusting screw until reading on CO% meter is between 0.06 and 0.13 while idle speed is at 725 rpm (S/H1.50-2.00XM [S/H25-40XM]) or 800 rpm (S/H2.00-3.20XM [S/H40-65XM]).

8. Reconnect electrical connector to fuel injector. If reading on CO% meter is not between 0.20 and 0.70, check fuel injector. See the procedures for the fuel injector in the Fuel Injector Repair section.

16

1.

2.

3.

4.

5.

6.

IDLE AIR BYPASS ADJUSTING SCREW IDLE-UP ADJUSTING SCREW IDLE CONTROL ACTUATOR POWER VALVE ACTUATOR FUEL INJECTOR THROTTLE ADJUSTING SCREW Figure 13. LPG Carburetor (Top View)

IDLE CONTROL ADJUSTMENT 1. Warm engine, transmission, and hydraulic system to normal operating temperatures. Make sure that idle control actuator is not in contact with idle-up adjusting screw. See Figure 13 and Figure 14.

900 SRM 948

Governor Checks and Adjustments

2. Set idle speed and idle mixture according to Idle Speed and Fuel Mixture procedure.

3. Adjust idle-up adjusting screw until there is 0.10 to 0.20 mm (0.004 to 0.008 in.) clearance between screw and idle control actuator.

4. Disconnect vacuum hose from idle control actuator and check engine speed. If it is within idle-up specification (1400 +0/ 150 rpm), no further adjustment is required. If engine speed exceeds specification, adjust idle-up adjusting screw until engine speed is within specification.

1. CARBURETOR 2. IDLE AIR BYPASS ADJUSTING SCREW 3. GOVERNOR 4. LOCKSCREW

5. MAIN ADJUSTMENT WHEEL 6. SECONDARY ADJUSTING SCREW

Figure 14. LPG Carburetor (Side View)

Governor Checks and Adjustments The governor does not normally need adjustment.

If adjustment is necessary, do not turn adjusting screws more than 1/4 turn at a time. See Figure 14 and Figure 15. Otherwise, the governor can be difficult to adjust.

CHECKS Before making any adjustments to the governor, check the following: 1. Make sure that the mechanical, electrical, and fuel systems are operating correctly.

2. Make sure that tachometer will work with ignition system.

3. Make sure that air filter is clean and connected to carburetor.

1.

2.

3.

4.

SECONDARY ADJUSTING SCREW ADJUSTMENT SPRING MAIN ADJUSTMENT WHEEL LOCKSCREW Figure 15. Governor

17

Throttle Linkage Adjustment

900 SRM 948

ADJUSTMENTS With the engine at operating temperature, adjust governor as follows: 1. Remove lock wire from lockscrew. lockscrew. Apply parking brake.

Loosen

2. With no load on engine, run engine at full open throttle to obtain maximum engine speed.

To adjust maximum no-load speed, hold secondary adjusting screw and turn main adjustment wheel. Turn main adjusting screw clockwise to increase engine speed or counterclockwise to decrease engine speed.

Set maximum engine speed to 2800 rpm Mazda and GM 3.0L S2.00-3.20XM (S40-65XM), 2450 rpm S/H1.50-2.00XMS (S/H25-40XMS), and 2900 rpm GM3.0L H2.00-3.20XM (H40-65XM).

3. Tighten lockscrew.

4. Run engine with throttle fully open, then pull on tilt lever to load engine. The governor setting is

correct when the engine runs smoothly (without speed changes) and the difference in speed between the load and no-load conditions is within the limits of the specifications.

5. If the engine speed changes, loosen lockscrew and turn secondary adjusting screw 1/4 turn clockwise. Set maximum no-load engine speed by turning main adjustment wheel counterclockwise. Repeat this procedure until engine speed is steady.

6. If the engine speed difference between the load and no-load conditions is greater than specified, turn main adjustment wheel 1/4 turn clockwise.

Set maximum no-load engine speed by turning secondary adjusting screw counterclockwise. Repeat this procedure until engine runs correctly.

7. When governor adjustment is correct, tighten lockscrew and install wire between lockscrew and secondary adjusting screw.

Throttle Linkage Adjustment NOTE: Each time the throttle system is disassembled, it is important to adjust the throttle cables.

1. Adjust idle speed as described in Idle Control Adjustment.

2. Make sure that throttle linkage at pedal assembly is in correct position. See Figure 16.

3. Push MONOTROL® or throttle pedal until it stops against floor plate. Adjust throttle cable so that pedal stops on floor plate just as throttle plate reaches wide-open position. Use nuts at pedal end of cable housing to change adjustment of cable.

1. PIN 2. COTTER PIN 3. THROTTLE CABLE

4. PEDAL LINKAGE ASSEMBLY

Figure 16. Throttle Cable Arrangement

18

900 SRM 948

Throttle Linkage Adjustment

4. Adjust pedal return stop so there is no tension on throttle cable at idle position. See Figure 17.

To check this adjustment, perform the following steps: a. Run engine at idle speed. Make sure that rod on idle control actuator is retracted and throttle linkage is against idle air bypass adjusting screw. b. When pedal return stop is in correct position, tighten capscrew that holds stop to bracket.

NOTE: MONOTROL PEDAL SHOWN. 1.

2.

3.

4.

5.

6.

7.

8.

PEDAL PAD LINK CRANK PEDAL FRAME FORWARD SOLENOID (BLACK WIRE) BATTERY (RED WIRE) REVERSE SOLENOID (YELLOW WIRE) CORRECT HOLES FOR LINKAGE H2.00-3.20XM (H40-65XM) 9. CORRECT HOLES FOR LINKAGE S2.00-3.20XM (S40-65XM) Figure 17. Throttle Arrangement S/H2.00-3.20XM (S/H40-65XM)

19

Check Engine Light

900 SRM 948

MONOTROL Pedal Check Slowly move the MONOTROL pedal pad from FORWARD to REVERSE and back to FORWARD. See Figure 17. There must be some movement of the pedal pad before the pedal frame moves and the throttle opens.

Check Engine Light If this warning lamp is blinking while the lift truck is in operation, there is an abnormal condition in the air/fuel feedback system. Perform the following troubleshooting checks to determine the specific problem.

NOTE: Most of these checks require the use of a voltmeter or ohmmeter.

INSPECT WARNING LAMP 1. Run engine at idle speed.

2. Disconnect ECU check connector. Short-circuit terminals A and B. If warning lamp blinks intermittently (every 1.5 seconds), go to next check.

2. Disconnect ECU check connector. Short-circuit terminals A and B. 3. Operate accelerator pedal and measure VAC1 signal voltage between terminals A and D. When pedal is not pressed, signal should be 1 V or less.

When pedal is fully pressed, signal should be 4 V or more.

4. If voltage is within these ranges, go to next step.

If voltage is NOT within these ranges, go to procedure Check Vacuum Switch 1.

5. Short-circuit terminals A and B.

3. If warning lamp blinks rapidly (every 0.25 second), the problem is not in the feedback system.

Check wiring, ignition switch, and ECU. Repair or replace components, as necessary.

6. Disconnect and reconnect vacuum hose and measure VAC2 signal voltage between terminals A and C. When hose is connected, signal should be 1 V or less. When hose is disconnected, signal should be 4 V or more.

CHECK FEEDBACK OPERATION

7. If voltage is within these ranges, go to next check.

1. Run engine at maximum rpm for 2 minutes in order to warm up oxygen sensor, then set engine speed at 2000 rpm.

8. If voltage is NOT within these ranges, inspect wiring between the ECU and connector. If wiring is faulty, repair wiring and go to next check. If wiring is OK, go to procedure Check Vacuum Switch 2.

2. Disconnect ECU check connector. Use ECU check connector to check the signal voltage between terminals A and D. Keep terminal B open.

The signal voltage should be between 0 and 5 V.

CHECK RESISTOR 1. Stop engine.

3. If signal voltage is within this range, go to next check. If voltage is NOT within this range, inspect and repair wiring between the ECU and connector. Go to the procedure Check Resistor.

CHECK VAC1 AND VAC2 SIGNALS 1. Run engine at idle speed.

20

2. Use ohmmeter to check resistor for continuity.

Coil resistance should be 5.4 to 6.6 .

3. If resistance is within this range, go to next check. If resistance is NOT within this range, replace resistor and start troubleshooting process again at Check Feedback Operation.

900 SRM 948

CHECK FUEL INJECTOR 1. Inspect wiring between ECU and fuel injector.

If wiring is faulty, repair wiring and start troubleshooting process again at Check Feedback Operation.

2. If wiring is OK, remove fuel injector for cleaning and inspection. See the procedure for fuel injector in the Fuel Injector Repair section.

3. If fuel injector does not meet specifications, replace fuel injector and start troubleshooting process again.

4. If fuel injector meets specifications, install fuel injector and go to next check.

CHECK OXYGEN SENSOR

Check Engine Light 3. If vacuum switch does NOT meet specifications, replace switch and go to next check.

4. If vacuum switch meets specifications, inspect vacuum hoses. Replace any damaged hoses and go to next check. If no hoses are damaged, replace ECU before going to next check.

CHECK VACUUM SWITCH 2 1. Inspect wiring between ECU and vacuum switch.

If wiring is faulty, repair wiring and start troubleshooting process again at Check Feedback Operation.

2. If wiring is OK, remove vacuum switch for inspection. See the procedure for the vacuum switches in the Vacuum Switches Repair section.

1. Check wiring between ECU and oxygen sensor.

If wiring is faulty, repair wiring.

3. If vacuum switch does NOT meet specifications, replace switch and start troubleshooting process again.

2. Perform Step 1 and Step 2 of the procedure Check Feedback Operation. If signal voltage is within specifications, check VAC1 signal and VAC2 signal again. If signal voltage is NOT within specifications, replace oxygen sensor.

4. If vacuum switch meets specifications, inspect vacuum hoses. Replace any damaged hoses and start troubleshooting process. If no hoses are damaged, replace ECU before starting troubleshooting process again.

3. Perform Step 1 and Step 2 of the procedure Check Feedback Operation again. If signal voltage is within specifications, air/fuel feedback system is in normal operating condition. If signal voltage is still NOT within specifications, replace ECU.

AFTER COMPLETING CHECKS 1. Make sure that terminals A and B no longer have a short circuit.

CHECK VACUUM SWITCH 1

2. Make sure that vacuum hoses and all electrical wiring are connected.

1. Inspect wiring between ECU and vacuum switch.

If wiring is faulty, repair wiring and go to next check.

3. Disconnect negative battery terminal for more than 30 seconds in order to clear memory of diagnostic system. Reconnect terminal.

2. If wiring is OK, remove vacuum switch for inspection. See the procedure for vacuum switches in the Vacuum Switches Repair section.

4. Run engine and check that "Check Engine" Light does not come on. If light does come on, repeat Step 3.

21

Troubleshooting

900 SRM 948

Troubleshooting PROBLEM "Check Engine" blinking.

light

Engine will not start.

22

POSSIBLE CAUSE is

PROCEDURE OR ACTION

There is an abnormal condition in air/fuel ratio feedback system.

Perform the checking procedures in Check Engine Light.

Fuel tank is either empty or fuel tank valve is closed.

Fill fuel tank or open fuel tank valve.

There is tar accumulation in regulator.

Remove drain plug and drain tar from regulator.

Fuel hose is either damaged or disconnected.

Replace damaged hose or reconnect disconnected hose.

Fuel filter is clogged.

Replace fuel filter and clean tar from regulator.

Main fuel shutoff solenoid valve does not operate.

Disconnect solenoid from harness and connect directly to battery. Listen for a clicking sound. If solenoid does not energize, replace it with new one.

Main fuel solenoid relay may be faulty.

Disconnect relay and connect directly to battery across terminals 85 and 86.

Listen for a clicking sound. If relay does not energize, replace it with new one.

Idle fuel shutoff solenoid valve does not operate.

Disconnect solenoid from harness and connect directly to battery. Listen for a clicking sound. If solenoid does not energize, replace it with new one.

Main fuel shutoff solenoid connector is disconnected.

Connect main fuel solenoid connector.

Idle fuel shutoff solenoid connector is disconnected.

Connect idle fuel solenoid connector.

Main fuel shutoff solenoid wire harness is cut.

Repair or install new wiring harness.

Idle fuel shutoff solenoid wire harness is cut.

Repair or install new wiring harness.

900 SRM 948

PROBLEM Engine will not start. (Cont).

Engine is hard to start.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Coil of idle fuel shutoff solenoid is damaged.

Using an ohmmeter, measure resistance between terminals. Measurement should be 22.5 ±0.2 at 21 C (70 F). Install new solenoid if measurement is incorrect.

Coil of main fuel shutoff solenoid is damaged.

Using an ohmmeter, measure resistance between terminals. Measurement should be 8.5 ±0.5 at 21 C (70 F). Install new solenoid if measurement is incorrect.

Main fuel shutoff solenoid valve is clogged.

Clean main fuel shutoff solenoid valve.

Idle fuel shutoff solenoid valve is clogged.

Clean idle fuel shutoff solenoid valve.

Idle air bypass adjusting screw may be clogged.

Clean or replace idle adjusting screw as necessary.

Idle air bypass adjusting screw on carburetor is out of adjustment.

Perform adjustment procedures located in Carburetor and New Regulator Adjustment.

Idle mixture adjusting screw on regulator is out of adjustment.

Replace regulator.

Primary diaphragm on regulator is damaged.

Replace regulator.

Fuel hose is damaged.

Replace fuel hose.

A vacuum hose is either damaged or disconnected.

Replace damaged hose or reconnect disconnected hose.

Fuel filter is clogged.

Replace fuel filter.

There is tar accumulation in regulator.

Remove drain plug and drain tar from regulator.

There is an air leak between carburetor and governor.

Replace gasket if it is broken or tighten mounting nuts to correct torque.

Main mixture passage of carburetor may be clogged.

Replace carburetor.

Idle fuel solenoid valve does not seal.

Clean idle fuel solenoid or replace with new one.

23

Troubleshooting

PROBLEM Engine is hard to start.

(Cont.)

not idle Engine does fuel/air smoothly (lean mixture).

Engine does not idle smoothly (rich fuel/air mixture).

24

900 SRM 948

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is an internal clogging of main fuel solenoid.

Clean main fuel solenoid or replace with new one.

Main fuel solenoid does not seal.

Clean main fuel solenoid or replace with new one.

There is an internal clogging of idle fuel solenoid.

Clean idle fuel solenoid or replace with new one.

Idle air bypass adjusting screw on carburetor is out of adjustment.

Perform procedures located in Carburetor and New Regulator Adjustment.

Primary diaphragm on regulator is damaged.

Replace regulator.

Idle mixture adjusting screw on regulator is clogged or out of adjustment.

Replace regulator.

A vacuum hose is either damaged or disconnected.

Replace damaged hose or reconnect disconnected hose.

There is an air leak between carburetor and governor.

Replace gasket if it is broken or tighten mounting nuts to correct torque.

There is tar accumulation in regulator.

Remove drain plug and drain tar from regulator.

Fuel filter is clogged.

Replace fuel filter and clean tar from regulator.

Main fuel shutoff solenoid valve is clogged.

Clean main fuel shutoff solenoid valve.

Idle fuel shutoff solenoid valve is clogged.

Clean idle fuel shutoff solenoid valve.

Idle mixture adjusting screw is clogged.

Replace regulator.

Fuel injector is clogged.

Clean fuel injector.

Resonator hose is either damaged or disconnected.

Replace damaged hose or reconnect disconnected hose.

Resonator is damaged.

Replace resonator.

900 SRM 948

PROBLEM idle Engine does not fuel/air smoothly (rich mixture). (Cont.)

Engine does not idle smoothly (idle speed too low).

Engine does not idle smoothly (idle speed too high).

There is engine hesitation, surge, knocking, or loss of power due to lean or rich fuel/air mixture.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Fuel injector pulse rate does not drop at idle.

Check fuel injector and wiring, vacuum hose, vacuum switch 1, oxygen sensor, and ECU.

Idle mixture adjusting screw on regulator is out of adjustment.

Replace regulator.

Idle air bypass adjusting screw on carburetor may be clogged.

Clean or replace idle air bypass adjusting screw and clean tar from carburetor.

Idle air bypass adjusting screw on carburetor is out of adjustment.

Perform adjustment procedures located in Carburetor and New Regulator Adjustment.

Idle mixture adjusting screw on regulator is out of adjustment.

Replace regulator.

Idle air bypass adjusting screw on carburetor is out of adjustment.

Perform adjustment procedures located in Carburetor and New Regulator Adjustment.

Idle mixture adjusting screw on regulator is out of adjustment.

Replace regulator.

A vacuum hose is either damaged or disconnected.

Replace damaged hose or reconnect disconnected hose.

Main fuel shutoff solenoid valve is clogged.

Clean main fuel shutoff solenoid valve.

Idle fuel shutoff solenoid valve is clogged.

Clean idle fuel shutoff solenoid valve.

Fuel hose is damaged.

Replace fuel hose.

Fuel filter is clogged.

Replace fuel filter and clean tar from regulator.

Idle mixture adjusting screw may be clogged.

Clean or replace regulator as necessary.

There is tar accumulation in regulator.

Remove drain plug and drain tar from regulator.

25

Troubleshooting

PROBLEM There is engine hesitation, surge, knocking, or loss of power due to lean or rich fuel/air mixture. (Cont.)

Engine stops running during deceleration, immediately after engine startup, immediately after acceleration, during a sharp turn, or during load up/down operations due to lean or rich fuel/air mixture.

26

900 SRM 948

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is an air leak between carburetor and governor.

Replace gasket if it is broken or tighten mounting nuts to correct torque.

Carburetor is out of calibration.

If out of calibration, replace carburetor.

Idle mixture adjusting screw may be out of adjustment.

Replace regulator.

Coolant hose has become clogged or disconnected, causing regulator to become frozen.

Clear obstruction from coolant hose or reconnect coolant hose.

Resonator is damaged.

Replace resonator.

Resonator hose is either damaged or disconnected.

Replace damaged hose or reconnect disconnected hose.

There is no clearance between idle-up adjusting screw and idle control actuator.

Adjust idle-up adjusting screw.

Fuel injector is clogged with tar.

Clean the fuel injector.

Fuel injector is delivering too much fuel or too little/no fuel.

Check fuel injector and wiring, vacuum hose, vacuum switch 1, oxygen sensor, and ECU.

Main fuel shutoff solenoid valve is clogged.

Clean main fuel shutoff solenoid valve.

Idle fuel shutoff solenoid valve is clogged.

Clean idle fuel shutoff solenoid valve.

Fuel hose is damaged.

Replace fuel hose.

Fuel filter is clogged.

Replace fuel filter and clean tar from regulator.

Idle mixture adjusting screw may be clogged.

Replace regulator.

900 SRM 948

PROBLEM Engine stops running during deceleration, immediately after engine startup, immediately after acceleration, during a sharp turn, or during load up/down operations due to lean or rich fuel/air mixture. (Cont.)

Engine hesitation, surge, knocking, or loss of power due to lean or rich fuel/air mixture or loss of air.

Engine continues to run after being shut down (dieseling).

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is tar accumulation in regulator.

Remove drain plug and drain tar from regulator.

There is an air leak between carburetor and governor.

Replace gasket if it is broken or tighten mounting nuts to correct torque.

Vacuum hose is either damaged or disconnected.

Replace damaged hose or reconnect disconnected hose.

Carburetor may be out of calibration.

If out of calibration, replace carburetor.

Idle mixture adjusting screw may be out of adjustment.

Replace regulator.

Coolant hose has become clogged or disconnected, causing regulator to become overcooled.

Clear obstruction from coolant hose or reconnect coolant hose.

Regulator has become overcooled after engine has reached normal operating temperature.

Replace regulator.

Resonator is damaged.

Replace resonator.

Resonator hose is either damaged or disconnected.

Replace damaged hose or reconnect disconnected hose.

Idle fuel shutoff solenoid valve does not operate.

Disconnect solenoid from harness and connect directly to battery. Listen for a clicking sound. If solenoid does not energize, replace with new one.

Idle fuel shutoff solenoid valve is clogged.

Clean idle fuel shutoff solenoid valve.

27

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

28

TECHNICAL PUBLICATIONS 900 SRM 948

10/06 (9/05)(11/04)(2/04)(11/03)(8/02)(1/02)(1/01) Printed in U.S.A.

0$='$ (1*,1( M4-2.0G AND M4-2.2G H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]; S/H2.00-3.20XM (S/H40-65XM) [D177, D187, H177]

PART NO. 897477

600 SRM 496

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Mazda Engine

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

Engine Removal and Installation .....................................................................................................................

Cylinder Head, Camshaft, and Valve Mechanism Repair ...............................................................................

Remove ...........................................................................................................................................................

Clean ..............................................................................................................................................................

Inspect and Repair.........................................................................................................................................

Cylinder Head............................................................................................................................................

Rocker Shaft Assembly .............................................................................................................................

Camshaft....................................................................................................................................................

Valve Guides ..............................................................................................................................................

Valve Seats.................................................................................................................................................

Valves .........................................................................................................................................................

Valve Springs .............................................................................................................................................

Install .............................................................................................................................................................

Crankshaft and Main Bearings Repair ............................................................................................................

Remove ...........................................................................................................................................................

Inspect and Repair.........................................................................................................................................

Crankshaft .................................................................................................................................................

Main Bearings ...........................................................................................................................................

Install .............................................................................................................................................................

Pistons and Connecting Rods Repair................................................................................................................

Remove and Disassemble ..............................................................................................................................

Clean ..............................................................................................................................................................

Inspect and Repair.........................................................................................................................................

Pistons........................................................................................................................................................

Piston Rings...............................................................................................................................................

Connecting Rods and Bearings.................................................................................................................

Assemble and Install .....................................................................................................................................

Cylinder Block Repair........................................................................................................................................

Oil Pump Repair ................................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Clean ..............................................................................................................................................................

Inspect ............................................................................................................................................................

Assemble ........................................................................................................................................................

Install .............................................................................................................................................................

Cooling System Repair ......................................................................................................................................

Thermostat.....................................................................................................................................................

Replace .......................................................................................................................................................

Fan Assembly.................................................................................................................................................

Remove and Disassemble..........................................................................................................................

Assemble and Install.................................................................................................................................

Water Pump ...................................................................................................................................................

Remove and Disassemble..........................................................................................................................

Assemble and Install.................................................................................................................................

Distributor Repair..............................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)...................................................................

Remove ...........................................................................................................................................................

©2002 HYSTER COMPANY

1 1 1 2 2 3 4 4 4 4 5 6 6 7 7 10 10 10 10 10 11 12 12 12 12 12 12 13 13 15 15 15 16 16 17 17 18 18 18 18 18 18 19 19 19 20 21 21 21 22 22

i

Table of Contents

Mazda Engine

TABLE OF CONTENTS (Continued) Ring Gear, Replace ........................................................................................................................................

Install .............................................................................................................................................................

Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)........................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Valve Adjustment...............................................................................................................................................

Compression Pressure Check ............................................................................................................................

Engine Timing Adjustment ...............................................................................................................................

Throttle Linkage Adjustment............................................................................................................................

Gasoline Engines ...........................................................................................................................................

LPG Engines (IMPCO) ..................................................................................................................................

LPG Engines (AISAN)...................................................................................................................................

Engine Specifications.........................................................................................................................................

Engine Data ...................................................................................................................................................

Thermostat.....................................................................................................................................................

Cylinder Head ................................................................................................................................................

Valve Mechanism...........................................................................................................................................

Camshaft ........................................................................................................................................................

Crankshaft .....................................................................................................................................................

Connecting Rods ............................................................................................................................................

Cylinder Block ...............................................................................................................................................

Pistons ............................................................................................................................................................

Oil Pump ........................................................................................................................................................

Torque Specifications .........................................................................................................................................

Troubleshooting..................................................................................................................................................

This section is for the following models: H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]; S/H2.00-3.20XM (S/H40-65XM) [D177, D187, H177]

ii

22 22 23 23 23 24 25 25 26 26 26 26 26 26 26 26 27 27 27 28 28 28 28 29 30

600 SRM 496

Engine Removal and Installation

General This section has the instructions for removal, disassembly, repair, assembly, installation, checks, adjustments, and troubleshooting for the Mazda M4-2.0G and M4-2.2G engines. The engine specifications are given at the end of the section.

Additional information on engine components can be found in the sections for Gasoline Fuel System, LPG Fuel System, and Electrical System.

Description WARNING Some gaskets used in this engine can contain dangerous fibers. Breathing dust from these fibers is a cancer or lung disease hazard. Do not create dust! Use vacuum equipment for asbestos or follow the cleaning procedure described below.

• Make sure the gasket material is wet with water or oil to prevent particles in the air.

• Use a hand scraper to remove old gasket material. Do not use a power tool or compressed air.

• Discard all asbestos material in a closed container while it is still wet.

• Put a DANGEROUS FIBERS warning label on the container. Discard dangerous fiber material safely.

CAUTION Disconnect the battery cables before doing any disassembly and repair to the engine or parts of the electrical system.

The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors.

• Do not disconnect an electric wire before the engine is stopped and the key switch is OFF.

• Do not cause a short circuit by connection of the electric wires to the wrong terminals.

Make sure a correct identification of the wire is made wire before it is connected.

• Make sure a battery is the correct voltage and polarity before it is connected.

• Do not check for current flow by making a spark because the transistors can be damaged.

The Mazda M4-2.0G and M4-2.2G engines have four cylinders. The displacement of the M4-2.0G is 1998 cm 3 (121.9 in. 3 ). The displacement of the M4-2.2G is 2184 cm 3 (133.2 in. 3 ). The firing order is 1 – 3 – 4 – 2. They are both available with either a gasoline or LPG fuel system. The No. 1 cylinder is toward the end of the engine with the cooling fan.

The overhead camshaft is driven by a cog belt. The camshaft operates the rocker arms that actuate the valves.

The crankshaft has five main bearings. The main bearing in the center of the crankshaft is also the thrust bearing.

The pistons are aluminum alloy and have three piston rings. Each of the two compression rings have a special shape designed for its position on the piston.

The third piston ring is the oil control ring.

Engine Removal and Installation The removal and installation procedures for the engine are not included in this section. For model units H1.50-1.75 (S/H25-35XM) and H2.00 (S/H40XMS), see the section Frame 100 SRM 545. For model units S/H2.00-3.20 (S/H40-65XM), see the section Frame 100 SRM 505.

1

Cylinder Head, Camshaft, and Valve Mechanism Repair

600 SRM 496

Cylinder Head, Camshaft, and Valve Mechanism Repair REMOVE 1. Disconnect connections at battery.

8. Use chalk to mark direction of timing belt rotation. See Figure 2. Remove timing belt.

2. Drain cooling system.

3. Remove air cleaner, carburetor linkage, inlet, and exhaust manifolds.

4. Remove coolant hoses.

5. Remove bracket for cooling fan.

6. Remove upper and lower timing belt covers. See Figure 1.

Figure 2. Timing Belt 9. Put labels on wires to aid in correct installation.

Disconnect wires at distributor. Remove capscrew for distributor mount and pull distributor from front housing.

10. Remove camshaft pulley. Keep pulley from rotating and loosen capscrew. Remove capscrew and pulley. See Figure 3.

1. LOWER TIMING BELT COVER 2. UPPER TIMING BELT COVER Figure 1. Timing Belt Covers 7. Loosen capscrews for timing belt tensioner and remove spring. Remove capscrews and timing belt tensioner.

2

Figure 3. Camshaft Gear Removal 11. Remove nuts and capscrews for front housing.

Then remove housing. See Figure 4.

600 SRM 496

1. FRONT HOUSING 2. GASKET

Cylinder Head, Camshaft, and Valve Mechanism Repair

3. OIL SEAL

Figure 4. Front Housing 12. Remove valve cover.

Figure 6. Cylinder Head Removal Sequence 16. Use valve spring compressor to remove valve retainers, springs, and valves from head. See Figure 7.

13. Loosen capscrews for rocker shaft supports in proper sequence. See Figure 5. Remove rocker shaft assembly and camshaft.

Figure 7. Valve Removal

CLEAN WARNING Figure 5. Rocker Assembly Removal Sequence 14. Remove capscrews for cylinder head in proper sequence. See Figure 6.

15. Lift cylinder head from the block.

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

Clean all parts in solvent. Make sure all oil passages are clean and all machined surfaces are smooth.

3

Cylinder Head, Camshaft, and Valve Mechanism Repair

INSPECT AND REPAIR Cylinder Head

600 SRM 496 0.6293 in.). If components do not meet specifications, replace rocker arm(s) or rocker shaft(s) as necessary.

Use straight edge and thickness gauge to check bottom surface of cylinder head for distortion. Do the measurements at the positions shown in Figure 8.

Camshaft

Maximum amount of distortion is 0.15 mm (0.0059 in.). If grinding of cylinder head is necessary, maximum amount of correction is 0.2 mm (0.008 in.).

2. Use dial indicator on end of camshaft to check movement of camshaft in cylinder head. See Figure 9. Maximum movement is 0.20 mm (0.008 in.).

1. Check camshaft for cracks or damage.

Figure 9. Camshaft Check

Figure 8. Cylinder Head Inspection

Rocker Shaft Assembly 1. Disassemble rocker shaft assembly. Put marks on rocker arms so they can be installed on correct shafts.

2. Clean oil passages in rocker shafts and rocker arms.

3. Check clearance between rocker arms and rocker shafts. Maximum clearance is 0.10 mm (0.004 in.).

Correct dimension for inside diameter of rocker arm is 16.000 to 16.027 mm (0.6299 to 0.6311 in.).

Correct dimension for outside diameter of rocker shaft is 15.966 to 15.984 mm (0.6286 to

4

3. Measure height of camshaft lobes. See Figure 10.

Minimum height of intake and exhaust lobes is 36.902 mm (1.4528 in.).

4. Measure camshaft journals at four points (A-D) as shown in Figure 10. Minimum dimensions for the journals are as follows: Front and Rear Journals (Nos. 1 and 5) 31.940 to 31.965 mm (1.2575 to 1.2585 in.)

Center Journals (Nos. 2, 3 and 4) - 31.910 to 31.935 mm (1.2563 to 1.2573 in.)

Front Oil Seal Surface - 33.961 to 34.000 mm (1.3371 to 1.3386 in.)

Fuel Pump Lobe - 37.1 mm (1.46 in.)

5. Check camshaft for straightness. Put front and rear journals in V blocks and rotate camshaft one complete turn. See Figure 11. Maximum amount that the dial indicator should indicate is 0.03 mm (0.0012 in.).

600 SRM 496

Cylinder Head, Camshaft, and Valve Mechanism Repair

6. Measure clearance between camshaft and bore in cylinder head as follows: a. Install camshaft in cylinder head. b. Put plastic gauge material between each camshaft journal and cap. Do not allow camshaft to rotate. c. Tighten capscrews for caps to 18 to 27 N•m (13 to 20 lbf ft). See Figure 12.

Correct clearance for journals No. 1 and 5 is 0.035 to 0.085 mm (0.0014 to 0.0033 in.).

Correct clearance for journals No. 2, 3, and 4 is 0.065 to 0.115 mm (0.0026 to 0.0045 in.).

If any clearances are greater than 0.15 mm (0.0059 in.), replace cylinder head assembly.

Figure 11. Camshaft Check

7. Replace camshaft if there is any damage or if it does not meet specifications.

1. PLASTIC GAUGE

2. SCALE

Figure 12. Camshaft Clearance Measurement

Valve Guides 1. Measure clearance between valve stems and valve guides. Normal clearance is 0.025 to 0.060 mm (0.001 to 0.002 in.).

If clearance is more than 0.20 mm (0.008 in.), replace valve or valve guide.

1.

2.

3.

4.

5.

FRONT OIL SEAL SURFACE FRONT JOURNAL (NO. 1) CENTER JOURNALS (NOS. 2, 3, AND 4) REAR JOURNAL (NO. 5) FUEL PUMP LOBE Figure 10. Camshaft Inspection

2. If replacement is necessary, remove seal from valve guide(s). Then use tool to remove valve guide(s).

3. To install valve guide, install retaining ring on valve guide. Use tool to install valve guide so that retaining ring contacts cylinder head. See Figure 13.

Correct height of valve guide above valve spring seat is 19.1 to 19.6 mm (0.75 to 0.77 in.).

5

Cylinder Head, Camshaft, and Valve Mechanism Repair

600 SRM 496

Valves 1. Inspect stem of each valve for wear. Use micrometer to measure outside diameter of stem. See Figure 15.

Minimum dimension for intake valve is 7.980 mm (0.3142 in.). Minimum dimension for exhaust valve is 7.975 mm (0.3140 in.).

2. Inspect valves for cracks, burned faces, and distortion. Inspect seat face of valves for wear and damage.

1. CYLINDER HEAD 2. RETAINING RING

3. VALVE GUIDE

Figure 13. Valve Guide Inspection

3. Measure thickness of valve head. Minimum thickness for intake valve is 0.5 mm (0.020 in.).

Minimum thickness for exhaust valve is 1.0 mm (0.040 in.).

If valves need grinding, correct surface angle is 30 for both intake and exhaust valves.

Valve Seats 1. Inspect condition of valve seats. If valve seats have cracks, cylinder head must be replaced.

2. If valve seats are in good condition, check contact pattern of valve and valve seat. Use valve seat grinder to make sure valve seats are within specifications shown in Figure 14. Use valve compound to make sure valves fit seats.

A. EXHAUST

B. INTAKE

1. VALVE SEAT WIDTH 2. EXHAUST VALVE SEAT

3. INTAKE VALVE SEAT

Figure 14. Valve Seat Specifications

6

1. DIAMETER

2. THICKNESS, VALVE HEAD

Figure 15. Valve Inspection

600 SRM 496

Cylinder Head, Camshaft, and Valve Mechanism Repair

Valve Springs 1. Check valve springs for damage.

2. Measure free length of outer valve springs. See Figure 16.

Minimum length of intake spring is 44.3 mm (1.74 in.). Minimum length of exhaust spring is 50.8 mm (2.00 in.).

3. Check outer valve springs for squareness. See Figure 16.

If measurement is more than 1.81 mm (0.071 in.), replace valve spring(s).

Figure 17. Cylinder Head Installation

A. MEASURE HERE Figure 16. Valve Springs Inspection

INSTALL 1. Clean surface of cylinder head and surface of engine block.

2. Install new gasket and cylinder head on engine block.

1. DOWEL PIN

2. APPLY SEALANT HERE

3. Install capscrews and washers for cylinder head. Tighten capscrews to 82 to 88 N•m (60 to 65 lbf ft) in proper sequence. See Figure 17.

Figure 18. Camshaft Installation

4. Apply gasket sealer to areas shown by arrows.

Lubricate camshaft with clean engine oil. Then install camshaft. Make sure dowel pin is at top of camshaft. See Figure 18.

5. Assemble rocker shaft assembly. See Figure 19.

Lubricate rocker arms and shafts engine oil. Put capscrews in rocker shaft supports. Then install assembly on cylinder head.

7

Cylinder Head, Camshaft, and Valve Mechanism Repair

600 SRM 496 9. Install capscrew and washer for camshaft pulley.

See Figure 22. Keep pulley from turning and tighten capscrew to 48 to 66 N•m (35 to 49 lbf ft).

A. NO. 1 AND NO. 3 ARE THE SAME B. NO. 2 AND NO. 4 ARE THE SAME Figure 19. Rocker Shaft Assembly 6. Tighten capscrews for rocker shaft supports to 18 to 27 N•m (13 to 20 lbf ft) in proper sequence. See Figure 20.

1. FRONT HOUSING 2. GASKET

3. OIL SEAL

Figure 21. Front Housing

Figure 20. Rocker Shaft Assembly Installation 7. If necessary, install oil seal in front housing. See Figure 21. Use new gasket and install front housing on cylinder head. Tighten capscrews for front housing to 19 to 26 N•m (14 to 19 lbf ft).

8. With dowel pin at top of camshaft, install camshaft pulley. Check that letter A on pulley is aligned with timing mark on front housing. See Figure 22.

1. TIMING MARKS

2. CAMSHAFT PULLEY

Figure 22. Camshaft Pulley Installation

8

600 SRM 496

Cylinder Head, Camshaft, and Valve Mechanism Repair

10. Align timing marks for crankshaft pulley. See Figure 23. Install crankshaft pulley, tapered ring, and capscrew. Tighten capscrew to 160 to 170 N•m (118 to 125 lbf ft).

1. TENSIONER 2. SPRING

3. LOCK BOLT 4. TENSION SIDE

Figure 24. Timing Belt Installation 1. CRANKSHAFT PULLEY

2. TIMING MARK

Figure 23. Timing Belt Installation 11. Install timing belt tensioner and spring. Move tensioner fully toward intake side of engine and temporarily tighten lock bolt.

12. Clean any oil or grease from pulleys. Install timing belt so that it goes in same direction as mark made during removal.

13. Loosen lock bolt and apply spring tension on belt.

Rotate crankshaft pulley clockwise two complete turns and check timing marks.

If timing marks are correct, tighten lock bolt for tensioner to 20 to 35 N•m (15 to 26 lbf ft). Check movement on tension side of timing belt. If tension is correct, belt will move 12 to 14 mm (0.47 to 0.55 in.) with 10 kg (20 lb) of force. See Figure 24.

14. Install lower timing belt cover and gasket.

Tighten capscrews to 7 to 8 N•m (5 to 6 lbf ft).

Install upper timing belt cover and gasket.

Tighten capscrews to 8 to 12 N•m (6 to 9 lbf ft).

See Figure 25.

15. Install distributor. See Distributor Repair for procedures.

1. LOWER TIMING BELT COVER 2. UPPER TIMING BELT COVER Figure 25. Timing Belt Covers

9

Crankshaft and Main Bearings Repair

600 SRM 496

Crankshaft and Main Bearings Repair REMOVE 1. Remove bracket for cooling fan.

8. Put identification marks on bearing caps. Loosen capscrews for main bearing caps in steps. Then remove capscrews, caps, and crankshaft.

2. Remove six capscrews and plate from crankshaft pulley. Remove six capscrews that hold crankshaft pulley to timing pulley.

INSPECT AND REPAIR

3. Remove capscrew from timing pulley. Install special tool on crankshaft to remove timing pulley.

Rotate tool until it touches front of crankshaft.

Hit tool with hammer to loosen timing pulley. Remove pulley, dowel pin, and tapered ring. Remove tool.

1. Inspect crankshaft for wear, cracks, or other damage. Replace crankshaft if it has cracks.

4. Remove oil pan and oil strainer.

5. Remove rear cover. Remove front cover with oil pump.

6. Remove caps for connecting rods. Put identification mark on each cap so they will be installed in correct location.

7. Before removing crankshaft, measure clearance between crankshaft and flange of center main bearing. See Figure 26. Push crankshaft fully forward before making measurement.

Maximum clearance is 0.30 mm (0.012 in.). If clearance is greater than specification, replace center main bearing or crankshaft.

Crankshaft

2. Use micrometer to measure diameter of journals for crankshaft. See Figure 27. Make measurement at several locations for each journal. Correct dimensions for journals are as follows: Main Journal Diameter - 59.937 to 59.995 mm (2.3597 to 2.3620 in.)

Connecting Rod Journals - 50.940 to 50.955 mm (2.0055 to 2.0061 in.)

Rear Oil Seal Surface - 89.946 to 90.000 mm (3.5412 to 3.5433 in.)

Front Oil Seal Surface - 33.961 to 34.000 mm (1.3371 to 1.3386 in.)

If measurements are less than specifications, grind crankshaft and install undersize bearings.

3. Check crankshaft for straightness. See Figure 27. Put front and rear journals in V blocks and rotate crankshaft one complete turn. Maximum amount that dial indicator should indicate is 0.03 mm (0.0012 in.).

4. Check oil passages crankshaft. Make sure passages are clean and have no restrictions.

Main Bearings NOTE: Do not clean main bearings. If any bearings are too dirty, replace all main bearings.

1. Inspect main bearings for damage. If any main bearing is damaged, all main bearings must be replaced.

2. To inspect main bearings for wear, measure clearance between main bearings and crankshaft. See Figure 28. a. Install crankshaft in cylinder block.

1. CENTER MAIN BEARING Figure 26. Crankshaft Clearance Measurement

10

600 SRM 496

Crankshaft and Main Bearings Repair

1. PLASTIC GAUGE MATERIAL

2. SCALE

Figure 28. Main Bearings Clearance Check

INSTALL 1. Clean areas of cylinder block around main bearings. Carefully install bottom half of new main bearings if necessary. Lubricate bearings with clean engine oil.

2. Install crankshaft.

1. REAR OIL SEAL SURFACE 2. CONNECTING ROD JOURNALS

3. MAIN BEARING JOURNALS 4. FRONT OIL SEAL SURFACE

Figure 27. Crankshaft Inspection b. Put plastic gauge material on journals and install main bearing caps. Tighten capscrews for bearing caps to 84 to 90 N•m (62 to 66 lbf ft). c. Remove bearing caps. Plastic gauge material will adhere to journals or bearing caps. d. Use graduations on scale to measure width of plastic gauge material at its widest point.

Correct clearance is 0.031 to 0.049 mm (0.0012 to 0.0019 in.). If any clearance is greater than specification, replace all main bearings.

3. Install top half of main bearings in caps and lubricate with oil. Use identification marks to install main bearing caps in correct locations.

Tighten capscrews for main bearing caps to 84 to 90 N•m (62 to 66 lbf ft).

4. Install pistons and connecting rods as described in Pistons and Connecting Rods Repair.

5. Make sure O-ring is in oil pump housing. Lubricate oil seal with engine oil. Use adhesive sealant to install housing to cylinder block. Make sure there is no sealant in oil port. Tighten M10 capscrews to 38 to 53 N•m (28 to 39 lbf ft). Tighten M8 capscrews to 19 to 26 N•m (14 to 19 lbf ft).

6. Lubricate surfaces of oil seal with engine oil. Use press to install oil seal in rear cover. Install alignment pin in cylinder block.

7. Install gasket and rear cover. See Figure 29.

Make sure dowel pin is installed. Tighten capscrews to 8 to 12 N•m (6 to 9 lbf ft). Cut off part of gasket that extends past bottom of cylinder block.

11

Pistons and Connecting Rods Repair

600 SRM 496

8. Install oil strainer. Tighten M6 capscrews to 8 to 12 N•m (6 to 9 lbf ft). Tighten M8 capscrews to 16 to 23 N•m (12 to 17 lbf ft).

9. Install gasket and oil pan. Tighten capscrews to 7 to 12 N•m (5 to 9 lbf ft).

1. REAR COVER 2. OIL SEAL

3. CRANKSHAFT

Figure 29. Rear Cover

Pistons and Connecting Rods Repair REMOVE AND DISASSEMBLE

INSPECT AND REPAIR

1. Remove cylinder head as described in Cylinder Head, Camshaft, and Valve Mechanism Repair.

Pistons

2. Remove oil pan and oil strainer.

1. Inspect pistons for wear and cracks. Replace any piston that is damaged.

3. Put identification mark on top of each piston.

4. Clean carbon from top of each cylinder bore.

5. Remove caps and bearings from each connecting rod. Keep caps and bearings with correct piston assemblies.

2. Measure outside diameter of piston.

See Figure 30.

Correct dimension is 85.944 to 85.964 mm (3.3836 to 3.3844 in.). Maximum clearance between piston and cylinder bore is 0.15 mm (0.0059 in.).

6. Push connecting rod and piston from cylinder block.

7. Carefully remove piston rings from pistons. Use tool to push piston pin from connecting rod.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow solvent manufacturer’s recommended safety procedures.

Clean all parts in solvent. Make sure all oil passages and grooves are clean. Make sure all machined surfaces are smooth.

12

Figure 30. Piston Measurement

Piston Rings 1. Install piston ring into cylinder bore where it will be used. Use thickness gauge to measure amount

600 SRM 496

Pistons and Connecting Rods Repair

of end clearance of each piston ring. See Figure 31. Correct dimensions are as follows: Top Piston Ring - 0.20 to 0.35 mm (0.008 to 0.014 in.)

2nd Piston Ring - 0.15 to 0.30 mm (0.006 to 0.012 in.)

Oil Ring - 0.30 to 0.90 mm (0.012 to 0.035 in.)

Maximum clearance is 1.0 mm (0.039 in.)

2. Clean rod bearings and crankshaft journals. To check bearings for wear, measure clearance between rod bearings and journals. See Figure 32.

2. Measure clearance between piston ring and groove in piston. See Figure 31. Correct dimensions are as follows: Top Piston Ring - 0.03 to 0.07 mm (0.0012 to 0.0028 in.)

2nd Piston Ring - 0.03 to 0.07 mm (0.0012 to 0.0028 in.)

Maximum clearance is 0.15 mm (0.0059 in.)

b. Remove rod caps. Plastic gauge material will adhere to journals or rod caps.

a. Put plastic gauge material on crankshaft journals and install rod caps. Tighten capscrews for rod caps to 51 to 56 N•m (38 to 41 lbf ft). Do not rotate connecting rod.

c. Use graduations on scale to measure width of plastic gauge material at its widest point.

Correct clearance is 0.027 to 0.067 mm (0.0011 to 0.0026 in.). If any clearance is greater than specification, replace all rod bearings.

1. BEARING

2. PLASTIC GAUGE

Figure 32. Connecting Rod Bearings Clearance Check 1. PISTON RING END CLEARANCE 2. PISTON RING GROOVE CLEARANCE Figure 31. Piston Rings Measurement

Connecting Rods and Bearings 1. Use alignment tool to check connecting rods for straightness. Maximum amount of distortion per 100 mm (4.0 in.) is 0.04 mm (0.0016 in.).

If amount of distortion is greater than specification, install new rod or use press to straighten connecting rod.

ASSEMBLE AND INSTALL 1. Align oil port on large end of connecting rod with F mark on piston. See Figure 33. Lubricate piston pin and bore in piston with engine oil.

2. Use press to install piston pin. Amount of force required to push pin into piston must be 500 to 1500 kg (1102 to 3306 lb). If force is not correct, replace piston pin and/or connecting rod.

Use special tool to make sure piston pin is installed to correct depth. After installation, check that piston moves freely on piston pin.

13

Pistons and Connecting Rods Repair

1. F MARK

600 SRM 496

2. OIL PORT

Figure 33. Connecting Rod and Piston 3. Install piston rings on pistons. During installation, writing on each piston ring must be toward top of piston. Check that rings rotate freely.

Then put ends of rings in positions shown in Figure 34. Make sure ends of upper and lower oil control rings are each 30 from piston pin. Also make sure that top and second rings are each 30 from piston pin. Lubricate rings with engine oil.

4. Apply clean engine oil to piston assembly. Install bearings for connecting rods. Install piston into correct cylinder, making sure F is toward front (timing belt end) of engine. See Figure 35.

A. OIL CONTROL RING B. TOP AND SECOND RINGS 1. EXPANDER RING 2. OIL RING (UPPER) 3. OIL RING (LOWER)

4. TOP RING 5. SECOND RING

Figure 34. Piston Rings

5. Apply clean engine oil to bearing. Then install each cap to correct connecting rod. During installation of caps, make sure to align identification marks that were made during disassembly. Tighten nuts for caps to 51 to 56 N•m (38 to 41 lbf ft).

1. F MARK Figure 35. Piston Installation

14

600 SRM 496

Oil Pump Repair

Cylinder Block Repair 1. After cylinder block is cleaned, check its surface for distortion. See Figure 36.

If amount of distortion is greater than 0.15 mm (0.0059 in.), grind surface of cylinder block. Maximum amount of correction permitted is 0.20 mm (0.008 in.).

2. Check cylinder bores for wear and damage. Measure each bore. Correct dimension is 86.00 to 86.019 mm (3.3858 to 3.3866 in.). Wear limit above this dimension is 0.015 mm (0.001 in.).

Repair cylinder block or use bigger pistons as necessary.

Figure 36. Cylinder Block Insepction

Oil Pump Repair Before removing oil pump, replace sending unit with pressure gauge and check oil pressure. Minimum oil pressure at governed rpm is approximately 275 kPa (40 psi). If pressure is less than specification, oil pump or engine bearings need repair.

REMOVE 1. Remove bracket for cooling fan.

2. Remove upper and lower timing belt covers. See Figure 37.

3. Loosen capscrews for timing belt tensioner and remove spring. Remove capscrews and timing belt tensioner.

4. Use chalk to mark direction of rotation of timing belt. See Figure 38. Remove timing belt.

5. Remove six capscrews and plate from crankshaft pulley. Remove six capscrews that hold crankshaft shaft pulley to timing pulley.

6. Remove capscrew from timing pulley. Install special tool on crankshaft to remove timing pulley.

Rotate tool until it touches the front of crankshaft. Hit tool with hammer to loosen timing pulley. Remove pulley, dowel pin, and tapered ring.

Remove tool.

7. Remove capscrews that hold oil pan to cylinder block. Remove oil pan.

8. Remove capscrews that hold front cover (pump housing) to cylinder block. Remove front cover and oil pump assembly.

1. UPPER TIMING BELT COVER 2. LOWER TIMING BELT COVER Figure 37. Timing Belt Covers

Figure 38. Timing Belt

15

Oil Pump Repair

600 SRM 496

DISASSEMBLE 1. Remove screws and pump cover. See Figure 39.

2. Remove outer gear and inner gear from pump body.

3. Remove snap ring and plunger assembly from housing.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

Clean all parts in solvent. Make sure all machined surfaces are smooth.

1.

2.

3.

4.

SCREW COVER OUTER GEAR INNER GEAR

5. FRONT COVER (HOUSING) 6. OIL SEAL 7. PLUNGER 8. SNAP RING

Figure 39. Oil Pump

16

600 SRM 496

Oil Pump Repair

INSPECT 1. Check front cover (pump housing) and pump cover for wear or damage. Check plunger spring for damage.

2. Measure parts of oil pump. See Figure 40. a. Measure clearance between gears and crescent. Correct clearance is 0.20 to 0.32 mm (0.008 to 0.013 in.). If clearance is more than 0.35 mm (0.014 in.), repair as necessary. b. Measure clearance between crescent and teeth of inner gear. Correct clearance is 0.267 to 0.380 mm (0.0105 to 0.0150 in.). If clearance is more than 0.40 mm (0.0157 in.), repair as necessary.

d. Measure clearance between body and outer gear. Correct clearance is 0.090 to 0.184 mm (0.0035 to 0.0072 in.). If clearance is more than 0.20 mm (0.008 in.), repair as necessary.

ASSEMBLE 1. Install oil seal in oil pump housing. Make sure front edge of oil seal is even with outer edge of housing. See Figure 39.

2. Lubricate gears with engine oil. Then install gears in housing.

3. Install pump cover. Apply thread-locking compound on screws for pump cover. Then install screws.

4. Install plunger assembly and snap ring.

c. Use straight edge to measure side clearance of gears. Correct clearance is 0.03 to 0.63 mm (0.0012 to 0.0248 in.). If clearance is more than 0.10 mm (0.004 in.), repair as necessary.

1. CLEARANCE BETWEEN CRESCENT AND INNER GEAR 2. CLEARANCE BETWEEN CRESCENT AND GEARS

3. SIDE CLEARANCE OF GEARS IN HOUSING 4. CLEARANCE BETWEEN HOUSING AND OUTER GEAR

Figure 40. Oil Pump Measurement

17

Cooling System Repair

600 SRM 496

INSTALL 1. Install O-ring on oil pump housing. Use grease to hold O-ring in position. Lubricate oil seal with engine oil. See Figure 41.

2. Use adhesive sealant to install oil pump housing on cylinder block. Make sure there is no sealant in oil port. Tighten M10 capscrews to 38 to 53 N•m (28 to 39 lbf ft). Tighten M8 capscrews to 19 to 26 N•m (14 to 19 lbf ft).

3. Install suction tube assembly. Install gasket and oil pan.

1. O-RING Figure 41. Oil Pump

Cooling System Repair THERMOSTAT

3. Test operation of thermostat. See Cooling System 700 SRM 626.

Replace 1. Drain cooling system to level of thermostat.

2. Disconnect hose and remove thermostat housing.

Remove thermostat. See Figure 42.

Thermostat must begin to open at 82 ±1.5 C (180 ±3 F). Thermostat must be completely open at 95 C (203 F).

4. Install thermostat and new gasket. Make sure print side of gasket is toward thermostat.

5. Install thermostat housing and tighten capscrews to 12 to 18 N•m (9 to 13 lbf ft).

6. Connect hose and fill cooling system. Start engine and check for leaks.

FAN ASSEMBLY Remove and Disassemble 1. Loosen alternator and remove fan belt.

2. Remove capscrews for fan. Remove fan and pulley from hub.

1. CYLINDER BLOCK 2. GASKET

3. THERMOSTAT 4. HOUSING

Figure 42. Thermostat

18

3. Remove capscrews that hold fan bracket to engine. Remove fan bracket.

4. Use press to remove fan hub from shaft. Remove snap ring, and push bearing and shaft from bracket. See Figure 43.

600 SRM 496

Cooling System Repair

WATER PUMP Remove and Disassemble NOTE: If either the shaft or impeller is damaged, the complete water pump must be replaced.

1. Drain cooling system.

2. Loosen alternator and remove fan belt.

3. Remove capscrews for the fan. Remove fan and pulley from the hub.

4. Remove capscrews that hold fan bracket to engine. Remove fan bracket.

1.

2.

3.

4.

FAN PULLEY HUB SNAP RING

5. SHAFT 6. SUPPORT BRACKET 7. BRACKET

Figure 43. Fan Assembly

Assemble and Install

5. Remove upper and lower timing belt covers. See Figure 44.

1. UPPER TIMING BELT COVER 2. LOWER TIMING BELT COVER Figure 44. Timing Belt Covers

1. Use press to install shaft and bearing in bracket.

See Figure 43. Push bearing in until it touches bracket. Install snap ring. Install hub on shaft.

When installed, shaft must extend 2.1 mm (0.083 in.) past hub.

2. Install bracket assembly on cylinder block.

Tighten M8 capscrews to 32 to 47 N•m (24 to 35 lbf ft). Tighten M10 capscrews to 38 to 64 N•m (28 to 47 lbf ft).

3. Install pulley and fan on hub. Tighten capscrews to 8 to 11 N•m (6 to 8 lbf ft).

4. Install fan belt. Adjust tension of the fan belt.

Check movement of fan belt between fan and alternator.

Tension for NEW belt is correct when it moves 8 to 10 mm (0.32 to 0.39 in.) with 10 kg (22 lb) of force. Tension for USED belt is correct when it moves 10 to 12 mm (0.39 to 0.47 in.) with 10 kg (22 lb) of force. Tighten alternator when tension is correct.

19

Cooling System Repair

600 SRM 496

6. Loosen capscrews for timing belt tensioner and remove spring. Remove capscrews and timing belt tensioner.

CAUTION Do not rotate the camshaft gear or the crankshaft gear while the timing belt is removed. If either of the gears is moved, it will be necessary to align the timing marks.

7. Use chalk to mark direction of rotation of timing belt. See Figure 45. Align timing marks. Then remove timing belt.

Figure 45. Timing Belt 8. Disconnect hose at water pump. Remove capscrews for water pump. Then remove water pump from cylinder block.

1. PULLEY 2. SHAFT AND BEARING ASSEMBLY

3.

4.

5.

6.

WASHER HOUSING SEAL IMPELLER

Figure 46. Water Pump

9. Use puller to remove pulley from shaft. See Figure 46.

4. Install water pump with a new gasket. Tighten capscrews to 19 to 26 N•m (14 to 19 lbf ft).

10. Use press to remove impeller from shaft and bearing assembly from housing. Remove water seal from housing.

5. Clean any oil or grease from pulleys. Install timing belt so that it goes in same direction as mark made during removal.

Assemble and Install

6. Loosen lock bolt and apply spring tension on belt.

Rotate crankshaft pulley clockwise two complete turns and check timing marks.

1. Install water seal in housing. Put antifreeze on lip of the seal. See Figure 46.

2. Use press to install shaft and bearing in pump body. Make sure shaft turns smoothly.

3. Use a press to install the shaft and bearing in the pump body. Make sure the shaft turns smoothly.

If timing marks are correct, tighten lock bolt for tensioner to 20 to 35 N•m (15 to 26 lbf ft). Check movement on tension side of timing belt. If tension is correct, belt will move 12 to 14 mm (0.47 to 0.55 in.) with 10 kg (22 lb) of force. See Figure 47.

7. Install lower timing belt cover and gasket.

Tighten capscrews to 7 to 8 N•m (5 to 6 lbf ft).

Install upper timing belt cover and gasket.

Tighten capscrews to 8 to 12 N•m (6 to 9 lbf ft).

See Figure 44.

8. Install fan assembly as described in the procedure for Fan Assembly, Assemble and Install.

9. Install coolant hoses. Fill cooling system with coolant.

10. Start engine and check cooling system for leaks.

20

600 SRM 496

Distributor Repair

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. DO NOT remove the cover for the radiator when the engine is running.

11. After engine has been operated, stop engine. If coolant is hot, give engine time to cool. Check coolant level and add coolant if necessary.

1. TENSIONER 2. SPRING

3. LOCK BOLT 4. TENSION SIDE

Figure 47. Timing Belt Installation

Distributor Repair NOTE: This section only has the removal and installation procedures for the distributor. Service procedures for the ignition system are found in the Electrical System section.

REMOVE 1. Rotate crankshaft until No. 1 piston is at TDC on compression stroke. Make note of position of distributor rotor. See Figure 48.

2. Disconnect wires at spark plugs.

3. Remove capscrew from flange of distributor shaft housing. Lift distributor assembly from engine.

INSTALL 1. Rotate crankshaft until No. 1 piston is at TDC on compression stroke. Put rotor in correct position.

See Figure 48.

2. Lubricate O-ring and gear on distributor engine oil. Install distributor, making sure to align marks on distributor housing, distributor gear, and engine.

3. Connect wires at spark plugs.

Figure 48. Distributor Replacement

21

Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)

600 SRM 496

Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM) REMOVE 1. Remove capscrews for flywheel. Then remove flywheel and drive plate. See Figure 49.

1. Use hammer and chisel to break ring gear. See Figure 50. Be careful to not damage flywheel.

2. If necessary, remove flywheel housing.

Figure 50. Ring Gear Removal

WARNING Parts are hot. Wear protective clothing and gloves to prevent burns.

2. Heat ring gear before installation on flywheel.

Make sure ring gear is not heated to more than 200 C (392 F).

A. TIGHTENING SEQUENCE 1. COVER PLATE 2. FLYWHEEL HOUSING 3. FLYWHEEL

4. DRIVE PLATE 5. SUPPORT PLATE 6. CAPSCREW

Figure 49. Flywheel Arrangement

RING GEAR, REPLACE WARNING Wear eye protection for this operation to prevent eye injury from metal chips. You will be using a hammer and chisel to break the ring gear.

NOTE: Before ring gear is removed, note position of chamfer on teeth.

22

3. Install ring gear on flywheel. Make sure chamfer on teeth is in correct direction toward starter.

INSTALL 1. If flywheel housing was removed, install it on engine. Tighten M14 capscrews to 114 to 136 N•m (84 to 100 lbf ft). Tighten M8 capscrews to 21 to 25 N•m (15 to 18 lbf ft).

2. Install flywheel on crankshaft. plate and support plate.

Install drive

3. Apply adhesive sealant on threads of capscrews.

Then install capscrews for flywheel. Tighten capscrews to 96 to 103 N•m (71 to 76 lbf ft) in proper sequence. See Figure 49.

600 SRM 496

Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)

Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS) REMOVE

2. Install flange and flywheel on crankshaft.

1. Remove capscrews for flywheel. Then remove flywheel and flange. See Figure 51.

3. Apply thread-locking adhesive on threads of capscrews. Then install capscrews and lockwashers. Tighten capscrews to 96 to 103 N•m (71 to 76 lbf ft).

2. If necessary, remove adapter plate.

INSTALL 1. If adapter plate for the torque converter housing was removed, install it on engine. See Figure 51. Tighten capscrews to 43 to 51 N•m (32 to 38 lbf ft).

NOTE: EARLIER MODEL TORQUE CONVERTER HOUSING IS SHOWN. LATER MODEL IS SIMILAR. 1. FLANGE 2. FLYWHEEL 3. DRIVE PLATE

4. TORQUE CONVERTER 5. ACCESS COVER 6. TORQUE CONVERTER HOUSING Figure 51. Flywheel and Torque Converter

23

Valve Adjustment

600 SRM 496

Valve Adjustment 1. Rotate crankshaft until No. 1 piston is at TDC on compression stroke (intake and exhaust valves closed).

2. Adjust clearance of intake valves for No. 1 and No. 2 cylinders and exhaust valves for the No. 1 and No. 3 cylinders. See Figure 52. Correct clearance for all valves when engine is hot is 0.3 mm (0.012 in.).

To adjust clearance, loosen lock nut and turn adjustment screw. Tighten lock nut to 16 to 21 N•m (12 to 15 lbf ft).

NOTE: During adjustment of valves, check position of balls in ends of rocker arms. Flat surface of ball must be in contact with stem of valve.

3. Rotate crankshaft clockwise one complete turn.

Adjust remaining valves.

4. If valves are adjusted when engine is cold, check adjustments again after engine is warm.

A. INTAKE VALVES

B. EXHAUST VALVES

1. CAMSHAFT 2. ROCKER ARM

3. BALL 4. VALVE STEM

Figure 52. Valve Adjustment

24

600 SRM 496

Engine Timing Adjustment

Compression Pressure Check 1. Remove spark plugs from cylinder head. Disconnect high tension wire at ignition coil. See Figure 53.

2. Install compression gauge in No. 1 cylinder. Make sure gauge has minimum range of 1725 kPa (250 psi).

3. Use starter to crank engine at least six revolutions. Check pressure reading and release pressure. Repeat test again and make note of highest pressure. Do this test for each cylinder.

• If pressure reading increases to normal reading, low pressure was caused by worn or damaged piston rings. Cylinder bore may also be damaged.

• If pressure reading does not increase, low pressure was caused by worn valves, valve seats, or valve guides.

• If low pressure readings are in two cylinders next to each other, cylinder head may be leaking.

Standard pressure reading is 1130 kPa (164 psi).

Minimum reading is 793 kPa (115 psi).

4. If the readings are lower than minimum reading, there is a problem with the valves, piston rings, or cylinder head gasket. Do the following tests to find the problem: a. Add approximately 30 ml (1.0 oz) of engine oil to each cylinder at spark plug hole. b. Crank engine approximately 10 revolutions to distribute oil. c. Install compression gauge and do same tests as described in Step 3.

1. ADAPTER Figure 53. Compression Pressure Check

Engine Timing Adjustment See Ignition System Check and Adjustment in the section Mazda M4-2.0G And M4-2.2G Gasoline/ LPG Engines 2200 SRM 524 for the adjustment procedure for engine timing.

The correct timing for the H1.50-1.75XM, H2.00XMS (S/H25-35XM, S/H40XMS) units is as follows: • Gasoline Engine = 0 BTDC @ 725 ±25 rpm (white mark)

• LPG Engine = 8 BTDC @ 725 ±25 rpm The correct timing for the S/H2.00-3.20XM (SH4065XM) units is as follows: • Gasoline Engine = 0 BTDC @ 725 ±25 rpm (white mark) • LPG Engine = 9 BTDC @ 725 ±25 rpm (red mark)

25

Engine Specifications

600 SRM 496

Throttle Linkage Adjustment Whenever the throttle linkage is disassembled, the throttle cable must be adjusted after installation.

GASOLINE ENGINES For the H1.50-1.75XM, 2.00XMS (S/H25-35XM, 40XMS) units, see Gasoline Fuel System 900 SRM 547 for the correct adjustment procedure. For the S/H2.00-3.20XM(S/H40-65XM) units, see Gasoline Fuel System 900 SRM 502 for the correct adjustment procedure.

LPG ENGINES (IMPCO) For earlier units, see LPG Fuel System 900 SRM 523 for the correct adjustment procedure.

LPG ENGINES (AISAN) For later units, see LPG Fuel System, Aisan Open-Loop 900 SRM 925 or LPG Fuel System, Aisan Closed-Loop 900 SRM 948 for the correct adjustment procedure.

Engine Specifications ENGINE DATA Engine Type........................ In-line, Four Cylinders Bore × Stroke (M4-2.0G).... 86 mm (3.39 in.) × 86 mm (3.39 in.)

Bore × Stroke (M4-2.2G).... 86 mm (3.39 in.) × 94 mm (3.70 in.)

Displacement (M4-2.0G) .... 1998 cm 3 (121.9 in. 3 ) Displacement (M4-2.2G) .... 2184 cm 3 (133.2 in. 3 ) Firing Order ....................... 1 - 3 - 4 - 2 Compression Ratio ............. 8.6 : 1 Compression Pressure ....... 1131 kPa (164 psi) @ 270 rpm Engine Timing (No. 1 Cylinder): – Gasoline....................... 0 /TDC – LPG, H1.50 -1.75XM, 2.00 XMS (S/H25-35XM, 40XMS)........................... 8 BTDC – LPG, S/H2.00 -3.20XM (S/H40-65XM) ................ 9 BTDC Engine Speed, M4-2.0G (IMPCO): – Idle Speed.................... 725 ± 25 rpm – Governed Speed .......... 2650 ± 50 rpm Engine Speed, M4-2.0G and M4-2.2G (AISAN): – Idle Speed.................... 800 ±25 rpm – Governed Speed .......... 2750 ±50 rpm Stall Speed (New M4-2.0G Engine):

26

– Gasoline....................... 1980 ±50 rpm – LPG.............................. 1930 ±50 rpm Stall Speed (M4-2.0G Engine With 30 Hours or More): – Gasoline....................... 2100 ±50 rpm – LPG.............................. 2050 ±50 rpm Stall Speed (New M4-2.2G Engine): – Gasoline....................... 2150 ±50 rpm – LPG.............................. 2100 ±50 rpm Stall Speed (M4-2.2G Engine With 30 Hours or More): – Gasoline....................... 2270 ±50 rpm – LPG.............................. 2220 ±50 rpm Oil Pressure @ 2400 rpm ... 226 to 362 kPa (33 to 53 psi)

THERMOSTAT Starts to Open .................... 82 ±1.5 C (180 ±3 F) Fully Open.......................... 95 ±1.5 C (203 ±3 F)

CYLINDER HEAD Height ................................. 91.25 to 92.05 mm (3.620 to 3.624 in.)

Distortion Limit ................. 0.15 mm (0.006 in.)

Grinding Limit ................... 0.20 mm (0.008 in.)

600 SRM 496

VALVE MECHANISM Inside Diameter of Valve Guide................................... 8.07 to 8.09 mm (0.3177 to 0.3185 in.)

Clearance in Guide (Exhaust) ............................ 0.025 to 0.060 mm (0.001 to 0.0024 in.)

Clearance in Guide (Intake) ............................... 0.025 to 0.060 mm (0.001 to 0.0024 in.)

– Service Limit (Intake and Exhaust)..... 0.20 mm (0.008 in.)

Diameter of Valve Stem (Intake) ............................... 8.03 to 8.045 mm (0.3161 to 0.3167 in.)

– Service Limit............... 7.980 mm (0.3142 in.)

Diameter of Valve Stem (Exhaust) ............................ 8.025 to 8.045 mm (0.3159 to 0.3167 in.)

– Service Limit............... 7.975 mm (0.3140 in.)

Valve Head Thickness (Intake) ............................... 0.5 mm (0.020 in.)

Valve Head Thickness (Exhaust) ............................ 1.0 mm (0.040 in.)

Valve Face Angle (Intake and Exhaust) ......... 30 Spring Free Length - Outer (M4-2.0G)............... 52.4 mm (2.063 in.)

– Service Limit (M4-2.0G) ....................... 50.8 mm (2.00 in.)

Spring Free Length - Outer (M4-2.2G) ........... 52.2 mm (2.055 in.)

– Service Limit (M4-2.2G) ....................... 50.6 mm (1.992 in.)

Spring Free Length - Inner (M4-2.0G) ............... 45.7 mm (1.799 in.)

Engine Specifications

Rocker Arm Shaft Diameter............................. 15.966 to 15.984 mm (0.6286 to 0.6293 in.)

Rocker Arm Bore Diameter............................. 16.000 to 16.027 mm (0.6299 to 0.6311 in.)

Clearance Between Rocker Arm and Shaft ................................... 0.016 to 0.061 mm (0.0006 to 0.0024 in.)

CAMSHAFT Cam Lobes to Production Limit ................ 37.102 mm (1.4607 in.)

Cam Lobes to Service Limit ................................... 36.902 mm (1.4528 in.)

Bearing Journals (Nos. 1 and 5) ..................... 31.940 to 31.965 mm (1.2575 to 1.2585 in.)

Bearing Journals (Nos. 2, 3, and 4) ................ 31.910 to 31.935 mm (1.2563 to 1.2573 in.)

Bearing Journal Wear Limit ................................... 0.05 mm (0.002 in.)

Clearance Between Journals and Bore (Nos. 1 and 5) ..................... 0.035 to 0.085 mm (0.0014 to 0.0033 in.)

Clearance Between Journals and Bore (Nos. 2, 3, and 4) ................ 0.065 to 0.115 mm (0.0026 to 0.0045 in.)

End Clearance .................... 0.08 to 0.16 mm (0.003 to 0.006 in.)

– Service Limit............... 0.20 mm (0.008 in.)

CRANKSHAFT

– Service Limit (M4-2.0G) ....................... 44.3 mm (1.744 in.)

Distortion (M4-2.0G).......... less than 0.03 mm (0.0012 in.)

Spring Free Length - Inner (M4-2.2G) ............... 47.7 mm (1.878 in.)

Distortion (M4-2.2G).......... less than 0.04 mm (0.0016 in.)

– Service Limit (M4-2.2G) ....................... 46.3 mm (1.823 in.)

Main Bearing Journal Diameter............................. 59.937 to 59.955 mm (2.3597 to 2.3604 in.)

– Service Limit............... 0.05 mm (0.002 in.)

27

Engine Specifications

– Grinding Limit ............ 0.75 mm (0.030 in.)

Clearance Between Journals and Main Bearings.............................. 0.031 to 0.049 mm (0.0012 to 0.0019 in.)

600 SRM 496

– Service Limit............... 0.15 mm (0.0059 in.)

Piston Pin Diameter .......... 21.974 to 21.980 mm (0.8651 to 0.8654 in.)

– Service Limit............... 0.08 mm (0.003 in.)

Groove Width for Piston Rings Nos. 1 and 2 ............. 1.520 to 1.540 mm (0.0598 to 0.0606 in.)

Connecting Rod Journal Diameter............................. 50.940 to 50.955 mm (2.0055 to 2.0061 in.)

Groove Width for Oil Ring............................... 4.020 to 4.040 mm (0.1583 to 0.1591 in.)

– Service Limit............... 0.05 mm (0.002 in.)

Piston Ring Clearance in Groove (Nos. 1 and 2) ........ 0.03 to 0.07 mm (0.0012 to 0.0028 in.)

– Grinding Limit ............ 0.75 mm (0.030 in.)

Thrust Bearing Clearance............................ 0.08 to 0.18 mm (0.003 to 0.007 in.)

– Service Limit............... 0.30 mm (0.012 in.)

CONNECTING RODS Small End Bore .................. 21.943 to 21.961 mm (0.8639 to 0.8646 in.)

Clearance Between Piston Pin and Bore..................................... 0.015 to 0.040 mm (0.0006 to 0.0016 in.)

Clearance Between Crankshaft Journals and Rod Bearings ............... 0.027 to 0.067 mm (0.0011 to 0.0026 in.)

– Service Limit............... 0.10 mm (0.004 in.)

CYLINDER BLOCK Distortion at Top Surface... 0.15 mm (0.0059 in.)

Bore Diameter .................... 86.00 to 86.019 mm (3.3858 to 3.3866 in.)

– Wear Limit .................. 0.15 mm (0.0059 in.)

PISTONS Diameter............................. 85.944 to 85.964 mm (3.3836 to 3.3844 in.)

Clearance Between Piston and Bore .................. 0.036 to 0.075 mm (0.0014 to 0.0030 in.)

28

– Service Limit............... 0.15 mm (0.0059 in.)

Piston Ring End Clearance: – Top Ring ...................... 0.20 to 0.35 mm (0.008 to 0.014 in.)

– Second Ring................. 0.15 to 0.30 mm (0.006 to 0.012 in.)

– Oil Control Ring.......... 0.30 to 0.90 mm (0.012 to 0.035 in.)

– Service Limit (All Rings) ...................... 1.0 mm (0.039 in.)

OIL PUMP Clearance Between Inner Gear and Crescent ... 0.267 to 0.380 mm (0.0105 to 0.0150 in.)

– Service Limit............... 0.40 mm (0.0157 in.)

Clearance Between Crescent and Outer Gear... 0.20 to 0.32 mm (0.008 to 0.013 in.)

– Service Limit............... 0.35 mm (0.014 in.)

Clearance Between Outer Gear and Housing .............. 0.090 to 0.184 mm (0.0035 to 0.0072 in.)

– Service Limit............... 0.20 mm (0.008 in.)

Side Clearance Between Gears and Housing ............ 0.03 to 0.063 mm (0.0012 to 0.0025 in.)

– Service Limit............... 0.10 mm (0.004 in.)

600 SRM 496

Torque Specifications

Torque Specifications Camshaft Pulley Lock Bolt 48 to 66 N•m (35 to 49 lbf ft)

Oil Pan 7 to 12 N•m (62 to 106 lbf in)

Cooling Fan 8 to 11 N•m (71 to 97 lbf in)

Oil Pump M8 Capscrews 19 to 26 N•m (14 to 19 lbf ft) M10 Capscrews 38 to 53 N•m (28 to 39 lbf ft)

Connecting Rod Cap M4-2.0G 51 to 56 N•m (38 to 41 lbf ft) M4-2.2G 66 to 70 N•m (49 to 52 lbf ft) Crankshaft Pulley 30 to 33 N•m (22 to 24 lbf ft)

Rocker Cover M4-2.0G 30 to 40 N•m (22 to 30 lbf ft) M4-2.2G 40 to 60 N•m (30 to 44 lbf ft) Rocker Shaft Assembly 18 to 27 N•m (13 to 20 lbf ft)

Cylinder Head Cold 81 to 88 N•m (60 to 65 lbf ft) Hot 95 to 100 N•m (70 to 74 lbf ft)

Spark Plugs 15 to 23 N•m (133 to 204 lbf in)

Engine Mount to Engine 55 N•m (41 lbf ft)

Starter 66 to 79 N•m (49 to 58 lbf ft)

Engine Mount Capscrew 66 N•m (49 lbf ft)

Thermostat Cover M4-2.0G 12 to 18 N•m (107 to 159 lbf in) M4-2.2G 19 to 31 N•m (14 to 23 lbf ft)

Exhaust Manifold 22 to 29 N•m (195 to 257 lbf in) Flywheel Housing M10 Capscrews 41 to 49 N•m (30 to 36 lbf ft) M14 Capscrews 114 to 136 N•m (84 to 100 lbf ft) Fuel Pump 16 to 22 N•m (142 to 195 lbf in) Intake Manifold 19 to 31 N•m (14 to 23 lbf ft) Main Bearing Cap 84 to 90 N•m (62 to 66 lbf ft)

Timing Belt Cover M4-2.0G Upper Capscrews 8 to 12 N•m (71 to 106 lbf in) M4-2.0G Lower Capscrews 7 to 8 N•m (62 to 71 lbf in) M4-2.2G Capscrews 7 to 10 N•m (62 to 89 lbf in) Timing Belt Tension Lock Bolt M4-2.0G 20 to 35 N•m (15 to 26 lbf ft) M4-2.2G 38 to 53 N•m (28 to 39 lbf ft) Water Pump 19 to 26 N•m (168 to 230 lbf in)

29

Troubleshooting

600 SRM 496

Troubleshooting PROBLEM The engine will not start.

The engine does not run smoothly.

30

POSSIBLE CAUSE

PROCEDURE OR ACTION

The fuel tank is empty.

Fill fuel tank.

The battery is not fully charged.

Charge battery.

The connections at the battery are loose or they have corrosion.

Check and tighten battery connections.

The starter system has a problem.

Check electrical circuit for starter.

There are damaged parts in the engine.

Repair engine.

The valves are worn or damaged.

Install new valves.

The piston rings are worn or damaged.

Install new piston rings.

The fuel system has a problem.

Check and repair fuel system.

Ignition timing is not correct.

Adjust timing.

Fuel line has a restriction.

Clean or use new fuel lines.

Fuel filter has a restriction.

Install new fuel filter.

Ignition system does not operate correctly.

Check and repair ignition system.

The valve mechanism does not operate correctly.

Check and repair valve mechanism.

The cylinder head has cracks.

Install new cylinder head.

The head gasket has a leak.

Install new gasket.

There is a leak in the intake system.

Check and repair intake system.

Engine is too hot.

Check cooling system.

Fuel lines or fuel filter has a restriction.

Clean or use new fuel lines.

The ignition timing is not correct.

Adjust timing.

600 SRM 496

PROBLEM The engine does not have enough power.

There is noise inside the engine.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

The fuel is the wrong type.

Fill tank with correct fuel.

The air filter is dirty.

Install new air filter.

The ignition timing is not correct.

Adjust timing.

The valve mechanism does not work correctly.

Check and repair valve mechanism.

The piston assemblies are worn or damaged.

Install new pistons.

The exhaust system has restrictions.

Clean parts or install new muffler or pipes.

Fuel lines or fuel filter has a restriction.

Clean or use new fuel lines and filter.

Engine is too hot or too cold.

Check cooling system.

Cylinder head gasket leaks.

Install new gasket.

The main bearings are worn or damaged.

Install new main bearings.

Engine is too hot.

Check and repair cooling system.

Valves are not adjusted correctly.

Adjust valves.

The bearings for the connecting rods are worn or damaged.

Install new bearings.

The pistons are worn or damaged.

Install new pistons.

Valve spring is broken.

Install new valve springs.

There is not enough oil in the engine.

Fill engine with correct oil.

The flywheel is loose.

Tighten capscrews for flywheel.

A connecting rod is bent.

Repair engine.

There is a leak in the exhaust system.

Repair exhaust system.

The valve mechanism does not operate correctly.

Check and repair valve mechanism.

Spark plugs are dirty.

Install new spark plugs.

31

Troubleshooting

PROBLEM The engine gets too hot.

32

600 SRM 496

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is not enough coolant in the cooling system.

Fill cooling system.

The air filter has a restriction.

Install new air filter.

The water pump has damage.

Install new water pump.

The radiator is dirty.

Clean or repair the radiator.

The cooling system has restrictions.

Check radiator and hoses.

The belt for the water pump is worn or not adjusted correctly.

Check and adjust the belt.

The thermostat has damage.

Install new thermostat.

The exhaust system has restrictions.

Check and repair exhaust system.

Ignition timing is not correct.

Adjust timing.

Cylinder head gasket leaks.

Install new head gasket.

Engine compression is not correct.

Check and repair engine.

TECHNICAL PUBLICATIONS 600 SRM 496

2/01 (4/96)(1/96)(1/95)(9/93)(4/93) Printed in U.S.A.

METRIC AND INCH (SAE) FASTENERS ALL MODELS

PART NO. 910442

8000 SRM 231

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Metric and Inch (SAE) Fasteners

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Threaded Fasteners.......................................................................................................................................

Nomenclature, Threads.................................................................................................................................

Strength Identification ..................................................................................................................................

Cotter (Split) Pins..........................................................................................................................................

Fastener Torque Tables .................................................................................................................................

Conversion Table ...........................................................................................................................................

1 1 1 2 2 7 9

This section is for the following models: All Models

©2004 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 231

General

General THREADED FASTENERS Threaded fasteners, like bolts, nuts, capscrews, and studs, are made to specifications that describe the mechanical strength and hardness of the fastener.

A fastener used in a design application is selected according to its specifications. Hyster® Company buys parts from many countries. Parts that are purchased must be to Hyster® Company standards.

There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar, but cannot be used as a direct replacement. To make sure that you have the correct fastener, order fasteners and parts through the Hyster® Parts Depot.

Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called "Grade" for SAE standards and "property class" for metric standards. This section describes the identification of some common fasteners.

The metric system used by Hyster® Company is described as SI (Le Systeme d’Unites or the International System of units, also called SI in all languages). The SI System of measurement is described in ISO Standard 1000, 1973. A conversion table of common measurements is shown in Table 7.

shown first in the series [M12 = 12 mm, M20 = 20 mm (1/2 = 1/2 in., 3/4 = 3/4 in.)].

The number of threads per inch is normally not shown for inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter. Metric fasteners show the number of threads per millimeter.

The length of the shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners.

A capscrew will have the following description: Metric

Inch

M12 × 1.75 × 50

1/2 × 13 UNC × 1-1/2

ABC

ABCD

A = Thread Size

A = Shank Diameter

B = Pitch

B = Number of Threads Per Unit of Length

C = Length

C = type of Thread D = Shank Length

NOMENCLATURE, THREADS The thread design is specified by a series of numbers and letters for inch and metric fasteners. See Figure 1. The diameter of the shank of the fastener is

Figure 1. Thread Design

1

General

8000 SRM 231

STRENGTH IDENTIFICATION CAUTION When fasteners must be replaced, the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size.

NOTE: Identification marks are according to bolt strength. The higher the number or the increase in the number of marks indicates increased bolt strength.

The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the capscrew or on a nut. Property classes less than 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have any marks. The following tables show the marks that identify the grades and property classes for different fasteners.

Figure 2. Minimum Angle Between Cotter Pin Legs Unless otherwise specified, the legs of chain anchor cotter (split) pins are to be bent against the pin. See Figure 3.

COTTER (SPLIT) PINS Cotter (split) pins are used in many applications on your forklift. They are typically used to retain parts such as pins and nuts. Cotter (split) pins are typically not used as load-bearing members. Service personnel must use new cotter (split) pins. Do not reuse a cotter (split) pin. Replacement cotter (split) pin must be of the correct size. See Table 8.

The legs of a cotter (split) pin are bent for the following reasons: • To retain the cotter (split) pin in the part • To provide clearance between the cotter pin legs and other parts or members. One or both cotter (split) pin legs must be bent to provide a minimum 90 angle between the legs. See Figure 2.

2

1. COTTER PIN Figure 3. Cotter (Split) Pins Used On Mast Chain Anchors

8000 SRM 231

General Table 1. Bolts and Screws

3

General

8000 SRM 231 Table 2. Studs and Nuts

4

8000 SRM 231

General Table 3. Torque Nuts

5

General

8000 SRM 231 Table 4. Torque Nuts With Nylon Insert

6

8000 SRM 231

General

FASTENER TORQUE TABLES Table 5. Torque Values for Metric Fasteners*

Size and Pitch

Property Class 5.8 1

Grade 8.8 2

Grade 10.9 3

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

M3 × 0.5 M3.5 × 0.6 M4 × 0.7 M5 × 0.8 M6 × 1

0.62 0.97 1.44 2.91 4.94

0.5 0.7 1.1 2.1 3.6

0.99 1.55 2.30 4.65 7.90

0.7 1.1 2.1 3.6 6

1.34 2.11 3.13 6.33 10.8

1.0 1.6 2.3 4.7 8

M8 × 1.25 M8 × 1 M10 × 1.5 M10 × 1.25

12.0 12.8 23.8 25.1

9 9 18 19

19.2 20.5 38.0 40.1

14 15 28 30

26.1 27.9 52 55

19 21 38 41

M12 × 1.75 M12 × 1.25 M14 × 2 M14 × 1.5

41.4 45.3 66 72

31 33 49 53

66 72 105 115

49 53 77 85

90 98 145 155

66 72 105 115

M16 × 2 M16 × 1.5 M20 × 2.5 M20 × 1.5

105 110 200 225

77 81 150 165

165 175 320 355

122 130 235 260

225 240 435 485

165 175 320 360

345 375 505 550

255 275 370 405

555 605 810 875

410 445 600 645

755 820 1,100 1,190

560 605 810 880

690 715 765 940 1,030

510 530 565 695 760

1,100 1,140 1,220 1,500 1,640

810 840 900 1,100 1,210

1,500 1,550 1,660 2,040 2,240

1,100 1,140 1,230 1,510 1,660

1,200 1,280 1,560 1,640

885 945 1,150 1,210

1,930 2,040 2,490 2,630

1,430 1,510 1,840 1,940

2,620 2,780 3,390 3,570

1,940 2,050 2,500 2,640

1,930 2,070 2,410 2,580 2,900 3,160

1,430 1,530 1,780 1,910 2,140 2,330

3,080 3,320 3,850 4,120 4,630 5,040

2,280 2,450 2,840 3,040 3,420 3,720

4,200 4,510 5,240 5,610 6,300 6,860

3,100 3,330 3,870 4,140 4,650 5,060

M24 M24 M27 M27

× × × ×

3 2 3 2

M30 × 3.5 M30 × 3 M30 × 2 M33 × 3.5 M33 × 2 M36 M36 M39 M39

× × × ×

4 3 4 3

M42 × 4.5 M42 × 3 M45 × 4.5 M45 × 3 M48 × 5 M48 × 3

* Unless otherwise specified 1 Approximately equal to Grade 2 2 Approximately equal to Grade 5 3 Approximately equal to Grade 8

7

General

8000 SRM 231 Table 6. Torque Values for Inch Fasteners* Grade 21

Size and Pitch

Grade 52

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

1/4 1/4

20 UNC 28 UNF

4 5

6 6

6 7

9 10

9 10

12 14

5/16 5/16

18 UNC 24 UNF

8 9

11 13

13 14

18 20

18 20

25 28

3/8 3/8

16 UNC 24 UNF

15 17

20 23

23 26

31 36

33 37

44 50

7/16 7/16

14 UNC 20 UNF

24 27

33 36

37 41

50 56

52 58

71 79

1/2 1/2

13 UNC 20 UNF

37 41

50 56

57 64

77 86

80 90

110 120

9/16 9/16

12 UNC 18 UNF

53 59

72 80

82 91

110 125

115 130

155 175

5/8 5/8

11 UNC 18 UNF

73 83

99 110

115 130

155 175

160 180

215 245

3/4 3/4

10 UNC 16 UNF

130 145

175 195

200 225

270 300

280 315

380 425

7/8 7/8

9 UNC 14 UNF

125 140

170 185

320 355

435 480

455 500

615 680

1 1

8 UNC 14 UNF

185 210

255 285

485 540

655 735

680 765

925 1,040

1-1/8 1-1/8

7 UNC 12 UNF

265 300

360 405

595 670

805 905

965 1,080

1,310 1,470

1-1/4 1-1/4

7 UNC 12 UNF

375 415

510 565

840 930

1,140 1,260

1,360 1,500

1,850 2,050

1-3/8 1-3/8

6 UNC 12 UNF

490 560

665 760

1,100 1,250

1,490 1,700

1,780 2,040

2,420 2,760

1-1/2 1-1/2

6 UNC 12 UNF

650 735

885 995

1,460 1,650

1,980 2,230

2,370 2,670

3,210 3,620

* Unless otherwise specified 1 Approximately equal to metric Property Class 5.8 2 Approximately equal to metric Property Class 8.8 3 Approximately equal to metric Property Class 10.9

8

Grade 83

8000 SRM 231

General

CONVERSION TABLE Table 7. Conversion Table for Metric and English Units By

Multiply

To Get

Multiply

By

To Get

× 0.155

= inches

Area inches feet

2

2

2

(in. )

(ft 2)

× 6.452

= centimeters

× 0.093

= meters

2

2

2

(cm )

centimeters

(m 2)

meters

2

2

(cm 2)

(m 2)

× 10.764 = feet

2

2

(in. 2)

(ft 2)

Linear inches (in.)

× 25.4

= millimeters (mm)

millimeter (mm)

× 0.039

= inches (in.)

feet (ft)

× 0.305

= meters (m)

meter (m)

× 3.281

= feet (ft)

yards (yd)

× 0.914

= meters (m)

meter (m)

× 1.094

= yards (yd)

miles (mi)

× 1.609

= kilometers (km)

kilometer (km)

× 0.621

= miles (mi)

Mass ounces (oz)

× 28.35

= grams (g)

grams (g)

× 0.035

= ounces (oz)

pounds (lb)

× 0.454

= kilograms (kg)

kilograms (kg)

× 2.205

= pounds (lb)

tons (2,000 lb)

× 907.18

= kilograms (kg)

kilograms (kg)

× 0.001

= tons (2,000 lb)

tons (2,000 lb)

× 0.907

= metric ton (t)

metric ton (t)

× 1.102

= tons (2,000 lb)

× 1.34

= horsepower (hp)

Power horsepower (hp)

× 0.746

= kilowatts (kW)

kilowatts (kW)

Pressure pounds/in.

2

(psi)

× 6.895

= kilopascal (kPa)

kilopascals (kPa)

× 0.145

= pounds/in.

2

(psi)

pounds/in.

2

(psi)

× 0.007

= megapascal (MPa)

megapascals (MPa)

× 145.04 = pounds/in.

2

(psi)

Temperature ( Fahrenheit 32)

× 0.56

= Celsius (C)

( Celsius × 1.8) +32

= Fahrenheit

Torque pound inches (lbf in.)

× 0.113

= Newton meter (N•m)

Newton meter (N•m)

× 8.851

= pound inches (lb f in.)

pound feet (lbf ft)

× 1.356

= Newton meter (N•m)

Newton meter (N•m)

× 0.738

= pound feet (lb f ft)

× 0.621

= miles/hour (mph)

× 0.061

= inches

3

(in. 3)

3

(in. 3)

Velocity miles/hour (mph)

× 1.609

= kilometer/hour (km/h) kilometer/hr (km/h)

Volume inches

3

3

3

3

(in. )

× 16.387

= centimeters

inches

3

(in. 3)

× 0.016

= liters (l)

liters (l)

× 61.024 = inches

quarts, U.S. (qt)

× 0.946

= liters (l)

liters (l)

× 1.057

= quarts, U.S. (qt)

quarts, U.S. (qt)

× 0.83

= quarts, Imp. (qt)

quarts, Imp. (qt)

× 1.205

= quarts, U.S. (qt)

gallons, U.S. (gal)

× 3.785

= liters (l)

liters (l)

× 0.264

= gallons, U.S. (gal)

gallons, U.S. (gal)

× 0.83

= gallons, Imp. (gal)

gallons, Imp. (gal)

× 1.205

= gallons, U.S. (gal)

ounces (oz)

× 29.57

= milliliters (ml)

milliliters (ml)

× 0.034

= ounces (oz)

(cm )

centimeters

3

(cm 3)

9

General

8000 SRM 231 Table 8. Cotter Pin Dimensional Data

Nominal Size A

Shank Diameter A

Head Dia. B

Length of Extended Prong C

Recommended Hole Size

max

min

min

max

min

min

max

1.00 mm (0.031 in.)

0.90 mm (0.035 in.)

0.70 mm (0.028 in.)

1.50 mm (0.060 in.)

1.52 mm (0.060 in.)

0.25 mm (0.01 in.)

0.91 mm (0.036 in.)

1.37 mm (0.054 in.)

1.60 mm (0.047 in.)

1.20 mm (0.048 in.)

0.90 mm (0.035 in.)

1.50 mm (0.060 in.)

2.54 mm (0.10 in.)

0.51 mm (0.02 in.)

1.50 mm (0.059 in.)

1.78 mm (0.070 in.)

2.00 mm (0.062 in.)

1.50 mm (0.060 in.)

1.30 mm (0.051 in.)

2.40 mm (0.094 in.)

2.54 mm (0.10 in.)

0.76 mm (0.03 in.)

1.90 mm (0.075 in.)

2.18 mm (0.086 in.)

2.50 mm (0.094 in.)

2.30 mm (0.091 in.)

2.10 mm (0.083 in.)

4.00 mm (0.158 in.)

2.54 mm (0.10 in.)

1.00 mm (0.04 in.)

2.41 mm (0.095 in.)

2.95 mm (0.116 in.)

3.20 mm (0.125 in.)

3.00 mm (0.120 in.)

2.70 mm (0.106 in.)

5.10 mm (0.201 in.)

3.30 mm (0.13 in.)

1.52 mm (0.06 in.)

3.12 mm (0.123 in.)

3.76 mm (0.148 in.)

4.00 mm (0.156 in.)

3.80 mm (0.150 in.)

3.50 mm (0.138 in.)

6.50 mm (0.256 in.)

4.06 mm (0.16 in.)

1.78 mm (0.07 in.)

3.94 mm (0.155 in.)

4.55 mm (0.179 in.)

5.00 mm (0.188 in.)

4.60 mm (0.181 in.)

4.40 mm (0.172 in.)

8.00 mm (0.315 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

4.93 mm (0.194 in.)

5.33 mm (0.210 in.)

6.30 mm (0.250 in.)

5.90 mm (0.232 in.)

5.60 mm (0.220 in.)

10.3 mm (0.406 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

6.22 mm (0.245 in.)

6.96 mm (0.274 in.)

8.00 mm (0.312 in.)

7.50 mm (0.295 in.)

7.00 mm (0.275 in.)

13.1 mm (0.516 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

7.85 mm (0.309 in.)

8.28 mm (0.326 in.)

9.50 mm (0.375 in.)

9.50 mm (0.374 in.)

8.40 mm (0.329 in.)

16.6 mm (0.654 in.)

6.35 mm (0.25 in.)

4.06 mm (0.16 in.)

9.45 mm (0.372 in.)

9.73 mm (0.383 in.)

13.0 mm (0.500 in.)

12.4 mm (0.488 in.)

11.9 mm (0.467 in.)

21.7 mm (0.854 in.)

6.35 mm (0.25 in.)

3.05 mm (0.12 in.)

12.62 mm (0.497 in.)

13.21 mm (0.520 in.)

16.0 mm (0.625 in.)

15.4 mm (0.606 in.)

15.0 mm (0.590 in.)

27.0 mm (1.063 in.)

8.89 mm (0.35 in.)

3.05 mm (0.12 in.)

15.80 mm (0.622 in.)

16.28 mm (0.641 in.)

10

8000 SRM 231

General Table 9. Cotter Pin Dimensional Data

Nominal Length L

Length Range

Nominal Size - Part Numbers 1.00 mm (0.031 in.)

1.60 mm (0.047 in.)

2.00 mm (0.062 in.)

2.50 mm (0.094 in.)

3.20 mm (0.125 in.)

5.50 mm (0.217 in.)

0221870

0221875

10.5 mm (0.413 in.)

8.80 mm (0.345 in.)

0221871

0221876

12.7 mm (0.500 in.)

13.5 mm (0.530 in.)

11.5 mm (0.453 in.)

0221872

0221877

0015200

0015211

0015221

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

18.3 mm (0.720 in.)

0221873

0221878

0015201

0015212

0015222

25.4 mm (1.000 in.)

26.9 mm (1.060 in.)

23.9 mm (0.940 in.)

0221874

0221879

0015202

0015213

0015223

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

29.2 mm (1.150 in.)

0015203

0015216

0015224

38.1 mm (1.500 in.)

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

0015204

0015217

0015225

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

0015205

0015218

0015226

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

0015206

0015219

0015227

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

0015220

0056997

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

0221894

0015229

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

0015230

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

0015279

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

max

min

6.35 mm (0.250 in.)

7.10 mm (0.280 in.)

9.525 mm (0.375 in.)

11

General

8000 SRM 231

Table 9. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range max

min

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

123.7 mm (4.870 in.)

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

5.460 mm (138.7 in.)

Nominal Size - Part Numbers 1.00 mm (0.031 in.)

1.60 mm (0.047 in.)

2.00 mm (0.062 in.)

2.50 mm (0.094 in.)

3.20 mm (0.125 in.)

Table 10. Cotter Pin Dimensional Data Nominal Length L

Length Range 4.00 mm (0.156 in.)

5.00 mm (0.188 in.)

18.3 mm (0.720 in.)

0015232

0015241

23.9 mm (0.940 in.)

0015233

0015242

max

min

6.35 mm (0.250 in.)

7.10 mm (0.280 in.)

5.50 mm (0.217 in.)

9.525 mm (0.375 in.)

10.5 mm (0.413 in.)

8.80 mm (0.345 in.)

12.7 mm (0.500 in.)

13.5 mm (0.530 in.)

11.5 mm (0.453 in.)

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

25.4 mm (1.000 in.)

26.9 mm (1.060 in.)

12

Nominal Size - Part Numbers 6.30 mm (0.250 in.)

8.00 mm (0.312 in.)

0015251

0015261

9.52 mm (0.375 in.)

8000 SRM 231

General

Table 10. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range

Nominal Size - Part Numbers 4.00 mm (0.156 in.)

5.00 mm (0.188 in.)

6.30 mm (0.250 in.)

8.00 mm (0.312 in.)

9.52 mm (0.375 in.)

29.2 mm (1.150 in.)

0015234

0015243

0015252

0015262

0221884

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

0015235

0015244

0015253

0015263

0221885

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

0015236

0015245

0015254

0015264

0221886

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

0015237

0015246

0015255

0015265

0015271

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

0015238

0015247

0015256

0221880

0221887

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

0015240

0015248

0015257

0221881

0015273

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

0015280

0015249

0015258

0221882

0015286

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

0015283

0015250

0015259

0015267

0015272

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

0015239

0015284

0015266

0015274

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

0015301

0015260

0128754

0015275

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

123.7 mm (4.870 in.)

0221883

0015277

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

5.460 mm (138.7 in.)

max

min

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

38.1 mm (1.500 in.)

0221888

13

General

8000 SRM 231 Table 11. Cotter Pin Dimensional Data

Nominal Length L

14

Length Range

Nominal Size - Part Numbers 13.0 mm (0.500 in.)

16.00 mm (0.625 in.)

max

min

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

18.3 mm (0.720 in.)

25.4 mm (1.00 in.)

26.9 mm (1.060 in.)

23.9 mm (0.940 in.)

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

29.2 mm (1.150 in.)

38.1 mm (1.500 in.)

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

0221889

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

0221890

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

0221891

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

0221892

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

0221893

0221895

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

0015291

0221896

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

0015292

0221897

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

0015293

0221898

8000 SRM 231

General

Table 11. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range

Nominal Size - Part Numbers 13.0 mm (0.500 in.)

16.00 mm (0.625 in.)

123.7 mm (4.870 in.)

0015295

0221899

138.7 mm (5.460 in.)

0015297

0221900

max

min

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

15

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

16

TECHNICAL PUBLICATIONS 8000 SRM 231

12/04 (3/04)(3/03)(9/00)(3/98)(6/83) Printed in U.S.A.

STEERING AXLE H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

PART NO. 897545

1600 SRM 532

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Steering Axle

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

Steering Axle Assembly Repair.........................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Wheels and Hubs Repair ...................................................................................................................................

Pneumatic Tires, Remove and Disassemble.................................................................................................

Cushion Tires, Remove and Disassemble.....................................................................................................

Pneumatic Tires, Assemble and Install........................................................................................................

Cushion Tires, Assemble and Install............................................................................................................

Spindles, Bearings, and Tie Rods Repair .........................................................................................................

Pneumatic Tires, Remove..............................................................................................................................

Cushion Tires, Remove..................................................................................................................................

Pneumatic Tires, Install................................................................................................................................

Cushion Tires, Install ....................................................................................................................................

Steering Cylinder Repair...................................................................................................................................

Remove and Disassemble ..............................................................................................................................

Clean and Inspect ..........................................................................................................................................

Assemble and Install .....................................................................................................................................

Torque Specifications .........................................................................................................................................

Troubleshooting..................................................................................................................................................

1 1 2 2 2 2 2 4 4 4 5 5 5 5 6 6 6 6 6 7 8

This section is for the following models: H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]

©2004 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1600 SRM 532

Description

General This section has the description and repair procedures for the steering axle. For additional information on the parts of the steering system, see the sections Steering Housing and Control Unit 1600 SRM 720 and Hydraulic System and Gear Pump Assembly 1900 SRM 539.

Description The steering axle assembly includes an axle frame, steering cylinder, and two spindle and hub assemblies. See Figure 1. The steering axle is connected to the frame with center pivot mounts. The center pivot mounts on the axle frame are fastened to the lift truck frame with rubber mounts. The steering axle can make an articulated motion, which gives the lift truck smoother travel over rough surfaces.

There are two plates welded to the steering cylinder that allow the cylinder to be mounted to the axle

frame. The oil is kept inside the cylinder by O-rings, seals, and wipers in the end caps. The piston rod extends from both ends of the cylinder. A single piston and seal are at the center of the rod. Oil pressure on one side of the piston moves the piston in the bore, pushing an equal amount of oil from the opposite end of the cylinder. This oil returns to the steering control unit. When the piston reaches the end of the stroke, a relief valve controls the oil pressure so the components are not damaged.

NOTE: H1.50-1.75XM AND H2.00XMS (H25-35XM AND H40XMS) ARE SHOWN HERE. S25-35XM AND S40XMS ARE SIMILAR. 1.

2.

3.

4.

5.

SPINDLE AND HUB ASSEMBLY AXLE FRAME BRACKET RUBBER MOUNT STEERING CYLINDER

6.

7.

8.

9.

CYLINDER MOUNTING CAPSCREW AXLE MOUNTING CAPSCREW PIN LINK

Figure 1. Steering Axle

1

Wheels and Hubs Repair

1600 SRM 532

Links connect the spindle arms to the cylinder. Each spindle turns on two tapered roller bearings. The spindle and bearings are held in the axle frame by a kingpin. A roll pin and lock nut assembly hold each kingpin in the axle frame. The wheel or hub

rotates on two tapered-roller bearings and is held on the spindle by a castle nut. The castle nut adjusts the preload on the bearings. Grease seals in the inner hub and a hub cap protect the bearings from dirt and water.

Steering Axle Assembly Repair REMOVE WARNING The steering axle assembly without the wheels weighs approximately 115 kg (253.5 lb). To avoid possible injury, use a lifting device if the steering axle assembly must be lifted.

NOTE: The steering axle can be removed without removing the counterweight.

1. Make sure the wheels are set for straight travel.

Put the lift truck on blocks so the steering axle can be removed. See How to Put Lift Truck on Blocks in the Periodic Maintenance section for your lift truck. The top of the axle frame must have clearance under the counterweight so the steering axle can be removed. See Figure 1.

2. Disconnect hydraulic lines at steering cylinder.

Install caps on cylinder and put plugs in hydraulic lines. The caps will prevent the spindles from turning when the axle is removed from under the lift truck.

it holds the weight of axle assembly. Remove four capscrews that fasten two brackets under rubber mounts. Remove brackets and slowly lower axle assembly onto wheels. Carefully roll axle assembly from under lift truck.

INSTALL NOTE: The mounts of the steering axle have TOP moulded into the rubber. Verify TOP is up when installing the mounts.

1. Install rubber mounts onto axle. See Figure 1.

2. Install bottom brackets. Tighten four bracket capscrews and nuts to 41 to 49 N•m (30 to 36 lbf ft).

3. Remove plugs and caps and connect hydraulic lines to steering cylinder.

4. Operate steering system to remove air from system. Turn steering wheel several times from one stop to other stop. Check for hydraulic leaks.

3. Slide a floor jack or the forks of another lift truck under the steering axle. Raise lifting device until

Wheels and Hubs Repair PNEUMATIC TIRES, REMOVE AND DISASSEMBLE WARNING Completely remove the air from the tires before removing them from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode which can cause serious injury or death.

Never loosen the nuts that hold together the inner and outer wheel halves when there is air pressure in the tire.

2

1. Put axle onto blocks so tires are raised from floor.

Completely remove air from tires.

2. Remove wheels, grease cap, cotter pin, castle nut, and outer bearing cone. Slide hub from spindle.

Remove inner bearing cone and seal from spindle. See Figure 2.

3. If new wheel bearings must be installed, use a brass drift to remove bearing cups.

4. Repeat the procedure for the other wheel.

1600 SRM 532

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

AXLE FRAME KNUCKLE KINGPIN UPPER SLEEVE LOWER SLEEVE BEARING O-RING GROOVE PIN OIL SEAL COTTER PIN CASTLE NUT GREASE FITTING LINK PIN

Wheels and Hubs Repair

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

BUSHING SCREW LOCK NUT GREASE FITTING STEERING CYLINDER SPACER BOLT WASHER HUB (PNEUMATIC TIRES) BOLT (PNEUMATIC TIRES) WHEEL NUT (PNEUMATIC TIRES) 26. HUB CAP 27. WASHER

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

BEARING BEARING OIL SEAL FITTING FITTING LOCK NUT RUBBER CUSHION CUSHION COVER WASHER LOCKWASHER BOLT TIRE/WHEEL (CUSHION)

Figure 2. Steering Axle

3

Wheels and Hubs Repair

CUSHION TIRES, REMOVE AND DISASSEMBLE WARNING The steer wheel and tire assembly weighs approximately 41 kg (90 lb). To avoid possible injury, use a lifting device if the steer wheel and tire assembly must be lifted.

NOTE: The steer axle does not have to be removed from the truck to remove the wheel/hub assembly.

1. Apply a coat of axle grease to bottom surface of tire. Put axle onto blocks so side of tire with the grease just touches the floor.

2. Remove grease cap, cotter pin, castle nut, and outer bearing cone. Slide wheel/hub assembly from spindle. Remove inner bearing cone and seal from spindle. See Figure 2.

3. If new wheel bearings must be installed, use a brass drift to remove bearing cups.

4. Repeat the procedure for the other wheel.

PNEUMATIC TIRES, ASSEMBLE AND INSTALL WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s safety procedures.

1. Clean all parts with solvent. Make sure the bearings are clean.

CAUTION Do not damage the seals during installation.

2. If new wheel bearings are installed, use a press to install new bearing cups in wheel or hub. See Figure 2. Install grease seal on spindle. Lubricate bearing cones and seal lips with grease.

Make sure bearings are filled with grease. Install bearing cone onto spindle.

3. Carefully slide hub onto spindle. Install outer bearing cone.

4. Install castle nut. Tighten castle nut to 200 N•m (150 lbf ft) while hub is rotated.

4

1600 SRM 532 5. Loosen castle nut to less than 27 N•m (20 lbf ft).

Tighten castle nut to at least 34 N•m (25 lbf ft).

6. Install cotter pin. If the hole for the cotter pin is blocked, tighten castle nut until the cotter pin can be installed.

WARNING Add air pressure to the tires only in a safety cage. Inspect the safety cage for damage before use. When air pressure is added, use a chuck that fastens onto the valve stem of the inner tube. Make sure there is enough hose to permit the operator to stand away from the safety cage when air pressure is added to the tire. Do not sit or stand by the safety cage.

7. Inflate the tire to 698 kPa (101 psi). Mount wheel and torque wheel nuts to 114 to 136 N•m (84 to 100 lbf ft).

8. Repeat the procedure for the other wheel.

CUSHION TIRES, ASSEMBLE AND INSTALL WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s safety procedures.

1. Clean all parts with solvent. Make sure the bearings are clean.

WARNING The steer wheel and tire assembly weighs approximately 41 kg (90 lb). To avoid possible injury, use a lifting device if the steer wheel and tire assembly must be lifted.

CAUTION Do not damage the seals during installation.

2. If new wheel bearings are installed, use a press to install new bearing cups in hub. See Figure 2.

Install grease seal on spindle. Lubricate bearing cones and seal lips with grease. Make sure bearings are filled with grease. Install bearing cone onto spindle.

1600 SRM 532

Spindles, Bearings, and Tie Rods Repair

3. Apply a coat of axle grease to bottom surface of tire. Carefully slide wheel/hub assembly onto spindle. Install outer bearing cone.

4. Install castle nut. Tighten castle nut to 200 N•m (150 lbf ft) while tire and wheel assembly is rotated.

5. Loosen castle nut to less than 27 N•m (20 lbf ft).

Tighten castle nut to at least 34 N•m (25 lbf ft).

6. Install cotter pin. If the hole for the cotter pin is blocked, tighten castle nut until cotter pin can be installed.

7. Repeat the procedure for the other wheel.

Spindles, Bearings, and Tie Rods Repair PNEUMATIC TIRES, REMOVE WARNING Completely remove the air from the tires before removing them from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, which can cause serious injury or death.

Never loosen the nuts that hold together the inner and outer wheel halves when there is air pressure in the tire.

1. Put the lift truck onto blocks so the tires are raised from the floor. See How to Put Lift Truck on Blocks in the Periodic Maintenance section for your lift truck. Completely remove air from tires.

2. Remove wheels. See the section Wheels and Hubs Repair for the procedure.

3. Remove hub from steering axle spindle.

4. Remove kingpin lock nuts. Use a driver to remove kingpin.

5. Use a driver to remove bearings and seals from axle.

PNEUMATIC TIRES, INSTALL 1. If new spindle bearings are installed, use a press to install new bearing cups into spindle. See Figure 2. Lubricate bearing cones and seal lips with grease. Lubricate O-rings with O-ring lubricant.

2. Install bearings, seals, sleeves, and O-rings into spindle. If groove pin was removed from kingpin, install new groove pin. Apply grease to kingpin.

Position spindle in axle and install king pin.

3. Install first lock nut onto kingpin and tighten lock nut to 121 N•m (89 lbf ft). Completely loosen lock nut, then tighten lock nut to 30 N•m (22 lbf ft).

4. Remove pin to disconnect link from spindle.

4. Install second lock nut onto kingpin. While holding first lock nut so it does not turn, tighten second lock nut to 81.5 to 98 N•m (60 to 72 lbf ft).

5. Remove kingpin lock nuts. Use a driver to remove kingpin.

5. Connect links. Align setscrews with setscrew holes in pins. Tighten setscrews and lock nuts.

6. Use a driver to remove bearings and seals from axle.

CUSHION TIRES, REMOVE 1. Put the lift truck onto blocks so the tires are raised from the floor. See How to Put Lift Truck on Blocks in the Periodic Maintenance section for your lift truck.

2. Remove steer wheel and tire assembly from steering axle spindle. See the section Wheels and Hubs Repair for the procedure.

3. Remove pin to disconnect link from spindle.

WARNING Add air pressure to the tires only in a safety cage. Inspect the safety cage for damage before use. When air pressure is added, use a chuck that fastens onto the valve stem of the inner tube. Make sure there is enough hose to permit the operator to stand away from the safety cage when air pressure is added to the tire. Do not sit or stand by the safety cage.

6. Inflate tires to 689 kPa (100 psi). Mount wheels and tighten wheel nuts to 114 to 136 N•m (84 to 100 lbf ft).

5

Steering Cylinder Repair

1600 SRM 532

CUSHION TIRES, INSTALL 1. If new spindle bearings are installed, use a press to install new bearing cups into spindle. See Figure 2. Lubricate bearing cones and seal lips with grease. Lubricate O-rings with O-ring lubricant.

2. Install bearings, seals, sleeves, and O-rings into spindle. If the groove pin was removed from the kingpin, install new groove pin. Apply grease to kingpin. Position spindle in axle and install kingpin.

loosen lock nut, then tighten lock nut to 30 N•m (22 lbf ft).

4. Install second lock nut onto kingpin. While holding first lock nut so that it does not turn, tighten second lock nut to 81.5 to 98 N•m (60 to 72 lbf ft).

5. Connect links. Align setscrews with setscrew holes in pins. Tighten setscrews and lock nuts.

6. Install steer wheel and tire assembly. See the section Wheels and Hubs Repair for the procedure.

3. Install first lock nut onto kingpin and tighten lock nut to 121 N•m (89 lbf ft). Completely

Steering Cylinder Repair REMOVE AND DISASSEMBLE 1. Disconnect hydraulic lines at steering cylinder.

See Figure 3. Mark the locations of the hydraulic lines to make sure of correct assembly. Install caps in fittings on cylinders and put caps on hydraulic lines.

2. Remove setscrews from links. Remove pins.

3. Remove capscrews that fasten cylinder to axle frame. Remove steering cylinder.

4. Hold end of steering cylinder over a drain pan.

Remove cap for hydraulic fitting from each end cap. Push rod toward end of shell that is over drain pan. Oil will drain from cylinder. Repeat the procedure for the other end.

5. Carefully remove one guide assembly from shell.

Carefully pull cylinder rod and piston from shell.

Keep cylinder rod aligned in center of shell during removal so the parts are not damaged. Remove guide assembly from rod. Remove other guide assembly from shell. Remove all seals, wipers, and O-rings.

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s safety procedures.

1. Clean all parts in solvent.

6

2. Inspect piston rod for grooves or damage. Remove small scratches with fine emery cloth. Inspect cylinder bore for damage. Inspect mounts for cracks.

ASSEMBLE AND INSTALL 1. Put dust seals, U-packings, O-rings, and piston seals into warm hydraulic oil.

CAUTION Do not damage the O-rings, seals, U-packings, or wipers during installation.

2. Lubricate dust seals and U-packings with O-ring lubricant and install them into guide assemblies.

Lubricate piston seals and install them onto piston. Install one guide assembly onto cylinder rod.

See Figure 3.

3. Carefully slide cylinder rod and piston into shell.

Keep cylinder rod aligned in center of shell during installation so the parts are not damaged.

Carefully slide guide assembly into shell. Carefully install other guide assembly onto rod and shell. Put caps on hydraulic fittings of end caps.

4. Install cylinder onto axle frame using capscrews.

Install spacers between cylinder mounts and axle frame. Tighten capscrews to 294 to 353 N•m (217 to 260 lbf ft).

5. Install links between cylinder and spindles. Install pins. Align setscrews with setscrew holes in pins. Tighten setscrews and lock nuts.

1600 SRM 532

Torque Specifications

6. Remove caps and connect hydraulic lines to steering cylinder. Operate steering system to remove air from cylinder and hydraulic system.

1.

2.

3.

4.

5.

ROD ASSEMBLY GUIDE ASSEMBLY DUST SEAL U-PACKING O-RING

Turn steering wheel several times from one stop to the other.

6.

7.

8.

9.

10.

O-RING PISTON SEAL SNAP RING ROD BUSHING PIN BUSHING

Figure 3. Steering Cylinder

Torque Specifications Steering Axle Mounting Bolts 41 to 49 N•m (30 to 36 lbf ft)

Spindle Nut (Final) 30 N•m (22 lbf ft)

Castle Nut (Initial) 200 N•m (148 lbf ft)

Spindle Lock Nut (Initial) 81 to 98 N•m (60 to 72 lbf ft)

Castle Nut (Final) 34 N•m (25 lbf ft)

Steering Cylinder Mounting Bolts 294 to 353 N•m (217 to 260 lbf ft)

Spindle Nut (Initial) 121 N•m (89 lbf ft)

7

Troubleshooting

1600 SRM 532

Troubleshooting PROBLEM Steering wheels do not move when the steering wheel is turned.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Oil level is low or there is no oil in the tank.

Fill tank. Check for leaks.

Steering control unit is damaged.

Repair or install new control unit.

No oil is flowing from the steering control unit to the steering cylinder.

Repair or install new components.

Check for leaks.

Relief valve for steering system needs adjustment.

Adjust or install new relief valve.

There is low oil pressure from hydraulic pump.

Check for restrictions. See Troubleshooting Chart in the Hydraulic System SRM for your lift truck.

A seal in the steering cylinder has a leak.

Install new seal.

Steering control unit is worn or damaged.

Repair or install new control unit.

Steering wheel turns the tires in the wrong direction.

Hydraulic lines are not connected correctly at the steering cylinder or at the steering control unit.

Connect lines properly. Remove air from system.

Steering function continues after the steering wheel stops.

Steering control unit was assembled incorrectly or is damaged.

Repair or install new control unit.

There is air in the steering system.

Oil level in the tank is low.

Add hydraulic oil as necessary.

Check for leaks.

Air was not removed after repair to the hydraulic or steering system.

Remove air from system.

Hydraulic pump has an air leak at the inlet.

Repair system. Remove air from system.

Steering is slow or difficult.

8

TECHNICAL PUBLICATIONS 1600 SRM 532

10/04 (2/01)(11/94)(8/93) Printed in U.S.A.

STEERING HOUSING AND CONTROL UNIT H2.00-3.20XM (H40-65XM) [H177]; S1.50-1.75XM, S2.00XMS (S25-40XM) [D010]; E1.50-1.75XM, E2.00XMS (E25-40XM 2S) [D114]; H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS) [E001]; J2.00-3.20XM (J40-60XM 2) [A216]; E2.00-3.20XM (E45-65XM 2) [F108]; J2.00-3.20XM (J40-65Z) [A416/B416]; E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114]; N30XMH, N30XMH 2 [C210]; V30ZMD [D210/E210]; E2.00-3.20XM (E45-65Z) [G108]; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

PART NO. 1459370

1600 SRM 720

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Steering Housing and Control Unit

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

Operation............................................................................................................................................................

Steering Wheel and Column Assembly Repair ................................................................................................

Assembly Components, Remove ...................................................................................................................

Steering Control Unit, Disassemble .............................................................................................................

Steering Control Unit, Clean ........................................................................................................................

Steering Control Unit, Assemble ..................................................................................................................

Assembly Components, Install .....................................................................................................................

System Air Removal ..........................................................................................................................................

Troubleshooting..................................................................................................................................................

1 1 2 4 4 7 9 9 11 12 13

This section is for the following models: H2.00-3.20XM (H40-65XM) [H177]; S1.50-1.75XM, S2.00XMS (S25-40XM) [D010]; E1.50-1.75XM, E2.00XMS (E25-40XM 2S) [D114]; H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS) [E001]; J2.00-3.20XM (J40-60XM 2) [A216]; E2.00-3.20XM (E45-65XM 2) [F108]; J2.00-3.20XM (J40-65Z) [A416/B416]; E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114]; N30XMH, N30XMH 2 [C210]; V30ZMD [D210/E210]; E2.00-3.20XM (E45-65Z) [G108]; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

©2006 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1600 SRM 720

Description

General This section has the description and repair procedures for the steering housing and the steering control unit.

Additional information on parts of the steering system can be found in the Steering Axle and Hydraulic System service manual sections for your lift truck.

Description The steering column assembly uses a steering control unit with hose connections on the bottom of the unit. The steering housing has mounts for the steering column and the steering control unit. The steering wheel is installed on the steering column. See Figure 1. The housing is adjustable and is held in position by a latch. The position of the housing can be changed for operator comfort. The steering housing is also the mount for control levers and some instrument clusters.

The steering system is a hydraulic system that does not have a mechanical connection between the steering wheel and the steering axle. The control of the steering is through a hydraulic circuit.

If the hydraulic pump for the steering system does not operate, steering is still possible. A check valve permits the steering control unit to control the steering cylinder. The lift truck is difficult to steer when the steering pump is not operating, but the steering control unit can operate the steering cylinder and make steering possible.

NOTE: INSTRUMENT CLUSTER NOT SHOWN. H2.00-3.20XM (H40-65XM) SHOWN. 1. STEERING WHEEL 2. STEERING COLUMN 3. STEERING CONTROL UNIT

4. COLUMN TILT LEVER 5. LATCH 6. COVER 7. COWL 8. MOUNT

Figure 1. Steering Housing Assembly

1

Operation

1600 SRM 720

Operation The steering control unit is a rotary valve operated by the steering wheel. See Figure 2. During the steering operation, the steering control unit controls the direction and amount of oil flow to the steering cylinder. The steering cylinder in the axle actuates the steering linkage to move the steer tires. Hydraulic oil returns from the steering cylinder to the steering control unit and then to the hydraulic tank.

Turning the steering wheel actuates three main parts of the steering control unit: the spool for the control section, the sleeve for the control section, and the rotor in the metering section. When the steering wheel is not moving, the spool and sleeve are held in the NEUTRAL (center) position by springs. During this time, oil flows freely through the steering control unit but none flows to the steering cylinder.

As the steering wheel is turned, the spool just begins to rotate. The springs try to move the sleeve to keep the NEUTRAL position between the spool and sleeve. However, the necessary force to turn the rotor is greater than the pressure of the springs. The springs begin to bend, letting the spool move a small

2

amount within the sleeve. The spool stops moving when it touches the center pin. In this position, the holes in the sleeve and the spool are aligned. Oil coming into the control unit flows to the metering section.

More rotation of the steering wheel causes the spool to rotate the pin. This action causes the rotation of the sleeve and the rotor in the metering section. The oil then flows to one side of the steering cylinder. Oil from the other side of the cylinder returns through the control section of the steering control unit.

When the steering wheel stops moving, the metering action in the metering section also stops. The NEUTRAL position springs return the sleeve to the NEUTRAL position, stopping oil flow to or from the cylinder. The pressure stays in the steering cylinder to keep the steer tires in position. Oil from the pump flows through the steering control unit to the tank or other parts of the system. To return the steer wheels to the straight position, the steering wheel must be rotated in the opposite direction. The steering control unit will operate as described, but all parts will rotate in the opposite direction.

1600 SRM 720

1.

2.

3.

4.

SPRING SET SPOOL SLEEVE CENTER PIN

Operation

5. GEAR SET 6. CONTROL SECTION 7. METERING SECTION Figure 2. Steering Control Unit

3

Steering Wheel and Column Assembly Repair

1600 SRM 720

Steering Wheel and Column Assembly Repair The upper end of the steering shaft has splines for the steering wheel. A large hex nut holds the steering wheel onto the steering column. The horn button is the cover for the center of the steering wheel. The lower end of the steering column has splines or a tang to engage the steering control unit. See Figure 5 and Figure 6.

3. On units with the Direction Control Handle, Remove the direction switch assembly from the housing of the steering column. Make an identification of the electric wires and disconnect them from the direction switch. See Figure 3.

The steering column assembly is adjustable and held in position by a latch. The position of the steering column assembly can be changed as needed for different operator requirements. An access cover on the steering column gives access to the steering control unit, key switch, horn switch, and if installed, the direction switch.

ASSEMBLY COMPONENTS, REMOVE NOTE: This procedure is for the removal of all components of the steering column assembly. All components are not often removed for a repair procedure.

Do only those steps of the procedure necessary to remove the required component. See Figure 5 and Figure 6.

WARNING The hydraulic hoses must be connected to the correct ports or the steering system will not operate as expected, which can cause damage or personal injury. Make sure the hoses are identified and connected correctly.

CAUTION Disconnect the negative battery cable on internal combustion trucks. Disconnect the battery connector on electric trucks. Disconnect the battery before removing any covers.

1. Attach a tag on the battery connector or negative cable stating DO NOT CONNECT BATTERY. Move the steering column to the most FORWARD position. Remove the column tilt lever.

Remove the upper and lower access covers from the steering column.

2. Remove the key switch and static strap from the housing of the steering column. Make an identification of the electric wires and disconnect them from the key switch.

4

NOTE: DIRECTION CONTROL HANDLE ASSEMBLY FOR MODELS J2.00-3.20XM [J40-65Z] (A416/B416), E1.50-2.00XM [E25-35Z, E40ZS] (E114/F114), N30XMH, AND N30XMH 2 (C210), V30ZMD (D210/ E210), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098), AND E2.00-3.20XM [E45-65Z] (G108) IS SHOWN. OTHER TRUCK DIRECTION CONTROL HANDLE ASSEMBLIES ARE SIMILAR. 1.

2.

3.

4.

DIRECTION SWITCHES SHIFT LEVER ASSEMBLY SCREW ELECTRICAL CONNECTORS

Figure 3. Direction Control Handle Assembly 4. Remove the plastic rivets that fasten the bracket for the horn switch to the housing of the steering column. Move the horn switch and bracket away from the steering column. See Figure 5 and Figure 6.

1600 SRM 720

Steering Wheel and Column Assembly Repair

CAUTION If a puller tool is used to remove steering wheel from steering column, be careful not to damage the horn wires.

5. Remove the horn button assembly and electrical wires. Remove the large hex nut and the steering wheel from the shaft. A puller tool makes removal of the steering wheel easier, but not all steering wheels have puller holes.

6. On lift truck models J2.00-3.20XM (J4060XM 2) (A216), E1.50-1.75XM, E2.00XMS (E25-40XM 2S) (D114), N30XMH, N30XMH2 (C210), and E2.00-3.20XM (E45-65XM 2) (F108) units, remove the optical encoder housing and optical encoder from the steering column. Make an identification of the electrical wires and disconnect them from the assemblies. See Figure 5.

7. On lift truck models J2.00-3.20XM [J4065Z] (A416/B416), E1.50-2.00XM [E25-35Z, E40ZS] (E114/F114), V30ZMD (D210/E210), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098), and E2.00-3.20XM [E45-65Z] (G108), disconnect the connector. Remove the two capscrews and steering sensor from the steering column. See Figure 6.

8. Make an identification of the hydraulic hoses at the steering control unit so they can be connected correctly during assembly. See Figure 4, Figure 5, Figure 6, and the WARNING in the beginning of this section. Some hydraulic hoses have fittings that will permit disconnection at the steering control unit. Disconnect the other hydraulic hoses at the base of the cowl, the control valve, or the steering pump. Remove all mount clamps so that the hoses will turn freely and not become twisted. Disconnect the hydraulic hoses at the bottom of the steering control unit. Install plugs at all hoses and ports to prevent dirt from entering the steering hydraulic system.

1.

2.

3.

4.

5.

HYDRAULIC HOSE ENDS HOSE PORTS STEERING CONTROL UNIT SCREWS HORN SWITCH Figure 4. Hydraulic Hose Connections

9. If your model of lift truck has an instrument cluster that wraps around the steering column, remove the instrument cluster.

The removal procedures for the instrument cluster can be found in the service manual sections Instrument Cluster 2200 SRM 514 for models H2.00-3.20XM (H40-65XM) (H177), S1.50-1.75XM, S2.00XMS (S25-40XM) (D010) and H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS) (E001), or Electrical System, Replacement, Checks, and Adjustments Trucks with EV-100/200ZX or SR (SEM) and SP Motor Controllers 2200 SRM 560 for models E1.50-1.75XM (E25-35XM 2) (D114), E2.00XMS (E40XM 2S), E2.00-3.20XM (F108), and J2.00-3.20XM (E45-65XM 2) (J40-60XM 2) (A216).

10. If there is a instrument cluster on the steering column housing, disconnect all plugs connected to the display panel.

5

Steering Wheel and Column Assembly Repair

1600 SRM 720

Figure 5. Steering Column Assembly, For Models J2.00-3.20XM (J40-60XM 2) (A216), E1.50-1.75XM, E2.00XMS (E25-40XM 2S,(D114), N30XMH, N30XMH 2 (C210), and E2.00-3.20XM (E45-65XM 2) (F108)

6

1600 SRM 720

Steering Wheel and Column Assembly Repair Legend for Figure 5

NOTE: * NOT INCLUDED ON LIFT TRUCK MODELS H2.00-3.20XM (H40-65XM) (H177), S1.50-1.75XM, S2.00XMS (S25-40XM) (D010), AND H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS (E001) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

ON-DEMAND STEERING COMPONENTS UPPER ACCESS COVER BRACKET PIVOT (STEERING) SHAFT PLATE LOCKWASHER CAPSCREW LOCK NUT SCREW STATIC GROUND PATCH LOWER ACCESS COVER COLUMN TILT LEVER PUSH ROD LATCH SPRING WASHER COTTER PIN

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

PIN STEERING CONTROL UNIT PLUG (WITHOUT TURN SIGNAL) OPTICAL ENCODER HOUSING* GEAR* OPTICAL ENCODER* HORN BUTTON ASSEMBLY STEERING WHEEL STEERING COLUMN RETURN SPRING LARGE HEX NUT INPUT RIGHT TURN LEFT TURN RETURN PLASTIC RIVET

11. Remove the tilt stop screw located at the bottom left side of the steering column bracket.

4. Remove the cardan shaft from the spool assembly.

12. Remove the capscrews, lockwashers, and lock plates that fasten the steering column to the pivots on the lift truck. Remove the steering column from the lift truck. Make sure the electric wires and the hydraulic hoses are not damaged as the steering column is removed.

5. Remove the check ball, ball stop, and emergency steering ball from the pump housing.

13. Remove the four capscrews that hold the steering column to the bracket. Remove the four capscrews or nuts that fasten the steering control unit to the steering column.

STEERING CONTROL UNIT, DISASSEMBLE 1. Place the steering pump into a soft jaw vise with the splined shaft facing down.

2. Remove the hydraulic fittings and the special screws, and rotate the steering pump 90 degrees sideways in the vise. Discard the O-rings. See Figure 7.

3. Remove the end cover, spacer, gear housing, and gear from the steering pump. Discard the O-rings.

6. Remove the spool assembly from the pump housing.

NOTE: To help with installation of the thrust bearing assembly, note the positions of the thrust washers on either side of the thrust bearing while performing Step 7.

7. Remove the thrust bearing assembly from the shaft end of the spool assembly.

8. Remove the retaining ring from the spool assembly.

9. Press the cross pin out of the spool assembly.

10. Press the spool from the sleeve and remove the springs from the spool. Press the spool from the sleeve and remove the springs from the spool.

11. Remove the shaft seals from the pump housing.

Discard the seals.

7

Steering Wheel and Column Assembly Repair

1600 SRM 720

Figure 6. Steering Column Assembly, Models J2.00-3.20XM [J40-65Z] (A416/B416), E1.50-2.00XM [E25-35Z, E40ZS] (E114/F114), V30ZMD (D210/E210), E2.00-3.20XM [E45-65Z] (G108), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)

8

1600 SRM 720

Steering Wheel and Column Assembly Repair Legend for Figure 6

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

ON-DEMAND STEERING COMPONENTS UPPER ACCESS COVER BRACKET PIVOT (STEERING) SHAFT PLATE LOCKWASHER CAPSCREW LOCK NUT SCREW STATIC GROUND PATCH LOWER ACCESS COVER COLUMN TILT LEVER PUSH ROD LATCH SPRING WASHER

STEERING CONTROL UNIT, CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

Clean all the parts in solvent. Dry the parts with compressed air. Do not dry the parts with a cloth.

Make sure all surfaces are free of scratches and sharp edges.

STEERING CONTROL UNIT, ASSEMBLE 1. Using a seal installer, install the shaft seals in the pump housing.

2. Install the spool into the sleeve with the key slots opposite each other.

3. Insert the curved springs between the flat springs. See Figure 7. Install the spring set into the spool assembly.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

COTTER PIN PIN STEERING CONTROL UNIT PLUG (WITHOUT TURN SIGNAL HORN BUTTON ASSEMBLY STEERING WHEEL STEERING COLUMN RETURN SPRING STEERING SENSOR LARGE HEX NUT INPUT RIGHT TURN LEFT TURN RETURN PLASTIC RIVET

4. Center the springs in the spool assembly, and install the retaining ring over the sleeve.

5. Install the cross pin into the spool assembly.

6. Install the thrust bearing assembly, as noted during removal, on the spool assembly.

7. Place the pump housing in a soft-jawed vise in the horizontal position. Install the spool assembly into the housing while holding the cross pin in a horizontal position.

8. Rotate the pump housing to the vertical position, and rotate the spool so that the pin in the spool is pointing to the "P" port position. See Figure 5 and Figure 6.

9. Install the emergency steering ball, ball stop, and check ball in the "P" port. See Figure 5 and Figure 6.

10. Install a new O-ring on the housing and place the distributor plate on the housing, with the holes properly aligned with the pump housing.

11. Install the cardan shaft and rotate it until it is engaged with the pin in the spool assembly, and until the teeth of the gear end are aligned as shown in Figure 7.

12. Install the gear wheel onto the cardan shaft as shown in Figure 7.

NOTE: The retaining ring must be able to rotate unimpeded by the springs.

9

Steering Wheel and Column Assembly Repair

1600 SRM 720

A. ORIENTATION OF NEUTRAL SPRINGS

B. ORIENTATION OF GEAR WHEEL

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

PUMP HOUSING EMERGENCY STEERING BALL BALL STOP SHAFT SEAL THRUST WASHER THRUST BEARING SPOOL RETAINING RING CROSS PIN SLEEVE SPRING SET CARDAN SHAFT SPACER O-RING

DISTRIBUTOR PLATE GEAR GEAR HOUSING END COVER O-RING SCREW SPECIAL SCREW (HYDRAULIC FITTING) CHECK BALL CARDAN SHAFT GEAR TEETH SPOOL ASSEMBLY PIN FLAT SPRING CURVED SPRING FLAT SPRING

Figure 7. Steering Pump

10

1600 SRM 720

Steering Wheel and Column Assembly Repair

13. Install new O-rings onto the gear housing and install the gear housing onto the distributor plate, making sure that the holes are properly aligned.

14. Place the spacer over the cardan shaft, and install the end cover with the "P" hole lined up with the "P" port in the housing.

15. Install new O-rings, hydraulic fittings, and special screws. Tighten the fittings and the special screws to 30 ±3 N•m (266 ±27 lbf in) in a cross pattern.

ASSEMBLY COMPONENTS, INSTALL NOTE: This procedure is for the installation of all components of the steering column assembly. All components are not often installed for a repair procedure. Do only those steps of the procedure necessary to install the required component. See Figure 5 and Figure 6.

WARNING The hydraulic hoses must be connected to the correct ports or the steering system will not operate as expected, which can cause damage or personal injury. Make sure the hoses are identified and connected correctly.

1. Using four capscrews, attach the steering control unit assembly to the steering column. Install the steering column and steering control unit assembly on the bracket Install the four capscrews that mount the steering column to the bracket. See Figure 5 and Figure 6.

2. If a instrument cluster was removed from the steering column housing, install it by connecting all plugs.

3. If an instrument cluster was removed, Install the instrument cluster on the front cover. for the installation procedures, see the service manual sections Instrument Cluster 2200 SRM 514 for models H2.00-3.20XM (H4065XM), S1.50-1.75XM, S2.00XMS (S25-40XM) and H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS), or Electrical System, Replacement, Checks, and Adjustments Trucks with EV-100/200ZX or SR (SEM) and SP Motor Controllers 2200 SRM 560 for models E1.50-1.75XM (E25-35XM 2), E2.00XMS (E40XM 2S), E2.00-3.20XM (E45-65XM 2), and J2.00-3.20XM (J40-60XM 2).

1. MOUNT 2. PIVOT (STEERING) SHAFT 3. PLATE 4. LOCKWASHER 5. CAPSCREW 6. RETURN SPRING 7. SCREW 8. COLUMN TILT LEVER

9.

10.

11.

12.

13.

14.

15.

16.

LATCH PUSH ROD WASHER SPRING COTTER PIN PIN BRACKET SOCKET HEAD SCREW

Figure 8. Install Steering Components

WARNING The hydraulic hoses MUST be connected to the correct ports and fittings or the steering system will not operate as expected. This unexpected operation can cause damage or personal injury. Make sure the hoses are identified and connected correctly.

4. Connect the hydraulic hoses to the steering control unit, the cowl, the control valve, or the steering pump as removed during removal. Make sure each hydraulic hose is connected to the correct

11

System Air Removal

1600 SRM 720

ports or fittings as identified during removal. See Figure 4.

5. On lift trucks models J2.00-3.20XM (J4060XM 2) (A216), E1.50-1.75XM, E2.00XMS (E25-40XM 2S) (D114), N30XMH, N30XMH 2 (C210), and E2.00-3.20XM (E45-65XM 2) (F108) install the optical encoder components by connecting the electrical wires to the optical encoder.

Install the optical encoder and optical encoder housing to the steering column. See Figure 5.

wheel. If the control unit was not assembled correctly or the hoses not connected correctly, the steering wheel can rotate with a strong force and cause serious injury. If this action occurs, disassemble the control unit and correct the problem.

12. Remove the DO NOT CONNECT BATTERY tag from battery connector and connect the battery.

Operate the steering system to check for correct operation and leaks.

6. On lift truck models J2.00-3.20XM [J40-65Z] (A416/B416), E1.50-2.00XM [E25-35Z, E40ZS] (E114/F114), V30ZMD (D210/E210), E2.003.20XM [E45-65Z] (G108), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) models, connect the connector and using two capscrews, install the steering sensor on the steering column. See Figure 6.

7. Install the steering wheel and large hex nut.

Tighten the large hex nut to 40 to 54 N•m (30 to 40 lbf ft). Connect the wire at the horn button and install the horn button.

8. If removed, install the static strap and wires on the key switch that were identified during removal. Install the key switch.

9. If removed, install the wires on the direction switch that were identified during removal.

Install the direction switch in the housing and install the two capscrews. See Figure 3.

10. Connect the wire connectors at the bottom of the steering column. Install the upper and lower access covers on the steering column. See Figure 9.

11. Install the column tilt lever.

1. UPPER ACCESS COVER

2. LOWER ACCESS COVER

Figure 9. Install Steering Housing

WARNING After making repairs, do not extend the hands or arms through the center of the steering

System Air Removal To remove air from the steering system, use the following procedure:

3. Turn and hold the steering wheel full right for ten seconds.

1. Start the engine.

4. Repeat ten times to bleed the air from the steering system.

2. Turn and hold the steering wheel full left for ten seconds.

12

1600 SRM 720

Troubleshooting

Troubleshooting PROBLEM Steering wheels do not move when steering wheel is turned.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Oil level is low or there is no oil in the tank.

Fill tank to the correct level. Check for leaks.

Steering control unit is damaged.

Repair or install new control unit.

There is no oil flow from the steering control unit to the steering cylinder.

Repair or install new components.

Check for leaks.

Sleeve and spool in the control unit will not move.

Install new components.

Hydraulic hoses are not connected or are damaged.

Check for leaks. Tighten connections. Install new components as necessary.

Relief valve for the steering system is not adjusted correctly.

Adjust or install new relief valve.

Oil pressure from the hydraulic pump is low.

Check for restrictions. See Troubleshooting Table, Hydraulic System.

A seal in the steering cylinder has a leak.

Repair cylinder. Install new seal or new cylinder.

Hydraulic lines are too small or have restrictions.

Remove any restrictions.

Install larger or new hydraulic lines.

Steering control unit is worn, not assembled correctly, or is damaged.

Repair or install new control unit.

Steering wheel turns the tires in the wrong direction.

Hydraulic lines are not connected correctly at the steering cylinder or at the steering control unit.

Connect lines correctly. Remove air from system.

Steering operation is not smooth.

Oil level in the tank is low.

Fill tank. Check for leaks.

Air was not removed after repair to the hydraulic system.

Remove air from system.

Steering control unit is assembled incorrectly or is damaged.

Repair or install new control unit.

Hydraulic pump has a leak at the inlet.

Fix any leaks. Remove air from system.

Steering is slow or difficult.

13

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

14

TECHNICAL PUBLICATIONS 1600 SRM 720

11/06 (3/06)(7/05)(3/05)(5/04)(11/03)(3/03)(5/02)(2/01)(4/98) Printed in U.S.A.

TILT CYLINDERS ALL MODELS EXCEPT H3.50-5.50XM (H70-120XM) [K005, L005]; S3.50-5.50XM (S70-120XM) [E004, F004]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]; E30-40HSD [A219]; W25-30-40ZC [B454]

PART NO. 910102

2100 SRM 103

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Tilt Cylinders

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

Tilt Cylinder Repair ...........................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Clean ..............................................................................................................................................................

Assemble ........................................................................................................................................................

Tilt Cylinders With O-Ring or Single-Lip Seals ......................................................................................

Tilt Cylinders for XM and XMS Models ...................................................................................................

Tilt Cylinders for XL, XLS, and XL 3 Models ...........................................................................................

Tilt Cylinders for H700-800A and Early Model H700-920B ...................................................................

Install .............................................................................................................................................................

Tilt Cylinders Using Chevron Packing ....................................................................................................

Install.....................................................................................................................................................

Tilt Cylinder Leak Check ..................................................................................................................................

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment ....................................................................................

Torque Specifications .........................................................................................................................................

Piston Rod Nut...............................................................................................................................................

Retainer..........................................................................................................................................................

Troubleshooting..................................................................................................................................................

1 1 1 1 1 1 1 1 3 4 6 7 7 8 10 12 12 12 13 15

This section is for the following models: All Models except H3.50-5.50XM (H70-120XM) [K005, L005];S3.50-5.50XM (S70-120XM) [E004, F004]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]; E30-40HSD [A219]; W25-30-40ZC [B454]

©2007 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

2100 SRM 103

Tilt Cylinder Repair

General This section has a description and the repair procedures for several different types of tilt cylinders. The

number and the design of the parts can be different, but the operation of the tilt cylinders is the same.

Description The tilt cylinders [Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6] are used to move the mast forward and backward. To extend the cylinder rod (tilt forward), oil enters the tilt cylinder port behind the piston. The oil pressure pushes the cylinder

rod out of the cylinder. Oil in front of the piston returns to the hydraulic tank. To retract the cylinder rod (tilt backward), the oil enters the port in front of the piston. The oil pressure pushes the cylinder rod into the tilt cylinder. The oil behind the piston returns to the hydraulic tank.

Tilt Cylinder Repair REMOVE WARNING Before removing the tilt cylinder(s), tilt the mast forward. Use a chain to hold the mast to the frame and prevent the mast from moving forward.

1. Disconnect the hydraulic lines at the tilt cylinder.

Install caps on the hydraulic lines and ports.

WARNING Do not push the anchor pins out of the rod end with your fingers. Do not permit the tilt cylinders to drop and cause damage.

2. Remove the retainers for the anchor pins. Push the anchor pins out of the rod end with a tool.

3. Use a lifting device to move large tilt cylinders.

Remove the anchor pins from the frame anchors.

Remove the tilt cylinder from the frame.

DISASSEMBLE 1. Put the tilt cylinder in a vise with soft jaws. Remove the rod end from the rod.

2. Remove the retainer from the tilt cylinder. Remove the rod and piston from the cylinder.

3. Disassemble the tilt cylinder as necessary. See Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

Clean all parts in solvent and dry with compressed air.

ASSEMBLE Tilt Cylinders With O-Ring or Single-Lip Seals NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: During 1980 and 1981, a change was made in the tilt cylinders used in most lift trucks. The O-ring seal between the retainer and the cylinder shell was moved from above the threads to the area below the threads. A backup ring was added to increase the strength of the O-ring. The assembly of the tilt cylinders is the same, but caution must be used so that the O-ring seal is not damaged by the threads.

1

Tilt Cylinder Repair

2100 SRM 103

1. Install the O-ring inside the piston bore. See Figure 1. Install the piston on the piston rod. Make sure the O-ring is not damaged. Tighten the nut on the piston rod to the specifications given in Torque Specifications.

2. Install the O-ring, seal ring, and guide ring on the piston. The seal ring may be heated to ease installation. Polyurethane rings (brown) will return to shape; Teflon rings (yellow) should be re-sized by using a spring compressor.

3. If used, install the O-ring and the backup ring in the groove of the outer retainer. Install the

1.

2.

3.

4.

5.

6.

7.

PISTON ROD PISTON RING O-RING O-RING PISTON GUIDE RING NUT

rod seal (O-ring and sealing lip facing toward the piston) and wiper seal in the inner retainer.

4. Install the retainer on the piston rod. Install the piston and rod assembly and the retainer in the cylinder. If used, install the O-ring on the retainer. Tighten the retainer to specifications given in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the piston rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

8.

9.

10.

11.

12.

13.

14.

CYLINDER SHELL O-RING BACKUP RING RETAINER SEAL RING WIPER RING SPACER (SOME MODELS)

Figure 1. Tilt Cylinders With O-Ring or Single-Lip Seals

2

2100 SRM 103

Tilt Cylinder Repair

Tilt Cylinders for XM and XMS Models NOTE: The following procedure is for these models: • S/H/E/2.00-3.00XM (S/H/E/40-65XM) • J2.00-3.00XM (J40-60XM, J40-60XM 2) (A216) • J2.00-3.00XM (J40-65Z) (A416) • E1.50-2.00XM (E25-35Z, 40ZS) (E114) • J1.60-2.00XMT (J30-40XM) • H/S/E1.25-1.75XM, H/S/E2.00XMS (S/H/E2535XM, S/H/E40XMS)

1. Install the piston seal and O-ring(s) onto the piston. See Figure 2 and Figure 3. Install the piston onto the cylinder rod. Make sure the piston seal is not damaged. Tighten the nut on the piston rod to the value shown in Torque Specifications.

2. Install a new wiper and rod seal. Install the O-ring and backup ring onto the retainer.

3. Install the retainer assembly onto the rod.

NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

4. Install the piston and rod assembly into the cylinder. Tighten the retainer to the value shown in Torque Specifications.

NOTE: If a new piston was not installed, the piston rod nut must be retightened to the value shown in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

1.

2.

3.

4.

CYLINDER SHELL NUT PISTON O-RING

5.

6.

7.

8.

SEAL RING PISTON ROD O-RING BACKUP RING

9. SEAL RING 10. RETAINER 11. WIPER RING

Figure 2. Tilt Cylinders for S/H/E/2.00-3.20XM (S/H/E/40-65XM), J2.00-3.00XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z) (A416/B416), and E2.00-3.20XM (E45-65Z) (G108)

3

Tilt Cylinder Repair

1.

2.

3.

4.

5.

CYLINDER SHELL RETAINER ROD WIPER RING ROD SEAL

2100 SRM 103

6.

7.

8.

9.

10.

BACKUP RING O-RING NUT PISTON PISTON SEAL

Figure 3. Tilt Cylinders for H/S/E/J1.25-1.75XM, XMS, XMT (H/S/E/J25-40XM, XMS, XMT) and E1.50-2.00XM (E25-35Z, 40ZS) (E114/F114)

Tilt Cylinders for XL, XLS, and XL 3 Models NOTE: The following procedure is for these models: (E70-120XL, • E3.50-5.50XL, E3.50-5.50XL 3 E70-120XL 3) (C098) • E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: If a new piston was not installed, the piston rod nut must be retightened to the value shown in Torque Specifications.

1. Install the guide ring, piston seal and O-ring onto the piston. See Figure 4. Install the piston onto the cylinder rod. Make sure the piston seal is not

4

damaged. Tighten the nut on the piston rod to the value shown in Torque Specifications.

2. Install a new wiper and rod seal. Install o-ring and backup ring onto retainer.

3. Install retainer assembly onto piston rod.

4. Install O-ring and shims onto piston rod.

5. Install the piston and rod assembly into the cylinder. Tighten the retainer to the value shown in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

2100 SRM 103

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

O-RING BACKUP RING CAP/RETAINER ROD SEAL ROD WIPER SHIM [3.0 mm (0.120 in.)]

SHIM [1.5 mm (0.060 in.)]

NUT LOCKWASHER ROD END

Tilt Cylinder Repair

11.

12.

13.

14.

15.

16.

17.

18.

19.

BUSHING ANCHOR PIN ANCHOR RETAINER CAPSCREW ROD PISTON PISTON SEAL GUIDE RING FITTING

Figure 4. Tilt Cylinders for E3.50-5.50XL, E3.50-5.50XL 3 (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) Models

5

Tilt Cylinder Repair

2100 SRM 103

Tilt Cylinders for H700-800A and Early Model H700-920B NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

1. Install the thrust plate on the rod. Install the backup ring and O-ring on the rod. Install the piston on the rod. Install the piston rings and seals on the piston. See Figure 5.

2. Install the lock nut on the rod. Tighten the lock nut until the thrust plate is tight against the rod.

Install the pin in the lock nut and rod if necessary, drill a hole in the rod for the pin. Install the snap ring to hold the pin in position.

1.

2.

3.

4.

5.

6.

7.

CYLINDER SHELL SNAP RING LOCK NUT DOWEL PISTON RING O-RING SEAL RING

8.

9.

10.

11.

12.

13.

14.

PISTON RING PISTON THRUST PLATE O-RING BACKUP RING PISTON ROD O-RING

3. Install the piston and rod assembly in the shell.

Install the seals on the retainer. Install the retainer in the shell.

4. Install the lock ring in the shell, but do not tighten it. Install the capscrews in the lock ring.

Turn the lock ring until it is even with the end of the shell. Install the pipe plug in the lock ring and tighten the plug to 34 to 48 N•m (25 to 35 lbf ft). Tighten the capscrews in the lock ring to 14 to 20 N•m (10 to 15 lbf ft).

5. Install the rod end on the rod. Tighten the capscrews on the rod end to 610 N•m (450 lbf ft).

15.

16.

17.

18.

19.

20.

21.

BACKUP RING RETAINER SEAL RING WIPER RING RETAINER RING PLUG CAPSCREW

Figure 5. Tilt Cylinders for H700-800A, Early Model H700-920B

6

2100 SRM 103

Tilt Cylinder Repair

INSTALL 1. Use a lifting device to move large tilt cylinders.

Put the cylinder in the lift truck. Install the anchor pin in the frame. Install the retainer pin or cotter pin.

2. Install the anchor pin at the mast mount. Install the retainer pin or cotter pin for the anchor pin.

Tighten the capscrews for the retainer pins.

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.

Tilt Cylinders Using Chevron Packing NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: The following procedure is for the H360-650C (early model). See Figure 6.

3. Connect the hydraulic lines to the tilt cylinder.

4. Operate the tilt cylinders. Check for correct operation and leakage. Adjust the tilt cylinders as described in Tilt Cylinder Leak Check and

1.

2.

3.

4.

5.

6.

7.

CYLINDER SHELL NUT PISTON HEAD O-RING NYLON RING PACKING NYLON RING

8.

9.

10.

11.

12.

13.

14.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

PISTON HALF (FLAT) PISTON ROD O-RING BACKUP RING RETAINER O-RING BACKUP RING

15.

16.

17.

18.

19.

BUSHING PACKING RETAINER RING SETSCREW WIPER RING

Figure 6. Tilt Cylinders With Chevron Packing (Early Model H360-650C)

7

Tilt Cylinder Repair

2100 SRM 103

Install STEP 1.

Install the O-ring and the backup ring on the bushing. Install the packing in the bushing. The end of the packing must extend 3 mm (0.125 in.) beyond the end of the bushing.

1.

2.

3.

4.

O-RING BACKUP RING PACKING BUSHING

STEP 2.

Install the O-ring and the backup ring on the retainer. Use your hand to push the bushing into the retainer. Make sure the O-ring is not damaged during installation. Install the retainer and bushing assembly on the cylinder rod.

1. O-RING 2. BACKUP RING 3. BUSHING STEP 3.

Install the flat piston half on the cylinder rod. Put the O-ring on the rod halfway between the threads and the piston half.

1. PACKING 2. PISTON HALF

8

2100 SRM 103

Tilt Cylinder Repair

STEP 4.

Install the piston half with the packing on the cylinder rod. Make sure the O-ring fits into the piston groove when the piston half is installed. Install the piston rod nut. Tighten to the specifications given in Torque Specifications.

1. O-RING 2. PISTON HALF 3. PISTON HALF WITH PACKING STEP 5.

Push the piston into the cylinder bore. Push the retainer into the bore. Make sure the O-ring is not damaged.

1. CYLINDER ROD 2. PISTON AND PACKING 3. ROD NUT

9

Tilt Cylinder Leak Check

2100 SRM 103

STEP 6.

Install a new wiper seal in the retainer. Turn the retainer into the cylinder shell until the threads have started. Push the piston in and out several times to make sure the alignment is correct.

1. WIPER SEAL 2. RETAINER STEP 7.

Tighten the retainer to the specifications given in Torque Specifications. Tighten the setscrew.

1. RETAINER 2. SETSCREW

Tilt Cylinder Leak Check WARNING Never allow anyone under a raised carriage.

Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Do not try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure.

1. Put a capacity load on the forks. Use a safety chain to hold the load to the carriage. Raise the load approximately 2.5 m (8 ft). Put the mast in a vertical position.

10

2. Measure the distance that the rod for tilt cylinder extends from the shell. Check the distance the rod moves in five or ten minutes. Multiply the rate in Table 1 by the time of the test and compare the numbers.

3. If the tilt rate is greater than the specifications, lower the mast and remove the load from the forks. Install a gate valve between the port at the front of the tilt cylinder and the hydraulic line.

Put the load on the forks again. Close the gate valve. Tilt the mast forward just past the vertical position. If the mast continues to tilt slowly forward, the seals on the piston are leaking.

2100 SRM 103

Tilt Cylinder Leak Check

4. If the mast does not move, open the gate valve and check the movement again. If the mast moves forward when the gate valve is open, check for leaks in the hydraulic lines and fittings.

If no leaks are found, the main control valve can be worn or damaged. Remove the load from the forks when the checks are complete.

Table 1. Movement Rates (Maximum) for Tilt Cylinders Lift Truck Model

Hydraulic Oil Temperature/Mast Tilt Rate 20 C (68 F)

60 C (140 F)

mm/min

in./min

mm/min

in./min

A1.00-1.50XL (A20-30XL)

1.3

0.05

9.1

0.50

E1.25-5.50XL, XL 3(E25-120XL, XL 3)

0.8

0.03

5.0

0.20

E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098)

0.74

0.03

5.0

0.20

J1.60-2.00XMT (J30-40XM)

0.8

0.03

5.0

0.20

E2.00-3.20XM (E40-65XM) (F108)

0.8

0.03

5.0

0.20

J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) E1.50-1.75XM, E2.00XMS (E25-40XMS, 40XM 2S) (D114)

0.8

0.03

5.0

0.20

J2.00-3.20XM (J40-65Z) (A416) E1.50-2.00XM (E25-35Z, E40ZS) (E114)

0.8

0.03

5.0

0.20

H1.25-1.75XL (H25-35XL)

0.8

0.03

5.0

0.20

S/H1.50-1.75XM, S/H2.00XMS (S/H25-35XM, S/H40XMS)

0.8

0.03

5.0

0.20

H2.00-3.00XL (H40-60XL)

1.1

0.04

7.3

0.30

S/H2.00-3.20XM (S/H40-65XM)

1.0

0.04

6.8

0.30

H3.50-7.00XL (H70-155XL)

1.3

0.05

8.9

0.34

H8.00-16.00XL (H165-360XL)

1.8

0.07

11.7

0.05

H8.00-14.00XM (H170-330HD), H16.00XM-6 (H360HD), H10.00-12.00XM12EC (H360HD-EC)

1.8

0.07

11.7

0.05

H20.00-32.00F (H440-700F/FS)

1.3

0.05

3.8

0.15

H36.00-48.00C (H800-1050C)

1.3

0.05

3.8

0.15

J2.00-3.00XL (J40-60XL)

0.8

0.03

5.0

0.20

J25-35A,B

1.3

0.05

3.8

0.15

S1.25-5.50XL (S25-120XL)

0.8

0.03

5.0

0.20

S6.00-7.00XL (S135-155XL)

1.2

0.05

8.2

0.32

11

Torque Specifications

2100 SRM 103

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment Adjust the tilt cylinders as described in the Mast section.

Torque Specifications PISTON ROD NUT E1.25-1.75XL (E25-35XL) 163 to 190 N•m (120 to 140 lbf ft) J1.60-2.00XMT (J30-40XM) 163 to 190 N•m (120 to 140 lbf ft) E2.00-3.00XL (E40-60XL) 320 to 400 N•m (236 to 295 lbf ft) E2.00-3.20XM (E40-65XM) (F108) 150 N•m (110 lbf ft) J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) 150 N•m (110 lbf ft)

H30-60H, H40-60J 244 to 271 N•m (180 to 200 lbf ft) H3.50-5.00XL (H70-110XL) 400 to 440 N•m (295 to 325 lbf ft) H6.00-7.00XL (H135-155XL) 407 to 440 N•m (300 to 325 lbf ft) H7.00-12.50H (H150-275H) 447 to 475 N•m (330 to 350 lbf ft) H8.00-12.00XL (H165-280XL) 950 to 985 N•m (701 to 726 lbf ft)

J2.00-3.20XM (J40-65Z) (A416) 150 N•m (110 lbf ft)

H8.00-12.00XM (H170-280HD), H10.0012.00XM-12EC (H360HD-EC), H13.00-14.00XM (H300-330HD) and H16.00XM-6 (H360HD) 950 to 985 N•m (701 to 726 lbf ft)

E20-30B 244 to 271 N•m (180 to 200 lbf ft)

H13.00-16.00XL (H300-360XL) 1105 to 1140 N•m (815 to 840 lbf ft)

E30-60B, E30-60AC 407 to 475 N•m (300 to 350 lbf ft)

H16.00-30.00C (H360-650C) - Early 1356 to 1492 N•m (1000 to 1100 lbf ft)

E3.50-5.50XL, E3.50-5.50XL 3 (E70-120XL, E70-120XL 3) [C098] and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098] 400 to 440 N•m (295 to 325 lbf ft)

H16.00-30.00C (H360-650C) - Late 1500 to 1600 N•m (1107 to 1181 lbf ft)

E60-100B 407 to 440 N•m (300 to 325 lbf ft) H1.25-1.75XL (H25-35XL) 163 to 190 N•m (120 to 140 lbf ft) H/E1.50-1.75XM, H/E2.00XMS (H/E25-35XM, H/E40XMS) and E1.50-2.00XM (E25-35Z, E40ZS) (E114) 163 to 190 N•m (120 to 140 lbf ft) H20-30E 136 to 170 N•m (100 to 125 lbf ft) H2.00-3.00XL (H40-60XL) 163 to 190 N•m (120 to 140 lbf ft) S/H2.00-3.20XM (S/H40-65XM) 150 N•m (110 lbf ft)

12

H17.00-32.00C (H370-700C) 1500 to 1600 N•m (1107 to 1181 lbf ft) H20.00-32.00F (H440-700F/FS) 1500 to 1600 N•m (1107 to 1181 lbf ft) H32.00-44.00B (H700-920B) - Late 1500 to 1600 N•m (1107 to 1181 lbf ft) H36.00-48.00C (H800-1050C) 1500 to 1600 N•m (1107 to 1181 lbf ft) H60-90C 407 to 447 N•m (300 to 330 lbf ft) H60-110E 400 to 440 N•m (295 to 325 lbf ft) H110-150F 678 to 746 N•m (500 to 550 lbf ft)

2100 SRM 103 H300A 678 to 746 N•m (500 to 550 lbf ft) H300-350B 447 to 475 N•m (330 to 350 lbf ft) H360-620B 1356 to 1492 N•m (1000 to 1100 lbf ft)

Torque Specifications

RETAINER E1.25-1.75XL (E25-35XL) 169 to 237 N•m (125 to 175 lbf ft) J1.60-2.00XMT (J30-40XM) 163 to 176 N•m (120 to 130 lbf ft)

H700-800A, H700-920B - Early See Text

E2.00-3.00XL (E40-60XL) 400 to 500 N•m (295 to 369 lbf ft)

J2.00-3.00XL (J40-60XL) 320 to 400 N•m (236 to 295 lbf ft)

E2.00-3.20XM (E40-65XM) (F108) 170 to 237 N•m (125 to 175 lbf ft)

J25-35A 244 to 271 N•m (180 to 200 lbf ft)

J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) 170 to 237 N•m (125 to 175 lbf ft)

J25-35B 320 to 400 N•m (236 to 295 lbf ft)

J2.00-3.20XM (J40-65Z) (A416) 170 to 237 N•m (125 to 175 lbf ft)

J40-60A, J50-60AS 407 to 475 N•m (300 to 350 lbf ft)

E20-30B 407 to 475 N•m (300 to 350 lbf ft)

P40-50A, P60-80A 407 to 447 N•m (300 to 330 lbf ft)

E30-60B, E30-60AC 475 to 542 N•m (350 to 400 lbf ft)

P7.00-8.00B (P150-200B) 447 to 475 N•m (330 to 350 lbf ft)

E3.50-5.50XL, E3.50-5.50XL 3 (E70-120XL, E70-120XL 3) [C098] and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098]) 400 to 500 N•m (295 to 370 lbf ft)

S20-30A 136 to 170 N•m (100 to 125 lbf ft) S30-60E, S40-50F 407 to 475 N•m (300 to 350 lbf ft) S40-50C 224 to 271 N•m (165 to 200 lbf ft) S1.25-1.75XL (S25-35XL) 163 to 190 N•m (120 to 140 lbf ft) S25-35XM, S40XMS 163 to 190 N•m (120 to 140 lbf ft) S2.00-3.00XL (S40-60XL) 320 to 400 N•m (236 to 295 lbf ft) S3.00-5.50E (S60-120E) 407 to 440 N•m (300 to 325 lbf ft) S3.50-5.50XL (S70-120XL) 400 to 440 N•m (295 to 325 lbf ft) S5.50-7.00A (S125-150A) 542 to 610 N•m (400 to 450 lbf ft) S6.00-7.00XL (S135-155XL) 407 to 440 N•m (300 to 325 lbf ft)

E60-100B 576 to 644 N•m (425 to 475 lbf ft) H1.25-1.75XL (H25-35XL) 169 to 237 N•m (125 to 175 lbf ft) H/E1.50-1.75XM, H/E2.00XMS (H/E25-35XM, H/E40XMS) and E1.50-2.00XM (E25-35Z, E40ZS) (E114) 163 to 176 N•m (120 to 130 lbf ft) H20-30E 203 to 271 N•m (150 to 200 lbf ft) H2.00-3.00XL (H40-60XL) 169 to 237 N•m (125 to 175 lbf ft) S/H2.00-3.20XM (S/H40-65XM) 170 to 237 N•m (125 to 175 lbf ft) H30-60H, H40-60J 407 to 475 N•m (300 to 350 lbf ft) H3.50-5.00XL (H70-110XL) 400 to 500 N•m (295 to 369 lbf ft)

13

Torque Specifications H6.00-7.00XL (H135-155XL) 542 to 610 N•m (400 to 450 lbf ft) H7.00-12.50H (H150-275H) 475 to 542 N•m (350 to 400 lbf ft) H8.00-12.00XL (H165-280XL) 542 to 610 N•m (400 to 450 lbf ft) H8.00-12.00XM (H170-280HD) 542 to 610 N•m (400 to 450 lbf ft) H10.00-12.00XM-12EC (360HD-EC), H13.00-14.00XM (H300-330HD) and H16.00XM-6 (H360HD) 610 to 675 N•m (450 to 500 lbf ft)

2100 SRM 103 H700-800A, H700-920B - Early See text J2.00-3.00XL (J40-60XL) 400 to 500 N•m (295 to 369 lbf ft) J25-35A 407 to 475 N•m (300 to 350 lbf ft) J25-35B 400 to 500 N•m (295 to 369 lbf ft) J40-60A, J50-60AS 475 to 542 N•m (350 to 400 lbf ft) P40-50A, P60-80A 475 to 542 N•m (350 to 400 lbf ft)

H13.00-16.00XL (H300-360XL) 610 to 675 N•m (450 to 500 lbf ft)

P7.00-8.00B (P150-200B) 475 to 542 N•m (350 to 400 lbf ft)

H16.00-30.00C (H360-650C) - Early 542 to 610 N•m (400 to 450 lbf ft)

S20-30A 203 to 271 N•m (150 to 200 lbf ft)

H16.00-30.00C (H360-650C) - Late 450 to 550 N•m (332 to 406 lbf ft)

S30-60E, S40-50F 475 to 542 N•m (350 to 400 lbf ft)

H17.00-32.00C (H370-700C) 450 to 550 N•m (332 to 406 lbf ft)

S40-50C 407 to 475 N•m (300 to 350 lbf ft)

H20.00-32.00F (H440-700F/FS) 450 to 550 N•m (332 to 406 lbf ft)

S1.25-1.75XL (S25-35XL) 169 to 237 N•m (125 to 175 lbf ft)

H32.00-44.00B (H700-920B) - Late 450 to 550 N•m (332 to 406 lbf ft)

S25-35XM, S40XMS 163 to 176 N•m (120 to 130 lbf ft)

H36.00-48.00C (H800-1050C) 450 to 550 N•m (332 to 406 lbf ft)

S2.00-3.00XL (S40-60XL) 400 to 500 N•m (295 to 370 lbf ft)

H60-90C 475 to 542 N•m (350 to 400 lbf ft)

S3.00-5.50E (S60-120E) 576 to 644 N•m (425 to 475 lbf ft)

H60-110E 542 to 610 N•m (400 to 450 lbf ft)

S3.50-5.50XL (S70-120XL) 400 to 500 N•m (295 to 370 lbf ft)

H110-150F 271 to 305 N•m (200 to 225 lbf ft)

S5.50-7.00A (S125-150A) 176 to 244 N•m (130 to 180 lbf ft)

H300A

S6.00-7.00XL (S135-155XL) 542 to 610 N•m (400 to 450 lbf ft)

H300-350B 475 to 542 N•m (350 to 400 lbf ft) H360-620B 542 to 610 N•m (400 to 450 lbf ft)

14

2100 SRM 103

Troubleshooting

Troubleshooting PROBLEM Tilt cylinder movement is slow or not smooth.

The tilt cylinders permit the mast to move when the Tilt control lever is in the Neutral position.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Air is in the hydraulic system.

Remove air from hydraulic system.

The hydraulic pump is worn or damaged.

Repair or replace hydraulic pump.

Restriction in the hydraulic lines.

Repair hydraulic lines.

Seals in tilt cylinder are damaged.

Replace seals and inspect cylinder bore for damage.

Tilt cylinders have internal damage.

Repair or replace cylinder.

Load is greater than capacity.

Reduce load.

Pressure relief valve(s) is not adjusted correctly or is damaged.

Repair or adjust relief valve(s).

Large leaks between spool and bore.

Replace valve section.

Spool is not fully extended or retracted.

Adjust linkage to spool.

Tilt control spool is damaged.

Repair control valve.

There are leaks in the hydraulic lines.

Tighten fittings or repair leaks.

Seals in tilt cylinder are damaged.

Replace seals and inspect cylinder bore for damage.

Tilt cylinders have internal damage.

Repair or replace cylinder.

Tilt control spool is damaged.

Repair control valve.

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NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

16

TECHNICAL PUBLICATIONS 2100 SRM 103

3/07 (3/05)(11/04)(10/03)(3/03)(9/00)(6/96)(11/95)(5/95)(1/95)(11/94)(3/94) Printed in U.S.A.