Wiggins Fork Lift 20K

or TITLE PAGE 0532-LP-000-4220 Sue | 2 TECHNICAL MANUAL OPERATION, MAINTENANCE, REPAIR AND OVERHAUL ILLUSTRATED PARTS LIST Qe TRUCK, FORK LIFT PNEUMATIC RUBBER TIRES, DIESEL ENGINE 20,000 LB CAPACITY @ 24” LOAD CENTER DS SAFETY RATED, U.L. FILE #AU2113 WIGGINS LIFT COMPANY MODEL W200YSB, 2H-220/145 CONTRACT NO. DLA730-94-C-8054 (US. NAVY REGISTRATION NUMBERS AND END ITEM SERIAL he NUMBERS ON PAGE FOLLOWING TITLE PAGE) me = = iy \ WISSANS " —_—— a Wa 2571 Carta Street amt ‘ “i a ‘Oxnard, CA 93030 al + r. mn, (805) 485-7821 ae Distribution f authorized to U.S. Government agencies and their Other requests for this document shall be ditgetéth in writing to “Commanding Officer, Navy Ships Parts Control Center MHE Department ‘od: O36B), Mechanicsburg, PA 17055-0788.” WEC96-200YSB-1TABLE OF CONTENTS 0532-LP-000-4220 » “ae Table of Contents ‘ @ SECTION 1. GENERAL INFORMATION. ..... 1.3 SECTION 1. GENERAL INFORMATION. 1.3 1.1 LIFT TRUCK DESCRIPTION. eee 1.3 1.2 FRAME AND BODY DESCRIPTION. . 1.4 1.3 ENGINE SYSTEMS DESCRIPTION. . 1.3.1 General Description. 1.8.2 Description of the Air Intake System, 1.8.3 Description of the Turbocharger. 1.3.4 Description of the Cylinder Head. 1.3.5. Description of the Cylinder Block. 1.3.6 Description of the Timing Gears. 1.3.7 Description of the Engine Fuel System. 1.8.8 Description of the Fuel Tank. 1.3.9 Description and Operation of the Fuel Transfer Pump. 1.8.10 Description and Operation of the Fuel Injection Pump, 4.8.11 Description and Operation of the Fuel Injectors, 1.8.12 Deseription of the Engine Cooling System, 1.3.18 Description of the Engine Lubrication System. 1.4 ELECTRICAL SYSTEM DESCRIPTION. . 1.4.1 General Description. i 1.4.2 Description and Operation of the Deadman Control Module... Bia, 97 1.4.3 Description and Operation of the Battery Se Rai 1.4.4 Description and Operation of the Alternator. yer 1.4.5 Description and Operation of the Starter Motor. .... one 12t 1.4.6 Description and Operation of the Switches and Gauges. 02... sc sess ee 182 1.5 TRANSMISSION. . 1.5.1 General Description. . 1.5.2 Description and Operation of the Transmission Gears and Shas... s,s...) 425 1.5.3 Description and Operation of the Transmission Clutch Assemblies. 1.25 1.5.4 Description and Operation of the Transmission Valve Body. : ha as é 1.5.5 Description and Operation of the Torque Converter. .. x é 1.25 1.5.6 Description and Operation of the Pump Drive. ........... cereus aap as) 1.6 DRIVESHAFT ASSEMBLY. ....... é seven 1.26 1.7 DRIVE AXLE ASSEMBLY. ....... ° 1.27 1.7.4 General Information on the Drive Axle Assembly. 127 1.7.2 Description and Operation of the Ring and Pinion Gear Set, .........0.00.0 127 3 1.7.8 Description and Operation of the Differential. ..........4.+ “ 127 , 1.7.4 Description and Operation of the Planetary Gear Sets... .. COL aS ag fore ir 1.32 1.8 STEERING AXLE, .. ee a 1.8.1 Description and Operation of the Steering Axle Frame. 1.8.2 Description and Operation of the Steering Cylinder...TABLE OF CONTENTS 4.8.3 Description and Operation of the Hub Assemblies. 1.8.4 Description and Operation of the Spindle Assemblies. 1.9 STEERING CONTROL UNIT. .. poreednnsn 1.9.1 Description and Operation of the Stearing Column 1.9.2 Description and Operation of the Handpump/Motor Section 1.9.8 Description and Operation of the Metering Section 1.10 HYDRAULIC SYSTEM. . 1.10.1 Main Control Valve-General Information, 10.2 Operation of the Main Control Valve. 10.3 Operation of the Lift Section of the Main Control Valve. 10.4 Operation of the Tilt Section of the Main Control Valve, 10.5 Description and Operation of the Steering Control Section. 10.6 Operation of the Relief Valves. 10.7 Description and Operation of the Auxiliary Steering Pump. 1.11 BRAKE SYSTEM. . ee 411.1 Description and Operation of the Brake System. 411.2 Description of the Air Compressor, 11.3 Operation of the Air Compressor. 11.4 Operation of the Governor. 11.5 Description of the Inversion Valve, 1.12 LIFT SYSTEM. .. oon 1.12.1 Description and Operation of the 2-Stage Mast Assembly. .. 1.13 TILT CYLINDERS. ......... 1.19.1 Description and Operation of the Tilt Cylinders. 1.14 SIDESHIFT CARRIAGE ASSEMBLY. ... 1.14.1 Description and Operation of the Sideshift Carriage t 1.14.2 Description and Operation of the Sideshitt Cylinder. : 1.14.8 Description and Operation of the Fork Positioner Cylinders. 1.15 TIRES AND WHEELS. .... 1.16 LIFT TRUCK CONTROLS. ... SECTION 2. OPERATING INSTRUCTIONS. ...........0ecs0esseeeeeee ees SECTION 2, OPERATING INSTRUCTIONS. ... 2.1 GENERAL INFORMATION. ...... 2.1.4 Know Your Lift Truck. 2.1.2 Stabillty and Centar Of Gravity, * 2.1.3 Capacity (Weight and Load Center). 2.2 INSPECTION BEFORE OPERATION .. 2.2.1 Checks With the Key Switch OFF 2.2.2 Checks With the Engine Running . 2.3 OPERATING TECHNIQUES. . MQ —-2.8.1 Special Vehicle. . 1.35 1.35 1.36 1.38 1.38 1.38 1.37 1.97 1.40 1.41 141 1.43 1.44 1.45 1.48 1.48 1.55 1.58 1.58 1.87 1.58 1.58 1.61 1.61 1.61 1.61 1.61 1.63 1.65 1.66 24 23 2.3 23 28 24 2.4 2.4 24 25 25TABLE OF CONTENTS 0532-LP-000-8Le 2.8.2 Authorized And Trained Operator Only. . A 2s 33 pining And Direction Changes ee ee 2.3.4 Steering (Turning). . ee Nos @ 285 Lond Hending - General : : : Mee 2 a fing, Lowering And tng... : ad 238 Load an To Engage And Osangage A Loss. os Ba 338 Lond Hending - Tavaing nnn ee) a0 aa on ar, Ralvoad Cars And Docks. o-oo s00 SES bie 2.3.10 Stopping. S . . | 2.12 pat Pang = co ae Bee Stating the Engine. fe eee ais 2.3.12 Stang Sai Conon. yovvsveeeveeseesns 218 33.14 Bato-Roady Preparation. rare neee = a 2.4 LIFT TRUCK CONTROLS. ..- 2.16 SECTION 3. SAFETY RATING. 34 3.1 MAINTAINING THE DS SAFETY RATING. .- 3.2 saaltistof Required Components nee : 32 371. eloesea Sytem Components : Sallie 132 3.1.1.2 Fuel System. peau wee @. iv) seeee 32 Bt a exnaust System ee a 32 bs hated Pas lusts. — se 32 3.2 OVERLOAD TEST. .- 3.22 @ SECTION 4. PREVENTIVE MAINTENANCE. .-- 43 4.1 GENERAL INFORMATION ON PREVENTIVE MAINTENANCE. .- 43 4.2 HOW TO MOVE A DISABLED LIFT TRUCK. ..----ee 43 43 HOW TO TOW THE LIFT TRUCK. ... 43 4.4 HOW TO PUTA LIFT TRUCK ON BLOCKS. ...- oe re 44 4.5 HOW TO REMOVE THE DRIVE AXLE WHEELS. 44 4.6 HOW TO REMOVE THE STEERING AXLE WHEELS. ..- 44 4.7 HOW TO MAKE CHECKS WITH ignition switch OFF (DAILY). 48 Ha apa peal Sym, .avevvvvvereeeeseesesset 4 2 4.7.2. Checking the Engine Oil. « Soon — 48 4.7.8 Checking the Battery... ---TABLE OF CONTENTS: 4.7.9 Maintenance of the Fuel System. : 4.10 4.7.10 Inspection of tho Forks 2 : vee 4.40 4.7.11 Inspection of the Mast And Lit Gains, 20777 + 440 4.7.12 Inspection of the Tires And Wheels (Daily). 2” cate e 47.19 Maintenance ofthe Operator Restrain System (Dail) 413 4.7.14 Maintenance of the Safety Labels (Dai) : 413, 47-18 Removing Water from the Air Tanks (Dall)... se 418 4.7.16 Checking the Service Brakes, . : = ts 4.7.17 Checking the Parking Brakes, : 418 48 HOW TO MAKE CHECKS WITH THE ENGINE RUNNING (DAILY), ... 414 4.8.1 Checks of the Gauges, Hom and Fuse, a 44 4.8.2 Checks of the Control Lovers and Pedal, |” te 44 4.8.3 Checks of the Operation of the Lift System : 414 4.8.4 Checks of the Cooling System : 444 4.8.5 Checks of the Transmission Oi a : : 414 4.8.6 Checks of the Steering Systom. coe : 415 4.9 MAINTENANCE EVERY 100 HOURS OR TWO MONTHS. . 4.15 4.9.4 Changing the Engine Oil and Fiter a : 415 4.9.2 Replacing the Hydraulic Oil Filter ; : = 415 4.9.8 Checks of the Hydraulic Tank Breather, 20” a : 4.16 4.9.4 Lubrication of the Steering Tie Rods : con aie 4.8.5 Checks of the Drive Axle and Planetary Housings, | : ne at6 4.9.6 Checks of the Wheel Nuts... Seer 4.16 4.9.7 Checks of the Mast Assembly, coe : co 416 49.8 Checks of the Lit Chains. 1... 417 4.9.9 Checks of the Forks. — GospuOnSSAaoOCEE a o 4.7 @ 4.8.10 Other Lubrication, : = : 417 4.9.11 Checks of the Cooling System, = : : 447 4.9.12 Checks of the Orive Axle Brakes ecees : 417 4.9.13 Chocks of the Rotors ofthe Steering Avie Brakes, 202.” = 418 4.10 2000 HOUR OR YEARLY MAINTENANCE, 4.18 4.10.1 Changing the Hydraulic Oil o ; vee . 448 4.10.2 Changing the Hydraulio Oil Fiter, vo coe : 4.18 4.10.3 Changing the Fuel Fiters, .... : —— fn 48 4.10.4 Adjusting the Clearance of tho Engine Valves, | : ve 448 4.10.5 Changing the Transmission Oi : foe 448 4.10.6 Changing the Transmission Gil Fiter : = 418 4.10.7 Changing the Drive Axle Gil... : er ae 4.10.8 Lubricating the Bearings in the Steering Axe Hubs. cll ats 4.10.8 hacks of the Steering Avie Brakes... co 420 4.10.10 Changing the Air Drier Fiter, co 420 SECTION S. REPAIR AND OVERHAUL OF THE LIFT TRUCK, ....... 53 5.1 LIFT TRUCK FRAME. .............., 5.3 5.1.1 Removal ofthe Overhead Guard Assembly, = tee 88 5.1.2 Installation of the Overhead Guard Assembly. : : 54 5.1.8 Removal ofthe Fuel Tank... : eee es 5.1.4 Repair of the Fuel Tank, -— 5 d 55 oe 5.1.5 Installation of the Ful Tank 2s : : . 85 5.1.6 Removal of the Hydraulic Oil Tank. 55TABLE OF CONTENTS 0532-LP-000-4220 6.1.7 Repair of the Hydraulic Oil Tank. poppeneoost00 . 55 . 5.1.8 Installation of the Hydraulic Oil Tank... ao ee 88 5.2 ENGINE. ...... ageeqqn0nd09 - 56 5.2.1. General information on Engine Overhaul : we 56 5.2.2 Removal of the Engine/Transmission Assembly. doo 4 56 5.2.3 Removal of the Transmission from the Engine. ..... 5 ae 5 5.2.4 Installing the Transmission on the Engine Assembly, ee ST 5.2.5 Installation of the Engine and Transmission Assembly. «...++++++ ++ sed BF 5.2.6 Intake Manifold. .... a ee a 87 5.2.6.1 Removal of the Intake Manifold. ...... : ee oe 5.2.62 Cleaning and Inspection ofthe Intake Manifold. =... ++. seseotead so BF 5.2.6.3 Installation of the Intake Manifold. . poopocnoopeer 1 8B 5.2.7 Exhaust Manifold. ..... c tertecorneete > 8 $27.41 Removal ofthe Exhaust Manifold. eo) 5.2.7.2 Cleaning and Inspection of the Exhaust Manifold... —— 58 5.2.7.3 Installation of the Exhaust Manifold. eeeof0 ee popooroandoceeR 58 5.2.8 Turbocharger. .... deenoonb tereteeresconspee, 58 3.2.8.1 Removal of the Turbocharger. ..... poooe : + 8B 5.2.8.2 Cleaning and Inspection of the Turbocharger. . ..-« S = 58 5.2.8.3 Installation of the Turbocharger. ......-.++ os 5 159 5.2.8.4 Turbocharger Lubrication. eeooroonoiooose Ptesteeeey | 8:10 5.2.9 Oil Filter and Oil Lines. 5.10 5.2.9.1 Removal ofthe Oil Filter and Gil Lines : see 5A 5.2.9.2 Cleaning and Inspection of the Oil Fiter and Oil Lines. ses esses fms 5.10) a 5.2.9.3 Installation of the Oil Filter and Lines, ee hiverseees 540 5.2.10 OllPan.... gc 5 siesuesseoseneh, 810 5.2.10.1 Removal ofthe Oil Pan. os cae 50 5,2.10.2 Cleaning and Inspection of the Oil Pan. .... seeocoor : 5.10 5.2.10.3 Installation of the Oil Pan. .... ee el 5.2.11 Oll Pump. . 5.11 5.2.11.1 Removal of the Oil Pump. co Seoaceoeee ee tl 5.2.11.2 Disassembly of the Oil Pump. ieectttceuigugreterrssssces 5.11 5.2.11. Cleaning and Inspection of the Oil Pump. 5.11 5.2.11.4 Assembly and Installation of the Oil Pump. 5.11 5.2.12 Oil Cooler. ee | ei 5.2.12.1 General Information on Oil Cooler. Boopienpontoa ss pees BAZ 5.2.12.2 Removal of the Oil Cooler... S : tevserseees 52 $212.3 Cleaning and inspection ofthe Oil Cooke. : ate 5,2.12.4 Installation of the Oil Cooler. pend : + 812 5.2.13 Water Pump. ... a0 Heseedomteipy 52 5.2.13.1 Removal of the Water Pump ere O12) 5.2.13.2 Inspection of the Water Pump. secretes vob nig 518 5,2.13.3 Installation of the Water Pump, ....-.-20000e008 feos! vote 818, 5.2.14 Thermostat. . sponne Diieleesneotecnspe: 75318 5.2.14.1 Removal of the Thermostat. sopoce pee ele) 5.2.14.2 Inspection of the Thermostat fact bso Lesteeeestee BAB 5,2.14.3 Installation of the Thermostat. ‘i Geocnnooceen 5.13 5.2.15 Timing Geer Cover Boor poooonee Berea 513 @e 5.2.15.1 Removal of the Timing Gear Cover. - becrereeseee SAB 5.2.15.2 Cleaning and Inspection of the Timing Gear Gover, sesseysesees TA abe 25.14, 5,2.15.3 Installation of the Timing Gear Cover. .....+. vives feat sheds SAG 5.2.16 Timing Gears and Timing Gear Housing. ; 5.14 5.2.16.1 Removal of the Timing Gears and Housing. hateTABLE OF CONTENTS 5.2.16.2 Cleaning and inspection of the Timing Gears and Housing, 5.2.16.3 Installation of the Timing Gears and Housing 5.2.17 Flywheel, . : 5.2.17.1 Removal of the Flywheel, 5.2.17.2 Inspection and Repair of the Flywheel. 5.2.17.3 Installation of the Flywheel. 5.2.18 Flywheel Housing. . 5.2.18.1 Removal of the Flywheel Housing 5.2.18.2 Inspection of the Flywheel Housing 5.2.18.3 Installation of the Flywheel Housing. 5.2.18 Rocker Arm Assembly. . 52.19.1 Removal and Disassembly of the Rocker Arm Assembly 5.2.1.2 Cleaning and Inspection of the Racker Arm Assembly, 5.2.19.3 Assembly and Installation of the Rocker Atm Assembly. 5.2.20 Cylinder Head Assembly. 5.2.20.1 Removal of the Cylinder Head. 5.2.20.2 Cleaning and Inspection of the Cylinder Head. 5.2.20. Preparation for Cylinder Head Installation, 5.2.20.4 Installation of the Cylinder Head. 5.2.21 Engine Valves. ae §.2.21.1 Removal of the Engine Valves, 5.2.21.2 Cleaning and Inspection of the Valves. 5.2.21.3 Repair of the Valve Guides. 5.2.21.4 Lapping the Valves and Seats, 5.2.21.5 Installation of the Engine Valves. . 5.2.21.6 Adjustment of the Engine Valves, 5.2.22 Cylinder Block Assembly, 5.2.2.1 Disassembly of the Cylinder Block. 5.2.22.2 Cleaning the Cylinder Block. bog 5.2.2.3 Inspection and Repair of the Cylinder Block. 5.2.2.4 Assembly of the Cylinder Block, 5.2.23 Crankshaft and Main Bearings, 5.2.23.1 Removal of the Crankshaft and Main Bearings, 5.2,28.2 Cleaning and Inspection of the Crankshaft. 5.2.23.3 Grinding the Crankshaft £3)" SONS 2.23.4 Installation of the Crankshaft and Main Bearings, PN $2.24 Pistons and Connecting Rods. 5.2.24.1 Removal and Disassembly of the Pistons and Connecting Rods. 5.2.24.2 Cleaning and Inspection of the Pistons and Connecting Rods, 5.2.24.3 Assembly of the Pistons and Connecting Rods. . 5.2.25 Camshaft, es 7 5.2.25.1 Removal of the Camshaft 5.2,25.2 Cleaning and Inspection of the Camshaft. 5.2.25.3 Installation of the Camshatt. 5.3 FUEL INJECTION PUMP... 5.3.1 Removal of the Fuel Injection Pump. 5.8.2 Disassembly of the Fuel Injection Pump. 5.8.3 Cleaning and Inspection of the Fuel Injection Pump. 5.8.3.1 Drive Shaft 5.8.3.2 Hydraulic Head 5.3.3.3 Distributor Rotor 5.3.3.4 Delivery Valve 5.8.3.5 Plungers 5.14 BAT 5.17 8.17 5.7 8.17 517 5.17 5.18 5.18 5.18 5.18 5.18 5.19 5.20 5.20 5.20 5.22 5.22 5.23 523 5.23 5.24 5.24 5.25 5.25 5.25 5.25 5.27 5.27 5.28 5.30 5.30 5.31 5.31 5.92X 5.83 5.93 5.34 5.34 5.36 5.36 5.37 5.38 5.46 5.48 56 587 5.57 5.57 5.58 5.58 5.58eo TABLE OF CONTENTS 5.3.3.6 Cam Rollers and Shoes 5.3.3.7 Leaf Spring and Screw 5.3.3.8Cam ..... . 5.3.3.9 Governor Weights 5.3.3.10 Transfer Pump Blades 5.3.4 Assembly of the Fuel injection Pump. 4 5.3.5 Installation and Timing of the Fuel Injection Pump. . 5.4 ALTERNATOR. ee 5.4.1 Removal of the Alternator. 5.4.2 Disassembly of the Alternator. 5.4.4 Assembly of the Alternator. 5.4.5 Installation of the Alternator. 5.4.6 Checking the Alternator for Low Output 5.4.7 Checking the Alternator Brush Circuit. 5.4.8 Checking the Alternator Diodes. 5.4.9 Checking the Rectifier Bridge. 3.4.10 Checking the Rotor and Field Windings. - 5.5 STARTER MOTOR. ....-.. 22-055 5.5.1 Removal of the Starter Motor. 5.5.2 Disassembly of the Starter Motor. 5.5.9 Cleaning and Inspection of the Starter Motor. 5.5.4 Assembly of the Starter Motor. 5.5.5 Installation of the Starter Motor. 5.6 TRANSMISSION. .... 5.6-1 General Information on Transmission Overhaul 5.6.2 Removal of the Transmission. 5.6.3 Disassembly of the Transmission. 5.6.4 Transmission Clutch Packs. 5.6.4.1 Dleassembly of the Transmission Clutch Packs. 5.6.4.2 Cleaning the Transmission Clutch Packs. 5,6.4.3 Inspection of the Transmission Clutch Packs. . 5.6.4.4 Assembly of the Transmission Clutch Packs. 5.6.5 Transmission Valve Body 5.6.8.1 Genera Information onthe Transmission Valve Body. 5.6.5.2 Removal and Disassembly of the Transmission Valve Body. 5.6.5.3 Cleaning the Transmission Valve Body. 5.6.5.4 Inspection of the Transmission Valve Body. . 5.6.5.5 Assembly of the Valve Body. 5.6.6 Cleaning the Transmission. 5.6.7 Inspection of the Transmission. 5.6.8 Assembly of the Transmission . 5.6.9 Installation of the Transmission Valve Body. 5.8.10 Tenapission Pressure Checks. 5.6.11 Troubllthooting the Transmission Assembly. 5,6.11.1 General 5.6.14.2 Troubleshooting the Torque Converter. 5.6.11.3 Troubleshooting the Transmission Clutches. 5.6.1.4 Troubleshooting the Transmission Valve Body. 8.7 DRIVE SHAFT ASSEMBLY. 5.7.1 General Information on the Drive Shaft Assembly. 0532-LP-000-4220 5.58 5.59 5.59 5.59 5.59 5.60 8.75 5.76 5.76 5.76 8.17 5.78 5.79 5.80 5.81 5.81 5.82 + 5.83 5.83 5.83 5.84 5.85 5.86 ssercteecs {SOT 5.87 5.88 5.88 5.94 5.94 5.94 5.96 5.98 5.99 5.99 5.99 5.101 5.102 5.102 5.103 5.103 5.103 5.103 5.107vill TABLE OF CONTENTS 5.7.2 Removal of the Drive Shaft. 5.7.3 Replacement of the U-joints. . 5.7.4 Installation of the U-joints, 5.7.5 Installation of the Drive Shatt. 5.8 DRIVE AXLE ASSEMBLY WITH DRUM BRAKES, . 5.8.1 Removal of the Drive Axle Assembly, . 5.8.2 Disassembly of the Drive Axle and Brakes. poten 5.8.3 Removal and Disassembly of the Planetary Gear Assemblies, 5.8.4 Cleaning and Inspection of the Planetary Gear Assemblies, 5.8.5 Removal and Disassembly of the Wheel Hubs 5.8.6 Cleaning and inspection of the Wheel Hubs, 5.8.7 Removal and Disassembly of the Drive Axle Brakes. 5.8.8 Cleaning and Inspection of the Drive Axle Brakes, $.8.9 Removal of the Differential Carrier Assembly 5.8.10 Disassembly of the Differential Cartier, : : 5.8.11 Cleaning and Inspection of the Parts of the Differential Carrier, 5.8.12 Assembly of the Differential Carrier Assembly o 5.8.13 Assembly of the Drive Axle Brakes. . 5.8.14 Installation of the Wheel Bearings and Hub, 5.8.15 Installation of the Planetary Gear Assemblies. 5.8.16 Installation of the Drive Axle, 5.9 AIR BRAKE SYSTEM. ... 5.9.1 Removal of the Air Compressor. 5.9.2 Disassembly of the Air Compressor. 8.9.3 Cleaning and Inspection of the Air Compressor. 5.9.4 Assembly of the Air Compressor. 5.8.5 Installation of the Air Compressor. 5.9.6 Repairs of the Governor. 5.9.7 Repair of the Brake Pedal Valve, 5.9.8 Repairs of the Inversion Valve, 5.9.9 Repairs of the Actuator and Hydraulic Master Cylinder for the Steer Axle Brakes: 5.8.10 Removing the Air from the Hydraulic System for the Steer Axle Brakes, 5.10 STEERING AXLE. ... : 5.10.1 Removal of the Steering Axle. 5.10.2 Inspection And Repair of the St. 5.10.3 Installation of the Steering Axle. . 5.10.4 Removal of the Steering Cylinder. 5.10.5 Disassembly of the Steering Cylinder. 5.10.6 Cleaning and inspection of the Steering Cylinder 5.10.7 Assembly of the Steering Cylinder. 5.10.8 Installation of the Steering Cylinder. 5.10.9 Removal of the Wheels, Calipers, And Hubs. 8.10.10 Repair of the Hubs. . ring Axle, 5.10.11 Removal of the Spindles. onan 5.10.12 Inspection And Repair of the Spindle Assembly, 5.10.13 Repair of the Brake Calipers, 5.10.14 Installation of the Spindles. é 5.10.15 Installation of the Wheels, Calipers and Hubs. 5.10.16 Removal of the Tie Rod Links............. 5.10.17 Inspection of the Tie lod Links. 5.107 5.107 5.108 5.108 5.109 5.109 5.109 5.108 5.110 5.110 5.110 5.110 5.112 5.115 5.115. 5.119 5.120 5.124 5.126 5.127 5.127 5.127 5.127 5.128 5.130 5.131 5.133 5.135 5.186 5.197 5.138 5.140 5.141 5.141 5.142 5.142 5.142 5.142 5.143 5.143 5.143 5.144 5.144 5.145 5.145 5.146 5.147 5.148 5.149 5.149TABLE OF CONTENTS: 0532-LP-000-4220 : 5.10.18 Installation of the Tie lod Links. eornecpacos wee 5.149 5.11 STEERING CONTROL UNIT. .. : we 5.150 5.11.1 Removal of the Steering Control Assembly. : 5.150 3.11.2 Removal of the Steering Control Unit rpnroaeoeana : 5.150 5.11.3 Disassembly of the Steering Column Assembly. ...+ +++. ++ - 5.150 5.11.4 Inspection of the Steering Control Unit : 5.154 5.11.5 Assembly of the Steering Control Unit. : : 5.185 5.11.6 Installation of the Steering Control Unit... : bones 5.163 5.12 HYDRAULIC SYSTEM. ......+ sees 5.164 5.12.1 Main Control Valve-General information vee Sa 5.164 3.12.2 Removal of the Main Control Valve. pepnppeest : 5.187 5.12.3 Disassembly of the Main Control Valve. . .. eee + 5.167 5.12.4 Cleaning and Inspection of the Main Control Valve, MEDI 5.68 5.12.5 Assembly of the Main Control Valve. one ve 5.168 5.12.6 Installation of the Main Control Valve. WINIII e Bt68 5.12.7 Adjustment of the Reliet Valve for the Main Hydraulic System. ...- vie 5.169 5.12.8 Adjustment of the Relief Valve for the Steering System. ....+4+++1+000+0++ 5.169 5129 Removal of the Hydraulic Oil Pump. cto 1 8.169 ' 5.12.10 Disassembly of the Hycraulic Oil Pump. ers wei) e8170 5:12.11 Cleaning and Inspection of the Hydraulic Oil Pump. 5.170 5.12.12 Assembly of the Hydraulic Pump. etccrceoou 5.170 5.12.13 Installation of the Hydraulic Ol Pump. ..-.-. opt Shee “sam f -@ 5.13 HYDRAULIC CYLINDERS. .. oo : eee BATT 5.13.1 Romoval of the Lift Gyinders from a 2-Stage Mast. ........scererecsssssrrers SA7t 5.18.2 Installation ofthe Lift Cyinders on 2-Stage Masts. es epee eis 5.13.3 Disassembly of the Lift Cylinders. _ DLL cosegeeeep SBATZ 5.13.4 Cleaning and Inspection of the Lift Cylinders... ++ Altec eA S72 5.13.5 Repair of the Lift Cylinders. : . a Ste 5.13.6 Assembly of the Lift Qylinders. ...- be : Lae ehigea7s 5.13.7 Removal of the Titt Cylinders. vies Ltghed Se SATS 5.13.8 Disassembly of the Tit Cylinders. .- wo Beceends 5.174 5.13.9 Cleaning and Inspection of the Tit Oylinders. ......-.sseeeecererssesssrsseed SATE 5.19.10 Repair ofthe Titt Cylinders. vies ee wef BATE 3.13.11 Assembly of the Tit Cylinders. ... TIE Rica case 5.13.12 Installation of the Tit Cylinders. teonsets COR Loy 8.178 5.13.13 Removal of the Fork Postioner Cylinders. .......+sssceeseseertutecseeseses SATS 5.13.14 Disassembly of the Fork Postioner Cylinder. files ect joe BATS: 4 5.18.15 Cleaning and Inspection of the Fork Positioner Oylinder. «+. ++ +++ 1 8.176 5.1318 Repair of the Fork Positioner Cylinder. veengseeietedoeesae le pe 3.19.17 Assembly of the Fork Positioner Cylinder. . SUIIBET A Bag: 5.13.18 Installation of the Fork Positioner Cylinders. ae LLL Teas “ale 5.13.19 Removal of the Sideshift Cylinder. ee 2 eae . 5.13.20 Disassembly of the Sidesnift Cylinder. Dh Biebegfsegs de 50 5.13.21 Cleaning and Inspection of the Sideshift Cylinder. ......- ae 5.178 5.19.22 Repair of the Sideshitt Cylinder. ceeereeoaoD : 5.178 5.13.23 Assembly of the Sideshit Cylinder. ......++++ TTI A Sag f5t80 @ 5.13.24 Installation of the Sidestitt Cylinder. cncneeeoro seve 5.180 5.14 TIRES AND WHEELS. «....00000000000 2: ste 5.14.1 Removal of the Tires and Wheels. Pete vale Sit8 5.14.2 Removal of the Tire from the Wheel, ...-..ssseeeeeeererseers se seaite’: SATABLE OF CONTENTS 5.14.3 Installation of the Tire on the Wheel. 5.14.4 Adding Air to the Tires. 5.14.5 Installation of the Wheels, 5.16 2-STAGE MAST ASSEMBLIES. 5.16.1 Removal of the Forks, 5.16.2 Inspection of the Forks. 5.16.3 Installation of the Forks. 5.16.4 Removal of the Carriaga. 5.16.5 Installation of the Carriage... : fi 5.16.6 Removal of the 2-Stage Mast from the Lift Truck, 5.16.8 Disassembly of the 2-Stage Mast. 5.16.9 Cleaning and Inspection of the 2-Stage Mast. . 5.16.10 Assembly of the 2-Stage Masts. 5.16.11 Installation of the 2-Stage Mast, 5.16.12 Removal of the Sideshift Carriage, 5.16.13 Disassembly of the Sideshift Carriage. 5.16.14 Assembly of the Sideshift Carriage, 5.16.15 Installation of the Sideshift Carriage, c 5.16.16 Check for Leakage Outside the Hydraulic Lift System. 5.16.17 Check for Leakage Inside the Hydraulic Lift System. 5.16.18 Adjust The Tilt Cylinder Stroke And The Backward Tit Anglo, 5.16.19 Adjustments of the Lift Chains, 5.16.20 Adjustments of the 2-Stage Mast. 5.16.21 Adjustment of the Carriage. 5.17 TROUBLESHOOTING. . . 5.18 TORQUE SPECIFICATIONS, . 5.21 FASTENERS ...... 0.2... 5.21.1 General Information on Fasteners, 5.21.2 Thread Nomenclature, 5.21.3 Strength Identification, SECTION 6. ILLUSTRATED PARTS BREAKDOWN ......:....... 6.1 GENERAL. ..........,. 6.1.1 Figure and Index Numbers, 6.1.2 Wiggins Part Numbers. 6.1.3 OEM Part Number. 6.1.4 CAGE Code, 6.1.5 Description, 6.1.6 Quantity, 6.1.7 Notes 6.2 CAGE LIST GENERAL INFORMATION... 6.4 ILLUSTRATED PARTS BREAKDOWN. . ‘SECTION 7. NUMERICAL INDEX ;.. 5.182 5.183 5.184 5.185 5.185 5.185 5.185 5.186 5.187 5.188 5.189 5.191 5.192 5.192 5.193 5.193 5.193 5.193 5.194 5.194 5.194 5.195 5.196 5.197 5.198 5.216 5.219 5.219 5.219 5.219 7A 6.4 64 64 64 64 64 64 64 6.4 6.10 7ALIST OF ILLUSTRATIONS 0532-LP-000-4220 List of Illustrations e Figure 1.1. Lift Truck Assembly ..... . 0000 13 Figure 1.10, Parts of the Gear Housing and Idler Gear wee weno qa Figure 1.17, Connections for the Deadman Control Module tees . 47 Figure 1.25. Drive Axle Housing . ve 1.27 Figure 1.32. Steer Axle Assembly .....5...2s0escsesseeereses : se 1.83 Figure 1.88, Steen Cyinder tes Figure 138, Wheel Hub Assembly forthe Stor Alo. 135 Figure 1.35, Steering Axle Spinco - HH ee AEP iss Figure 188, Pars ofthe Steering ConralUnit =... eee 137 Figure 137, Hydraulic Contol Vave (it end Tit Sections Show) sevvvecccsessecssss 198 Figure 138, Schematic for Hydraulic System with 2-Stage Mast ...ecvvccscsesssceses 1.89 Figure 1.28 Parts ofthe in Control Valve as -t-seos2- Ah ata Figure 140, Inside the Main Contl Vale sss sssosscvisee Na Figure 141, Tt Spool Tit Back) : : SED aaa Figure 12, Tit Spool Operation uring Tit Forward SOEEINEID aa 4 Figue 149, Hydraulic Plumbing Steering .--+.-.-- SEED gas ii Figure 144, Hydraule Plumbing - Lit COURSE! SIE tas Figure 1.45. Hydraulic Plumbing - Tt 146 Figure 1.48, Hydraulic Pumbing - Sidesit : CIID a7 Figure 147, Hydraule Plumbing - Fork Postioner y........cssccscceecceeeevseese 447 ® Figure 1.48, Parts of th Brae Actuators CIIEEIINE III 4a Figut 149, Brake Pedal VaNe vssssassscsssssssiesiisiiceeeceeceeeeceeeseses 16M Figure 150, Air Brake System». 148 Figure 1.1. AlrDiyer Assembly +50i LIST OF ILLUSTRATIONS Figure 1.52. Operation of the Brake Actuators Figure 1.59. Drive Axle Brakes Figure 1.54. Slack Adjuster Assembly Figure 1.85, Brake Shoes on Drive Axle co Figure 1.56. Master Cylinder and Actuator forthe Steering Axle Brakes Figure 1.57. Steer Axle Brakes . : : Figure 1.88, Brake Calipers on Steering Axle Figure 1.59. Air Compressor : Figure 1.60. Parts of the Governor Figure 1,62. Parts of the 2-Stage Mast Figure 1.63, Mast Assembly (2 Stg) Figure 1.64, Parts of the Tit Cylinder Figure 1.65. Carriage ....,. Figure 1,66, Sideshitt and Carriage Assembly Figure 1.67. Parts of the Sideshift Cylinder .. Figure 1.68. Inside the Sideshitt Cylinder Figure 1.68. Lift Truck Wheels and Tires Figure 1.70. Lift Truck Instruments and Controls Figure 2.1. Weight on Drive Tires. Figure 2.2. Centers of Gravity : Figure 2.3. Combined Center of Gravity Changes Figure 2.4. Unstable Conditions Figure 2.5. Liting Long Loads : Figure 2.6. Avoid Lifting Loose Loads Figure 2.7. Accelerate Smoothly to Avoid Damage Figure 2.8. Loads Shorter than Forks Figure 2.9, Maximum Length of Load. Figure 2.10, Placing the Load on the Ground igure 2.11. Traveling with a Raised Load Figure 2.12, Placing the Load Figure 2.13, Litting a Round Load Figure 2.14. Traveling with Round Loads Figure 2.15, Lit Forks when Traveling . Figure 2.16, Traveling in Reverse Gears Figure 2.17. Traveling a Hill with No Load Figure 2.18, Traveling a Hil with a Load Figure 2.19, Overhead Objects . Figure 2.20. Brake Smoothly to Avoid Damage Figure 2.21. Position of Battle-Ready Lift Truck Figure 2.22. Tie Down Chains For Battle-ready Position Figure 2.23. Lift Truck Instruments and Controls Figure 3.1. INJECTOR PUMP ASSEMBLY Figure 3.2, INJECTOR COMPONENTS ...... Figure 3.2. INJECTOR COMPONENTS (REPEATED) Figure 3.9. FUEL INJECTOR NOZZLE : Figure 3.4. FUEL INJECTOR LINES Figure 9.5. FUEL FILTER SYSTEM |... Figure 3.6. FUEL TANK AND FILLER CAP Figure 3.7. EXHAUST SYSTEM ecco Figure 8.8, ALTERNATOR ASSEMBLY & BRACKET Figure 3.8, ALTERNATOR COMPONENTS Figure 3.10. STARTER MOTOR ASSEMBLY Figure 3.11. BATTERY AND CABLE ........ Figure 8.12, LIGHTS, SWITCHES & SENDERS 1.51 1.82 1.53 1.83 1.54 1.54 1.55 1.55 1.56 1.58 1.60 1.61 1.62 1.63 1.64 1.64 1.65 1.66 23 23 23 24 27 27 2.8 28 2.8 29 29 29 29 210 2.10 an 24 2a 2.12 2.12 214 2.15 216 3.3 34 36 38 3.9 3.10 att 3.12 3.13 314 3.15 3.16 3.17LIST OF ILLUSTRATIONS. 0532-LP-000-4220 Figure 318, AUXILIARY STEERING MOTORPUMP ASSEMBLY «ove0s0ssosss0000-+ 3.18 Figure 3.14. INSTRUMENT PANEL cereoeooore 3.19 Figure 3.18. WIRE HARNESS COMPONENTS : — ci 8.20 Figure 3.16. WINTERIZATION COMPONENTS wee 32t Figure 4.1, Lubrication and Maintenance Locations .....+.+.++++ — 46 Figure 4.2. Air Dryer Assembly Seeteeoo peocen09 43 Figure 4.3, Checks Of The Forks Se ne 4a Figure 4.4, Check The Lift Chains : — Vices 442 Figure 4,5. Check the Tires ..... ve eo Dives 448 Figure 4.8, Seat Assembly .... 5 secon ee 4.18 Figure 4.7, Hydraulic Oil Fitter Assembly 5 Livres 446 Figure 4.8. Steering Axle Hub Assembly 5 ‘i ce 49 Figure 5.1. Location of Mounts on Frame ......- ” : 53 Figure 5.2, Parts of the Frame Sore ore Aor CoGooET rE 54 Figure 5.3. Removing the Hydraulic Tank Uli 88 Figure 5.4, Hercules Engine .......+.+eeeeeseseseos = we 56 Figure 5.5, Intake Manifold : : fepoopreoueo coor 58 Figure 5.6. Exhaust Manifold . poreeeecnood Ditiees BB Figure 5.7. Turbocherger : ihe 59 Figure 5.8, Oil Pan Assembly . 10 Figure 5.9, Oil Pump Assembly ........-++ SenecrceceRconco : Bat Figure 5.10. Water Pump and Pulley ......2+0.2000+ Diieceeeereds SAB Figur 5.11, Water Inlet Pipe and Thermostat. 5.13 ire 5.12, Parts of the Gear Housing 5.16 Faure 612, Pat of the Rocker Arm and Push Rod Assembly Finesse SA9 Figure 5.14. Parts of the Cylinder Head = 521 File § 15. Cylinder Head Nut Tightening Sequence and Torque Values... 522 Figure 5.16. Parts of the Fuel Injector Cpocro + 523 Figure 5.17. Angle of the Valve Seat . ee ee Sek Figure 5.18. Installation of the Valve Guide . ee oe Figure 8.18. Reaming the Valve Guide ....2....sccsseerseseeersternees 5.24 Figure 5.20. Parts of the Cylinder Block 5 : Liles 8.28 Figure 5.21. Fuel Injection Lines 5 cons tiene 529 Figure 5.22, Crankshat and Main Bearings 5 So : 5.30 Figure 5.23. Crankshaft Pulley ....... oo De 880 Figure 5.24, Removing the Main Bearings rR : 531 Figure 5.25. Crankshaft Specifications ........+++++ Seco : 5.82 Figure 5.26. Checking Crankshaft End Thrust .....-.++ ee 5.32 Figure 5.27. Removing the Piston Assemblies ......++.0+0+++ : 5.34 Figure 5.28. Parts of the Piston and Connecting od... erence 534 Figure 5.28. Installing the Pistons ..... : IINIIII a 8.88 Figute 6.20, Measuring the Rod Bearing Clearance fou poreesecoeonstca 526 Figure 5.31. Camshaft Drive Gear .... ie ee 587 Fiuure 5.22, Removing the Camshaft and Thrust Plate Assembly... te 5.37 Figure 5.33. Changing the Camshatt End Clearance ..... eee 5.28 Filme & 34 allgning Camshaft Gear and Crankshat Gear Timing Marks « vee 5.89 Figure 5.35. Removing the Pump Flange Seal .........++ Se 5.46 Figure 5.36. Governor Control . Soe non eo sS0E0s O80 Ye 547 Figure 6.37, Throttle Shaft Assembly : iis SAT Figure 5.38, Loosening the Guide Stud .....2....esses00 : i 8a7 Figure 5.98. Removing the Governor Spring . SEDER OacEITCS 547 Figure 5.40, Disengaging the Linkage Hook 5.48 Figure 5.41. Metering Valve Assembly ....... — roo 5.48 Figute 6.42, Removing the Vent Wire Screw Assembly ....csscccrereesceeceessesss S48 ii eeeFigure 5.43, Figure 5.44, Figure 5.45, Figure 5.46, Figure 5.47, Figure 5.48, Figure 5.49, Figure 5.50, Figure 5.51 Figure 5.52. Figure 5.53, Figure 5.54, Figure 5.55. Figure 5.56, Figure 5.57, Figure 5.58, Figure 5.59, Figure 5.60, Figure 5.61 Figure 5.62, Figure 5,63, Figure 5.64 Figure 5.65, Figure 5.66, Figure 5.67. Figure 5.68, Figure 5.69, Figure 5.70, Figure 5.71. Figure 5.72, Figure 5.73, Figure 5.74, Figure 5.75, Figure 5.76, Figure 5.77, Figure 5.78, Figure 5.79. Figure 5.80, Figure 5.81 Figure 5.82, Figure 5.83. Figure 5.84 Figure 5.85, Figure 5.86. Figure 5.87. Figure 5.88, Figure 5.89, Figure 5.90, Figure 5.91 Figure 5.92. Figure 5.93. Figure 5.94, Figure 5.95, Figure 5.96. LIST OF ILLUSTRATIONS Removing the Locking Screw Removing the End Cap Regulator Assembly o Removing the Transfer Pump Blades Removing the End Cap Seal Removing the Head Locking Screw Loosening the Head Locating Screw Removing the Head Locating Screw . Loosening the Advance Plug Removing the Advance Plug Loosening the Spring Side Piston Plug Removing the Spring Side Piston Assembly Loosening the Power Side Piston Plug Feemoving the Power Side Piston Assembly Auto Advance Components : Removing the Cam Advance Screw . Loosening the Hydraulic Head Assembly Removing the Hydraulic Head Assembly , Removing the Weights, Thrust Washer and Sleeve Removing the Pivot Shaft Nut cee Removing the Pivot Shaft and Linkage Hook Assembly Removing the Liner Locating Ring coeur Removing the Rotor Retainers p Removing the Snap Ring for the Weight Retainer Removing the Weight Retainer Removing the Cam Ring oe Removing the Adjustment Screw and Leaf Spring .. Removing the Cam Roller and Cam Roller Shoe Removing the Pumping Plungers . Removing the Rotor Rotor Assembly Delivery Valve Assembly Removing the Arm from Metering Valve Measuring the Drive Shaft .. Checking the Vent Wire Assembly Inspecting the Delivery Valve Retraction Cutt Checking the Rotor Plungers ............. Inspecting the Cam Rollers and Shoes . Inspecting the Leaf Spring Inspecting the Cam ... : Inspecting the Governor Weight Inspecting the Transfer Pump Blades Delivery Valve Assembly = Rotor Assembly a Installing the Rotor Assembly Installing the Cam Ring . Installing the Weight Retainer. oo Installing the Snap Ring for the Weight Retainer Installing the Rotor Retainers Installing the Liner Locating Ring . Installing the End Cap Seal Installing the Transfer Pump Liner Installing the Transfer Pump Blades . Regulator Assembly sa es 5.49 @ esa 5.50 20 Seo sa a a ear ea se sa oa oa oa Se oa oe ser oa ou Ses oe Ss a ) Sa See 5.56 ae oar oer oa oa ca oa es Sas sa Sa a0 Sm ser sa se se Sa oa se = © Ses 5.64 5.64LIST OF ILLUSTRATIONS 0532-LP-000-4220 Figure 5.97. Installing the Regulator Figure 5.98. Fitter Screen and Pressure PLate . Figure 5.99. nstaling the Filter Screen and Pressure Plate Figure 5.100, Installing the Transfer Pump End Cap Figure 5.101. Installing the Governor Arm Figure 5.102, Installing the Pivot Shaft Nuts Figure 5.103, Installing the Governor Weights Figure 5.104, Installing the Thrust Washer and Sleeve Figure 5.105. Installing the Hydraulic Head Assembly . Figure 5.106, Installing the Hydraulic Head . Figure 5.107. Installing the Head Locking Screw Figure 5.108. Installing the Vent Wire Screw Assembly Figure 5.109, Assembly of the Metering Valve . Figure 5.110. installing the Metering Valve Assembly . Figure 5.111. Installing the Guide Stud . . Figure 5.112. insaling the Governor Linkage Hook Figure 5.113. Installing the Governor Spring Assembly Figure 5.114. Installing the Throttle Shaft Assembly . Figure 5.115. Installing the Head Locating Screw Figure 5.116. Tightening the Head Locating Screw Figure 5.117. Installing the Cam Advance Screw .... Figure 5.118. Auto Advance Components Figure 5.119. Installing the Advance Piston Assemblies Figure 5.120. Installing the Plug for the Advance Screw Hole Figure 5.121. Tightening the Plugs for the Advance Piston Holes Figure 5.122. Adjusting the Linkage Gap — Figure 5.123. Instaling the Shut-Off Cam .... Figure 5.124, Instaling the Governor Control Cover Figure 5.125. Tightening the End Cap Figure 5.126. Installing the Locking Plate for the End Cap Figure 5.127. Tightening the Head Locking Screws Figure 5.128. Instaling the Flange Seal Figure 5.129. Parts of the Alternator .... Figure 5.130. Alternator Cutaway Figure 5.132. Schematic for Alternator . Figure 5.133. Checking the Current Output Figure 5.194, Test for Full Output = Figure 5.135. Checking the Brush Circuit... Figure 5.196, Checking the Diodes . Figure 5.137. Checking the Rectifier Bridge Figure 5.138. Checking the Rotor Figure 5.139. Checking the Stator Windings . Figure 5.140. Starter Solenoid Figure 5.141. Removal of the Snap Ring Reteiner Figure 5.142, Parts of the Starter Figure 5.143. Inspection of the Armature Figure 5.144. Installation of the Snap Ring Retainer Figure 5.148, Starter Circuit .. Figure 5.146, Powershift Transmission - Cutaway View Figure 5.147. Transmission Housing Parts : Figure 5.148, Transmission and Hydraulic Pump Drives . Figure 5.149. Transmission Oil Pump Figure 5.150. Parts of the Transmission Figure 5.151. Transmission with Forward Clutch Assemblies Removed . 5.65 5.65 5.65 5.65 5.66 5,66 5,66 5.66 5.67 5.67 5.87 5.68 5.68 5.68 5.68 5.69 5.69 5.70 5.70 5.70 5.70 871 5.72 5.72 5.72 5.73 5.73 5.73 8.74 574 8.74 5.75 5.76 8.77 5.78 5.79 5.79 5.80 5.81 5.81 5.82 5.82 5.83 5.83 5.84 5.85 5.85 5.86 5.87 5.88 5,89 5.89 5.89 5.89LIST OF ILLUSTRATIONS Figure 5.152, Transmission with High Gear and Output Sit Removed Figure 5.153. Hydraulic Pump Drive a - Figure 5.154, Parts of the Transmission Figure 5.155. Parts of the Clutch Assembly Figure 5.156. Parts of the Clutch Packs Clutch Apply Piston Assembly . Cluteh Housing Assembly Figure 5.159. Parts of the Clutch Packs Figure 5.160, Parts of the Transmission Valve Body Figure 5.161. Prepare the Clutch Assembly for Installation of the Gear Hub . Figure 5.162. Clutch Assembly Figure 5.163. Installation of the Reverse Clutch Assemblies Figure 5,164, Installation of the Forward Clutch Assembly .. Figure 5.165. Installation of Clutch Assemblies Figure 5.166. Transmission Oil Pump Figure 5.167! Power Flow in REVERSE Figure 5.168. Power Flow in FORWARD . Figure 5.169. Oil Flow through the Transmission Control Valves . Figure 5.170. Transmission Hydraulic Circuit Figure 5.171. Driveshaft Assembly Figure 5.172, Drive Axle Housing ; Figure 6.173. Planetary Gear and Wheel Hub Assembly Figure 5.174. Removing the Cam Roller Figure 5.175, Removing the Anchor Pins. Figure 5.176. Brake Camshaft Assembly Figure 5.177. Brake Shoe Inspection Figure 5.178. Measure Inside of Brake Drum . Testing Fit of New Brake Shoes ). Differential Carrier Assembly . Checking the Clearance at the Ring Gear Teeth Before Disassembly Figure 5.182, Checking the Contact Pattern of the Ring Gear Teeth Before Disassembly Figure 5.183. Alignment Marks for Side Bearing Caps : Figure 5.184, Checking the Tooth Contact Pattern . Figure 5.185, Parts of the Ring and Pinion Carrier Assembly Figure 5.186. Pinion Bearing Support Assembly Figure 5.187. Removing the Side Bearing Caps. Figure 5.188. Removing the Differential Case Assembly Figure 5.189. Disassembly of the Differential Figure 5.190. Parts of the Ditferential Figure 5.191. Assembling the Differential Figure 5.192. Installing the Differential Case Assembly Figure 5.193. Installing the Adjuster Wheels Figure 6.194. Checking the Contact Pattern of the Ring Gear Teeth Figure 5.195, Checking the Tooth Contact Pattern Figure 6.196, Checking the Clearance of the Ring and Pinion Gears Figure 5.197. Ring and Pinion Cartier Assembly : Figure §.198, Brake Camshaft Seal Installation . Figure 5.198. Installing the Return Spring Figure 5.200. installing Top Brake Shoe . Figure 5.201. Installing the Roller and Retainer Clip. Figure 5.202. Checking the Camshaft Endplay Figure 5.203. Wheel Hub Assembly Fre 5.204, Fneary Gear Assonby Figure 5.208. Air Compressor cece : 5.90 5.91 5.92 5.93 5.94 5.95 5.95 5.95 5.98 5.99 5.100 5.100 5.101 5.101 5.101 5.103 5.104 5.104 5.105 5.107 5.109 5.110 5.At att 5.111 5.112 5.112 5.113 5.114 5.115 5.115 5.115 5.116 5.117 5.118 5.118 5.119 5.119 5.119 5.120 5.121 5.122 5.122 5.123 5.123 5.124 5.125 5.125 5.125 5.126 5.126 5.126 5.127 5.128LIST OF ILLUSTRATIONS 0532-LP-000-4220 Figure 5.208. Air Compressor Head ....... co a 5.128 Figute 5207, Parts of the Air Compressor Assembly . = on + 5.429 Figure 5.208. Compressor Head Assembly .....-.-- especucto w 5192 Figure 5.209. Dryer Assembly-Air Brake 12V...... Distress 5.194 Figure 5.210. Parts of the Governor _ — bee 8185 Figure 5.212. Inversion Valve .... : — 5.137 Figure 5.211. Brake Pedal Valve — tess 5136 Figure 5.218. Brake Master Cylinder wth A Actuator... , bon 5.138 Figure 8214, Raster Oyinder and Actuctor for Steering Axo Brakes bees 5199 Figure 5.215, Parts of the Master Cylinder for the Steer Axle Brakes .........s0.10001 5.198 Figure 5.216, Parts of the Steer Axle Assembly 5 . fees SAM Figure 5.217. Steering Cylinder .... es wees 5143, Figure 5.218, Wheel Hub Assembly forthe Steer Axle - 500 : 5.144 Figure 5.219. Steer Axle Brake Calipers .......+0+++ Soin teseeees S146 Figure 5.220. Steering Axle Spindle - RH —— nee 8.147 Figure 5.221. Steer Axle Assembly . 5 as : 5 5.148 : Figure 5222. Disassembly of the Steering Contral Unit. bones tenes 5.150 Figure 5.223. Removing the Steering Column .....+.++0+++ testustsesectecsae » BAS Figure 5.224, Removing the Endplate Capscrews veseenetsdsesececesene GABH Figure 5.225. Check the Operation of the Spool : rt S82 Figure 5.226. Spool and Housing Brosepnenorocanoxe 5.152 Figure 5.227. Parts of the Metering Section ....-.+.++ eoo5000 bee 5.152 Figure 5.228, Removing the End Cap Fepeocuoone cecseigsers, SZ Figure 5.229. Removing the Bushing : Sepocac teeteseenieye SASS Figure 5.230, Removal of the Check Valve Seal ......-.cccssssteseseseteesssessess SABO Figure 5.231. Removal of the Check Valve Seat ..... = + 8.153 Figure 5.232. Loosen the Spool Assembly oe tee 554 Figure 5.233. Push Spool from Sleeve .....--- Licietietesteesereteeere 8.154 Figure 5.234. Spool Removal from Sleeve Se t 5.154 Figure 5.235. Removal of the Centering Springs .........s.2+000+ ficeesees 5154 Figure 5.236. Check the Surface for Flatness 5.155 Figure 5.237. Spool! Installation 5.155 Figure 5.238. Installation ofthe Check Vaive Spring . 5.155 Figure 5.239, Check Valve Installation .... cocipbocd wee BASE Figute 5.240. Insta the Plug forthe Check Valve Assembly 5.186 Figure 5.241. Tightening the Check Valve Seat . teense 5.156 Figure 5.242. Installing Spool into Sleeve poosn00 fectgeeee 5AB7 Figure 5.243, Spool and Sleeve Assembly 5.157 Figure 5.244, Installing the Centering Springs oe » 5457 Figure 5.245. Installation of the Cross Pin ..... cllittenteseneeteers 8457 Figure 5.246. Installation of the Centering Springs .....-...+00++ sees 558 Figure 5.247. Installation of the Spool Assembly 5.188 Figure 5.248. Align the Spool Assembly with the End of the Housing 5.188 Figure 5.249. Installation of the Check Plug ; 5.159 Figure 5.250. Installation of the Bushing 5.159 Figure 5.251. Installation of the Seals cebopenotopecgsn cee 5.160 Figure 5.252. Tighten the Mounting Plate Capscrews so. ...2+.scse01= ; 5.160 Figure 5.253. Alignment of the Spool Assembly .......+++ es 5.161 Figure 5.254. Installing the Metering Section .......-.+ feces 5A61 Figure 5.255. Alignment of the Metering Section . poeousocuonndhose vee 5.162 Figure 5.256. Tighten the Capscrews Evenly . sescerseoetessegee 8188 Figure 5.257. Hydraulic Control Valve (Lift and Tit Sections Shown) 5.164 Figure 5.258. Schematic for Hydraulic System with 2-Stage Mast . 5.165 Figure 5.259. Parts of the Main Control Valve = 5.168 vil OOvill LIST OF ILLUSTRATIONS Figure 5.260. Litt Spool Positions Figure 5.261. Hydraulic Oil Pump... Figure 5.262. Inside the Hydraulic Oi Pump Figure 5.263. Lift Cylinder Parts. Figure 5.264. Parts of the Tit Cylinder Figure 5.265, Inside the Fork Positioner Cylinder viens Figure 5.266. Location of the Sideshift and Fork Positioner Cylinders Figure 5.267. Parts of the Sideshift Cylinder A Figure 5.268, Inside the Sideshift Cylinder . Figure 5.269, Loosen Tire Bead Figure 5.270. Remove the Side Flange Figure 5.271. Loosen the Bead on the Other Side of the Tire Figure 5.272. Remove the Rim from the Tire Figure 5.273. install Inner Tube and Flap oe Figure §.274. Align the Valve Stem with the Slot in the Wheel Rim Figure 5.275. Install the Side Flange Into Position on the Wheel Fim Figure 5.276. Add Arto Tire in a Cage Figure 5.277, Checks of the Forks . Figure 5.278. Carriage (2stg) vo Figure 5.279. Sideshift and Carriage Assembly Figure 5.280. Parts of the 2-Stage Mast Figure 5.281, Mast & Carriage (2 Stg) Figure 5.282. Check the Lift Chains for Length Figure 5.283, Mast Assembly (Top View) Figure 5.284. Adjustment of the Carriage Lift Chains Figure 5.285. Adjustment of the Load Roller Clearances Figure 5.286, Thread Pitch — igure 6.1 LIFT TRUCK ASSEMBLY Figure 6,2 ENGINE ASSEMBLY Figure 6.8 CYLINDER BLOCK ASSEMBLY Figure 6.4 CYLINDER BLOCK SUB-ASSEMBLY Figure 6.5 CRANKSHAFT ASSEMBLY Figure 6.6 PISTONS AND CONNECT RODS Figure 6.7 CAMSHAFT AND GEAR Figure 6.8 FLYWHEEL AND HOUSING Figure 6.9 OIL PUMP ...... Figure 6.10 OIL FILTER Figure 6.11 OIL PAN ASSEMBLY Figure 6.12 OIL COOLER ASSEMBLY Figure 6.1 GEAR HOUSING Figure 6.14 HEAD AND VALVES... Figure 6.18 ROCKER ARM ASSEMBLY Figure 6.16 VALVE COVER AND DIPSTICK Figure 6.17 TURBOCHARGER ASSEMBLY Figure 6.18 INTAKE AND EXHAUST MANIFOLDS Figure 6.19 ENGINE AND TRANS. MOUNTS , Figure 6.20 INJECTOR PUMP ASSEMBLY Figure 6.21 INJECTOR COMPONENTS 5 Figure 6.21 INJECTOR COMPONENTS (REPEATED) Figure 6.22 FUEL INJECTOR NOZZLE . Figure 6.23 FUEL INJECTOR LINES . Figure 6.24 FUEL FILTER SYSTEM Figure 6.25 FUEL TANK AND FILLER CAP. Figure 6.26 AIR COMPRESSOR 5.167 5.170 BAT 5.172 S174 S177 5.178 5.179 5.180 5.181 5.181 5.182 5.182 5.183 5.183 5.183 5.184 5.185 5.188 5.187 5.188 5.190 5.191 5.192 5.195 5.196 5.219 6.10 et 6.12 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.24 6.26 6.28 6.29 6.30 6.92 6.33 6.34 6.38 6.38 6.40 eat 6.42 6.43 6.44LIST OF ILLUSTRATIONS Figure 6.27 AIR CLEANER AND CONNECTION Figure 6.28 ACCELERATOR / INCHING PEDALS Figure 6.29 EXHAUST SYSTEM Figure 6.30 WATER PUMP ASSEMBLY Figure 6.31 THERMOSTAT AND WATER INLET Figure 6.32 FAN AND CRANKSHAFT PULLEY Figure 6.33 RADIATOR ASSEMBLY Figure 6.34 ALTERNATOR ASSEMBLY & BRACKET Figure 6.35 ALTERNATOR COMPONENTS Figure 6.36 STARTER MOTOR ASSEMBLY Figure 6.37 HORNS AND STEERING COLUMN, Figure 6.38 BATTERY AND CABLE ...... Figure 6.39 LIGHTS, SWITCHES & SENDERS Figure 6.40 TRANSMISSION AND CONVERTER: Figure 6.41 HYDRAULIC PUMP DRIVE . Figure 6.42 TRANSMISSION ASSEMBLY Figure 6.43 TRANSMISSION CLUTCH PACK ASSEMBLIES Figure 6.49 TRANSMISSION CLUTCH PACK ASSEMBLIES (REPEATED) . Figure 6.44 VALVE BODY ASSEMBLY Figure 6.45 TRANSMISSION COOLER, Figure 6.46 DRIVELINE ASSEMBLY Figure 6.47 DRYER ASSEMBLY-AIR BRAKE 12V Figure 6.48 INVERSION VALVE . : Figure 6.49 GOVERNOR Figure 6.50 BRAKE CALIPER FOR STEER AXLE... Figure 6.51 TRANSMISSION SHIFTER ASSEMBLY Figure 6.52 AIR BRAKE SYSTEM Figure 6.53 DRIVE AXLE ASSEMBLY .... Figure 6.54 AXLE GEAR CARRIER ASSEMBLY Figure 6.55 BRAKE AND SPIDER ASSEMBLY Figure 6.56 AXLE SHAFT AND HUB Figure 6.57 DRIVE AXLE HOUSING Figure 6.58 BRAKE PEDAL ASSEMBLY Figure 6.59 AIR/HYDRAULIC BRAKE ACTUATOR Figure 6.60 STEER AXLE WHEEL Figure 6.61 DRIVE WHEEL ASSEMBLY ... Figure 6.62 STEER AXLE ASSEMBLY Figure 6.63 AXLE MOUNT .... Figure 6.64 FRAME BODY Figure 6.65 HEADGUARD/BODY Figure 6.66 SEAT ASSEMBLY Figure 6.67 MAST 220/145/6 (2 STG) Figure 6.68 CARRIAGE 220/145/6 (2STG) Figure 6.69 STEERING CYLINDER ASSEMBLY Figure 6.70 SIDESHIFT CYLINDER ......... Figure 6.71 FORK POSITIONER CYLINDER . Figure 6.72 TILT CYLINDER . Figure 6.73. LIFT CYLINDER (2ST 220/145) Figure 6.74 HYDRAULIC PUMP ASSEMBLY Figure 6.75 STEERING MOTOR ASSEMBLY Figure 6.76 HYDRAULIC CONTROL VALVE . Figure 6.77 HYDRAULIC CONTROL VALVE - INLET Figure 6.78 HYDRAULIC CONTROL VALVE-STEERING SECTION Figure 6.79 HYDRAULIC CONTROL VALVE-LIFT cxcK 0532-LP-000-4220 6.46 6.47 6.48 6.49 6.50 6.51 6.52 6.53 6.54 6.55 6.56 6.57 6.58 6.59 6.60 6.62 6.64 6.66 6.68 6.70 671 6.72 674 675 6.76 677 6.78 6.80 6.82 6.84 6.86 6.88 6.90 6.92 6.93 6.94 6.96 6.98 6.99 6.100 6.101 6.102 6.104 6.105 6.108 6.107 6.108 6.109 6.110 6.111 6.112 6.113 6.114 6.115LIST OF ILLUSTRATIONS Figure 6.80 HYDRAULIC CONTROL VALVE-TILT Figure 6.81 HYD. CONTROL VALVE-SIDESHIFT/FORK POSITIONER Figure 6.82 HYDRAULIC CONTROL VALVE-OUTLET 5 Figure 6.88 HYDRAULIC CONTROL VALVE - HANDLES: Figure 6.84 HYDRAULIC RESERVOIR ....... : Figure 6.85 AUXILIARY STEERING MOTOR/PUMP ASSEMBLY Figure 6.86 HYDRAULIC PLUMBING - STEER, Figure 6.87 HYDRAULIC PLUMBING - TILT Figure 6.88 HYDRAULIC PLUMBING - MAIN . Figure 6.89 HYDRAULIC PLUMBING -LIFT (220/145 2STG) . Figure 6.90 HYDRAULIC PLUMBING -SIDESHIFT 220/145 (2STG) Figure 6.91 HYDRAULIC PLUMBING-FORK POSITIONER: asta 220/145) Figure 6.92 INSTRUMENT PANEL ........ Figure 6.93 WIRE HARNESS COMPONENTS . Figure 6.94 WINTERIZATION COMPONENTS Figure 6.95 DECAL AND DECAL PLATE Figure 6.96 CYLINDER & MAST TOOLS : st Goam0e0LIST OF TABLES 0532-LP-000-4220 List of Tables TABLE 1.1 INSTRUMENTS AND CONTROLS TABLE 2.1 INSTRUMENTS AND CONTROLS: TABLE 4,1 MAINTENANCE SCHEDULE. TABLE 5.1 ENGINE SPECIFICATIONS . TABLE 5.2 TRANSMISSION SPRING SPECIFICATIONS TABLE 5.3 TRANSMISSION PRESSURE SPECIFICATIONS TABLE 5.4 TRANSMISSION TORQUE SPECIFICATIONS TABLE 5.5 TROUBLESHOOTING .. TABLE 5.6 TORQUE SPECIFICATIONS TABLE 5.7 BOLTS AND SCREWS, TABLE 5.8 STUDS AND NUTS.. TABLE 5.9 TORQUE VALUES FOR NUTS TABLE 5.10 TORQUE NUTS WITH NYLON INSERT TABLE 5.11 GENERAL GUIDE TO TORQUE VALUES (LBF-FT) TABLE 5.12 GENERAL GUIDE TO TORQUE VALUES: TABLE 5.13 METRIC CONVERSION CHART 1.67 217 48 5.39 3.97 5.102 5.108 5.198 5.218 5.222 5.223 5.204 5.225 5.226 5.227 5.228LIST OF TABLES THIS PAGE INTENTIONALLY LEFT BLANKUSN REGISTRATION & END ITEM SERIAL NUMBERS. U.S.NAVY REG.NOS. 13-24.) 13-24391 13-24392 13-24393 13-24394 13-24395 13-24396 13-24397 13-24398 13-24399 13-24400 13-24401 13-24402 13-24403 13-66375 13-66376 13-66400 13-6401 13-66402 13-66403 13-70054 13-70055 13-70056 13-70057 13-70058 13-70059 13-70060 13-70061 13-70062 13-70161 13-70162 13-70179 13-70063 13-70064 13-70065 13-70066 13-70067 13-70068 13-70069 13-70070 13-70088 13-70089 END ITEM SERIAL NOS. HWIGGINSWLC955001 HWIGGINSWLC955002 HWIGGINSWLC955003 HWIGGINSWLC955004 HWIGGINSWLC955005 HWIGGINSWLC955006 HWIGGINSWLC955007 HWIGGINSWLC955008 HWIGGINSWLC955009 HWIGGINSWLC955010 HWIGGINSWLC955011 HWIGGINSWLC955012 HWIGGINSWLC955013 HWIGGINSWLC955014 HWIGGINSWLC955015 HWIGGINSWLC955016 HWIGGINSWLC955017 HWIGGINSWLC955018 HWIGGINSWLC955019 HWIGGINSWLC955020 HWIGGINSWLC955021 HWIGGINSWLC955022 HWIGGINSWLC955023 HWIGGINSWLC955024 HWIGGINSWLC955025 HWIGGINSWLC955026 HWIGGINSWLC955027 HWIGGINSWLC955028 HWIGGINSWLC955029 HWIGGINSWLC955030 HWIGGINSWLC955031 HWIGGINSWLC955032 HWIGGINSWLC955033 HWIGGINSWLC955034 HWIGGINSWLC955035, HWIGGINSWLC955036 HWIGGINSWLC955037 HWIGGINSWLC955038 HWIGGINSWLC955039 HWIGGINSWLC955040 HWIGGINSWLC955041 HWIGGINSWLC955042SPECIFICATION SHEETS + _0532-LP-000-4220 SPECIFICATIONS FOR WIGGINS W200YSB LIFT TRUCK (Sheet 1 of 2) ‘COMPONENT ‘OEM/CAGE ‘SPECIFICATIONS ‘TYPE/PART NUMBER ENGINE | HERCULES/28265 _| 4 CYLINDER DIESEL ENGINE DT2300x025 | TURBOCHARGED 140 CU. IN (2.3 L) DISPLACEMENT 95 HP FUEL INJECTION PUMP | STANDYNE/84760 | 4 CYLINDER, MECHANICAL INJECTION DB2433-5114 ALTERNATOR DELCO/16764 14VOLT, V-BELT DRIVE, 66 AMP_ 1101228 DS SAFETY RATED-SHIELDED STARTER DELCO/16764 GEAR REDUCTION - 3.875:1 28-MT/1113274 SOLENOID ACTIVATED ONE-WAY CLUTCH 12V SYSTEM TRANSMISSION BORG WARNER PR2 4000/79410 3833/1022-000-029 POWERSHIFT 2 SPEED RANGES (IN FORWARD AND RE- VERSE) INCHING CONTROL TORQUE CONVERTER BORG & BECK/75958 | 11 INCH (280 MM) DIAMETER 2083-10819 DRIVE AXLE ROCKWELL/78500 | OVERALL REDUCTION 25.8:1 209/PRC 416P 209 | PLANETARY RATIO 3.6:1 HYPOID RING AND PINION AIR/S-CAMSHAFT BRAKES RADIATOR HERCULES/28265 HORIZONTAL FLOW/WATER-AIR: 40-3096203 SERVICE BRAKES - ROCKWELL/78500 AIR/S-CAMSHAFT DRUM/SHOE BRAKES DRIVE AXLE SERVICE BRAKES - BRUDI/62389 AIR/HYDRAULIC MASTER CYLINDER STEER AXLE 400972 BRAKE ROTORS PART OF HUBS MICo/92865 CALIPERS PIVOT WITH SPINDLES een ROTORS 14,25 INCH DIA., 0.5 INCH THICK 2.5 INCH (62.5 MM) CALIPER PISTON DIA. HYDRAULIC OIL BRAKE FLUID PARKING BRAKE ROCKWELL/78500 PULL VALVE ON DASH COMPRESSED AIR RELEASE U65-3276-D-30 SPRING APPLY DRIVE AXLE BRAKES STEERING CONTROL | CHAR-LYNN/ LOAD SENSING HANDPUMP/MOTOR JNIT 213-1013-001 INTEGRAL COLUMN 23.8 CU. IN/REV (0.39 LITRES/REV) STEERING AXLE BRUDI/62389 ARTICULATED AT CENTER PIVOT 4100957 KING.PINS-AT SPINDLES ER HUB BEARINGS: DOUBLE ACTING STEERING CYLINDER NON-ADJUSTABLE TIE RODS -} + SPECIFICATION SHEETS SPECIFICATIONS FOR WIGGINS W200YSB LIFT TRUCK (Sheet 2 of 2) COMPONENT OEM/CAGE SPECIFICATIONS TYPE/PART NUMBER BATTERY INTERSTATE/25244__|712 VOLT TERMINAL TYPE 9. TYPE SG24 | CAPACITY 64 AH@20HR RATE DISCHARGE 20HR RATE MA@3.20A, TIRES - DRIVE (DUAL) | NATIONAL INDUSTRIAL | 10.00X20 HAULER TYPE TIRE JOWKV2 LUG TREAD HAULER. TUBE-TYPE WITH FLAP, 16 PLY BIAS LT-10.00X20 PRESSURE=120 PSI (810 kPa) TIRES - STEER NATIONAL INDUSTRIAL | 10,00X20 HAULER TYPE TIRE /OWKV2 LUG TREAD HAULER: TUBE-TYPE WITH FLAP LT-10.00X20 16 PLY BIAS PRESSURE=120 PSI (810 kPa) HYDRAULIC PUMP ‘SUNSTRAND/6Me92_| GEAR PUMP CPCO30R1AABC 30 GPM HYDRAULIC CONTROL HUSCO/93784 OPEN CENTER VALVE 6000635 4 MANUAL SPOOL SECTIONS STEERING FLOW CONTROL SECTION 2 RELIEF VALVES: MAIN at 27 gpm (105 It/m) 2450-2550 psi(1.69-1.76 MPa) STEERING at 8 gpm (31 It/m) 1450-1550 psi (1.0-1.07 MPa) MAST ASSEMBLY BRUDI/62960 LUFT HEIGHT TOP OF LOWERED MAST ‘2-STAGE MAST 220/145 IN 185902 220 IN (5588 MM) —_ 145 IN (3683 MM) MAIN LIFT CYLINDERS | BRUDI/62389 SINGLE ACTING 2-STAGE MASTS STROKE BORE 220/1451N 096196.11 TIOIN (2794 MM) 3.75 IN (95.25 MM) _ |SIDESMIFT CYLINDER | BRUDTE2309 DOUBLE ACTING “| { 062056 12 IN (300 MM) STROKE } BORE 3 INCH (76.2 MM) FORK POSITIONER CYL- | BRUDI/62389 DOUBLE ACTING INDERS 099384 STROKE BORE 22.5 INCH (571 MM) 2 INCH (51 MM) ‘STEERING CYLINDER BRUDI/62389 DOUBLE ACTING/DOUBLE END 050328 STROKE BORE 16 INCH (400 MM) 4 INCH (101 MM) TILT CYLINDERS BRUDI/62389 DOUBLE ACTING 051626 STROKE BORE INCH (254. MM)_4.5 INCH (414. MM). FORKS, KENHAR/1C623 2.5X7X72X34.25 to 2.75 INCH DIAMETER EYE 2.5X7X72X34.25 INCH o0532-LP-000-4220 OUTLINE DRAWING a [scorJo'set ‘2104 SSTINA "UA TAY SHOSNMD DRIAL TW *L ‘aagvown 99 ‘SHl0N = {aovzIs6 st an (c-z#22}201 — MY ‘3a¥01 99 wy Uris}eoe ———[ezer lez ow forztjos 2 9 Les'votto =| T (s101J0% T : (izez}601 S w bo ra (216+) 961 ssw oN93S831NI vant “punss3ed Se sl S133HM sv04 HOM ¥608-2-¥6-0040dS ON LO¥INOD Sd QdAL ‘ShI/ozz-H2 "ASAOOZM SNIDDIA ae Care ¥S08-9-P6=OEL0dS “ON LOVHLNOS: ‘ONT "09 dal SNIDSUAOUTLINE DRAWING OVS JTONV LHORE {sess}svz ~ eee sniava Nun +——_ [spoba]setg —————— (cavz}es 7 (ezeulez lzsslisz a = (189) 961 sms dS ON LORUINOD Sd GdAL ‘ShI/ozz-Hz 'ASkO00ZM SNIDDIA 908-9-¥6-Of20dS ‘ON LOVYLNOD ONT “09 LaTT SNIDDIASECTION 1.GENERAL INFORMATION _0532-LP-000-4220 Section 1 General Information with Preparation for UseSECTION 1. GENERAL INFORMATION Section 1. Contents SECTION 1. GENERAL INFORMATION. ......0....000eeee0eee 13 4.4 LIFT TRUCK DESCRIPTION. .......0.cccceeeeeseeeesees 13 1.2 FRAME AND BODY DESCRIPTION. .. 14 1.3 ENGINE SYSTEMS DESCRIPTION. ..........0.c000e000+ 1.4 1.4 ELECTRICAL SYSTEM DESCRIPTION. .........2220000++ 1.417 1.5 TRANSMISSION. .......000.cccseecceeeeseeeeteeenaeeee 1.22 1.6 DRIVESHAFT ASSEMBLY. .....0...60.ccceceeeseeeeeeees 1.26 1.7 DRIVE AXLE ASSEMBLY. 1.27 1.8 STEERING AXLE. .....00.cecceceeeeseceeeeesteeeeeeees 1.32 4.9 STEERING CONTROL UNIT. .00.......cccceceseeeeeeees 1.36 4.10 HYDRAULIC SYSTEM. .0...0..ecccseceeeeesteeeneeees 1.37 1.11 BRAKE SYSTEM. ....... 1.48 482 LIFT SYSTEM. 1.58 4.13 TILT CYLINDERS. «22... ..0.ccceccceceeseeeseeeeeeeees 1.61 1.14 SIDESHIFT CARRIAGE ASSEMBLY. ...........1+0e0e0e4 1.61 ig 1S TIRES AND WHEY soapge 1.65 1.15 LIFT TRUCK CONTROLS. . 1.66SECTION 1. GENERAL INFORMATION 0532-LP-000-4220 SECTION 1. GENERAL INFORMATION. This section has the description, operation and function of the lift truck and its parts. This section also has the procedures for preparation for lift truck use. Figure 1.1. Lift Truck Assembly 1.1 LIFT TRUCK DESCRIPTION. 1.1.1 The lift ruck described in this manual has a load capacity of 20,000 Ibs at 24 inch load center (9,000 kg. at61 cm). See Figure 1.1. The lift truckis for shipboard use and has a sideshift carriage with fork positioners 1.1.2 The frame of the lift truck has the counterweight plates as part of the weldment. The frame supports the ‘outer mast section and allows the mast to tilt forward or back on the mast pivots. The overhead guard, seat weldment, cowl and floorplate are all one weldment. The drive axle housing is fastened to the frame with capscrews and nuts. The steering axle pivots atthe center to allow the wheels to stay on the ground on rough surfaces. 1.1.3 The engine is an inline 4 cylinder diese! with ‘overhead valves and a turbocharger. The engine displacement is 140 cu, inch (2300 cc). The engine is ‘cooled by a fan that blows air through a water/air radiator. The engine has a high pressure injection fuel pump that supplies fuel to the four injectors. 1.1.4 The powershift transmission has two speeds for- converter transfers the power from the engine to the transmission and increases the torque available when the lift truck is under load. A short drive shaft connects the transmission output to the pinion shaft of the drive axle-assembly,————___ 1.1.5 The drive axle assembly has a hypoid ring and pinion gear set, a differential and a planetary gears each hub. The drive axle brake drums are part of the. planetary hub assemblies. The drive axle housing has ~ the mounts for the air brake actuators. The dual wheels of the drive axle mount to studs on the hubs. 1.1.6 The steering axle pivots on the center shaft and is the frame for mounting the steering cylinder. The steering cylinder has a rod extending out the shell at each end. The tie rod links connect the steering cylinder rod to the spindle arms. 1.4.7 The spindles have tapered roller bearings that al- Jow the spindle to rotate on the kingpin. The kingpin bearings are adjusted by shims under the steer axle frame. The wheel hub bearings mount on part of the spindles and are adjusted by the nut at the end of the spindle. The brake calipers for the steer axle brakes ‘mount to part of the spindle weldments and the brake rotors are part of the hubs. The shims between the caliper and the spindle mount puts the rotor in the center of the caliper. 1.1.8 The 12 Volt electrical system has a belt driven alternator and regulator assembly, a lead acid battery, a gear reduction starter, lights, gauges and switches, 1.1.9 The hydraulic system has a removable hydraulic tank with sight gauge, hoses and fittings, a gear pump. driven by a chain from the torque converter, a hydraulic control valve with two relief valves and flow control for the steering circuit. The steering control unit, controlled by the operator, receives oil from the hydraulic pump. ‘The lift truck has two lift cylinders for a 2-stage mast, two tilt cylinders, two fork positioner cylinders and a side shift cylinder. 4.1.10 The brake system uses compressed airto actuate the drum brakes atthe drive axle and to actuate the mas- tercylinder for the steer axle brakes. The steer axle sys- ‘tem uses hydraulic ol to actuate the dise brake calipers on the spindles. The park brake uses springs in the brake actuators on the drive axle to apply the drum brakes. 1.1.11 The compressed air system has an air compr sor that is driven by a V-belt from the engine. The compressed air is held in three tanks. The operator controls a foot activated valve to control the air pressure at th oO body has shift spools moved by solenoids when the direction lever is moved by the operator. The torque certain range and allow temporary control of the brakes, ‘even when the air system has a defect.SECTION 1. GENERAL INFORMATION 1.FRAME WITH COUNTERWEIGHT 2. LIFTING EYE. 3. TILT CYLINDER MOUNT 4, STEER AXLE MOUNT Figure 1.2. Frame Assembly 1.2 FRAME AND BODY DESCRIPTION. 1.2.1 The frame weldment has the mounts for the engine and transmission assembly, the steering axle pivots, the drive axle housing and the mast assembly. The fuel tank mounts on the right-hand side of the frame and fetes hydraulic ol tank mounts on the le-hand side of Po she itt tcuck. The overhead guard, seat and cowl weld- “ment mounts to the top of the frame. The hood lifts on ahinge and covers the engine and radiator assembly. A tow hook is mounted at the rear side of the counterweight. # 14 1.3 ENGINE SYSTEMS DESCRIPTION. 1.3.1 General Description. The engine is a turbocharged 4 cylinder diesel with overhead valves. Theen- gine displacement is 140 cu. inch (2300 ce). The cylinder block and head are cast iron with one intake valve and one exhaust valve for each eylinder. 1.3.1.1 A gear train drives the camshaft and the fuel injection pump. A fuel transfer pump is actuated by the ‘engine camshaft. Maximum engine speed is controlled with a mechanical governor in the fuel injection pump. An electrical solenoid shuts off the flow of fuel to the injectors when deenergized. 1.3.2 Description of the Air Intake System. The air intake system has an air cleaner with replaceable filter, turbocharger, intake manifold, intake valve system and connecting tubes and hoses.SECTION 1.GENERALINFORMATION _0532-LP-000-4220 @ INTAKE PIPE . CROSS-OVER TUBE : . OIL INLET LINE CONNECTOR HOSE . TURBOCHARGER OIL DRAIN HOSE CLAMP (EXHAUST PIPE) ‘ATTACHMENT NUT Z GASKET = bh Figure 1.3. Turbocharger 1.3.2.1 The air cleaner is mounted on the frame above the turbocharger. The air cleaner uses a replaceable dry air filter to clean the air as it enters the intake system. A tube connects the air cleaner to the compressor side of the turbocharger. 15SECTION 1. GENERAL INFORMATION rod assembly connect the valves to the camshaft. The valve clearance is adjustable at the rocker arm, 1.3.3 Description of the Turbocharger. The turbocharger is installed on the exhaust manifold where 1. CONNECTOR HOSE 2. AIR INTAKE PIPE 8. INTAKE MANIFOLD igure 1.4. Intake Manifold 1.3.2.2 The turbocharger is installed on the exhaust fold where the turbine and impeller are driven by exhaust gas from the engine, Intake air flows from the air cleaner through the impeller housing to the intake manifold. The impeller accelerates the flow of air through the intake system increasing the air pressure in the intake manifold. 1.3.2.3 A cross-over tube connects the turbocharger to an air intake pipe on the intake manifold, The intake raanifold distributes the air to the intake ports in the cylinder head, 1.3.2.4 The intake valves operate in replaceable valve guides pressed into the cylinder head. They are held to their seats with springs that connect to the valves with spring rotators and valve locks. A rocker arm and push- 16 chaust gas drives a turbin installed on a common shaft, The turbine and impeller are installed in separate housings. A bearing housing connects the turbine and impeller housings. The turbine-impeller shaft is supported on sleeve bearings lubricated and cooled with oil supplied under pressure from the engine. The bearing housing is fitted with an oil supply line and a drain line that returns the oil to the engine sump. Seals prevent the oil from entering the turbine and impeller housings and exhaust gas from entering the bearing housing. 1.3.3.1 Exhaust gas flows from the exhaust manifold and into the turbine housing through an inlet port. The flow of gas rotates the turbine and impeller and leaves the housing through an outlet port connected to the ex aust pipe. Intake air flows from the air cleaner into the impeller housing through an inlet port. The air flows from the housing through an outlet port to the intake ‘manifold. The impeller increases the flow of air through the intake system increasing the air pressure in the intake manifold. 1.3.4 Description of the Cylinder Head. The cylinder head i cast iron and has one intake valve and one exhaust valve for each eylinder. The valves are held to their seats with springs that connect to the valves with spring rotators and valve locks. The valve rotators cause the valves to rotate a short distance each lft cycle. This rotation helps keep the sealing surfaces clean. The intake valves use stem seals atthe guides, The valve seats and valve guides are replaceable inserts pressed into the cylinder head. Sleeves for the fuel nozzles are also pressed into the eylinder head at each fuel injection inlet, Valve clearance is adjustable for each valve at the rocker arm. \da.compressorimpeller__™SECTION 1. GENERAL INFORMATION 0532-LP-000-4220 CYLINDER HEAD 2. WASHER (ATTACHMENT) |. ATTACHMENT NUT VALVE SPRING KEEPER ROTATOR VALVE SPRING ‘SEAL (INTAKE VALVE) PIPE PLUG. FUEL NOZZLE SLEEVE EXHAUST MANIFOLD STUD CYLINDER HEAD GASKET INSERT SEAT (EXHAUST VALVE) EXHAUST VALVE INTAKE VALVE. . INSERT SEAT (INTAKE VALVE) VALVE GUIDE, WATER DIRECTOR INTAKE MANIFOLD STUD BUSAPSRASe@NogEYDH Figure 1.5. Parts of the Cylinder Head 1.3.4.1 The rocker arm assembly is installed on the cy!- inder head to operate the intake and exhaust valves. The rocker arms pivot on a rocker arm shaft. Springs and spacers position the rocker arms on the shaft. Fach rock- cerarm has an adjusting screw for the adjustment of the valve clearance. Hollow push rods connect the camshaft toeach rocker arm. Oil flows to the rocker arm shaft under pressure through a passage in one of the eylinder head studs. 47SECTION 1. GENERAL INFORMATION SHAFT SUPPORT ROCKER ARM SHAFT ROCKER ARM VALVE ADJUSTMENT SCREW SPRING 1 SPACER CENTER SPACER SNAP RING VALVE TAPPET PUSH ROD Sey Figure 1.6. Parts of the Rocker Arm and Push Rod Assembly 1.3.5 Description of the Cylinder Block. The inder block is cast-iron and has four cylinders, The cylinder bores are machined in the casting and do not use sleeves. For evencylinder cooling, coolant passages ex- tend the length of the cylinders, Piston cooling jets are installed at the bottom of each cylinder. Oil supply passages connect to a main oil passage that extends the length of the cylinder bloc! 1.3.5.1 The crankshatt is a machined forging with surface-hardened bearing journals that should not be ma- 18 chined. The crankshaft has passages to move oil under pressure to the connecting rod bearings. The front and rear oil seals are lip seals. There are five main bearings with the center bearing being the thrust bearing that controls the axial movement of the crankshaft. The center ‘main bearing cap has four capscrews and the other main bearing caps use two capscrews. The crankshaft gear and pulley are pressed on to the crankshaft and held with woodruff keys and a capscrew.SECTION 1. GENERAL INFORMATION 0532-LP-000-4220 SENogsens . PLUG-PIPE, |. PLUG-PIPE, PLUG-CUP CYLINDER BLOCK PLUG-CUP PLUG-CUP PLUG-PIPE PLUG-PIPE i BEARING CAP (REAR MAIN) BEARING CAP (INTERMEDIATE MAIN) BEARING CAP (CENTER MAIN) WASHER FOR CENTER MAIN BEARING CAP CAPSCREW FOR CENTER MAIN BEARING CAP, CAPSCREW FOR MAIN BEARING CAPS BEARING CAP (FRONT MAIN) 3. CAPSCREW FOR SPRAY JET SPRAY JET (PISTON COOLING) DOWEL FOR GEAR HOUSING CAMSHAFT BEARINGS ). STUD FOR GEAR HOUSING PLUG-PIPE PLUG-PIPE |. PLUG-PIPE |. STUD FOR OIL PAN DOWEL FOR BELL HOUSING PLUG-PIPE PLUG-CUP. |. DOWEL FOR CYLINDER HEAD. ). STUD FOR CYLINDER HEAD 19SECTION 1. GENERAL INFORMATION CRANKSHAFT MAIN BEARING (FRONT) MAIN BEARING (INTERMEDIATE) MAIN BEARING (CENTER) MAIN BEARING (REAR) WOODRUFF KEY CRANKSHAFT GEAR Nogseps Figure 1.6, Crankshaft and Main Bearings PISTON & OIL RING COMPRESSION RING SNAP RING FOR PISTON PIN BUSHING FOR CONNECTING ROD BEARING FOR CONNECTING ROD CAPSCREW FOR BEARING CAP BEARING CAP FOR CONNECTING ROD CONNECTING ROD PISTON PIN 9; Paris of the Piston-and Connecting Rod 1.10 1.3.5.2 The pistons are the solid type without slots in the skirt. Each piston has three piston rings (two compression rings and an oil control ring. The piston pin is necting rod bushing. ‘bushings for the piston pins. Snap rings hold the piston pins in position. Alignment grooves are machined in the joint faces of the connecting rod and bearingcap. A serial number on each connecting rod and cap is used to match the parts for assembly. 1.3.5.3 The camshatt uses four large diameter bearings ‘The bearings are lubricated through holes in the b ings that align with oil passages in the cylinder block Oil flows to the rocker arm assembly through a metered groove at the rear camshatt journal. Camshaft end play is controlled by a thrust plate attached to the cylinder block with two capscrews. Access to the capscrews is through holes in the camshaft gear. 1.3.5.4 The camshatt is driven by a camshaft gear that meshes with the crankshaft gear. Timing marks on the camshatt gear and crankshaft gear align the gears during installation. The camshaft gear is pressed onto the camshaft and a woodruff key and nut hold the gear in position, 1.3.5.5 As the camshaft rotates, solid lifters are raised by the camshaft lobes to open the valves. A lobe on the camshaft actuates the diaphragm rocker arm for the fuel pump. A gear near the center of the camshaft drives the oil pump gear. 1.3.6 Description of the Timing Gears. The gears include the crankshaft gear, camshaft gear, idler gear and fuel injection pump gear. Allof the gears are pressed onto their shafts and use a key and nut to hold each gear in position, 1.3.6.1 The idler gear rotates on two tapered roller bearings supported by a shaft. A flange at the outer end of the shaft and a retaining ring hold the bearings in position. A capscrew is installed through the idler gear shaft and threaded into the cylinder block. The idler shaft capserew, crankshaft gearand injection pump gear support the idler gear assembly. 1,3.6.2 The camshaft gear is driven directly by the crankshaft gear. The gear for the fuel injection pump is drivenby the crankshaft gear through an idler gear. Tim- ing marks on the camshaft gear and crankshall Gearare— used to align the gears during installation. Holes in the ‘camshaft gear allow accesso the thrust plate capscrews,SECTION 1. GENERAL INFORMATION _0532-LP-000-4220 1, GEAR HOUSING 8. IDLER SHAFT CAPSCREW 2. ALIGNMENT DOWEL 9. IDLER SHAFT 3. HOUSING GASKET 10. BEARING 4. COVER GASKET 11. RETAINING RING 5. OIL SEAL 12. IDLER GEAR, 6 ACCESSCOVERFORTHE — 13. BEARING INJECTION PUMP GEAR 14, SPACER 7. ACCESS COVER GASKET Figure 1.10. Parts of the Gear Housing and Idler Gear -@ —F.3:6:3 The timing gear housings installed onthe cyi--—-thatis removed foraccess tothe pears. The frontuitseat — inder block with capscrews. Dowels align and support forthe crankshaft is installed in the cover. Asmall cover the housing during installation. The housing has acover aaSECTION 1. GENERAL INFORMATION located on the housing cover, is used for access to the injection pump gear. rocker arm releases its pull on the diaphragm and the spring pushes the diaphragm toward the inlet and outlet valves. The increase in chamber pressure closes the inlet valve and opens the outlet vaive. INJECTION PUMP GEAR IDLER GEAR CAMSHAFT GEAR ACCESS HOLES FOR THRUST PLATE CAPSCREWS. CAMSHAFT GEAR TIMING MARK CRANKSHAFT GEAR TIMING MARK. CRANKSHAFT GEAR Figure 7. 1.3.7 Description of the Engine Fuel System. The engine fuel system has a fuel tank, fuel transfer pump, fuel filter-water separator, fuel lines, fuel injec tion pump and fuel injectors. 1.3.8 Description of the Fuel Tank. The fuel tank mounts on the right-hand side of the frame. The tank in- cludes a fuel level sender unit, filler cap plate, filler cap, filter screen, fuel shut off valve, fuel outlet port and fuel return port. 1.3.9 Description and Operation of the Fuel Transfer Pump. The mechanical fuel pump is installed on the engine block and is actuated by the en- «gine camshaft. A flexible diaphragm in the fuel pump is actuated by a combination of rocker arm action and spring tension 1.3.9.1 On the fuel intake stroke, the camshaft pushes ‘on one end of the rocker arm. The rocker arm pivots on pin and pulls the diaphragm against the pressure of a diaphragm spring, This-causes-a-vacuum-in-the-dia phragm chamber that closes the fuel outlet valve and ‘opens the fuel inlet valve. As the camshaft rotates, the 112 43.9.2 16h senaiet pump.nceds.sosvi placed with a new pump. 1.3.10 Description and Operation of the Fuel In- jection Pump. The fvel injection pump is installed on the timing gear housing and is driven by an idler gear at ne half the speed of the crankshaft. The fuel injection pump has the following main components. © Drive Shaft © Housing © Metering Valve © Hydraulic Head Assembly © Transfer Pump Blades © Pressure Regulator Assembly © Distributor Rotor © Internal Cam Ring ‘© Pumping Plungers © Governor 1.3.10.1 The main rotating components are the drive shaft, transfer pump blades, distributor rotor and gover- not. The drive shaft engages the distributor rotor in the hydraulic head. The drive end of the rotor has two pumping plungers. The plungers are actuated toward cach other by an internal cam ring through rollers and shoes installed in slots on the rotor. 1.3.10.2 The transfer pump at the rear of the rotoris of the positive displacement vane type and is enclosed in the end cap, The end cap also contains the fuel inlet strainer and transfer pump pressure regulator. The face of the regulator assembly is compressed against the liner and distributor rotor and is an end seal for the transfer pump. The distributor rotor has two charging ports and single axial bore with one discharge port to service all head outlets to the injection lines. 1.3.10.3 The hydraulic head contains the rotor bore, metering valve bore, the charging ports and the head discharge fittings. The high pressure injection lines to the nozzles are fastened to these discharge fittings. 1.3.10.4 The injection pump contains its own mechanical governor. The centrifugal force of the weights in their retainer is transmitted through asleeveto the gov-—- ernor arm and through positive linkage to the metering valve, eoSECTION 1. GENERAL INFORMATION 0532-LP-000-4220 DRIVE SHAFT HOUSING |. METERING VALVE HYDRAULIC HEAD ASSEMBLY ‘TRANSFER PUMP BLADES PRESSURE REGULATOR ASSEMBLY DISTRIBUTOR ROTOR INTERNAL CAM RING. PUMPING PLUNGERS, GOVERNOR Seenonsens Figure 1.12, Parts of the Fuel Injection Pump, 1.3.10.5 An electrical solenoid is used to shut off the flow of fuel to the injectors. When deenergized, the solenoid closes the metering valve and shuts off the flow of fuel to the plungers. 1.3.10.6 Fuel under transfer pump pressure flows through the center ofthe transfer pump rotor, past the rotor retainets and into a circular groove on the rotor. ‘Transfer pump output volume and pressure increase as the pump speed increases. When displacement and pressure ofthe transfer pump exceed injection requirements, some of the fuel flows through the pressure regulator back to the inlet side of the transfer pump. 1.3.10.7 The fuel then flows through a connecting passage in the head to the automatic advance, through a ra~ dial passage and then through a connecting passage to the metering valve.-The radial position of the metering, valve, controlled by the governor, regulates the flow of, fuel into the radial charging passage and head charging, ports. 1.3.10.8 As the rotor turns, the two rotor inlet passages align with the charging ports in the hydraulic head. Fuel under pressure from the transfer pump and controlled by the opening of the metering valve flows into the pumping chamber and moves the plungers apart. As the rotor continues to rotate, the inlet passages move out of align- ‘ment and the discharge port ofthe rotor aligns with one of the head outlets. While the discharge port is opened. the rollers contact the cam lobes forcing the plungersto- gether. Fuel under pressure between the plungers flows through the discharge port and into the injection line. 1,3.10.9 The injection pump is Tubs AAs fuel at transfer pump pressure reaches th ports, slots on the rotor shank allow fuel and trapped air to flow into the pump housing. An additional air vent passage in the hydraulic head connects the outlet side of- the transfer pump with the pump housing. This allows air and some fuel to be bled back to the housing and through a return line to the fuel tank. As the fuel fills 1.13SECTION 1. GENERAL INFORMATION the housing, it lubricates and cools the internal components. The injection pump operates with the housing completely full of fuel. There are no air spaces any- where within the pump. b 4 TEE FITTING FOR RETURN LINE RETURN LINE (CYLINDER 3 TO CYLINDER 4) RETURN LINE (CYLINDER 2 TO CYLINDER 3) RETURN LINE (CYLINDER 1 TO CYLINDER 2) ELBOW FITTING FOR RETURN LINE, FUEL LINE (CYLINDER 1) CLAMP FOR FUEL LINE FUEL LINE (CYLINDER 2) FUEL LINE (CYLINDER 3) FUEL LINE (CYLINDER 4) RETURN DRAIN LINE (RETURNS TO PUMP) Figure 1.13. Fuel Injection Lines 1.3.11. Description and Operation of the Fuel Injectors. The fuel injectorsare located in the cylinder head. Each injector has a needle valve assembly, injec- torsleeve, sealing gasket and hold down clamp. The injectors are installed in the sleeves pressed into cylinder head ports. Fittings connect the injectors to fuel supply ines: Jeak off lines:~ 4.3.1.1 The fuel injector receives a timed fuel charge under high pressure from the fuel injection pump. The 1.14 pressure moves the needle valve against spring tension and fuel is injected into the combustion chamber. A small amount of fuel leaks by the injector needle valve during operation. This fuel is returned to the pump through the leak off line and a main drain line, 1.3.12 Description of the Engine Cooling Sys- tem. ‘The engine cooling system has engine water passages, a radiator with pressure cap, an engine oil cooler, coolant hoses, a belt driven fan, a centrifugal waterSECTION 1. GENERAL INFORMATION pump, a thermostat and bypass hose. The water pump pulley is connected by a V-belt and driven by the crank- pulley. The water pump pulley is also the mount for the far 1.3.12.1 The water pump is the centrifugal type, using an impeller to move the water. The impeller is connected to a drive shatf that rotates on bearings. A seal is used to prevent water from leaking past the drive shaft ‘and pump housing. If the water pump needs service, it is replaced with a new pump. 4.3.12.2 The engine oil cooler is connected by bracket to the engine timing gear cover. The engine oil flows through a tube inside of the oil cooler. The oil tube is ‘connected by hoses to the oil filter base and the engine block, Coolant hoses connect the oil cooler to the radiator and the water pump. 1.3.12.3 The thermostat valve is located in a housing on the cylinder head, When the thermostat valve is open, the coolant flow is from the bottom of the radiator, through the oil cooler and into the water pump. From the water pump the coolant flows through passages in the cylinder block and the cylinder head. From the cylinder 0532-LP-000-4220 head the coolant flows through the thermostat and into the top of the radiator. 4 When the thermostat valve is closed, instead cylinder head through the bypass hose and back to the ‘water pump. The thermostat valve opens and closes as needed to maintain the correct coolant temperature for the engine, 4.3.12.5 The radiator is connected by brackets to the frame. Tanks at the top and bottom of the radiator are connected with a core made of fins and copper tubes. The coolant flows from the top tank to the bottom tank through the tubes. The tubes and fins connected to the tubes, conduct the heat from the coolant. Air flowing, through the radiator cools the fins and tubes, The fan is used to move more air through the radiator. 1.3.12.6 A radiator pressure cap is installed on the radiator filler tube. The pressure cap uses a pressure and a vacuum valve to regulate the pressure in the cooling system. An overflow tube allows air to escape or enter the system as needed. BYPASS HOSE THERMOSTAT HOUSING |. THERMOSTAT GASKET PULLEY PLUG. WATER INLET PIPE WATER PUMP 1 2. 3. 4 5, 6 7. 8 Figure 1.14. Parts of the Cooling System

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