H1.5-3.5TX - H2.0TXS (B475) (B466) - Manual de Serviços EN

HMM800004
Capacities and Specifications

H1.5-1.8TX, H2.0TXS [B475]
H2.0-3.5TX [B466]
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 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), 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!
—1—
Lift Truck Lifting Capacity
Model kg
H1.5TX [B475] 1500
H1.8TX [B475] 1750
H2.0TXS [B475]
2000
H2.0TX [B466]
H2.5TX [B466] 2500
H3.0TX [B466] 3000
H3.5TX [B466] 3500
NOTE: Load center at 500 mm.
Counterweight Weights
Model kg
H1.5TX [B475] 810
H1.8TX [B475] 1015
H2.0TXS [B475] 1200
H2.0TX [B466] 1190
H2.5TX [B466] 1530
H3.0TX [B466] 1920
H3.5TX [B466] 2215
Tire Sizes
Truck Drive Tires Steer Tires
H1.5TX [B475] 6.00 - 9 5.00 - 8
H1.8TX, H2.0TXS [B475] 21 x 8 - 9 18 x 7 - 8
H2.0-2.5TX [B466] 7.00 - 12 6.00 - 9
H3.0-3.5TX [B466] 28 x 9 - 15 6.50 - 10
—2—
Capacities
Item Quantity Specifications
Fuel Capacity
Gas
52.0 liter 86 Octane
H1.5-1.8TX, H2.0TXS [B475]
Gas
69.0 liter 86 Octane
H2.0-3.5TX [B466]
LPG
H1.5-1.8TX, H2.0TXS [B475] 15/20 kg LPG-HD 5
H2.0-3.5TX [B466]
Diesel
52.0 liter Diesel No. 2
H1.5-1.8TX, H2.0TXS [B475]
Diesel
69.0 liter Diesel No. 2
H2.0-3.5TX [B466]
Engine Oil (With Oil Filter)
Mazda M4-2.0G −7°C and below

SAE 5W-20
16°C and below
SAE 5W-30
4.3 liter −18°C and above
SAE 10W-30
API SL
ILSAC GF3
SAE J2362
Mazda M4-2.2G −7°C and below

SAE 5W-20
16°C and below
SAE 5W-30
4.6 liter −18°C and above
SAE 10W-30
API SL
ILSAC GF3
SAE J2362
Yanmar Diesel 20°C and over

SAE 40
10 to 30°C
SAE 30
0 to 20°C
SAE 20
−16 to 40°C
9.4 liter
SAE 15W-40
−20 to 30°C
SAE 10W-30
−10 to 10°C
SAE 20W
−20 to 10°C
SAE 10W
—3—
Cooling System
Mazda M4-2.0G and M4-2.2G

Serpentine and Square Wave CAUTION
Additives may damage
the cooling system.
M4-2.0G/10.4 liter
Before using additives,
M4-2.2G/10.2 liter
contact your local Hyster
dealer.
5 0 % Wa t e r a n d 5 0 %
Ethylene Glycol, Boron-
Free Antifreeze
Yanmar Diesel
CAUTION
the cooling system.
2.7L/7.5 liter
Before using additives,
3.3L/7.3 liter
dealer.
5 0 % Wa t e r a n d 5 0 %
Ethylene Glycol, Boron-
Free Antifreeze
Hydraulic Tank Oil Capacity
All Trucks
CAUTION
22 - 42 liter the hydraulic system.
Initial fill Before using additives,
dealer.
ISO VG-46 Hydraulic Oil
−15°C and above
Transmission
Power Shift Transmission 20 liter Dexron II or III
Brake Fluid 0.2 liter SAE J-1703, DOT 3
Differential and Drive Axle Oil

5.0 liter SAE 80W-90 or 85W-140
H1.5-1.8TX, H2.0TXS [B475]
Differential and Drive Axle Oil

6.5 liter SAE 80W-90 or 85W-140
H2.0-3.5TX [B466]
—4—
Electrical System
Item Mazda M4-2.0G and M4-2.2G Yanmar
Battery 12-volt, negative ground 12-volt, negative ground
Spark Plugs ND W9EXR-U N/A
0.8±1 mm
Spark Plug Gap N/A
(0.031±.0.04 in.)
Ignition Timing:
Gas 6° BTDC (Orange timing mark) N/A
LPG 6° BTDC (Orange timing mark) N/A
2.7L engine preset @ 4° ATDC

Diesel N/A
3.3L engine preset @ 6° ATDC
Mazda M4-2.0G and M4-2.2G
Alternator Output (14 Volts) G and LPG
Idle 18 amps @ 800 rpm
High Idle 42 amps @ 2700 rpm
Yanmar
Alternator Output (13.5 Volts) D
Cold High Idle 45 amps @ 2400 rpm
Hot High Idle 36.5 amps @ 2400 rpm
—5—
Transmission Oil Pressures
All Pressures at 2000 rpm and Oil at 50 to 65°C
Port 3
Port 1 Port 2
Torque
Transmission Pump Clutch
Converter
*Relief Pressure
**Clutch pack pressure difference between the forward and reverse packs cannot exceed
manufacturing limit of 48 kPa or service limit of 70 kPa.
1.47 MPa 0.88~1.2 Mpa 0.29~0.69 Mpa

(15.0 kg/cm2) (9.0~12.0 kg/cm2) (3.0~7.0 kg/cm2)
—6—
Hydraulic System Relief Pressures
Item Specification
Oil Temperature 55 to 65°C
Primary Relief Valve Pressure (High Idle)
0
H1.5-3.0TX [B475, B466] 18.6 −0.5 MPa
0
H3.5TX [B466] 20.6 −0.5 MPa
Secondary Relief Valve Pressure (High Idle) 15.7 +0.5

0 MPa
Steering System
Item Quantity
Oil Temperature 55 to 65°C
Steering Relief Pressure at 800 rpms
H1.5-3.5TX [B475, B466] 7.9 +0.5

0 MPa
Steering Cylinder Stroke
H1.5-3.5TX [B475, B466] 154.65 mm
Inside Steering Tire Angle 84.5°
Number of Turns to Lock
H1.5-3.5TX [B475, B466] 4.25~4.5
Turning Radius (±50 mm NO LOAD) Outside
Pneumatic Tire Trucks
H1.5TX [B475] 1975
H1.8TX [B475] 2010
H2.0TXS [B475] 2040
H2.0TX [B466] 2150
H2.5TX [B466] 2210
H3.0TX [B466] 2305
H3.5TX [B466] 2355
—7—
Stall Speeds (in RPM ±100 rpm)
Mazda M4-2.0G
Engine New Engine Broken-In Engine
Gas / LPG 1880 1980
Mazda M4-2.2G
Engine New Engine Broken-In Engine
Gas / LPG 1960 2060
Yanmar 2.7L
Engine New Engine Broken-In Engine*
Diesel 2005 2015
*30 or more hours.
Yanmar 3.3L
Engine New Engine Broken-In Engine*
Diesel 2085 2185
*30 or more hours.
Mast Speeds
NOTE: Lift speed is measured in meters/sec at governed engine RPM with full open valve and 65°C oil
temperature.
Lowering speed is measured in meters/sec with full open valve and 65°C oil temperature.
Plus or minus 10% acceptable lifting or lowering.
Table 1. Lift Truck Models H1.5-1.8TX, H2.0TXS [B475]
Lowering M/Sec Lifting M/Sec

Model/Engine Mast
No Load Rated Load No Load H1.5TX H1.8TX H2.0TXS
2-Stage LFL 0.54 0.515 0.635 0.6 0.6 0.595

H1.5-2.0TX(S)
2-Stage FFL 0.485 0.465 0.575 0.545 0.545 0.54
Mazda M4-2.0G
3-Stage FFL 0.510 0.485 0.605 0.57 0.57 0.565
2-Stage LFL 0.54 0.515 0.67 0.63 0.62 0.61

H1.5-2.0TX(S)
Yanmar 2-Stage FFL 0.485 0.465 0.61 0.57 0.565 0.555
2.7L
3-Stage FFL 0.510 0.485 0.635 0.6 0.59 0.58
—8—
Table 2. Lift Truck Models H2.0-3.5TX [B466]
Lowering M/Sec Lifting M/Sec
Model/Engine Mast
Rated
No Load No Load H2.0TX H2.5TX H3.0TX H3.5TX
Load
2-Stage LFL 0.54 0.515 0.595 0.565 0.55 N/A N/A

H2.0-2.5TX
2-Stage FFL 0.52 0.495 0.560 0.530 0.52 N/A N/A
Mazda M4-2.0G
3-Stage FFL 0.52 0.495 0.565 0.535 0.520 N/A N/A
2-Stage LFL 0.54 0.515 0.65 0.615 0.61 N/A N/A

H2.0-2.5TX
2-Stage FFL 0.52 0.495 0.61 0.58 0.575 N/A N/A
Mazda M4-2.2G
3-Stage FFL 0.52 0.495 0.615 0.585 0.580 N/A N/A
2-Stage LFL 0.54 0.515 0.535 N/A N/A 0.505 N/A

H3.0TX
Mazda M4-2.2G 2-Stage FFL 0.480 0.46 0.465 N/A N/A 0.440 N/A
2700 rpm
3-Stage FFL 0.510 0.485 0.5 N/A N/A 0.475 N/A
3.0t 0.590
2-Stage LFL 0.54 0.515 N/A N/A 0.505 0.450
3.5t 0.550
H3.0-3.5TX 3.0t 0.555
Mazda M4-2.2G 2-Stage FFL 0.480 0.46 N/A N/A 0.440 0.390
3000 rpm 3.5t 0.515
3.0t 0.515
3-Stage FFL 0.510 0.485 N/A N/A 0.475 0.425
3.5t 0.480
2-Stage LFL 0.54 0.515 0.62 0.595 0.59 N/A N/A

H2.0-2.5TX
Yanmar 2-Stage FFL 0.52 0.495 0.585 0.56 0.555 N/A N/A
2.7L
3-Stage FFL 0.52 0.495 0.590 0.565 0.555 N/A N/A
2-Stage LFL 0.54 0.515 0.705 0.685 0.680 N/A N/A

H2.0-2.5TX
Yanmar 2-Stage FFL 0.52 0.495 0.665 0.645 0.640 N/A N/A
3.3L
3-Stage FFL 0.52 0.495 0.665 0.645 0.64 N/A N/A
2-Stage LFL 0.54 0.515 0.58 N/A N/A 0.56 N/A

H3.0TX
Yanmar 2-Stage FFL 0.48 0.46 0.505 N/A N/A 0.485 N/A
3.3L
3-Stage FFL 0.51 0.485 0.545 N/A N/A 0.525 N/A
2-Stage LFL 0.54 0.515 0.515 N/A N/A N/A 0.495

H3.5TX
Yanmar 2-Stage FFL 0.48 0.46 0.450 N/A N/A N/A 0.430
3.3L
3-Stage FFL 0.51 0.485 0.485 N/A N/A N/A 0.465
—9—
Tilt Angles
Truck should be on level ground and in unloaded condition.
Table 4. H1.5-3.5 TX [B475, B466]
Forward Tolerance Back Tolerance
10° +1°, −0.5° 6° +0°, −0.5°
6° +1°, −0.5° 10° +0°, −0.5°
6° +1°, −0.5° 6° +0°, −0.5°
6° +1°, −0.5° 12° +0°, −0.5°
Front End Equipment - Mast Creep
Mast Creep
Measure with load at 2.5 m high and with the lift, tilt, and auxiliary control levers in neutral
position.
NOTE: Mast should be 90° vertical prior to test.
Table 5. H1.5-3.5TX [B475, B466]
Maximum Tilt Creep

Hydraulic Oil Maximum Vertical Creep at
Temperature Carriage
Mast Angle Cylinder Stroke
°C mm/Min in./Min °/Min mm/Min in./Min
20 2.2 0.086 0.10 0.93 0.037
30 3.3 0.130 0.15 1.40 0.06
40 6.3 0.247 0.29 2.70 0.11
50 10.0 0.394 0.47 4.37 0.17
60 14.6 0.575 0.68 6.32 0.25
— 10 —
Engine Specifications
Table 6. H1.5-3.5TX [B475, B466]
Item Mazda M4-2.0G Mazda M4-2.2G
No. of Cylinders 4 4
Firing Order 1-3-4-2 1-3-4-2
Bore and Stroke 86 mm × 86 mm 86 mm × 94 mm
Displacement 1998 cc 2184 cc
6° BTDC 6° BTDC
Engine Timing
Gas/LPG Gas/LPG
Compression Ratio
Gas 8.6:1 8.6:1
LPG 8.6:1 8.6:1
Compression Pressure (Minimum Values)
1131 kPa 1131 kPa

Gas
@ 270 rpm @ 270 rpm
1131 kPa 1131 kPa

LPG
@ 270 rpm @ 270 rpm
226 to 362 kPa 226 to 362 kPa

Oil Pressure
@ 2400 rpm @ 2400 rpm
Valve Clearance
Intake 0.15 mm (COLD) 0.15 mm (COLD)
Exhaust 0.35 mm (COLD) 0.35 mm (COLD)
Idle Speed - Gas 725±25 rpm 725±25 rpm
Idle Speed - LPG 725±25 rpm 725±25 rpm
Governed Speed High Idle (No H1.5-1.8TX, H2.0TXS 2500±25 rpm H2.0-3.0TX 2700±25 rpm
Load) H2.0-3.5TX 2700±25 rpm H3.0-3.5TX 3000±25 rpm
Thermostat Range
START TO OPEN 82±1.5°C 82±1.5°C
FULL OPEN 95±1.5°C 95±1.5°C
Cooling System Pressure 103 kPa 103 kPa
— 11 —
Yanmar 2.7L Diesel Yanmar 3.3L Diesel
Item
(4TNE92-SNM) (4TNE98-SNM)
No. of Cylinders 4 4
Firing Order 1-3-4-2 1-3-4-2
Bore and Stroke 92 mm × 100 mm 98 mm × 110 mm
Displacement 2659 cc 3319 cc
Compression Ratio 21.5:1 21.5:1
Compression Pressure 2840 to 3040 kPa @ 250 rpm 2840 to 3040 kPa @ 250 rpm
(Minimum Values) Limit: 2350 kPa @ 250 rpm Limit: 2350 kPa @ 250 rpm
Horsepower/rpm 45.1 @ 2450 rpm 63.6 @ 2400 rpm
Oil Pressure @ 80°C (176°F) No Less than 58.6 kPa @ 850 rpm No Less than 58.6 kPa @ 850 rpm
Valve Clearance
Intake 0.20±0.05 mm (COLD) 0.20±0.05 mm (COLD)
Exhaust 0.20±0.05 mm (COLD) 0.20±0.05 mm (COLD)
Idle Speed 810±25 rpm 790±25 rpm
Governed Speed High Idle (No H1.5-1.8TX, H2.0TXS 2450±25 rpm

2625±25 rpm
Load) H2.0-3.5TX 2625±25 rpm
Thermostat Range
START TO OPEN 69 to 73°C 69 to 73°C
FULL OPEN Above 85±2.0°C Above 85±2.0°C
Cooling System Pressure 103 kPa 103 kPa
— 12 —
HMM060001
Mazda Engine
M4-2.0G and M4-2.2G
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

and Repair
weight of the load.
remove parts.
needs repairs.
WARNING
CAUTION
—1—
INTRODUCTION
[1] General
This section has the repair instructions for the engine. Removal, disassembly, repair, assembly,
installation, checks and adjustments and troubleshooting are included. The specifications are
given at the end of the section.
Additional information on engine components are in the sections for THE GASOLINE FUEL
SYSTEM, THE LPG FUEL SYSTEM and THE ELECTRICAL SYSTEM.
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 is made of the 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.
[2] Description
The M4-2.0G and M4-2.2G engines are four cylinder engines that have a displacement of 1998
cm3 for M4-2.0G and 2184 cm3 for M4-2.2G. They are available with either a gasoline or an LPG
fuel system. The firing order is 1-3-4-2. The number one 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 rocker arms are offset against the exhaust valve stem to rotate the
exhaust valve to prevent carbon damage and irregular wear.
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.
—2—
REPAIRS
[1] Removal and Installation of the Engine

NOTE: The removal and installation procedures for the engine are not included in this section. See the
section for THE FRAME for more information.
[2] Cylinder Head, Camshaft and Valve Mechanism
(1) Removal
1. Disconnect the connections at the battery.

2. Drain the cooling system.
3. Remove the air cleaner, the carburetor
linkage, the inlet and exhaust manifolds.
4. Remove the coolant hoses.
5. Remove the cooling fan, belt, alternator
and the alternator bracket.
6. Remove the bracket for the cooling fan.
7. Remove the upper and lower timing belt
covers. See Figure 26.
8. Loosen the capscrews for the timing Figure 1. Timing Belt
belt tensioner and remove the spring.
Remove the capscrews and the timing belt
tensioner.
9. Use chalk to mark the direction of rotation
of the timing belt. Remove the timing belt.
See Figure 1.
10. Disconnect the wires at the distributor.
Remove the capscrew for the distributor
mount and pull the distributor from the
front housing.
11. See Figure 2. Remove the camshaft pulley.
Prevent rotation of the pulley and loosen
the capscrew. Remove the capscrew and
the pulley.
12. Remove the nuts and capscrews for the Figure 2. Remove the Camshaft Gear
front housing, then remove the housing.
See Figure 22.
13. Remove the cylinder head cover.
14. Loosen the capscrews for the rocker
shaft supports in steps. See Figure 3.
Remove the rocker shaft assembly and
the camshaft.
15. Remove the capscrews for the cylinder
head in steps. Remove the capscrews in
the sequence shown in Figure 4.
16. Lift the cylinder head from the block.
17. Use a valve spring compressor and
remove the valve retainers, springs and
valves from the head. See Figure 5.
Figure 3. Sequence for Removal
of the Rocker Assembly
—3—
Figure 4. Sequence for Removal Figure 5. Remove the Valves
of the Cylinder Head
(2) Cleaning
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 of the parts in solvent. Make sure that all oil passages are clean. Make sure all
machined surfaces are smooth.
(3) Inspection and Repairs

Cylinder Head
Check the bottom surface of the cylinder head for distortion. Use a straight edge and a thickness
gauge. Do the measurements at the positions shown in Figure 6. The maximum amount of
distortion is 0.15 mm. When grinding the
cylinder head, the maximum amount of
correction is 0.2 mm.
Rocker Shaft Assembly

Disassemble the rocker shaft assembly. Put
marks on the rocker arms so that they can
be installed on the same shafts. Clean the
oil passages in the rocker shafts and rocker
arms. Check the clearance between the rocker
arms and the rocker shafts. The maximum
clearance is 0.10 mm. The correct dimension
for the inside diameter of a rocker arm is
16.000 to 16.027 mm. The correct dimension
for the outside diameter of a rocker shaft is
15.966 to 15.984 mm. If the parts do not meet
specification, replace the rocker arm(s) or the
rocker shaft(s).
Figure 6. Cylinder Head Inspection
—4—
Camshaft
Check the camshaft for cracks or damage.
Check the movement of the camshaft in the
cylinder head. Use a dial indicator on the end
of the camshaft as shown in Figure 7. The
maximum movement is 0.20 mm.
Measure the height of the camshaft lobes.
See Figure 8. The minimum height of the
intake and exhaust lobes are 36.902 mm.
Measure the camshaft journals at four points
A-D as shown in Figure 8. The minimum
dimensions for the journals are as follows:
Front and Rear Journals (Nos. 1 and 5) -

31.940 to 31.965 mm
Center Journals (Nos. 2, 3 and 4) - 31.910 Figure 7. Check the Camshaft
to 31.935 mm
Front Oil Seal Surface - 33.961 to 34.000
mm
Fuel Pump Lobe - 37.1 mm
1. FRONT OIL SEAL

SURFACE
2. FRONT JOURNAL (NO. 1)
3. CENTER JOURNALS
(NOS. 2, 3 AND 4)
4. REAR JOURNAL (NO. 5)
5. FUEL PUMP LOBE
Figure 8. Camshaft Inspection
Check the camshaft for being straight. Put the

front and rear journals in V blocks and rotate
the camshaft one complete turn. See Figure 9.
The maximum amount that the dial indicator
can indicate is 0.03 mm.
Figure 9. Check the Camshaft
—5—
Measure the clearance between the camshaft
and the bore in the cylinder head. Install the
camshaft in the cylinder head. Put a plastic
gauge material between the camshaft and the
cap. Tighten the capscrews for the caps to 18
to 27 N·m (180 to 270 kgf·cm). See Figure 10.
The correct clearance for journals Nos. 1 and
5 is 0.035 to 0.085 mm. The correct clearance
for journals Nos. 2, 3 and 4 is 0.065 to 0.115
mm. If any of the clearances are greater than
0.15 mm, replace the cylinder head assembly.
Replace the camshaft if there is any damage
or it does not meet specifications.
1. PLASTIC GAUGE
2. SCALE
Figure 10. Measure the Clearance for the Camshaft
Valve Guides
Measure the clearance between the valve
stems and the valve guides. Normal clearance
is 0.025 to 0.060 mm. Replace the valve or
valve guide when the clearance is more than
0.20 mm.
If replacement is necessary, use a tool to
remove the valve guide(s). Remove the seal
from the valve guide, then remove the valve
guide.
To install a valve guide, install the retaining
ring on the valve guide. Use the tool and
1. CYLINDER HEAD
install the valve guide until the retaining ring 2. RETAINING RING
contacts the cylinder head. See Figure 11. 3. VALVE GUIDE
The correct height of the valve guide above
the valve spring seat is 19.1 to 19.6 mm.
Figure 11. Valve Guide
Valve Seats
Inspect the condition of the valve seats. If the
valve seats have cracks, the cylinder head
must be replaced. If the condition of the valve
seats is good, check the contact pattern of
the valve and the valve seat. Use a valve seat
grinder to make sure the valve seats are with
the specifications shown in Figure 12. Use a
valve compound to make sure the valves fit
the seats.
1. VALVE SEAT WIDTH
2. EXHAUST VALVE SEAT
3. INTAKE VALVE SEAT
Figure 12. Valve Seat Specifications
—6—
Check the depth of the valve seat. Insert the
valve(s) from the combustion chamber and
measure the height from the cylinder head by
using a caliper shown in Figure 13. Replace
the cylinder head assembly when the height is
more than 48.0 mm.
Valves
1. See Figure 14. Inspect the stem of
each valve for wear. Use a micrometer
to measure the outside diameter of the
stem. The minimum dimension for an
intake valve is 7.980 mm. The minimum
Figure 13. Measure the Valve Seat Depth
dimension for an exhaust valve is 7.975
mm.
2. Inspect the valves for cracks, burned faces
and distortion. Inspect the seat face of the
1. DIAMETER
valves for wear and damage. Measure the 2. THICKNESS,
thickness of the valve head. See Figure VALVE HEAD
14. The minimum thickness for an intake
valve is 0.5 mm. The minimum thickness
for an exhaust valve is 1.0 mm.
3. If the valves need grinding the correct
surface angle is 45° for both intake and
exhaust valves.
Valve Springs
Check the valve springs for damage. See
Figure 15. Measure the free length of both
inner and outer valve springs. The minimum
length of the inner spring is 46.3 mm. The
minimum length of the outer spring is 50.6
mm. Check the valve springs for being square.
See Figure 15. If the measurement is more
tham 1.81 mm, replace the valve spring(s). Figure 14. Inspect the Valves
Figure 15. Inspect the Valve Springs
—7—
Timing Belt
CAUTION
Do not allow any oil or water to contaminate
the timing belt. Do not twist, turn inside out
or bend the timing belt.
Check the timing belt for damage, wear,

peeling, or hardening. See Figure 16. If there
is any oil, water or there is even a slight fault
on the timing belt, replace the timing belt.
(4) Cylinder Head, Installation
1. Use a valve spring compressor and install

the valves retainers, springs and valves
on the head. Tap the valve end so that the
valves and springs are settled down. Figure 16. Inspect the Timing Belt
CAUTION
Make sure the shape of the valve cotters
of the intake and exhaust valves to avoid
wrong usage. See Figure 17.
2. Clean the surface of the cylinder head and

the surface of the block.
3. Install a new cylinder head gasket to the Figure 17. Valve Cotters
block. Install the cylinder head.
4. Install the capscrews and washers for
the cylinder head. Tighten the capscrews
to 80 to 86 N·m (820 to 880 kgf·cm) as
shown in Figure 18.
5. See Figure 19. Apply a gasket sealer to
the areas shown by the arrows. Lubricate
the camshaft with clean engine oil, then
1. DOWEL PIN
2. APPLY SEALANT
HERE
Figure 18. Installation of the Cylinder Head Figure 19. Install the Camshaft
—8—
install the camshaft. Make sure the dowel pin is at the top of the camshaft.
6. Assemble the rocker shaft assembly. See Figure 20. Lubricate the rocker arms and shafts
with engine oil. Rocker arms Nos. 1 and 3 are the same and Nos. 2 and 4 are the same. Put
the capscrews in the rocker shaft supports, then install the assembly on the cylinder head.
7. Tighten the capscrews for the rocker shaft supports to 18 to 26 N·m (180 to 270 kgf·cm) in
the sequence shown in Figure 21.
Figure 20. Assemble the Rocker Shaft Figure 21. Installation of the Rocker Shaft Assembly
8. If necessary, install the oil seal in the front housing. See Figure 22. Install the front housing
and a new gasket on the cylinder head. Tighten the capscrews for the front housing to 19 to
25 N·m (190 to 260 kgf·cm).
9. With the dowel pin at the top of the camshaft, install the camshaft pulley. Check that the letter
“A” for M4-2.0G or the letter “1” for M4-2.2G on the pulley is aligned with the timing mark on
the front husing. See Figure 23.
10. Install the capscrew and washer for the camshaft pulley. See Figure 23. Keep the pulley from
turning and tighten the capscrew to 47 to 65 N·m (480 to 660 kgf·cm).
1. TIMING
MARKS
2. CAMSHAFT
PULLEY
1. FRONT HOUSING
2. GASKET
3. OIL SEAL
Figure 22. Front Housing Figure 23. Install the Camshaft Pulley
—9—
11. Align the timing marks for the timing pulley.
See Figure 24. Install the crankshaft 1. TIMING PULLEY
pulley, tapered ring and the capscrew. 2. TIMING MARK
Tighten the capscrew to 177 to 196 N·m
(1800 to 2000 kgf·cm).
12. Install the timing belt tensioner and spring.
Move the tensioner fully toward the intake
side of the engine and temporarily tighten
the lock bolt. On M4-2.2G engine, install
the idler and tighten the capscrew to 37 to
52 N·m (380 to 530 kgf·cm).
13. Clean any oil or grease from the pulleys.
Install the timing belt. Install the belt so Figure 24. Install the Timing Pulley
that it goes in the same direction as the
mark made during removal. See Figure 1.
14. See Figure 25. Loosen the lock bolt and
apply spring tension on the belt. Rotate
the crankshaft pulley two complete turns
clockwise and check the timing marks. If
the timing marks are correct, tighten the
lock bolt for the tensioner to 37 to 52 N·m
(380 to 530 kgf·cm). Check the movement
on the tension side of the timing belt.
When the tension is correct the belt will M4-2.0G/M4-2.2G
move 9 to 10 mm with 98 N (10 kgf) of
force. 1. TENSIONER
2. SPRING
3. LOCK BOLT
4. TENSION SIDE
5. IDLER
Figure 25. Install the Timing Belt
15. See Figure 26. Install the lower timing belt

cover and gasket. Tighten the capscrews
to 6.9 to 9.8 N·m (70 to 100 kgf·cm). Install
the upper timing belt cover and gasket.
Tighten the capscrews to 6.9 to 9.8 N·m
(70 to 100 kgf·cm) for M4-2.2G engine.
16. Install the distributor as described in the
procedures for the DISTRIBUTOR.
1. LOWER TIMING BELT COVER

2. UPPER TIMING BELT COVER
Figure 26. Timing Belt Covers
— 10 —
17. See Figure 27. Apply a gasket sealer to
the areas shown by the arrows. Install the
cylinder head covr and the gasket. Tighten
the capscrews to 3.9 to 5.9 N·m (40 to 60
kgf·cm).
18. Install the exhaust manifold and the
gasket. Tighten the capscrews to 22 to 28
N·m (220 to 290 kgf·cm).
19. Install the inlet manifold and the gasket.
Tighten the capscrews to 19 to 30 N·m
(190 to 310 kgf·cm).
20. Install the air cleaner and the carburetor
linkage. Tighten the capscrews for the
air cleaner to 19 to 25 N·m (190 to 260
kgf·cm). Figure 27. Install the Cylinder Head Cover
21. Install the alternator bracket. Tighten the
capscrews to 37 to 52 N·m (380 to 530
kgf·cm).
[3] Crankshaft and Main Bearings
(1) Removal

2. Prevent rotation of the crankshaft pulley. Remove the six capscrews and plate from the
crankshaft pulley. Remove the six capscrews that hold the crankshaft pulley to the timing
pulley.
3. Remove the capscrew from the timing pulley. Install the special tool on the crankshaft to
remove the timing pulley. Rotate the tool until it touches the front of the crankshaft. Hit the
tool with a hammer to loosen the timing pulley. Remove the pulley, dowel pin and the tapered
ring. Remove the tool.
4. Remove the oil pan. For M4-2.2G engine, remove the baffle plate. Remove the oil strainer.
5. Remove the rear cover. Remove the front cover with the oil pump.
6. Remove the caps for the connecting rods. Put a mark of identification on each cap so that
they will be installed to the same location.
7. Before removing the crankshaft, measure
the clearance between the crankshaft
and the flange of the center main bearing. 1. CENTER MAIN
See Figure 28. Push the crankshaft fully BEARING
forward before making the measurement.
The maximum clearance is 0.30 mm. If the
clearance is greater than the specification,
replace the center main bearing or the
crankshaft.
8. Put marks for identification on the bearing
caps. Loosen the capscrews for the main
bearing caps in steps, then remove the
capscrews and the caps. Remove the
crankshaft.
Figure 28. Measure the Crankshaft Clearance
— 11 —
Crankshaft
1. Visually inspect the crankshaft for wear,
cracks or other damage. Replace the
crankshaft if it has cracks.
2. U s e a m i c r o m e t e r t o m e a s u r e t h e
diameter of the journals for the crankshaft.
See Figure 29. Make the measurement
at several locations for each journal.
If the measurements are less than
specifications, grind the crankshaft and
1. REAR OIL SEAL SURFACE
install undersize bearings. The correct 2. CONNECTING ROD JOURNALS
dimensions for the journals are as follows: 3. MAIN BEARING JOUNALS
Main Journal Diameter — 4. FRONT OIL SEAL SURFACE
59.937 to 59.955 mm
Connecting Rod Journals —
50.940 to 50.955 mm
Rear Oil Seal Surface —
89.946 to 90.000 mm
Front Oil Seal Surface —
33.961 to 34.000 mm
3. Check the crankshaft for being straight.
See Figure 29. Put the front and rear
jour nals in V blocks and rotate the
c ra n k s h a f t o n e c o m p l e t e t u r n . T h e
maximum amount that the dial indicator
can indicate is 0.03 mm. Figure 29. Crankshaft Inspection
4. Check the passages for oil in the crank-
shaft. Make sure the passages are clean,
with no restrictions.
Main Bearings
1. Visually inspect the main bearings for
wear and damage. Replace the bearings
as necessary.
2. Measure the clearance between the
main bearings and the crankshaft. Install
the crankshaft in the block. Put a plastic
gauge mater ial on the jour nals and
install the main bearing caps. Tighten
the capscrews for the main bearing caps
to 82 to 88 N·m (840 to 900 kgf·cm).
Remove the bearing caps. See Figure 30.
The correct clearance is 0.031 to 0.049
mm. If the clearance is greater than the
Figure 30. Check the Clearance
specifications, replace the main bearings.
for the Main Bearings
(3) Installation
1. Clean the main bearings and the areas at the block for the main bearings. Install the main
bearings and lubricate them with oil.
2. Install the crankshaft on the bearings. Install the main bearings in the caps and lubricate
— 12 —
them with oil. Use the identification marks and install the main bearing caps. Tighten the
capscrews for the main bearing caps to 82 to 88 N·m (840 to 900 kgf·cm).
3. Install the pistons and the connecting rods as described in Pistons and the Connecting Rods,
Installation.
4. Install the oil pump housing. Make sure the O-ring is in the housing. Lubricate the oil seal
with engine oil. Use an adhesive sealant and install the housing to the block. Make sure there
is no sealant in the oil port. Tighten the
M10 capscrews to 37 to 52 N·m (380 to
530 kgf·cm). Tighten the M8 capscrews to
19 to 25 N·m (190 to 260 kgf·cm).
5. Install the oil seal in the rear cover.
Lubricate the surfaces of the oil seal
with engine oil and use a press to install
the seal. Install the alignment pin in the
cylinder block.
6. Install the rear cover and the gasket. See
Figure 31. Make sure the dowel pin is
installed. Tighten the capscrews to 8 to 12
N·m (80 to 120 kgf·cm). Cut the part of the
gasket that extends past the bottom of the
1. REAR COVER
cylinder block.
2. OIL SEAL
7. Install the oil strainer. Tighten the M6 3. CRANKSHAFT
kgf·cm). Tighten the M8 capscrews to 16
to 23 N·m (160 to 230 kgf·cm). Figure 31. Rear Cover
8. For M4-2.2G engine, install the baffle
plate and tighten the capscrews to 8 to 11
N·m (80 to 110 kgf·cm). Install the oil pan
and the gasket. Tighten the capscrews to
7 to 12 N·m (70 to 120 kgf·cm).
9. Install the crankshaft pulley. Align the
tip of timing indicator plate with the top
mark, left one of two. See Figure 32.
Prevent rotation of the crankshaft pulley.
Put the plain washers on the capscrews
for the crankshaft pulley and tighten the
kgf·cm) for M4-2.0G, to 32 to 37 N·m (330
to 380 kgf·cm) for M4-2.2G engine.
10. Install the drive plate on the crankshaft
pulley end. Tighten the capscrews to 24 to Figure 32. Crankshaft Pulley Alignment
26 N·m (240 to 270 kgf·cm).
[4] Pistons and Connecting Rods
(1) Removal and Disassembly
1. Remove the cylinder head as described in Cylinder Head, Removal.

2. Remove the oil pan, baffle plate (M4-2.2G) and oil strainer.
3. Put a mark for identification on the top of each piston.
4. Clean the carbon from the top of each cylinder bore.
5. Remove the caps and bearings from each connecting rod. Keep the caps and bearings with
the correct piston assemblies.
— 13 —
6. Push the connecting rod and piston from the block.
7. Carefully remove the piston rings from the pistons. Use a tool to push the piston pin from the
connecting rod.
(2) Cleaning
WARNING
procedures.
Clean all of the parts in solvent. Make sure that all oil passages and grooves are clean. Make
sure all machined surfaces are smooth.

Pistons
1. Inspect the pistons for wear and cracks.
Replace a piston that has damage.
2. Measure the outside diameter of the
piston as shown in Figure 33. The correct
dimension is 85.944 to 85.964 mm. The
maximum clearance between the piston
and the cylinder bore is 0.15 mm.
Piston Rings
1. Measure the end clearance of each piston Figure 33. Measuring the Piston
ring as shown in Figure 34. Install the
piston ring into the cylinder bore where
it will be used. Use a thickness gauge to
measure the amount of end clearance.
The correct dimensions are as follows:
Top Piston Ring - 0.20 to 0.35 mm 1. PISTON RING END
CLEARANCE
2nd Piston Ring - 0.15 to 0.30 mm
2. PISTON RING
Oil Ring - 0.30 to 0.90 mm GROOVE
Maximum clearance is 1.0 mm CLEARANCE
2. Measure the clearance between the piston
ring and the groove in the piston as shown
in Figure 34. The correct dimensions are
as follows:
Top Piston Ring - 0.03 to 0.07 mm
2nd Piston Ring - 0.03 to 0.07 mm
Maximum clearance is 0.15 mm
Figure 34. Measuring the Piston Rings
— 14 —
Connecting Rods and Bearings
1. Use an alignment tool to check the
connecting rods for being straight. The
maximum amount of distortion per 100
mm is 0.04 mm. If the amount of distortion
is greater than the specification, install a
new rod or use a press to straighten the
connecting rod.
2. C h e ck t h e c l e a r a n c e b e t w e e n t h e 1. PLASTIC GAUGE
rod bearings and the journals of the 2. SCALE
crankshaft. Clean the rod bearings and
journals. Use a plastic gauge material Figure 35. Check the Clearance of
between the journal and the bearing. the Connecting Rod Bearings
Tighten the capscrews for the rod caps
to 50 to 55 N·m (510 to 560 kgf·cm) for
M4-2.0G, to 65 to 69 N·m (660 to 700
kgf·cm) for M4-2.2G engine. Do not
rotate the connecting rod. See Figure 35.
The correct clearance is 0.027 to 0.067
mm. If the clearance is greater than the
specifications, replace the bearings.
(4) Assembly And Installation

1. “F” MARK
Pistons and Connecting Rods 2. OIL PORT
1. Align the oil port on the large end of the

connecting rod with the “F” mark on the
piston. See Figure 36. Lubricate the piston
pin and bore in the piston with engine oil. Figure 36. Connecting Rod and Piston
Use a press to install the piston pin. The
force to push the pin into the piston must
be 5 to 15 kN (500 to 1500 kg). If the force
is not correct, replace the piston pin and/
or connecting rod. Use the special tool to
make sure the piston pin is installed to the
correct depth. After installation, check that
the piston moves freely on the piston pin.
2. Install the piston rings on the pistons. 1. EXPANDER RING
During installation, the writing on each 2. OIL RING (UPPER)
piston ring must be toward the top of the 3. OIL RING (LOWER)
piston. Check that the rings rotate freely, 4. TOP RING
then put the ends of the rings in the 5. SECOND RING
positions shown in Figure 37. Make sure
the ends of the upper and lower oil control
rings are each 30° from the piston pin.
Also make sure that the top and second
rings are each 30° from the piston pin.
Lubricate the rings with engine oil.
3. Apply clean engine oil to the piston
assembly. Install the bearings for the
connecting rods. Install the piston into
the correct cylinder making sure the “F”
is toward the front (timing belt end) of the Figure 37. Piston Rings
— 15 —
engine. See Figure 38.
4. Apply clean engine oil to the bearing then 1. “F” MARK
install the cap to the correct connecting
rod. During installation of the caps, make
sure to align the identification marks that
were made during disassembly. Tighten
the nuts for the caps to 50 to 55 N·m
(510 to 560 kgf·cm) for M4-2.0G, to 65 to
69 N·m (660 to 700 kgf·cm) for M4-2.2G
engine.
[5] Cylinder Block

Figure 38. Install the Piston
(1) Repairs
1. After the engine block is cleaned, check its surface for distortion. See Figure 39. If the amount
of distortion is greater than 0.15 mm, grind the surface of the engine block. The maximum
amount of correction that is permitted is 0.20 mm.
2. Check the cylinder bores for wear and damage. Measure each bore. The correct dimension
is 86.000 to 86.019 mm. The wear limit above this dimension is 0.15 mm. Repair the cylinder
block or use bigger pistons as necessary.
Figure 39. Inspect the Cylinder Block
[6] Oil Pump
Before removing the oil pump, check the oil pressure. Replace the sending unit with a gauge. The
minimum oil pressure at governed rpm is approximately 0.29 MPa (3.0kgf/cm2). If the pressure is
less than the specification, the oil pump or the engine bearings need repair.
(1) Removal

2. Remove the upper and lower timing belt covers.
3. Loosen the capscrews for the timing belt tensioner and remove the spring. Remove the
capscrews and the timing belt tensioner.
4. Use chalk to mark the direction of rotation of the timing belt. Remove the timing belt.
5. Prevent rotation of the crankshaft pulley. Remove the six capscrews and plate from the
crankshaft pulley. Remove the six capscrews that hold the crankshaft shaft pulley to the
— 16 —
timing pulley.
6. Remove the capscrew from the timing pulley. Install the special tool on the crankshaft to
remove the timing pulley. Rotate the tool until it touches the front of the crankshaft. Hit the
tool with a hammer to loosen the timing pulley. Remove the pulley, dowel pin and the tapered
ring. Remove the tool.
7. Remove the capscrews that hold the oil pan to the block and remove the oil pan. For M4-
2.2G engine, remove the baffle plate. Remove the oil strainer.
8. Remove the capscrews that hold the front cover (pump housing) to the block. Remove the
front cover and oil pump assembly.
(2) Disassembly (See Figure 40.)

1. SCREW
1. Remove the screws and the pump cover. 2. COVER
2. Remove the outer gear and the inner gear 3. OUTER GEAR
4. INNER GEAR
from the pump body.
5. FRONT COVER
3. Remove the snap ring to remove the (HOUSING)
plunger assembly from the housing. 6. OIL SEAL
7. PLUNGER
(3) Cleaning 8. SNAP RING
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 of the parts in solvent. Make sure all

machined surfaces are smooth.
Figure 40. Oil Pump
(4) Inspection
1. Check the front cover (pump housing) and
the pump cover for wear or damage. Check the plunger spring for damage.
2. See Figure 41. Measure the parts of the oil pump as follows:
a. Measure the clearance between the teeth of the outer gear and the teeth of the inner gear.
1. CLEARANCE BETWEEN INNER GEAR AND OUTER GEAR

2. CLEARANCE BETWEEN HOUSING AND OUTER GEAR
3. SIDE CLEARANCE OF GEARS IN THE HOUSING
Figure 41. Mesure the Oil Pump
— 17 —
If the clearance is more than 0.18 mm, repair as necessary.
b. Use a straight edge and measure the side clearance of the gears. The correct clearance is
0.03 to 0.63 mm. If the clearance is more than 0.10 mm, repair as necessary.
c. Measure the clearance between the body and the outer gear. The correct clearance is 0.090
to 0.184 mm. If the clearance is more than 0.20 mm, repair as necessary.
(5) Assembly (See Figure 40.)

1. Install the oil seal in the oil pump housing. Make sure the front edge of the oil seal is even
with the outer edge of the housing.
2. Lubricate the gears with engine oil, then install them in the housing.
3. Install the pump cover. Use a thread locking compound on the screws for the pump cover,
then install the screws.
4. Install the plunger assembly and the snap ring.
(6) Installation (See Figure 42.)

1. Install the O-ring on the oil pump housing.
1. O-RING
Use grease to hold the O-ring in position.
Lubricate the oil seal with engine oil.
2. Use an adhesive sealant and install the
oil pump housing to the block. Make sure
there is no sealant in the oil port. Tighten
the M10 capscrews to 37 to 52 N·m (380
to 530 kgf·cm). Tighten the M8 capscrews
to 19 to 25 N·m (190 to 260 kgf·cm).
3. Install the suction tube assembly. Install
the gasket and the oil pan.
Figure 42. Oil Pump

[7] Cooling System
(1) Thermostat
Replacement (See Figure 43.)
1. Drain the cooling system to the level of the
thermostat.
2. D i s c o n n e c t t h e h o s e a n d r e m o v e
the thermostat housing. Remove the
thermostat.
3. Test the operation of the thermostat. The
thermostat must begin to open at 82 ±
1.5°C. The thermostat must be completely
open at 95°C.
4. Install the thermostat and new gasket.
Make sure the print side of the gasket is
toward thermostat. Install the thermostat
housing and tighten the capscrews to 19
to 30 N·m (190 to 310 kgf·cm).
5. Connect the hose and fill the cooling system. 1. CYLINDER BLOCK
2. GASKET
Start the engine and check for leaks.
3. THERMOSTAT
4. HOUSING
(2) Fan Assembly
Removal
Figure 43. Thermostat
1. Loosen the alternator and remove the fan
— 18 —
belt.
2. Remove the capscrews for the fan. Remove the fan and pulley from the hub.
3. Remove the capscrews that hold the fan bracket to the engine. Remove the fan bracket.
Disassembly and Repair (See Figure 44.)

1. Use a press to remove the fan hub from
the shaft. Remove the snap ring and push
the bearing and shaft from the bracket.
2. Use a press to install the shaft and
bearing in the bracket. Push the bearing in
until it touches the bracket. Install the snap
ring. Install the hub on the shaft. When
installed, the shaft must extend 2.1 mm
past the hub.
Installation (See Figure 44.)

1. Install the bracket assembly on the
cylinder block. For M4-2.0G engine, 1. FAN 5. SHAFT
2. PULLEY 6. SUPPORT
tighten the M8 capscrews to 19 to 30
3. HUB BRACKET
N·m (190 to 310 kgf·cm). Tighten the M10 4. SNAP RING 7. BRACKET
kgf·cm). For M4-2.2G engine, tighten the
capscrews to 64 to 89 N·m (650 to 910 Figure 44. Fan Assembly
kgf·cm).
2. Install the pulley and fan on the hub.
Tighten the capscrews to 8 to 11 N·m (80
to 110 kgf·cm).
3. Install the fan belt. Adjust the tension of the fan belt. Check the movement of the fan belt
between the fan and the alternator. When the tension is correct a NEW belt will move 7 to 8
mm with 98 N (10 kg) of force. The tension for an OLD belt is correct when it moves 10 to 12
mm with 98 N (10 kg) of force. Tighten the alternator when the tension is correct.
(3) Water Pump
NOTE: If either the shaft or impeller is damaged, the complete water pump must be replaced.
Removal
1. Drain the cooling system.
2. Loosen the alternator and remove the fan belt.
3. Remove the capscrews for the fan. Remove the fan and pulley from the hub.
4. Remove the capscrews that hold the fan bracket to the engine. Remove the fan bracket.
5. Remove the upper and lower timing belt covers. See Figure 26. Loosen the capscrews for
the timing belt tensioner and remove the spring. Remove the capscrews and the timing belt
tensioner.
6. Use chalk to mark the direction of rotation of the timing belt. See Figure 1. Align the timing
marks, then remove the timing belt.
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.
— 19 —
7. Disconnect the hose at the water pump. Remove the capscrews for the water pump, then
remove the water pump from the cylinder block.
NOTE: The water pump assembly can not be disassembled.
Installation
1. Install the water pump with a new gasket. Tighten the capscrews to 19 to 25 N·m (190 to 260
kgf·cm).
2. Install the timing belt and the covers as described in the procedures for Cylinder Head,
Installation.
3. Install the fan assembly as described in the procedures for Fan Assembly, Installation.
4. Install the coolant hoses.
5. Fill the coolant system with coolant.
6. Start the engine and check the cooling system for leaks.
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.
7. After the engine has been operated, stop the engine. If the coolant is hot, give the engine
time to cool. Check the coolant level.
[8] Distributor
NOTE: This section has only the removal and installation procedures for the distributor. The service
procedures for the ignition system are found in The
Electrical System.
(1) Removal (See Figure 46.)
1. Rotate the crankshaft until the number

one piston is at TDC on the compression
stroke. Make a note of the position of the
distributor rotor.
2. Disconnect the wires at the spark plugs.
3. Remove the capscrew from the flange of
the distributor shaft housing.
4. Lift the distributor assembly from the
engine.

stroke. Put the rotor in the correct position.
2. Lubricate the O-ring and the gear on
the distributor with engine oil. Install the
distributor, aligning the marks on the
distributor housing, distributor gear and Figure 46. Installation of the Distributor
— 20 —
engine.
3. Connect the wires at the spark plugs.
[9] Flywheel for Powershift Transmission
(1) Removal (See Figure 47.)
1. Remove the capscrews for the flywheel, then remove the flywheel and the flange.
2. If necessary, remove the engine end plate.
1. If the engine end plate was removed, install it on the engine. Tighten the M14 capscrews to
114 to 136 N·m (1160 to 1390 kgf·cm). Tighten the M8 capscrews to 21 to 25 N·m (210 to
250 kgf·cm).
2. Install the flange and the flywheel on the crankshaft. Apply an adhesive sealant on the
threads of the capscrews. Then install the capscrews, washers and the backplate. Tighten the
capscrews to 96 to 103 N·m (980 to 1050 kgf·cm).
1. ENGINE END PLATE 6. FLANGE

2. M14 CAPSCREW 7. CAPSCREW
3. M8 CAPSCREW 8. BACK PLATE
4. COVER PLATE 9. TORQUE CONVERTER
5. FLYWHEEL
Figure 47. End Plate, Flywheel and Torque Converter
— 21 —
CHECKS AND ADJUSTMENTS
[1] Adjust the Valves (See Figure 50.)

stroke (intake and exhaust valves closed).
Now adjust the clearance of the intake
valves for the No. 1 and No. 2 cylinders
and the exhaust valves for the No. 1 and
No. 3 cylinders. The correct clearance for
all the valves when the engine is hot is 0.3
mm. To adjust the clearance, loosen the
lock nut and turn the adjustment screw.
Tighten the lock nut to 16 to 21 N·m (160
to 210 kgf·cm).
NOTE: During adjustment of the valves, check

the position of the balls that are in the ends of the
rocker arms. The flat surface of the ball must be in
contact with the stem of the valve.
2. Rotate the crankshaft clockwise one 1. CAMSHAFT

complete turn (360 degrees). Now adjust 2. ROCKER ARM
3. BALL
the remaining valves.
4. VALVE STEM
Figure 50. Adjust the Valves
[2] Check the Compression Pressure (See Figure 51.)
1. Remove the spark plugs from the cylinder

head. Disconnect the high tension wire at 1. ADAPTER
the ignition coil.
2. Install a compression gauge in the number
1 cylinder. Make sure the gauge has a
minimum range of 2 MPa (20 kgf/cm2).
3. Use the starter to crank the engine at least
six (6) revolutions. Check the pressure
reading and release the pressure. Repeat
the test again and make a note of the
highest pressure. Do this test for each
cylinder.
4. The standard pressure reading is 1.13
MPa (11.5 kgf/cm2). The minimum reading
is 0.79 MPa (8.1 kgf/cm2). The maximum Figure 51. Check the Compression Pressure
variation between cylinders is 0.20 MPa (2
kgf/cm2).
5. If the readings are lower than the 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 of engine oil to each cylinder at the spark plug hole.
— 22 —
b. Crank the engine approximately ten revolutions to distribute the oil.
c. Install the compression gauge and do the same tests as described in step 3.
d. If the compression pressure increases to a normal reading, the low pressure was caused
by worn or damaged piston rings. The cylinder bore can also be damaged.
e. If the compression reading does not increase, the low pressure was caused by worn
valves, valve seats or valve guides.
f. If the low pressure readings are in two cylinders next to each other, the cylinder head can
be leaking.
— 23 —
ENGINE SPECIFICATIONS
Model M4-2.0G M4-2.2G
Item
Numbers and arrangement of cylinders In-line four cylinders ←
Bore x Stroke mm 86.0 x 86.0 86.0 x 94.0
Displacement cc 1998 2184
Compression ratio 8.6 ←
Valve opening/closing timing
Open (BTDC) −2° ←
Intake
Close (ABDC) 42° ←
Open (BBDC) 32° ←
Exhaust
Close (ATDC) 8° ←
Standard 1.13 (11.5) −270 ←
Compression pressure
Limit 0.79 (8.1) −270 ←
MPa (kgf/cm2) −rpm
Variation between cylinders 0.20 (2.0) or less ←
Valve clearance
Valve side Intake 0.15 ←

mm
(Cold condition) Exhaust 0.35 ←
Numbers of teeth of timing belt 109 110
Height 91.95 ~ 92.05 ←
Cylinder head mm Distortion limit 0.15 ←
Grinding limit 0.20 ←
Valve seat
Standard 46.5 ←
Intake
Depth amount mm Limit 48.0 ←
(Length) Standard 46.5 ←
Exhaust
Limit 48.0 ←
Intake 45° ←
Valve seat angle
Exhaust 45° ←
Intake 1.2 ~ 1.6 ←
Valve seat width mm
Exhaust 1.2 ~ 1.6 ←
Valve guide, valve, and valve spring
Intake 0.025 ~ 0.060 ←
Gap between the valve Standard
Exhaust 0.025 ~ 0.060 ←
stem and guide mm
Limit 0.20 ←
Valve guide inside diameter mm 8.07 ~ 8.09 ←
Standard 8.030 ~ 8.045 ←
Intake
Limit 7.980 ←
Valve stem diameter mm
Standard 8.025 ~ 8.040 ←
Exhaust
Limit 7.975 ←
— 24 —
Item
Intake 0.5 ←
Valve head thickness mm
Exhaust 1.0 ←
Intake 45° ←
Valve face angle
Exhaust 45° ←
Standard 52.2 ←
Valve spring outer free length mm
Limit 50.6 ←
Standard 47.7 ←
Valve spring inner free length mm
Limit 46.3 ←
Valve spring squareness mm 1.81 or less ←
Rocker arm and shaft
Gap between the arm and shaft Standard 0.016 ~ 0.061 ←
mm Limit 0.10 ←
Rocker arm shaft diameter mm 15.966 ~ 15.984 ←
Rocker arm inside diameter mm 16.000 ~ 16.027 ←
Cam shaft
Cam shaft deflection limit mm 0.03 ←
Standard 0.08 ~ 0.16 ←
Cam shaft end play mm
Limit 0.20 ←
No. 1 0.035 ~ 0.085 ←
No. 2 0.065 ~ 0.115 ←
Journal oil clearance mm No. 3 0.065 ~ 0.115 ←
No. 4 0.065 ~ 0.115 ←
No. 5 0.035 ~ 0.085 ←
Oil clearance limit mm 0.15 ←
No. 1 31.940 ~ 31.965 ←
No. 2 31.910 ~ 31.935 ←
Standard journal diameter mm No. 3 31.910 ~ 31.935 ←
No. 4 31.910 ~ 31.935 ←
No. 5 31.940 ~ 31.965 ←
Journal wear limit mm 0.05 ←
Standard 37.102 ←
Intake
Limit 36.902 ←
Cam height mm
Standard 37.102 ←
Exhaust
Limit 36.902 ←
Connecting rod and bearing
Length (distance between the holes) mm 135.95 ~ 136.05 158.45 ~ 158.55
Bending limit (for every 100mm) mm 0.04 ←
Small end diameter mm 21.943 ~ 21.961 ←
Clearance between the small end and piston pin mm 0.015 ~ 0.010 ←
— 25 —
Item
Standard 0.110 ~ 0.262 ←
Large end play
Limit 0.30 ←
Standard 0.027 ~ 0.067 ←
Oil clearance on large end mm
Limit 0.10 ←
Bearing under-size mm 0.025, 0.50, 0.75 ←
Crank shaft and bearing
Standard 50.940 ~ 50.955 ←
Crank pin diameter mm Wearing limit 0.05 ←
Standard 59.937 ~ 59.955 ←
Main journal diameter mm Wearing limit 0.05 ←
Standard 0.031 ~ 0.049 ←
Main journal oil clearance mm
Limit 0.08 ←
Main bearing under-size mm 0.25, 0.50, 0.75 ←
Crank shaft deflection limit mm 0.03 ←
Standard 0.08 ~ 0.18 ←
End play mm
Limit 0.30 ←
Thrust bearing over-size mm 0.25, 0.50, 0.75 ←
Cylinder block, piston, and piston pin
Block surface distortion limit mm 0.15 ←
Standard 86.000 ~ 86.019 ←
Cylinder bore diameter mm
Wearing limit 0.15 ←
Cylinder boring amount mm 0.25, 0.50 ←
Piston diameter mm 85.944 ~ 85.964 ←
Gap between piston and cylinder Standard 0.036 ~ 0.075 ←
mm Limit 0.15 ←
Piston over-size mm 0.25, 0.50 ←
Top compression ring 0.03 ~ 0.07 ←
Gap between piston ring
Second compression ring 0.03 ~ 0.07 ←
and ring groove mm
Limit 0.15 ←
Piston ring groove width mm Second compression ring 1.520 ~ 1.540 ←
Oil control ring 4.020 ~ 4.040 ←
Second compression ring 0.15 ~ 0.30 ←
Piston ring end clearance mm
Oil control ring 0.3 ~ 0.9 ←
Limit 1.0 ←
Piston ring over-size mm 0.25, 0.50 ←
Diameter mm 21.947 ~ 21.980 ←
Piston pin
Installation pressure kN (kg) 5 ~ 15 (500 ~ 1500) ←
— 26 —
TORQUE SPECIFICATIONS Unit: N·m (kgf·cm)
Item
Cylinder head cover 3.9 ~ 5.9 (40 ~ 60) ←
Rocker shaft assy 18 ~ 26 (180 ~ 270) ←
Cold 80 ~ 86 (820 ~ 880) ←
Cylinder head
Hot 93 ~ 98 (950 ~ 1000) ←
Upper 6.9 ~ 9.8 (70 ~ 100) ←
Timing belt cover
Lower 6.9 ~ 9.8 (70 ~ 100) ←
Cam shaft pulley lock bolt 47 ~ 65 (480 ~ 660) ←
Timing tensioner lock bolt 37 ~ 52 (380 ~ 530) ←
Drive plate 24 ~ 26 (240 ~ 270) ←
Crank shaft pulley 32 ~ 37 (330 ~ 380) ←
Timing belt crank pulley bolt 177 ~ 196 (1800 ~ 2000) ←
Front housing assy 19 ~ 25 (190 ~ 260) ←
Rear cover assy 8 ~ 12 (80 ~ 120) ←
Oil pan 7 ~ 12 (70 ~ 120) ←
M6 8 ~ 12 (80 ~ 120) ←
Oil strainer
M8 16 ~ 23 (160 ~ 230) ←
M8 19 ~ 25 (190 ~ 260) ←
Oil pump
M10 37 ~ 52 (380 ~ 530) ←
Oil pressure switch 12 ~ 18 (120 ~ 180) ←
Main bearing cap 82 ~ 88 (840 ~ 900) ←
Connecting rod cap 50 ~ 55 (510 ~ 560) 65 ~ 69 (660 ~ 700)
Intake manifold 19 ~ 30 (190 ~ 310) ←
Exhaust manifold 22 ~ 28 (220 ~ 290) ←
Spark plug 15 ~ 23 (150 ~ 230) ←
Cooling fan 8 ~ 11 (80 ~ 110) ←
M8 19 ~ 30 (190 ~ 310) ←
Cooling fan bearing
M 10 37 ~ 52 (380 ~ 530) ←
Cooling fan bracket 64 ~ 89 (650 ~ 910) ←
Water pump 19 ~ 25 (190 ~ 260) ←
Thermostat cover 19 ~ 30 (190 ~ 310) ←
Alternator bracket 37 ~ 52 (380 ~ 530) ←
Alternator strap 19 ~ 25 (190 ~ 260) ←
Alternator flange bolt 19 ~ 30 (190 ~ 310) ←
Air cleaner bracket 19 ~ 25 (190 ~ 260) ←
Carburetor 12 ~ 17 (120 ~ 170) ←
Fuel pump 16 ~ 22 (160 ~ 220) ←
— 27 —
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
The engine will not start. The fuel tank is empty. Fill fuel tank.
The battery is not fully charged. Charge battery.
The connections at the battery Check and tighten battery
are loose or they have corrosion. connections.
The starter system has a Check electrical circuit for starter.
problem.
There are damaged parts in the Repair engine.
engine.
The valves are worn or damaged. Install new valves.
The piston rings are worn or have Install new piston rings.
damage.
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 a new fuel filter.
Ignition system does not operate Check and repair ignition system.
correctly.
The engine does not run The valve mechanism does not Check and repair valve mechan-
smoothly. operate correctly. ism.
The cylinder head has cracks. Install a new cylinder head.
The head gasket has a leak. Install a new gasket.
There is a leak in the intake Check and repair intake system.
system.
Engine is too hot. Check cooling system.
Fuel lines or fuel filter has a Clean or use new fuel lines.
restriction.
The ignition timing is not correct. Adjust timing.
The engine does not have The fuel is the wrong type. Fill tank with correct fuel.
enough power. The air filter is dirty. Install a new air filter.
The ignition timing is not correct. Adjust timing.
The valve mechanism does not Check and repair valve mechan-
work correctly. ism.
The piston assemblies are worn Install new pistons.
or damaged.
The exhaust system has Clean parts or install new muffler
restrictions. or pipes.
Fuel lines or fuel filter has a Clean or use new fuel lines and
restriction. filter.
Engine is too hot or too cold. Check cooling system.
Cylinder head gasket leaks. Install a new gasket.
— 28 —
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
There is noise inside the engine. The main bearings are worn or Install new main bearings.
damaged.
Engine is too hot. Check and repair cooling
system.
Valves are not adjusted correctly. Adjust valves.
The bearings for the connecting Install new bearings.
rods are worn or damaged.
The pistons are worn or Install new pistons.
damaged.
Valve spring is broken. Install new valve springs.
There is not enough oil in the Fill engine with correct oil.
engine.
The flywheel is loose. Tighten capscrews for flywheel.
A connecting rod is bent. Repair engine.
There is a leak in the exhaust Repair exhaust system.
system.
The valve mechanism does not Check and repair valve mechan-
operate correctly. ism.
Spark plugs are dirty. Install new spark plugs.
The engine gets too hot. There is not enough coolant in Fill cooling system.
the cooling system.
The air filter has a restriction. Install a new air filter.
The water pump has damage. Install a new water pump.
The radiator is dirty. Clean or repair the radiator.
The cooling system has restric- Check radiator and hoses.
tions.
The belt for the water pump is Check and adjust the belt.
worn or not adjusted correctly.
The thermostat has damage. Install a new thermostat.
The exhaust system has restric- Check and repair exhaust
tions. system.
Ignition timing is not correct. Adjust timing.
Cylinder head gasket leaks. Install a new head gasket.
Engine compression is not Check and repair engine.
correct.
— 29 —
HMM090001
LPG Fuel System

Mazda M4-2.0G and M4-2.2G Engines
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]
and Repair
weight of the load.
remove parts.
needs repairs.
WARNING
CAUTION
—1—
GENERAL
This section has the repair procedures for the parts of the LPG fuel system used on the Mazda
M4-2.0G and M4-2.2G engines.
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.
LPG TANK REPLACEMENT
[1] Fuel Tank
The fuel tank is the reservoir for the LPG system. The fuel tank keeps the fuel in the liquid
condition. The pressure of the fuel is 920 kPa (133 psi) with 100% propane when the tank is full
and at an ambient temperature of 27°C (80°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.
(1) Remove
WARNING
LPG can cause an explosion. Do not cause sparks or permit flammable material near the
LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least
8 m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source.
Close the shutoff valve on the LPG tank before any part of the engine fuel system is
disconnected. Run the engine until the fuel in the system is used and the engine stops.
If the engine will not run, close the shutoff valve on the LPG tank. Loosen the fitting on the
supply hose from the LPG tank where it enters the filter unit. Permit the pressure in the fuel
system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your
hands from the cold fitting.
NOTE: The LPG tank bracket used on this line of trucks mounts the LPG tank onto the counterweight. The
tank bracket is the swing out to the side and drop down (EZXchange Bracket). See Figure 1.
1. LPG tanks can be removed and replaced indoors only if the lift truck is at least 8 m (26 ft)
from any flame or ignition source. Move the lift truck to an the area where LPG tanks are
changed.
2. Turn the shutoff valve clockwise until the valve is completely closed.
—2—
1. SHUT-OFF VALVE
Figure 1. LPG Tank and Bracket
3. Run the engine until it stops. Turn the key switch to the OFF position.
4. Disconnect the quick-disconnect fitting on the LPG tank. See Figure 1.
5. Push in the bracket release lever, grab the bracket handle, and pull in the bracket release pin,
and swing the tank and bracket out to the side of the lift truck. Drop the tank down to the side
of the truck for ease of removal. See Figure 1.
6. Unlatch the tank straps and remove the LPG tank from the bracket.
(2) Install
NOTE: The LPG bracket must be in the drop-down position to install the LPG tank.
WARNING
When closing the LPG tank strap, do not wrap your fingers around the strap handle. The
strap can close quickly and with enough force to cause injury to the fingers and hand.
1. Place the LPG tank into the bracket. Secure the tank straps around the tank and close the
straps.
2. Pull the release pin (see Figure 1) and swing the LPG tank bracket into the resting position
on the counterweight. Be sure that the bracket locks into position.
3. Connect the quick-disconnect fitting on the LPG tank. See Figure 1.
4. Turn the fuel valve counterclockwise to open the fuel valve.
5. Inspect the fuel system for leaks when the fuel valve is open. There are four methods used to
inspect the fuel system for leaks:
a. Sound - Listen for sound of LPG escaping from a tank fitting or hose connection.
b. Smell - LPG has a very distinctive odor. If you smell LPG, DO NOT start the engine.
c. Soapy Water - This method is used in conjunction with Step b above. If the odor of
LPG is present, but escaping fuel cannot be heard, apply soapy water to the fittings
and observe for bubbles.
d. Frost - If the amount of LPG escaping is sufficient, frost may appear on the fittings.
—3—
INTRODUCTION
[1] Regulator
(See Figure 3. and Figure 5.)
The function of the regulator is to change the liquid fuel to a vapor (gas) and to control the
pressure of the vapor. 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
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.
(1) 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. 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 10.1 inHg), the
diaphragm expands outward and closes the
inlet valve, maintaining a 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
1. IDLE BYPASS SOLENOID VALVE
for complete combustion. 2. FUEL OUTLET
3. MAIN SOLENOID VALVE
(2) Idle Mode 4. CHAMBER A
5. COOLANT PORTS
In the idle mode, the demand for fuel at the 6. RESONATOR PORT
carburetor is low and the vacuum is absent 7. CHAMBER C
at the fuel outlet por t. This causes the 8. CHAMBER B
9. FUEL FILTER CHAMBER
diaphragm in chamber C to relax and close 10. DRAIN PLUG
the inlet valve between chambers B and C.
Pressure in chamber B builds up to 24.5 to Figure 3. Regulator
—4—
34.5 kPa (7.2 to 10.1 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
amount of vapor escaping past the idle mixture adjusting screw in chamber D.
(3) 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. 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.
[2] Resonator
(See Figure 3. through Figure 5.)
The resonator is connected by vacuum hoses
to a special orifice fitting on the air filter
discharge elbow and to the resonator port of
the regulator (see Figure 3.). The resonator
port connects to vacuum chamber 2 (see
Figure 5.).
As the air filter clogs, the intake vacuum
increases for any relative throttle position.
T h i s i n c r e a s e d va c u u m h a s a s i m i l a r
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 Figure 4. Resonator
unchanged. See Figure 5. This maintains a
constant fuel mixture regardless of the air filter restriction.
The special orifice fitting and the resonator act as vacuum dampeners. The air being drawn
through 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 diaphragms. This would
cause the diaphragm to vibrate uncontrollably and force the engine mixture to be either very rich
or lean under certain operating conditions.
[3] 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.
(1) Start Mode (See Figure 7.)

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. An auxiliary switch on
the engine wiring harness counts the revolutions of the engine and provides an electrical signal
to energize the main solenoid and idle bypass solenoid when the engine reaches 80 rpm. Fuel
then flows from the regulator to the carburetor.
The fuel flows past the power adjusting screw 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
fuel and air mixture flows past the idle air bypass adjusting screw, through the bypass port, to the
intake manifold, and into the cylinder.
—5—
1. IDLE MIXTURE ADJUSTING SCREW 9. INLET VALVE
2. CHAMBER D 10. RESONATOR PORT
3. IDLE BYPASS SOLENOID 11. CHAMBER C
4. DIAPHRAGM 12. DIAPHRAGM
5. FUEL FILTER 13. INLET VALVE
6. MAIN SOLENOID 14. VACUUM CHAMBER 1
7. CHAMBER B 15. VACUUM CHAMBER 2
8. CHAMBER A
Figure 5. Inside the Regulator
(2) Idle Mode (See Figure 7.)

Engine idle is set by adjusting the fuel supply at the regulator with the idle mixture adjusting
screw and by adjusting the air flow at the carburetor with the idle air bypass adjusting screw.
(3) Run Mode (See Figure 8.)

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. Under heavy load, the vacuum in the
intake manifold decreases. Decreasing the vacuum on the manifold side of the power system
diaphragm opens the power valve. 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.)
—6—
(4) Governor (See Figure 6.)
The gover nor is installed between the
carburetor and the intake manifold. The
governor helps control the maximum speed of
the engine.
1. SECONDARY ADJUSTING SCREW

2. ADJUSTMENT SPRING
3. MAIN ADJUSTMENT WHEEL
4. LOCK SCREW AND WASHERS
Figure 6. Governor
1. POWER ADJUSTING SCREW 4. THROTTLE VALVE

2. POWER DIAPHRAGM 5. IDLE AIR BYPASS ADJUSTING SCREW
3. POWER VALVE
Figure 7. Carburetor, Start Mode and Idle Mode
—7—
1. POWER ADJUSTING SCREW 4. THROTTLE VALVE
2. POWER DIAPHRAGM 5. IDLE AIR BYPASS ADJUSTING SCREW
3. POWER VALVE
Figure 8. Carburetor, Run mode
—8—
REPAIRS
[1] Replacement of the Hoses

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.
[2] Relief Valve
(1) Removal and Installation
WARNING
LPG system. Close the fuel valve on the tank. Disconnect the negative battery cable to
prevent sparks.
1. Close the shut-off valve on the tank.

2. Slowly loosen the hose fitting for the relief valve. Let the fuel drain from the fitting before
removing the relief valve.
3. The valve cannot be repaired. If the valve is damaged, install a new valve. After installation,
open the shut-off valve slowly and inspect the system for leaks.
[3] CARBURETOR
(1) Removal
WARNING
Before disconnecting any part of the LPG fuel system, close the shut-off valve on the
fuel tank. Run the engine until the fuel lines are empty and the engine stops. If the engine
will not run, close the shut-off valve on the fuel tank and release the fuel slowly in a
non-hazardous area.
1. Turn the shut-off valve clockwise until the valve is completely closed.
2. Run the engine until it stops. Then turn the key to the OFF position.
3. Disconnect the hose from the carburetor (spark advance port) to the distributor.
4. Disconnect the hose from the air cleaner at the bonnet.
5. Disconnect the fuel inlet hose.
6. Disconnect the hose to the idle control actuator.
7. Disconnect the power valve hose.
8. Disconnect the throttle cable at the carburetor. Remove the carburetor from the governor.

NOTE: Note the position of the diaphragm prior to removal to aid in the installation.
—9—
1. Disassemble the power valve actuator by removing three screws, the cover, the spring, and
the diaphragm from the carburetor.
2. Remove the idle speed adjusting screw and spring from the carburetor.
3. While holding the power adjusting screw, loosen the jam nut. Remove the power adjusting
screw from the carburetor.
4. Remove two screws and the idle control actuator from the carburetor.
5. Remove the nut, the lockwasher, the throttle cable link, and the lever from the carburetor.
6. If damaged, remove the adjusting screw and the spring from the lever.
(3) Cleaning
WARNING
Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using
cleaning solvents, always follow the recommendations of the manufacturer.
Make sure that all of the carburetor parts are clean before assembly. Wash all of the parts (except
the diaphragm) in solvent. Make sure that the air passages in the metering valve are clean.

1. If removed, install the spring and the adjusting screw in the lever.
2. Install the lever, throttle cable link, lockwasher and nut on the carburetor. Tighten the nut to
10.5 ± 1.5 Nm (93 ± 13 lbf in).
3. Install the idle control actuator and two screws on the carburetor. Tighten the screws to 3.9 ±
0.5 Nm (34.5 ± 4.5 lbf in).
4. Install the power adjusting screw into the carburetor until the screw is seated. Unscrew the
power adjusting screw the number of turns that is specified for the engine in the lift truck. See
Table 1.
Table 1. Power Adjusting Screw
ENGINE M4-2.0G M4-2.2G
Number of Loosening Turns 3.5 4.0
5. Tighten the jam nut to 13.5 ± 1.5 Nm (119.5 ± 13.5 lbf in).
6. Install the idle speed adjusting screw into the carburetor until the screw is seated. Unscrew
the idle speed adjusting screw the number of turns that is specified for the engine in the lift
truck. See Table 2.
Table 2. Air Adjusting Screw
7. Using two screws, install the idle-up diaphragm on the carburetor.

8. Install the diaphragm (as noted during removal), the spring, the cover, and the three screws.
Tighten the screws to 1.75 ± 0.25 Nm (15.5 ± 2.5 lbf in).
— 10 —
1. SCREW
2. COVER 10. SCREW
3. SPRING 11. IDLE CONTROL ACTUATOR
4. DIAPHRAGM 12. NUT
5. CARBURETOR 13. LOCKWASHER
6. IDLE AIR BYPASS ADJUSTING SCREW 14. THROTTLE CABLE LINK
7. SPRING 15. LEVER
8. POWER ADJUSTING SCREW 16. SCREW
9. JAM NUT 17. SPRING
Figure 10. Parts of the Carburetor
(5) Installation
1. Install a new gasket on the governor. Install the carburetor on the governor.
2. Connect the power valve hose.
3. Connect the hose to the idle control actuator.
4. Connect the fuel inlet hose.
5. Connect the hose from the air cleaner to the bonnet.
6. Connect the hose from the carburetor (spark advance port) to the distributor.
7. Check and adjust the throttle linkage as described in the CHECKS AND ADJUSTMENTS
section.
[4] Governor
(1) Removal
Disconnect the vacuum hose from the governor and remove the governor from the intake
manifold. Remove and discard the gasket.
— 11 —
(2) Inspection
Inspect the governor assembly and all hoses for any damage. Replace any damaged
components.
(3) Installation
CAUTION
Make sure that all gasket material has been cleaned from the mating surfaces of the intake
manifold and the governor. Gasket material left on either surface will affect the performance
of the 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 the correct hoses are installed.
Install a new gasket on the intake manifold. Install the governor on the intake manifold and
connect the vacuum hose from the governor.
[5] Regulator
(1) Removal
WARNING
LPG can cause an explosion. Do not permit any sparks or flames in the work area.
1. Close the shut-off valve on the tank. Run the engine until it stops.
2. Disconnect the electrical connectors from the main solenoid valve and the idle bypass
solenoid valve respectively.
3. Put a drain pan under the drain valve for the radiator. Open the drain valve so that the coolant
drains into the pan.
4. Disconnect the cooling system hoses from the regulator.
5. Disconnect the liquid LPG hose from the regulator.
6. Disconnect the LPG vapor hose from the regulator.
7. Disconnect the balance line from the regulator. Remove the capscrews and the regulator
from the mount.
1. Remove six capscrews, the cover, two filter elements, two gaskets, and the O-ring from the
fuel filter chamber.
2. Remove two capscrews and the main solenoid valve from the fuel filter chamber. If damaged,
remove the O-ring from the main solenoid valve.
3. Remove two screws and the idle bypass solenoid valve. If damaged, remove the O-ring from
the idle bypass solenoid valve.
4. Remove seven screws, the fuel filter chamber, the spring, the diaphragm, and the O-ring from
the main housing.
5. Remove two screws and the lever assembly from the main housing. Remove the valve
assembly from the main housing.
— 12 —
NOTE: Note the position of the diaphragm prior to removal to aid in installation.
6. Remove four screws, the cover, and the diaphragm from the main housing.
NOTE: Note the position of the spring prior to removal of the regulator assembly.
7. Remove two screws, the regulator assembly, and the spring from the main housing.
8. Remove the idle mixture adjusting screw, the washer, the spring, and the O-ring from the
main housing.
9. If damaged, remove the float chamber plug and the gasket.
Table 3. Idle Mixture Adjusting Screw
(3) Cleaning
WARNING
Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using
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.
Wash all parts of the assembly (except the diaphragms and filters) in solvent. Use compressed
air to dry the parts. Wash the diaphragms in warm soapy water. Do not use compressed air on
the diaphragms.
(4) Inspection
Make sure that the regulator housing does not have cracks and damage. Inspect the threads for
damage.
1. If removed, install the gasket and the float chamber plug.
CAUTION
The regulator housing is easily damaged if the idle mixture adjusting screw is installed too
far.
2. To install the idle mixture adjusting screw, use the following procedure:
a. Remove the washer and the spring from the idle mixture adjusting screw.
b. Install the idle mixture adjusting screw in the regulator until the screw contacts the
housing.
— 13 —
c. Remove the idle mixture adjusting screw, counting the number of turns required.
d. Install the spring and the washer on the idle mixture adjusting screw.
e. Subtract the number of turns shown in Table 3. from the number of turns noted in Step
c and install the idle mixture adjusting screw that number of turns. (For example, 12
turns determined in Step c for removal, minus 4 turns from Table 3., equals 8 turns for
installation.)
3. Position the regulator assembly and
the spring in the main housing as noted
during removal. Tighten the two screws
alter nately to 3.9 ± 0.5 Nm (34.5 ±
4.5 lbf in). If this is a new regulator
assembly, check and adjust according
to the procedures in the CHECKS AND
ADJUSTMENTS section in this manual.
4. Install the diaphragm as noted during
disassembly. Install the cover and four
screws on the main housing. Tighten the
screws to 3.9 ± 0.5 Nm (34.5 ± 4.5 lbf in)
in the order shown in Figure 11.
5. Install the valve assembly in the main Figure 11. Diaphragm Cover
housing. Install the lever assembly and Tightening Sequence
tighten the two screws alternately to 3.9 ±
0.5 Nm (34.5 ± 4.5 lbf in).
6. Position the diaphragm as noted during
disassembly. Install the diaphragm by
hooking the shaft to the lever assembly.
Install the four alignment pins in the main
housing as shown in Figure 12.
7. Install the O-ring, the spring, the fuel filter
chamber, and three screws on the main
housing. Do NOT tighten the three screws.
8. Remove the four alignment pins and
install the four remaining screws. Tighten
the seven screws to 3.9 ± 0.5 Nm (34.5 ±
4.5 lbf in) in the order shown in Figure 13.
9. Install the idle bypass solenoid valve and
Figure 12. Alignment
two screws. Tighten the screws to 3.9 ± 0.5
Pin Installation
Nm (34.5 ± 4.5 lbf in).
10. Install the main solenoid valve and two
capscrews on the fuel filter chamber.
Tighten the capscrews to 7.2 ± 0.8 Nm (64
± 7 lbf in).
11. Install the O-ring, two filter elements, two
gaskets, the cover, and six capscrews
on the fuel filter chamber. Tighten the
capscrews to 7.2 ± 0.8 Nm (64 ± 7 lbf in).
(6) Installation
1. Connect the balance line to the regulator.

Install the regulator and the capscrews on
the mount.
2. Connect the LPG vapor hose to the Figure 13. Fuel Filter Chamber
regulator. Tightening Sequence
— 14 —
3. Connect the liquid LPG hose to the regulator.
4. Connect the cooling system hoses to the regulator.
5. Close the drain valve and fill the cooling system with the proper amount and mixture of
coolant. See the PERIODIC MAINTENANCE manual for your lift truck.
6. Connect the fitting from the LPG tank to the regulator assembly. Connect the electrical
connectors from the main solenoid valve and the idle bypass solenoid valve respectively.
7. Connect the hose to the carburetor. Open the shut-off valve on the tank. Start the engine.
1. CAPSCREW 16. MAIN HOUSING

2. COVER 17. SCREW
3. FILTER 18. LEVER ASSEMBLY
4. O-RING 19. VALVE ASSEMBLY
5. FUEL FILTER CHAMBER 20. SCREW
6. CAPSCREW 21. COVER
7. MAIN SOLENOID VALVE 22. DIAPHRAGM
8. O-RING 23. SCREW
9. SCREW 24. REGULATOR ASSEMBLY
10. IDLE BYPASS SOLENOID VALVE 25. SPRING
11. O-RING 26. IDLE MIXTURE ADJUSTING SCREW
12. SCREW 27. WASHER
13. SPRING 28. SPRING
14. DIAPHRAGM 29. O-RING
15. O-RING 30. FLOAT CHAMBER PLUG
31. GASKET
Figure 14. Parts of the Regulator
— 15 —
[1] Adjust the Regulator
NOTE: Use the special tool kit, Hyster Part No.
1490494, to perform the regulator height check
and adjustments as well as the main housing air
tightness test.
(1) Regulator Height Adjustment

(See Figure 15. through Figure 17.)
1. Place the “B” side of the regulator height

checking tool across the sides of the
chamber in the main housing. Move the
tool across the chamber, checking to
see that there is no contact between the
cupped end of the regulator and the flat
side of the tool. If there is contact, go to
Step 3.
2. Place the “A” side of the regulator height
checking tool across the sides of the
chamber in the main housing. Move the
tool across the chamber, checking to see Figure 15. Regulator Measuring
that there is contact between the cupped and Adjustment Tools
end of the regulator and the flat side of
the tool. If there is no contact, go to Step 3.
3. See Figure 17. Use the height adjustment
tools to bend the cupped end of the
regulator to meet the requirements of
Steps 1 and 2. Repeat Steps 1 and 2.
(2) Regulator Assembly Air Tightness Test
1. See Figure 18. Remove the idle mixture

adjusting screw from the main housing
and install the test screw in its place.
Tighten the test screw to 0.2 to 0.3 Nm (2
Figure 16. Check Regulator Height
to 3 lbf in).
2. Apply 12 VDC to the idle bypass solenoid.
3. S e e F i g u r e 1 9 . A t t a c h t h e g a u g e
assembly to the test screw and apply 48
kPa (7 psi) of pressure. There should be
no leaks.
4. If there are any leaks, adjust the sealing
between the regulator assembly and the
seat in the main housing. Flip the cupped
end of the regulator assembly by finger
several times to ensure air tightness. Then
apply an adhesive such as Super Glue®
between the backside of the rubber valve
1. HORIZONTAL CUT ADJUSTING TOOL
(metal part) and the regulator assembly 2. ANGLE CUT ADJUSTING TOOL
(metal lever) to lock them together.
5. Remove the gauge assembly and the test Figure 17. Adjust Regulator Height
— 16 —
screw from the main housing.
CAUTION
The regulator housing is easily damaged if
the idle mixture adjusting screw is installed
too far.
6. To install the idle mixture adjusting screw,

use the following procedure:
a. Remove the washer and the spring
Figure 18. Idle Mixture Adjusting
from the idle mixture adjusting screw.
Screw Location
b. Install the idle mixture adjusting
screw in the regulator until the
screw contacts the housing.
c. Remove the idle mixture adjusting
screw, counting the number of turns
required.
d. Install the spring and the washer on
the idle mixture adjusting screw.
e. Subtract the number of turns shown
in Table 4. from the number of turns
noted in Step c and install the idle
mixture adjusting screw that number
of turns. (For example, 12 turns
1. TEST SCREW/HOSE CONNECTION
determined in Step c for removal, 2. PRESSURE GAUGE
minus 4 turns from Table 4., equals
8 turns for installation.) Figure 19. Gauge Installation
Table 4. Idle Mixture Adjusting Screw
[2] Adjust the Carburetor
(1) Idle Speed and Fuel Mixture

(See Figure 20.)
WARNING
LPG can cause an explosion. Do not permit any sparks or open flames in work area.
1. Warm the engine, the transmission, and the hydraulic system to normal operating
temperatures. Make sure that the idle-up actuator is not in contact with the idle-up adjusting
screw.
2. Check the engine timing and the idle speed.
8°BTDC @725 ± 25 RPM
3. If the idle speed is not within specifications, adjust the speed using the idle air bypass
adjusting screw.
— 17 —
NOTE: For the following steps, a CO% meter will
be required.
4. Adjust the idle mixture adjusting screw on

the regulator lockout until the CO% is 3.0%
or less at idling.
5. Readjust the idle speed to the specified
RPM.
6. Repeat Steps 4 and 5 until the idle speed
and CO% are within the specified range.
7. With the engine at the governed speed
and the tilt lever pulled fully back, adjust
the main mixture adjusting screw to
achieve a CO% of 3.0% or less.
NOTE: CO% at hoist relief and torque converter
stall is not adjustable.
8. With wide open throttle, check the CO% 1. IDLE AIR BYPASS ADJUSTING SCREW
at hoist relief and at torque converter stall. 2. IDLE-UP ADJUSTING SCREW
3. IDLE CONTROL ACTUATOR
(2) Idle Control Adjustment 4. POWER VALVE ACTUATOR
Figure 20. LPG Carburetor, Top View
1. War m the engine, transmission and
hydraulic system to normal operating
temperatures. Make sure that the idle-up
actuator is not in contact with the idle-up
adjusting screw. See Figure 20.
2. Set the idle speed and idle mixture
according to the Idle Speed and Fuel
Mixture procedure.
3. Adjust the idle-up adjusting screw until
there is 0.10 to 0.20 mm (0.004 to 0.008
in) clearance between the screw and the
idle control actuator.
4. D i s c o n n e c t t h e va c u u m h o s e f r o m
the idle-up actuator and check the
engine speed. If it is within the idle-
up specification (1400 + 0 -150 RPM),
no further adjustment is required. If the 1. CARBURETOR
2. IDLE AIR BYPASS ADJUSTING SCREW
engine speed exceeds the specification, 3. MAIN MIXTURE ADJUSTING SCREW
adjust the idle-up adjusting screw until the 4. LOCKSCREW
engine speed is within the specification. 5. MAIN ADJUSTMENT WHEEL
6. SECONDARY ADJUSTING SCREW
[3] Governor (See Figure 22.) Figure 21. LPG Carburetor, Side View
The governor does not normally need adjustment. If adjustment is necessary, do not turn the
adjusting screws more than 1/4 turn at a time. If the adjusting screws are turned more than this,
the governor can be difficult to adjust.
(1) Checks
Before making any adjustments to the governor, check the following:
— 18 —
1. Make sure that the mechanical, electrical,
and fuel systems are operating correctly.
2. Make sure that the tachometer will work
with the ignition system.
3. Make sure that the air filter is clean and
connected to the carburetor.
(2) Adjustments
With the engine at operating temperature,

adjust the governor as follows: 1. SECONDARY ADJUSTING SCREW
1. Remove the lock wire from the lock screw. 2. ADJUSTMENT SPRING
Loosen the lock screw. Apply the parking 3. MAIN ADJUSTMENT WHEEL
4. LOCKSCREW
brake.
2. With no load on the engine, run the
engine at full open throttle to obtain Figure 22. Governor
maximum engine speed. To adjust the
maximum no load engine speed (high
idle), hold the secondary adjusting screw and turn the main adjustment wheel. Turn the main
adjusting screw clockwise to increase engine speed or counterclockwise to decrease engine
speed.
2600 to 2800 rpm.
3. Tighten the lock screw.
4. Run the engine with the throttle fully open. Then pull on the tilt lever to load the 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 the lock screw and turn the secondary adjusting screw
1/4 turn clockwise. Set the maximum no load engine speed by turning the main adjustment
wheel counterclockwise. Repeat this procedure until the engine speed is steady.
6. If the engine speed difference between the load and no load conditions is greater than
specified, turn the main adjustment wheel 1/4 turn clockwise. Set the maximum no load
engine speed by turning the secondary adjusting screw counterclockwise. Repeat this
procedure until the engine runs correctly.
7. When the governor adjustment is correct, tighten the lock screw and install the wire between
the lock screw and the secondary adjusting screw.
[4] Adjust the Throttle Linkage

(See Figure 23.)
CAUTION
The adjustment of the throttle cable must be correct or it can break during operation. The
accelerator pedal must reach the pedal stop by the time the throttle plate in the carburetor
is fully open.
NOTE: Each time the throttle system is disassembled, it is important to adjust the throttle cable.
Adjust the throttle pedal when the engine is running at idle and at the normal operating
temperature.
With the engine at idle and the throttle pedal released, adjust the up-position pedal stop until the
tension is removed from the throttle cable.
— 19 —
1. Adjust the idle speed to 725 ± 25 rpm.
2. Make sure the throttle linkage at the pedal assembly is in the correct position.
3. Push the throttle pedal until it stops against the pedal stop. Adjust the throttle cable so that
the pedal stops on the pedal stop just as the throttle plate reaches the wide open position.
Use the nuts at the pedal end of the cable housing to change the adjustment of the cable.
4. Adjust the pedal stop so that the pedal and throttle lever reach the full return positions at the
same time.
1. PEDAL
2. LEVER ACCEL
3. THROTTLE CABLE
Figure 23. Throttle Cable Arrangement
— 20 —
TROUBLESHOOTING
PROBLEM PROBLEM PROCEDURE OR ACTION
The engine will not start. The fuel tank is either empty or Fill the fuel tank or open the fuel
the fuel tank valve is closed. tank valve.
There is tar accumulation in the Remove the drain plug and drain
regulator. the tar from the regulator.
The fuel hose is disconnected or Connect or replace the fuel hose.

damaged.
The fuel filter is clogged. Replace the fuel filter and clean
the tar from the regulator.
The main fuel shutoff solenoid Disconnect the solenoid from the
valve does not operate. harness and connect directly to
the battery. Listen for a clicking
sound. If the solenoid does not
energize, replace with a new one.
The idle fuel shutoff solenoid valve Disconnect the solenoid from the
does not operate. harness and connect directly to
The main fuel shutoff solenoid Connect the main fuel solenoid
connector is disconnected. connector.
The idle fuel shutoff solenoid Connect the idle fuel solenoid
connector is disconnected. connector.
The main fuel shutoff solenoid R e p a i r o r i n s t a l l n ew w i r i n g

wire harness is cut. harness.
The idle fuel shutoff solenoid wire R e p a i r o r i n s t a l l n ew w i r i n g

harness is cut. harness.
The coil of the idle fuel shutoff Using an ohm meter, measure the
solenoid is damaged. resistance between terminals. The
measurement should be 22.5 ±
0.2Ω at 21°C (70°F). Install new
solenoid if the measurement is
incorrect.
The coil of the main fuel shutoff Using an ohm meter, measure
solenoid is damaged. the resistance between terminals.
The measurement should be 8.5
± 0.5Ω at 21°C (70°F). Install new
solenoid if the measurement is
incorrect.
The main fuel shutoff solenoid C l e a n t h e m a i n f u e l s h u t o f f

valve is clogged. solenoid valve.
The idle fuel shutoff solenoid valve Clean the idle fuel shutoff solenoid
is clogged. valve.
The idle adjusting screw may be Clean or replace the idle adjusting
clogged. screw as necessary.
The idle air bypass adjusting P e r f o r m t h e a d j u s t m e n t

screw on the carburetor is out of procedures located in Checks and
adjustment. Adjustments.
— 21 —
TROUBLESHOOTING
The engine will not start. T h e i d l e m i x t u r e a d j u s t i n g Perform the adjustment proce-
screw on the regulator is out of dures located in Checks and Ad-
adjustment. justments.
The primary diaphragm on the Replace the diaphragm.

regulator is damaged.
The engine is hard to start. The fuel hose is damaged. Replace the fuel hose.
The vacuum hose is either Replace a damaged hose or con-

damaged or disconnected. nect a hose that is disconnected.
There is an air leak between the Replace the gasket if it is broken

carburetor and the governor. or tighten the mounting nuts to the
correct torque.
The idle mixture adjusting screw Clean or replace the idle mixture
may be clogged. adjusting screw as necessary.
The main mixture adjusting screw Clean or replace the main mixture
on the carburetor may be clogged. adjusting screw as necessary.
The solenoid valve does not seal. Clean the idle fuel solenoid or
replace with a new one.
There is an internal clogging of Clean the main fuel solenoid or

the main fuel solenoid. replace with a new one.
The main fuel solenoid does not Clean the main fuel solenoid or
seal. replace with a new one.
There is an internal clogging of Clean the idle fuel solenoid or

the idle fuel solenoid. replace with a new one.
The idle air bypass adjusting Perform the adjustment proce-

screw on the carburetor is out of dures located in Checks and Ad-
The primary diaphragm on the Replace the diaphragm.

regulator is damaged.
T h e i d l e m i x t u r e a d j u s t i n g Perform the adjustment proce-

The engine does not idle smoothly. T h e v a c u u m h o s e i s e i t h e r Replace a damaged hose or con-
(Lean fuel/air mixture) damaged or disconnected. nect a hose that is disconnected.

carburetor and the governor. or tighten the mounting nuts to the
correct torque.
— 22 —
TROUBLESHOOTING
The engine does not idle smoothly. The main fuel shutoff solenoid Clean the main fuel shutoff sole-
(Lean fuel/air mixture) valve is clogged. noid valve.
is clogged. valve.
may be clogged with tar. adjusting screw as necessary.
The power adjusting screw on the Perform the adjustment proce-

carburetor is out of adjustment. dures located in Checks and Ad-
justments.

The engine does not idle smoothly. The resonator hose is discon- Connect the resonator hose or
(Rich fuel/air mixture) nected or damaged. replace the resonator hose.
The resonator hose is damaged. Replace the resonator.

justments.

The engine does not idle smoothly. The idle air bypass adjusting Clean or replace the idle air
(Idle speed too low) screw on the carburetor may be bypass adjusting screw and clean
clogged. the tar from the carburetor.
The idle air bypass adjusting Perform the adjustment proce-


The engine does not idle smoothly. The idle air bypass adjusting Perform the adjustment proce-
(Idle speed too high) screw on the carburetor is out of dures located in Checks and Ad-

There is engine hesitation, surge, A vacuum hose is either damaged Replace a damaged hose or con-
knocking or loss of power due to or disconnected. nect a hose that is disconnected.
lean or rich fuel/air mixture.
The main fuel shutoff solenoid Clean the main fuel shutoff sole-
valve is clogged. noid valve.
is clogged. valve.
The fuel hose is damaged. Replace the fuel hose.
— 23 —
TROUBLESHOOTING
There is engine hesitation, surge, The idle mixture adjusting screw Clean or replace the idle mixture
knocking or loss of power due to may be clogged. adjusting screw as necessary.
lean or rich fuel/air mixture.

carburetor and governor. or tighten the mounting nuts to the
correct torque.
T h e m a i n m i x t u r e a d j u s t i n g Perform the adjustment proce-

The idle mixture adjusting screw Perform the adjustment proce-

may be out of adjustment. dures located in Checks and Ad-
justments.
The coolant hose has become Clear the obstruction from the
clogged or disconnected, causing coolant hose or reconnect the
the regulator to become frozen. coolant hose.
The resonator is damaged. Replace the resonator.
The resonator hose is discon- Connect the resonator hose or

nected or damaged. replace the resonator hose.
There is no clearance between Adjust the idle-up adjusting screw.

the idle-up adjusting screw and
the idle-up actuator.
The engine stops running during The main fuel shutoff solenoid Clean the main fuel shutoff sole-
deceleration, immediately after valve is clogged. noid valve.
engine start-up, immediately after
acceleration, during a sharp turn, The idle fuel shutoff solenoid valve Clean the idle fuel shutoff solenoid
or during load up/down operations is clogged. valve.
due to lean or rich fuel/air mixture.
The fuel hose is damaged. Replace the fuel hose.
may be clogged. adjusting screw as necessary.

carburetor and governor. or tighten the mounting nuts to the
correct torque.
The vacuum hose is either dam- Replace a damaged hose or con-

aged or disconnected. nect a hose that is disconnected.

justments.
The idle mixture adjusting screw Perform the adjustment proce-

may be out of adjustment. dures located in Checks and Ad-
justments.
— 24 —
TROUBLESHOOTING
There is engine hesitation, surge, The coolant hose is clogged Clear the obstruction from the
knocking or loss of power due to or disconnected, causing the coolant hose or reconnect the
lean or rich fuel/air mixture or loss regulator to be over cooled. coolant hose.
of air.
The regulator has become over Repair or replace the regulator.
cooled after the engine has
reached normal operating tem-
perature.
The resonator is damaged. Replace the resonator.
The resonator hose is either Replace a damaged hose or con-

damaged or disconnected. nect a hose that is disconnected.
The engine continues to run after The idle fuel shutoff solenoid valve Disconnect the solenoid from the
being shutdown (Dieseling). does not operate. harness and connect directly to
is clogged. valve.
— 25 —
HMM070001
Cooling System
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

and Repair
weight of the load.
remove parts.
needs repairs.
WARNING
CAUTION
—1—
GENERAL
This section contains the repair and replacement instructions for the radiator, fan assembly (pusher
type), fan shroud, coolant hoses, coolant recovery bottle, and optional debris screen.
COOLING SYSTEM CHECKS
[1] Exhaust Leaks Into Cooling System
WARNING
During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with
these parts can cause serious injury.
To check for exhaust leaks into the cooling system, use a Combustion Leak Test Kit for this purpose.
Follow the manufacturer’s instructions when doing the test.
[2] Water Flow Restrictions in Radiator
WARNING
To check for water flow restrictions in the radiator, run engine until it is warm.
WARNING
The radiator or other parts of the cooling system may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of the cooling system.
Shut engine OFF and feel the radiator. The temperature must be even across the radiator. (The
radiator will be hotter near the top radiator hose.) Cold spots on radiator indicate restrictions.
If radiator has leaks, either replace the radiator or have it repaired by trained personnel.
[3] Radiator Hoses
WARNING
—2—
Inspect all radiator hoses. If they feel spongy or have visible cracks, replace hoses.
[4] Water Pump
WARNING
WARNING
cause serious injury.
Run engine until it is warm. Check the operation of water pump by holding the top radiator hose.
If the pump is operating, there will be pressure surges in the hose.
Check for leaks around the timing belt cover near the base of the oil pump.
Check the weep hole where water can drain by the oil filter. If there is a drip, check the pump
shaft seal and water pump. Replacement of the pump shaft seal or water pump may be
necessary.
For repair procedures for the Mazda M4-2.0G and M4-2.2G water pump, refer to the section
Mazda Engine, M4-2.0G and M4-2.2G.
For repair procedures for the Yanmar 2.7L and 3.3L water pump, refer to the section Yanmar
Diesel Engines.
—3—
RADIATOR REPLACEMENT
[1] Cooling System, Clean
WARNING
personnel. Make sure the path of the compressed air is away from all personnel. Wear
WARNING
The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves
while checking the radiator fins.
1. Check radiator fins. Clean exterior of radiator with compressed air or water as needed.
WARNING
and boiling coolant can cause burns.
WARNING
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
2. Drain cooling system. Fill cooling system with clean water. See the Radiator, Remove
section for more information.
3. Install radiator cap. Run engine until top radiator hose is hot. Stop engine and let engine cool.
4. Drain water from radiator. If water is dirty, fill system with water and repeat procedure until
water is clean.
CAUTION
Follow the manufacturer’s instructions when using a chemical radiator cleaner.
5. If water does not clean system, use a chemical radiator cleaner.
—4—
CAUTION
Follow the manufacturer’s instructions when using special equipment to reverse clean the
radiator.
6. If radiator or cooling system is very dirty or has a restriction, use reverse cleaning method.
This method uses water pressure to force water through radiator in opposite direction of
normal flow.
CAUTION
Additives may damage the cooling system. Before using additives, contact your local Hyster
dealer.
7. Fill cooling system with a mixture of 60 percent water and 40 percent ethylene glycol boron
free antifreeze. The 60/40 mixture will protect cooling system to –20°C (–4°F). Add coolant as
necessary to keep level between the ADD and FULL marks on the reservoir.
[2] Radiator, Remove
WARNING
1. Turn OFF truck.

2. Remove the radiator cover. See the section Frame.
WARNING
Always disconnect the cable at the negative terminal first. Install a tag on the battery
terminals so that no one connects the cables on the terminals.
3. Disconnect the negative battery cable.

4. Disconnect the positive battery cable.
WARNING
and boiling coolant can cause burns.
5. Let coolant cool to room temperature. Put a drain pan under radiator. Remove radiator cap.
—5—
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
6. Open the drain plug or disconnect the bottom radiator hose.

7. Cap radiator hoses.
8. Disconnect hose to auxilary coolant reservoir and remove reservoir.
9. Remove battery and battery tray.
NOTE: For LPG engine, the LPG hoses and air cleaner need to be moved for clearance of radiator.
10. Remove screws from the radiator shroud and lean radiator shroud toward the fan.
11. Remove radiator from truck.
[3] Radiator, Install
1. Install radiator into truck.

2. Install the radiator shroud.
3. Uncap radiator and reservoir parts and install the auxiliary coolant reservoir.
4. Connect the auxiliary coolant reservoir hose to the radiator.
5. Uncap the top radiator hose and connect the hose to radiator.
6. Close the drain plug or install bottom radiator hose.
WARNING
Do not use an alcohol or methanol base antifreeze. They are flammable and cause personal
injury or damage to the lift truck.
CAUTION
dealer.
8. Fill cooling system with a mixture of 60 percent water and 40 percent ethylene glycol boron-
free antifreeze. The 60/40 mixture will protect cooling system to –20°C (–4°F).
9. Use the same coolant mixture and fill the auxiliary coolant reservoir between the ADD and
FULL marks. See Figure 2.
10. Install battery and battery tray.
11. Connect the positive battery cable.
12. Connect negative battery cable.
13. Install the radiator cover. See the section Frame.
—6—
Figure 1. Cooling System
15. BRACKET RADIATOR LH 51. RADIATOR ASSY

16. BRACKET RADIATOR RH 53. FAN SHROUND WLDMT
17. WA HEX HEAD BOLT 54. HOUSE RADIATOR LOWER
18. TANK RESERVOIR 55. HOUSE RADIATOR UPPER
19. HOSE CLAMP 56. BRACKET RESERVE TANK
57. WA HEX HEAD BOLT M8*1. 25*12 S
—7—
WARNING
WARNING
cause serious injury.
14. Start and run engine until thermostat opens. (The top radiator hose will be warm.)
CAUTION
dealer.
15. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level
between the ADD and FULL marks on the reservoir.
Figure 2. Auxiliary Coolant Reservoir
1. AUXILIARY COOLANT RESERVOIR

2. ADD MARK
3. FULL MARK
—8—
FAN ASSEMBLY REPLACEMENT
[1] Remove
WARNING
WARNING
WARNING
while removing fan assembly.
NOTE: The fan that is used is a pusher type fan.
1. Turn OFF lift truck.

2. If equipped, turn the LPG tank valve to the OFF position.
3. If equipped, release the LPG tank bracket and swing tank away from the lift truck.
4. Release the steering tilt latch and move the steering wheel forward.
5. Release the seat latch and move the seat forward.
6. Release engine cover latch on engine cover and swing engine cover up.
WARNING
To prevent a short circuit during fan belt removal, disconnect the battery negative cable at
the battery negative terminal. Install a lock or tag on the connector to prevent connection. A
tool could cause a short circuit, the high current flow from the battery can cause an injury
or parts damage.
7. Disconnect the negative battery cable from the negative battery terminal.
8. Remove screws and washers from the radiator shroud. For the Yanmar 2.7L and 3.3L, see
Figure 4. For the Mazda M4-2.0G and M4-2.2G, see Figure 5. Lean radiator shroud toward
the fan.
—9—
Figure 4. Yanmar 2.7L and 3.3L Fan Removal
15. BRACKET RADIATOR LH 53. FAN SHROUND WLDMT

16. BRACKET RADIATOR RH 54. HOUSE RADIATOR LOWER
17. WA HEX HEAD BOLT 55. HOUSE RADIATOR UPPER
18. TANK RESERVOIR 56. BRACKET RESERVE TANK
19. HOSE CLAMP 57. WA HEX HEAD BOLT M8*1. 25*12 S
51. RADIATOR ASSY
— 10 —
Figure 5. Mazda M4-2.0G and M4-2.2G Fan Removal
1. RADIATOR ASSY 16. BRACKET RADIATOR RH

3. FAN SHROUD WLDMT 17. WA HEX HEAD BOLT M8*1. 25*12 S
4. HOSE RADIATOR LOWER 18. TANK RESERVOIR
5. HOSE RADIATOR UPPER 19. WA45 HOSE CLAMP
15. BRACKET RADIATOR LH
— 11 —
9. For Yanmar 2.7L and 3.3L engines, remove capscrews, washers, and spacer from the fan
pulley.
10. For Mazda M4-2.0G and M4-2.2G engines, remove the capscrews and washers retaining the
fan.
11. Remove the fan.
[2] Inspect
WARNING
DO NOT try to repair a damaged fan. If a fan has a bent blade or is cracked, install a new fan.
A damaged fan can break during use and cause damage or serious injury.
1. Inspect the fan for any damage.

2. If the fan is damaged, replace the entire fan.
[3] Install
WARNING
while installing fan assembly.
1. Install the lower portion of the shroud in the retaining clips and lean the shroud toward the
engine.
2. For the Yanmar 2.7L and 3.3L, install the spacer, washers, and capscrews to the fan. Tighten
the capscrews to 25.5 N·m (18.8 lbf·ft). See Figure 4.
3. For Mazda M4-2.0G and M4-2.2G engines, place the fan in position and intsall capscrews
and washers. Tighten the capscrews to 9.5 N·m (7 lbf·ft). See Figure 5.
4. Lean the radiator shroud back toward the radiator. Install the radiator shroud cover.
5. Install the screws and washers and tighten.
6. Reconnect the negative battery cable to the negative terminal of the battery.
7. Pull engine cover down and re-latch with engine cover latch.
8. Move the seat back.
9. Release the steering wheel tilt latch and move the steering wheel back.
10. If equipped, swing the LPG tank bracket back toward the truck and re-latch.
11. If equipped, turn the LPG tank valve to the ON position.
— 12 —
HMM180001
Brake System
H1.5-1.8TX, H2.0TXS [B475];
H2.5-3.5TX [B466]

and Repair
weight of the load.
remove parts.
needs repairs.
WARNING
CAUTION
—1—
GENERAL
This section has a description and the service procedures for the parts of the brake system. The
brake system includes the following parts: master cylinder, brake shoes, wheel cylinders, and
parking brake system.
[1] Service Brakes
A service brake assembly is installed on

the mounts at each end of the drive axle.
See Figure 1. The parts of the service brake
assembly are shown in Figure 4 for H2.0-
3.5TX [B466] lift trucks and Figure 6 for H1.5-
1.8TX, H2.0TXS [B475]. When the brake
pedal is pushed, fluid pressure from the
master cylinder causes the pistons in the
wheel cylinder to extend. The pistons expand
the brake shoes against the drums.
The clearance between the brake shoes and
the brake drum is adjusted automatically. An
adjuster linkage turns the adjuster wheel to
adjust the clearance. When the lift truck moves
in the REVERSE direction and the brakes are
applied, the rear brake shoe and the adjuster
links move with the drum. This linkage moves
the adjuster lever to rotate the adjuster wheel.
The adjuster wheel can turn only when there
is clearance between the lining of the brake
shoe and the brake drum. The adjuster wheel
can also be turned with a tool. A slot in the
back plate gives access to the adjuster wheel.
[2] Master Cylinder
The master cylinder is designed for a single-

circuit system. The master cylinder has a
piston that operates in the bore of the master
cylinder. See Figure 2. 1. PARKING BRAKE LEVER
2. ADJUSTMENT KNOB
NOTE: The reservoir is located to the right of the 3. PARKING BRAKE CABLE
4. INCHING/BRAKE PEDAL
park brake and is attached to the cowl.
5. MASTER CYLINDER
6. BRAKE ASSEMBLY
7. PARK BRAKE SENSOR
[3] Brake Position Sensor
This sensor senses the park brake hand Figure 1. Brake System
lever position. The sensor is located on the
left hand side of the park brake handle. See
Figure 1.
—2—
1. YOKE 10. PISTON
2. NUT 11. SPACER
3. PUSH ROD 12. PISTON CUP
4. BOOT 13. RETAINER
5. SNAP RING 14. SPRING
6. CYLINDER HOUSING 15. CHECK VALVE
7. SEAL 16. VALVE SEAT
8. FITTING 17. BLEEDER VALVE
9. PISTON SEAL 18. CAP
Figure 2. Master Cylinder
[4] Parking Brake
The parking brake system uses the service brake shoes. Additional linkage activates the parking
brake system. When the lever is moved to apply the parking brake, the cables and linkage
expand the brake shoes against the drums. The design of the parking brake linkage adjusts each
cable so that the tension is the same when the lever is moved to apply the parking brake. The
park brake sensor is located on the left side of the park brake handle.
—3—
SERVICE BRAKES REPAIR
[1] Remove and Disassemble
WARNING
Brake linings can contain dangerous fibers. Breathing the dust from these brake linings
is a cancer or lung disease hazard. Do not create dust! Do not clean brake parts with
compressed air or by brushing. Use vacuum equipment approved for brake dust or follow
the cleaning procedure in this section. When the brake drums are removed, do not create
dust.
Do not sand, grind, chisel, hammer, or change linings in any way that will create dust.
Any changes to brake linings must be done in a restricted area with special ventilation.
Protective clothing and a respirator must be used.
1. Remove the capscrews that hold the axle shaft to the hub. Remove the axle shaft.
2. See the procedure How to Put Lift Truck on Blocks in the section Periodic Maintenance
or the Operating Manual. Start the engine and tilt the mast fully backward. Put blocks under
the mast. Tilt the mast forward until the wheels just touch the floor. Stop the engine. Put
blocks under the frame of the lift truck.
3. Remove the set screw and remove the nut that holds the axle bearing. Remove the washer
and the bearing cone.
1. WHEEL CYLINDER
2. RETURN SPRING
3. RETURN SPRING
4. ANCHOR
5. ANCHOR GUIDE
6. BACK PLATE
7. SECONDARY BRAKE SHOE
8. ADJUSTER WHEEL ACTUATOR
9. PIVOT PLATE
10. SPRING AND CABLE ASSEMBLY
11. ADJUSTER WHEEL
12. ADJUSTER ASSEMBLY
13. PRIMARY BRAKE SHOE
14. PARKING BRAKE LEVER
15. LINK, PARKING BRAKE
16. SPRING, PARKING BRAKE
17. RETAINER, AND SPRING
WASHER
18. ADJUSTER ACTUATOR SPRING
19. SPRING
Figure 3. Brake Assembly (Left-Hand Shown), H2.0-3.5TX [B466]
—4—
WARNING
When the brake shoes are removed, do not create dust in the air. See the Clean procedure
in this section.
4. Put grease on the floor so that the wheel assembly will slide easily from the axle tube. Pull
the wheel assembly from the lift truck. If the wheel assembly cannot be removed easily, use
a small screwdriver to push the adjuster actuator away from the adjuster wheel. Use a brake
adjustment tool or a screwdriver to turn the adjuster wheel to loosen the brake shoes. Remove
NOTE: Right-hand brake assembly shown.
1. WHEEL CYLINDER 12. ADJUSTER ASSEMBLY

2. RETURN SPRING 13. PRIMARY BRAKE SHOE
3. RETURN SPRING 14. PARKING BRAKE LEVER
4. ANCHOR 15. PARKING BRAKE LINK
5. ANCHOR GUIDE 16. PARKING BRAKE SPRING
6. BACK PLATE 17. RETAINER, AND SPRING WASHER
7. SECONDARY BRAKE SHOE 18. ADJUSTER ACTUATOR SPRING
8. ADJUSTER WHEEL ACTUATOR 19. SPRING
9. PIVOT PLATE 20. RETAINING PIN
10. ADJUSTER ACTUATOR LINK 21. RETAINING WASHER
11. ADJUSTER WHEEL 22. PARKING BRAKE CABLE
Figure 4. Service Brake Parts, H2.0-3.5TX [B466]
—5—
the hub and drum assembly. Do not damage the grease seal when removing the hub.
5. Make a note of the arrangement of the parts. See Figure 3 and Figure 4 for H2.0-3.5TX [B466]
lift trucks. See Figure 5 and Figure 6 for H1.5-1.8TX, H2.0TXS [B475] lift trucks. Remove the
return springs with spring pliers.
6. Remove the retainers, springs, and anchor pins that hold the brake shoes to the back plate.
7. Disengage the link from the adjuster wheel actuator. Remove the link, washer, and pivot
plate. Remove the anchor guide.
8. Move the brake shoes away from each other to disengage the brake shoes from the wheel
cylinder. Disconnect the parking brake lever from the parking brake cable as the brake
assembly is removed from the back plate. The parking brake lever has a hook that engages
the parking brake cable.
NOTE: The adjuster wheel for the left brake is not the same as the adjuster wheel for the right brake. The
adjuster wheel for the left brake has left-hand threads.
9. Make a note of the arrangement of parts and disassemble the brake assembly. Remove the
parking brake link and spring if they are still engaged with brake shoes. The parking brake
link and spring will often fall from the brake assembly when the brake assembly is removed
from the back plate. The adjuster wheel will also disengage from the brake shoes after the
brake assembly is removed.
10. Remove the spring for the adjuster wheel actuator. Remove the adjuster wheel actuator from
the brake shoe.
11. Use a screwdriver or small pry bar to move apart the ends of the retainer. Remove the spring
washer and pivot pin to remove the parking brake lever from the brake shoe.
12. Disconnect the brake line from the wheel cylinder. Remove the capscrews that hold the wheel
cylinder to the back plate and remove the wheel cylinder.
1. BACKING PLATE
2. RETAINING RING
3. LEVER PIN
4. GUIDE PLATE
5. WHEEL CYLINDER
6. PAWL LEVER STOPPER
7. SPRING (ANTI-RATTLE)
8. RETURN SPRING
9. SPRING (ACTUATOR)
10. ADJUSTER WHEEL
ACTUATOR
11. SECONDARY BRAKE SHOE
12. ADJUSTER ASSEMBLY
13. ADJUSTER SPRING
14. PARK BRAKE LEVER
15. PRIMARY BRAKE SHOE
16. STRUT
Figure 5. Brake Assembly (Left Hand Side), H1.5-1.8TX, H2.0TXS [B475]
—6—
1. BOLT 13. ADJUSTER WHEEL ACTUATOR
2. WHEEL CYLINDER 14. PARK BRAKE CABLE
3. STRUT 15. ADJUSTER ASSEMBLY
4. SPRING 16. RETAINING RING
5. SECONDARY BRAKE SHOE 17. SPRING (ADJUSTER)
6. GUIDE PLATE 18. PRIMARY BRAKE SHOE
7. RETURN SPRING 19. PARK BRAKE LEVER
8. PAWL LEVER STOPPER 20. LEVER PIN
9. SPRING (ACTUATOR) 21. PLUG
10. WASHER 22. BACKING PLATE
11. SPRING (SHOE HOLD DOWN) 23. PIN
12. WASHER
Figure 6. Service Brake Parts, H1.5-1.8TX, H2.0TXS [B475]
NOTE: For H2.0-3.5TX [B466] lift trucks, the back plate is not normally removed from the axle housing for
brake repairs. Eight special capscrews are used to fasten the back plate to the axle mount, and the locking
function of the capscrews is reduced if they are removed. The capscrews are tightened to 255 to 306 N·m
(2600 to 3120 kgf·cm).
NOTE: For H1.5-1.8TX, H2.0TXS [B475] lift trucks, the back plate is not normally removed from the axle
housing for brake repairs. Six special capscrews are used to fasten the back plate to the axle mount, and
the locking function of the capscrews is reduced if they are removed. The capscrews are tightened to 152 to
167 N·m (1550 to 1700 kgf·cm).
13. Remove the push rods, dust covers, pistons, cups, and spring from the wheel cylinder. See
Figure 7.
—7—
1. PUSH ROD (2) 6. WHEEL CYLINDER BODY
2. DUST COVER (2) 7. INLET PORT
3. PISTON (2) 8. PRESSURE BLEEDER
4. CUP (2) 9. DUST COVER
5. SPRING
Figure 7. Wheel Cylinder
[2] Clean
WARNING
DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or brake linings. Use
a solvent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid
or on the brake linings. Oil and grease will cause damage and leaks in the seals of a brake
system. The brakes will not operate correctly if oil, grease, or brake fluid is on the brake
linings.
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using
cleaning solvents, always follow the safety instructions of the solvent manufacturer.
1. Do not release brake lining dust from the brake linings into the air when the brake drum is
removed.
2. Use a solvent approved for cleaning of brake parts to wet the brake lining dust. Follow the
instructions and cautions of the manufacturer for the use of the solvent. If a solvent spray is
used, spray at a distance so that the dust is not released into the air.
3. When the brake lining dust is wet, clean the parts. Put any cloth or towels in a plastic bag or
an airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on
the plastic bag or airtight container.
CAUTION
Do not permit oil or grease on the brake linings. Use a brake cleaning fluid as necessary to
clean linings that will not be replaced.
—8—
4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into
the air.
[3] Inspect
1. Inspect the bore of the wheel cylinder for holes or scratches. Replace the wheel cylinder
assembly if there is any damage.
2. Inspect the return springs for wear and damage. Inspect the back plate for wear where the
brake shoes touch the back plate. Remove any grooves or replace a worn or damaged back
plate.
WARNING
The brake shoes on both wheels must be replaced if any shoe is damaged. The brake
performance on both ends of an axle must be equal, or the lift truck can be difficult to steer
when the brakes are applied.
3. Inspect the brake shoes for cracks or damage. If the linings or shoes are worn or damaged,
replace the brake shoes. Maximum wear is to within 1 mm of contact with the rivets, or the
metal shoe on bonded linings. Brake shoes must be replaced in complete sets. Inspect the
brake drums for cracks or damage. Replace any damaged parts.
4. Inspect the brake drum for deep grooves or other damage.
NOTE: On H2.0-3.5TX [B466] lift trucks, if grooves must be removed from the brake drums, do not grind
more than 1.5 mm from the internal diameter of the brake drum. The maximum limit of the internal diameter
of the brake drum is 312 mm. If the internal diameter is larger than the limit, replace the brake drum.
NOTE: On H1.5-1.8TX, H2.0TXS [B475] lift trucks, if grooves must be removed from the brake drums, do
not grind more than 1.5 mm from the internal diameter of the brake drum. The maximum limit of the internal
diameter of the brake drum is 255.5 mm. If the internal diameter is larger than the limit, replace the brake
drum.
5. The teeth of the adjuster wheel must not be worn. The adjuster wheel must turn freely. Check
the adjuster links for damage.
6. Make sure the parking brake cables are in good condition.
7. Check the grease seals and the surfaces of the seals for wear or damage.
[4] Assemble and Install
1. If the wheel cylinder was disassembled for repair, assemble the wheel cylinder. See Figure 7.
Use only HYSTER APPROVED parts.
2. Install the wheel cylinder on the back plate and tighten the two capscrews to 18 to 26 N·m (180
to 260 kgf·cm) for H2.0-3.5TX [B466] and 15 to 23 N·m (150 to 230 kgf·cm) for H1.5-1.8TX,
H2.0TXS [B475]. Connect the brake line to the wheel cylinder.
3. Install the parking brake lever. Use the spring washer, and retainer to fasten the parking
brake lever to the brake shoe. Close the ends of the retainer to fasten the pivot pin in position.
See Figure 4 for H2.0-3.5TX [B466] and Figure 6 for H1.5-1.8TX, H2.0TXS [B475] lift trucks.
4. Fasten the adjuster actuator spring to the lever and the brake shoe.
5. Put antiseize compound on the threads of the adjuster wheel. Turn the adjuster wheel into
the adjuster nut so that the adjuster assembly is in its shortest position. This action permits
the brake drum to be easily installed over the brake shoes.
—9—
WARNING
The threads of the adjuster wheel are not the same for each side. If the adjuster assemblies
are installed on the wrong side, the brake shoe clearance will increase each time the brakes
are applied. The adjuster wheel for the right brake has right-hand threads. The adjuster
wheel for the left brake has left-hand threads.
6. Install the adjuster wheel between the two brake shoes. Make sure the adjuster wheel will be
toward the rear of the lift truck. Move the brake shoes apart so that the adjuster wheel is held
in position and the adjuster actuator spring is in tension.
7. Lubricate the back plate with a small amount of lithium grease where the brake shoes touch.
Install the brake shoes on the anchor and engage the push rods of the wheel cylinder.
Engage the parking brake lever in the slot in the parking brake cable as the brake shoes are
installed on the back plate.
8. Put an anchor pin that holds the brake shoes through the back plate. Put a spring seat,
spring, and retainer on the anchor pin. Push the retainer onto the anchor pin and rotate the
retainer 90 degrees. Make sure the retainer is in the correct position.
9. Install the link, parking brake, and spring between the parking brake lever and the brake
shoe.
10. Install the other spring retainer that holds the brake shoes. Make sure the parking brake link
and the spring are correctly engaged after the spring retainers are installed.
11. Install the anchor guide on the anchor. Install the pivot plate on its anchor.
12. Lubricate the adjuster cable where it slides in the pivot plate groove.
13. Fasten the link to the adjuster wheel actuator and put the cable around the pivot plate. Raise
the adjuster wheel actuator against the spring tension and connect the link to the anchor.
CAUTION
H2.0-3.5TX [B466]: Be sure to install the white return spring first and then the black return
spring. See Figure 9. Improper assembly can result in brake failure and/or component
damage.
1. RETURN SPRING 4. SPRING AND CABLE ASSEMBLY

2. ANCHOR GUIDE 5. PIVOT PLATE
3. RETURN SPRING
Figure 8. Return Springs, H2.0-3.5TX [B466]
— 10 —
1. WHITE SPRING
2. BLACK SPRING
Figure 9. Proper Installation of Return Springs, H2.0-3.5TX [B466]
NOTE: The shape of the return springs permits them to be installed correctly in only one position. The
arrangement of the return springs on the anchors is shown in Figure 8 and Figure 9.
14. H2.0-3.5TX [B466]: Using the correct tools, install the return springs as follows (see Figure 9):
a. Install the white spring.
b. Install the black spring.
15. H2.0-3.5TX [B466]: Verify that the return springs are properly installed as shown in Figure 9
1. RETURN SPRING
2. GUIDE PLATE
3. RETURN SPRING
4. SPRING ACTUATOR
Figure 10. Return Springs, H1.5-1.8TX, H2.0TXS [B475]
— 11 —
1. INNER SEAL
2. OUTER SEAL
3. BRAKE DRUM
4. INNER BEARING
5. OUTER BEARING
Figure 11. Grease Seals and Bearing Locations
16. H1.5-1.8TX, H2.0TXS [B475]: Use the

correct tools to install the return springs.
Install the return spring. Install the washer
and the retur n spring. The shape of
the return springs permits them to be
installed correctly in only one position. The
arrangement of the return springs on the
anchors is shown in Figure 10.
NOTE: Seal and bearings are to be installed flush

with the hub. Seal is to be installed with no grease
or oil on outside surface.
17. Clean the bearings and lubricate them Figure 12. Inner Grease Seal Installation
with wheel bearing grease. Install the
bearings and seals in the brake drum.
Install the assembly on the axle housing. See Figure 11 and Figure 12.
NOTE: To prevent damage to the inner oil seal when installing the hub, the hub and drum assembly can be
temporarily fastened to the wheel. Align the height of the axle housing with hub bearings. Put grease under
the wheel and slide the wheel toward the axle housing. Install the outer bearing and nut.
18. Adjust the hub bearings by tightening the nut until the hub cannot be rotated. Loosen the nut
30 to 60 degree and fix at hub rotating torque 3.0 to 3.4 N·m (30 to 35 kgf·cm).
19. Apply the loctite on the thread of the set screw and fasten to the thread where aligned to the
V-groove on the washer. See Figure 13
— 12 —
CAUTION
If there is too much clearance, the automatic
adjusters will not operate. If the clearance is
too small, the automatic adjuster cannot turn
the adjuster wheel to increase the clearance,
and the adjuster wheel will not turn until the
brake shoes wear. If the adjuster wheel does
not move for a long operating period, the
adjuster link can wear a spot on the adjuster
wheel so that it will not turn correctly.
NOTE: If the brake shoes were not replaced,

loosen the adjuster wheel approximately 20 teeth.
20. A d j u s t t h e c l e a r a n c e o f t h e b r a ke
1. WASHER
shoes. Put a brake adjustment tool or a 2. BRAKE DRUM ASSEMBLY
screwdriver through the slot in the back 3. WHEEL ADJUSTMENT NUT
plate. Use the tool to rotate the adjuster 4. SET SCREW
wheel. The actuator for the adjuster wheel
will only permit rotation in one direction.
Turn the adjuster wheel until the brake Figure 13. Lock Plate
shoes have expanded against the brake
drum and the hub will not turn. Use a
small screwdriver to lift the actuator away
from the adjuster wheel and turn the
adjuster wheel approximately 20 teeth
in the opposite direction. The brakes will
adjust to the correct clearance when they
are applied while the lift truck is traveling
in the reverse direction.
21. Put liquid sealant, Hyster Part Number
0264159, on the flange of the axle shaft.
Install the axle shaft and capscrews.
Tighten the capscrews in cross pattern to
a torque specified below for your lift truck.
a. For H2.0-3.5TX [B466] lift trucks, tighten
between 90 to 108 N·m (920 to 1100
kgf·cm).
b. For H1.5-1.8TX, H2.0TXS [B475] lift
trucks, tighten between 52 to 62 N·m
(530 to 630 kgf·cm). See Figure 14.
Figure 14. Axle Shaft Tightening Sequence
[5] Adjust
1. Remove the air from the brake hydraulic system. See Brake System Air Removal.
2. Install the wheel on the hub. Tighten the wheel nuts to the torque specified below for your lift
truck.
a. For H2.0-3.5TX [B466] lift trucks, tighten between 196 to 216 N·m (2000 to 2200 kgf·cm)
for 2-2.5 ton, 294 to 343 N·m (3000 to 3500 kgf·cm) for 3-3.5 ton.
b. For H1.5-1.8TX, H2.0TXS [B475] lift trucks, tighten between 196 to 216 N·m (2000 to 2200
kgf·cm).
— 13 —
1. PARKING BRAKE LEVER
2. ADJUSTMENT KNOB
3. PARKING BRAKE CABLES
4. CONNECTING PINS
5. COTTER PINS
6. WASHER
7. SLIDER
8. CLAMP
Figure 15.
3. Start the engine and tilt the mast backward to remove the blocks. Push on the brake pedal.
The pedal must not touch the floor plate. Move the lift truck in REVERSE and push on the
brake pedal to permit adjusting mechanism to operate. Repeat this operation several times.
4. The service brakes must be adjusted before the parking brake can be adjusted. See Figure
16 and the following paragraphs in this section for the correct adjustment of the parking
brake.
— 14 —
PARKING BRAKE REPAIR
[1] Remove and Disassemble
If the lever assembly for the parking brake must be removed from the cowl, use the following
procedure (see Figure 16):
1. Use blocks next to the wheels to make sure the lift truck cannot move. Release the parking
brake lever.
2. Remove the two capscrews that fasten the parking brake to the cowl. Remove the parking
brake lever assembly.
3. Turn the adjuster knob counterclockwise until the brake cables are loosened. Remove the
cotter pins, the washers and the connecting pins and the cables from the slider.
4. Loosen the nuts that fasten the threaded ends of the brake cables to the parking brake lever
assembly.
5. The service brake assembly must be removed before the parking brake cable can be
removed from the back plate of the service brake. A snap ring holds the sheath of the parking
brake cable in the back plate of the service brake. Remove the snap ring and remove the
parking brake cable from the back plate.
[2] Assemble and Install
1. Loosen the two capscrews on the parking lever assembly and install the bracket to the
parking lever assembly by using the capscrews loosened.
2. Make sure the parking brake lever is in the released position. Turn the adjustement knob
counterclockwise until the slider is adjusted to the bottom of the adjustment slot.
3. Adjust the nuts on the ends of the cable assemblies so that the threads of the cable sheaths
extend to 11 mm above the support plate in the lever assembly.
4. Install the cable ends to the slider with connecting pins, cotter pins and washers. Tighten the
upper nut to hold the sheath of the parking brake cables to the parking brake lever with the
support plate.
5. Install the parking brake lever to the cowl and tighten two capscrews.
[3] Adjust
Make sure the service brakes are adjusted and the operation of the automatic adjuster
mechanism is correct before the parking brake is adjusted.
1. Turn the adjustment knob to raise the slider and tighten the parking brake cables. Turn the
adjustment knob until the parking brakes are fully applied with 167 N (15 kgf) of the lever
effort at the top of the lever when the lever is used to apply the parking brake.
2. Test the operation of the parking brake. The lift truck with a capacity load must not move
when the parking brake is applied on a 15 percent grade [a slope that increases 1.5 m in 10 m].
[4] Inspection
Inspect each part by the following procedure. If there are any damages, replace the new parts.
1. Inspect the pin (30) for wear and damage.

2. Inspect the O-ring (3) for wear and damage. Replace if the o-ring is worn or damaged and
— 15 —
does not hold the adjustment knob in position.
3. Inspect any link (13), plate (40) (41) and pins (10) (39) for damage.
4. Inspect the threads on the inner collar (6) and outer collar (5) for damage.
5. Make sure the parking cables are in good condition.
1. GRIP 22. RETAINING RING

2. RELEASE BUTTON 23. CAPSCREW
3. O-RING 24. PUSH NUT
4. PLATE 25. CAPSCREW
5. ADJUSTMENT KNOB 26. SPACER
6. INNER COLLAR 27. RUBBER
7. LEVER 28. SPACER
8. HOOK 29. NUT
9. SPRING 30. PIN
10. PIN 31. NUT
11. PIN 32. SLIDER
12. RETAINING RING 33. PIN
13. LINK 34. PUSH NUT
14. SPACER 35. PIN
15. SWITCH 36. WASHER
16. CAPSCREW 37. NUT
17. GUIDE PLATE 38. CAPSCREW
18. GUIDE PLATE 39. SPACER
19. BRACKET 40. PLATE
20. CAPSCREW 41. PLATE
21. CAPSCREW 42. COTTER PIN
Figure 16. Parking Brake Lever Adjustment (Left Hand Side Shown)
— 16 —
MASTER CYLINDER REPAIR
[1] Remove
1. Remove the floor plate, and kick plate, from the lift truck for access to the master cylinder.
2. Remove the brake hydraulic line from the master cylinder. See Figure 17.
3. Disconnect the brake fluid supply hose from the master cylinder. Plug hose to prevent
reservoir from draining.
4. Remove the brake fluid reservoir and supply hose from the lift truck.
5. Remove the cotter pin and rod end pin that is attached to the brake linkage lever arm.
6. Remove capscrews that hold master cylinder to bracket assembly.
1. RESERVOIR
2. CAPSCREWS
3. BRAKE FLUID SUPPLY HOSE
4. CAPSCREWS
5. MASTER CYLINDER
6. BRAKE HOSE
7. PUSH ROD
8. NUT
9. YOKE
10. ROD END PIN
11. COTTER PIN
12. STOP LAMP SWITCH
13. BRACKET
14. CAPSCREWS
Figure 17. Master Cylinder and Reservoir Assembly
[2] Disassemble
CAUTION
When the piston is removed or installed, make sure the cylinder bore and piston are not
scratched or damaged.
1. Remove yoke, push rod, nut, boot, fitting, seal and bleeder valve. See Figure 18.
— 17 —
1. YOKE 10. PISTON
2. NUT 11. SPACER
3. PUSH ROD 12. PISTON CUP
4. BOOT 13. RETAINER
5. SNAP RING 14. SPRING
6. CYLINDER HOUSING 15. CHECK VALVE
7. SEAL 16. VALVE SEAT
8. FITTING 17. BLEEDER VALVE
9. PISTON SEAL 18. CAP
Figure 18. Master Cylinder
2. Remove snap ring, piston seal, and piston.

3. Remove spacer, piston cup, retainer, spring, check valve, and valve seat.
NOTE: Install new seals when the master cylinder is disassembled for repair.
— 18 —
[3] Clean and Inspect
CAUTION
DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or brake linings. Use
a solvent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid
or on the linings.
Inspect the bore of the master cylinder for holes or scratches. Replace the master cylinder
assembly, if there is damage.
[4] Assemble
1. Install valve seat, check valve, spring, retainer, piston cup, and spacer.
2. Install the piston, piston seal, and snap ring.
3. Install bleeder valve seal, fitting, boot, nut, push rod, and yoke.
[5] Install and Adjust
1. Install brake fluid reservoir, supply hose and master cylinder on lift truck as an assembly. See
Figure 17.
2. Install brake hydraulic line on master cylinder.
3. Orient master cylinder side of brake hose assembly.
4. Tighten fitting nuts at each end of brake pipe and hose assembly to 13 to 18 N·m (130 to 185
kgf·cm).
5. Apply a layer of multipurpose grease to the rod end pin and, with twisting motion, insert
through yoke and the inching/brake pedal. Install cotter pin into the rod end pin.
6. Adjust free pedal per the following procedure:
a. Loosen nut and screw it away from yoke.
b. Turn push rod counterclockwise, as viewed from top, until push rod can be moved from side to
side.
c. Turn push rod clockwise until it can no longer be moved from side to side.
d. Turn push rod counterclockwise 1/3 to 2/3 turns.
e. Tighten nut to lock the push rod and the yoke.
f. Verify free pedal is 3 to 5 mm. See Figure 19.
7. Flush with brake fluid and air bleed system. See Brake System Air Removal.
8. Adjust fluid level until level is within 2.5 mm of MAX line.
9. Verify all connections are leak-free.
10. Check adjustment of brake pedal as described in Brake Pedal Adjustment.
11. Install floor plate, and kick plate, on lift truck.
— 19 —
SERVICE BRAKES ADJUSTMENT
The following procedure is for newly installed brake shoes. If the lift truck has been operated for
more than 25 hours and has correct pedal height, the brakes normally will not need adjustment.
1. See the procedure How to Put Lift Truck on Blocks in the Periodic Maintenance section for
your lift truck or the Operating Manual for your lift truck. Put the lift truck on blocks so that
the drive wheels can be removed. Remove the drive wheels.
2. Use an adjuster tool to rotate the adjuster wheel so that the teeth of the wheel move
downward. This adjustment expands the brake shoes. Adjust the brake shoes so that the
brake drum will not rotate.
NOTE: If the brake shoes were not replaced, loosen the adjuster wheel approximately 20 teeth.
3. Push the automatic adjuster lever away from the adjuster wheel with a small screwdriver. Use
the adjuster tool to loosen the adjuster wheel approximately 20 teeth (new brake shoes).
4. Install the drive wheels. Remove the lift truck from the blocks. Operate the lift truck in the
FORWARD and REVERSE directions. Stop the lift truck 10 times in each direction. This
procedure causes the brake shoes to wear a small amount and fit the brake drum better.
— 20 —
BRAKE SYSTEM AIR REMOVAL
There are two commonly used methods to remove air from the brake system. The preferred
method is using a pressure bleed system. The other method is by applying pressure using the
brake pedal.
[1] Using Pressure Bleed System

NOTE: Adjust the service brakes before the air is removed from the brake system.
1. Fill the brake fluid reservoir with brake fluid.

2. Place one end of a rubber hose on the bleeder screw of each wheel cylinder. Place the other
end of each hose into a clear container of brake fluid.
3. Connect a pressure bleeder to the brake fluid reservoir.
4. Loosen the bleeder screws at the wheel cylinders one turn.
NOTE: While applying air pressure to the pressure bleeder, check the level of the brake fluid in the reservoir
for the master cylinder. Make sure to obtain the brake fluid at the correct level to avoid forcing more air into
the brake system.
5. Apply 34.5 kPa (0.4kgf/cm2) of air pressure to the pressure bleeder, forcing fluid through the
lines until all air is removed from the system. Close the bleeder screws.
6. Check the level of the brake fluid in the reservoir for the master cylinder. Fill the brake fluid
reservoir to the correct level.
[2] Using Brake Pedal Pressure
Perform the following procedure to remove used brake fluid from the remainder of the brake
system.
1. Ensure that the master cylinder reservoir is filled with brake fluid and the appropriate free
play exists between the push rod and the piston.
2. Put one end of a rubber hose on the bleeder valve of the master cylinder. Put the other end
of the hose into a empty container.
3. Loosen the bleeder valve at the master cylinder one turn so that the used brake fluid can be
removed from the brake system and close the bleeder valve.
4. Slowly push the brake pedal and hold it at the end of its stroke. Loosen the bleeder valve
so that the air in the master cylinder can be removed with the fluid. Close the bleeder valve
when the fluid flow stops. Release the brake pedal.
NOTE: The new brake fluid will be easily recognized, as the color will be more clear than the used fluid
which will be darker.
5. Repeat Step 4 until there is new brake fluid in the container and no air exists in the fluid
coming out of master cylinder.
6. Repeat Step 1 through Step 5 for the wheel cylinder.
7. Check the level of the brake fluid in the reservoir for the master cylinder during the procedure.
Make sure to keep the brake fluid at the correct level.
8. Repeat the procedure for the other wheel cylinder.
— 21 —
BRAKE PEDAL ADJUSTMENT, 1-PEDAL OPTION
Check and adjust the inching/brake pedal by the following procedure if the control valve on the
transmission, the master cylinder, the service brakes and the pedal linkage are repaired and re-
installed. See Figure 19.
1. Adjust the pedal height to 169 to 174 mm from the top surface of the floor plate (160 to 165
mm from the top of the floor mat) by the capscrew (3).
2. Adjust the inching/brake pedal stroke for actuating the bell crank (4) (overlap stroke of inching
and brake) to 17 to 21 mm by the stop lamp switch (5).
3. Adjust the free play on the pedal for actuating the master cylinder (6). See INSTALL AND
ADJUST of MASTER CYLINDER REPAIR.
4. Adjust the free play on the pedal for actuating the inching cable (7) to 2.5 to 7.5 mm by the
adjustment nut on the inching cable (8). Ensure the bell crank on the inching valve (9) does
not push the spool (10) when the pedal (2) in released.
1. BRACKET
2. INCHING/BRAKE PEDAL
3. CAPSCREW
4. BELL CRANK
5. STOP LAMP SWITCH
6. MASTER CYLINDER
7. INCHING CABLE
8. ADJUSTMENT NUTS
9. BELL CRANK
10. SPOOL
Figure 19.
— 22 —
BRAKE PEDAL ADJUSTMENT, 2-PEDAL OPTION
See Figure 20.
1. Adjust the inching pedal height to 160 to 165 mm from the top surface of the floor plate (151
to 156 mm from the top of the floor mat) by the capscrew (3).
2. Adjust the inching pedal stroke for actuating the brake pedal (4) (overlap stroke of inching
and brake) to 19 to 25 mm by the stop lamp switch (5).
3. Ensure the brake pedal height is 160 to 165 mm from the top surface of the floor plate (151
to 156 mm from the top of the floor mat). Repeat Step 1 through Step 3 if the measurement
is out of the range.
4. Adjust the free play on the brake pedal for actuating the master cylinder (6). See INSTALL
AND ADJUST of MASTER CYLINDER REPAIR.
5. Adjust the free play on the inching pedal for actuating the inching cable (7) to 2.5 to 7.5 mm
by the adjustment nut on the inching cable (8). Ensure the bell crank on the inching valve (9)
does not push the spool (10) when the inching pedal (2) is released.
1. BRACKET
2. INCHING PEDAL
3. CAPSCREW
4. BARKE PEDAL
5. STOP LAMP SWITCH
6. MASTER CYLINDER
7. INCHING CABLE
8. ADJUSTMENT NUT
9. BELL CRANK
10. SPOOL
Figure 20.
— 23 —
TORQUE SPECIFICATIONS
Back Plate to Axle Mount Capscrews
H2.0-3.5TX [B466]
255 to 306 N·m (2600 to 3120 kg·cm)
H1.5-1.8TX, H2.0TXS [B475]
152 to 167 N·m (1550 to 1700 kg·cm)
Wheel Cylinder Capscrews
H2.0-3.5TX [B466]
18 to 26 N·m (133 to 195 kg·cm)
H1.5-1.8TX, H2.0TXS [B475]
15 to 23 N·m (150 to 230 kg·cm)
Axle Shaft Capscrews
H2.0-3.5TX [B466]
90 to 108 N·m (920 to 1100 kg·cm)
H1.5-1.8TX, H2.0TXS [B475]
52 to 62 N·m (530 to 630 kg·cm)
Wheel Nuts
H3.0-3.5TX [B466]
294 to 343 N·m (3000 to 3500 kg·cm)
H1.5-1.8TX, H2.0TXS [B475] and H2.0-2.5TX [B466]
196 to 216 N·m (2000 to 2200 kg·cm)
— 24 —
HMM010001
Frame
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

and Repair
weight of the load.
remove parts.
needs repairs.
WARNING
CAUTION
—1—
GENERAL
WARNING
The lift truck must be put on blocks for some types of maintenance and repairs. The removal
of the following assemblies will cause large changes in the center of gravity: mast, drive
axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put
additional blocks in the following positions to maintain stability:
• Before removing the mast and drive axle, put blocks under the counterweight so the lift
truck cannot fall backward.
• Before removing the counterweight, put blocks under the mast assembly so the lift truck
cannot fall forward.
The surface must be solid, even, and level when the lift truck is put on blocks. Make sure
that any blocks used to support the lift truck are solid, one-piece units. See the Operator
Manual or the section Periodic Maintenance for lift truck models H2.0-3.5TX [B466] or
Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS [B475].
This section contains the description of the frame (see Figure 1) and some connected parts.
Procedures for removing and installing the counterweight, hood, overhead guard, engine, cooling
system, exhaust system, and LPG fuel tank and bracket are found in this section. Checks for the
operator restraint system and procedures for the repair of tanks and installation of safety labels
are also included.
DESCRIPTION
The frame is one weldment and includes the hydraulic tank and the fuel tank for gasoline or
diesel fuel. See Figure 1.
There is a counterweight for each capacity of lift truck. The counterweights are similar, but
are different weights (see Table 1 and Table 2). The muffler is fastened to the frame inside the
counterweight.
The overhead guard, cowl, and hood are installed on the frame. The hood is connected to the
frame with hinges. The gas-controlled spring provides assistance when raising the hood and hold
the hood in the open position. The floor plate and side covers can be removed for access to the
engine, transmission, and other components.
—2—
1. FRAME SIDE WLDMNT LH 10. PLATE REAR XMBR
2. FRAME SIDE WLDMNT RH 11. BRACKET PUMP
3. FRAME REAR WLDMT 12. BRACKET FLOOR PLATE LH
4. DA - MOUNT - L.H 13. BRACKET FLOOR PLATE RH
5. DA - MOUNT - R.H 16. BRACKET RADIATOR
6. PLATE STIFFNER 18. BRACKET MUFFLER LH
7. ENGINE BRACKET WLDMT 19. BRACKET MUFFLER RH
8. CROSS MEMBER 20. BRACKET TAIL PIPE
9. GUSSET REAR
Figure 1. Frame
—3—
HOOD, SEAT, AND SIDE COVERS REPLACEMENT
[1] Remove
1. Slide the seat to the closest position to the steering column.

2. Fully tilt the steering column forward.
3. If your truck is equipped with an LPG tank, swing the tank off to the side. See Figure 8.
4. Raise the latch on the left, front corner of the hood to unlatch and lift up the hood. See Figure 2.
5. Remove the floor mat and floor plate. See Figure 4.
1. HOOD
2. GROMMET
3. HINGE ASSY
4. HEXAGON FLANGE NUT
5. WA HEX HEAD BOLT
6. COVER HOOD LOCK
7. HOOD LOCK ASSY
8. HOOK
9. WA HEX HEAD BOLT
10. STRIP
11. GAS SPRING
12. WASHER
Figure 2. Hood and Seat Arrangement
—4—
6. Remove the two capscrews holding the left and right rear side panels to the frame. Remove
the covers from the frame. See Figure 3 and Figure 4.
7. Remove the four capscrews holding the left and right front side covers to the frame. Remove
covers.
8. Fully lower the steering column.
9. Remove back side steering column cover by loosening the retention screws, then remove the
front column cover by loosening the screws.
10. Remove the fasteners securing the dash panels to the top of the cowl. Lift to remove the
dash panels.
11. Lift the kick panel to remove it from the truck. See Figure 3.
12. Disconnect the seat harness connector.
CAUTION
When removing the seat from the hood, do not use an impact wrench to remove the
capscrews. Damage can be caused to the threads on the screws and in the holes.
13. If the seat is to be removed and truck is equipped with a non-swivel seat, remove the seat
harness from the brackets that are attached to the underside of the hood. Remove the cable
clips from the seat harness.
14. Remove the four nuts and washers holding the seat to the hood. Lift the seat off the hood.
Pull the seat harness through the hood.
15. Remove the capscrews and washers at the top of the gas spring to disconnect the gas spring
from the hood. Lay gas spring off to the side.
16. Remove the hinge screws, located in the rear of the hood.
17. Lift the hood from the truck. See Figure 2.
1. PANEL FRONT WLDMT LH

5. WA HEX HEAD BOLT
8. SPLASH GUARD
9. PACKING FUEL
18. KICK PANEL
19. WA HEX HEAD BOLT
20. PUSH RIVET
28. COVER COLUMN BACK
Figure 3. Side Cover, Floor Plate, and Cowl Components
—5—
2. PANEL FRONT WLDMT RH
3. PANEL REAR WLDMT LH
4. PANEL REAR WLDMT RH
5. WA HEX HEAD BOLT
6. COVER RADIATOR
7. BOLT SPECIAL
10. STEP WLDMT
11. STEP WLDMT
13. DASH PANEL LH
14. DASH PANEL RH
15. COVER PARKING LEVER
16. COVER RESERVE TANK
17. HOLDER CUP
21. PLATE C/V LEVER
22. TAPPING SCREW
23. FLOOR PLATE WLDMT
24. MAT FLOOR CENTER
25. MAT FLOOR RH
26. MAT FLOOR LH
27. COVER COLUMN FRONT
30. SCREW
Figure 4. Side Covers, Floor Plate, and Cowl Components
—6—
[2] Install
1. Place the hood onto the lift truck frame.

2. Install the hinge screws, located in the rear of the hood, and tighten them to 38 N·m (28
lbf ft). See Figure 2.
3. Align the top holes in the gas spring to the hole in the hood. Install the capscrews and
washers to attach the gas spring to the hood. Tighten the capscrew to 19.2 N·m (170 lbf in).
4. Install hook weldment to the frame. Check that hood lock is in center of the hook bar when
hood closes. Open and close the hood to ensure that the hood lock catches the hook bar
properly. If the hood lock and hook bar do not close properly, loosen the capscrews on the
hood lock or hook weldment, and adjust the alignment. See Figure 7.
5. Push down until hood just touches rubber bumper. Make sure hood lock is still in center of
hook bar. Open hood and tighten capscrews for hood lock and/or hook weld’t.
6. Check operation of hood lock. Have an operator sit in the seat. Make sure hood is fully
closed. Also check that hood touches rubber bumper. If necessary, repeat Step 5.
CAUTION
When installing the seat to the hood, do not use an impact wrench to install the capscrews.
Damage can be caused to the threads on the screws and in the holes.
7. Place the seat on the hood and thread the

seat harness through the hole in the hood.
See Figure 2.
8. Tighten the nuts and washers to attach
seat to hood.
9. Tie seat harness with cable clips and
insert harness into brackets under hood.
10. Install kick panel onto truck. See Figure 3
and Figure 4.
11. Install dash panels to top of cowl.
12. Install steering column covers to column
support.
13. Insert four capscrews and install the left
and right front side covers to frame. See
Figure 3 and Figure 4.
14. Install the left and right rear side covers to
frame using two capscrews. See Figure 3
and Figure 4.
15. Install the floor mat and floor plate.
16. If truck is equipped with an LPG tank, 1. LOCK ASS’Y
swing LPG tank into position on back of 2. HOOK WELD’T
counterweight. See Figure 8. 3. CAPSCREW
17. Adjust the steering column and seat
positions.
Figure 7. Hood Lock Adjustment
—7—
LPG TANK AND BRACKET REPLACEMENT
[1] Remove
(1) LPG Tank
WARNING
LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8
m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source.
NOTE: The LPG tank bracket used on this line of trucks to mount the LPG tank onto the counterweight is
the swings out to the side and drops down (EZXchange Bracket). See Figure 8.
1. LPG tanks can be removed and replaced indoors only if the lift truck is at least 8 m (26 ft)
from any flame or ignition source. Move the lift truck to an the area where LPG tanks are
changed.
2. Turn the shutoff valve clockwise until the valve is completely closed.
3. Run the engine until it stops. Turn the key switch to the OFF position.
4. Disconnect the quick-disconnect fitting on the LPG tank. See Figure 8.
5. Pull the bracket release pin, push the latch release button and swing the tank and bracket
out to the side of the lift truck. Then swing the tank down to the side of the truck for ease of
removal. See Figure 8.
6. Unlatch the tank straps and remove the LPG tank from the bracket.
(2) LPG Bracket
NOTE: The LPG tank must be removed from the lift truck before removing the LPG bracket. See LPG Tank.
1. Disconnect the hose from the LPG fuel adapter on the overhead guard leg and remove the
hose from the lift truck. See Figure 9
WARNING
When removing the capscrews for the LPG tank bracket, only remove the capscrew (Figure
10) with the LPG bracket in the swing-out or drop-down position. The LPG tank bracket
is heavy and difficult to handle if all the capscrews are removed with the bracket in the
swing-out position. Personal injury and damage to the lift truck can result if the bracket is
removed and handled while in the swing-out or drop-down position.
2. Pull the bracket release pin, grab the bracket handle, and swing the bracket out to the side of
the lift truck. Remove the capscrew (Figure 10).
3. Pull the bracket release pin and swing the LPG tank bracket back into the resting position on
the counterweight. Be sure that the latch clicks shut and locks.
—8—
1. HOSE LPG LINE
2. ELBOW
3. COUNTER WEIGHT
Figure 8. LPG Tank and Bracket
Figure 9. LPG Tank Hose Connections
—9—
1. CAPSCREW
2. RELEASE PIN
3. LATCH RELEASE BUTTON
4. HANDLE
Figure 10. LPG Tank Bracket Removal
4. Remove the rest of the capscrews, labeled (Figure 10), that attach the LPG bracket to the
counterweight.
5. Remove the LPG tank bracket from the lift truck.
[2] Install
(1) LPG Bracket
1. Place the LPG bracket onto the counterweight. Be sure to align the holes on the counter-
weight with the holes on the bracket. See Figure 9 and Figure 10.
2. Install and tighten the capscrews (Figure 10) to secure the LPG bracket onto the counter-
weight.
3. Pull the bracket release pin, push the latch release button and pull the bracket handle to
swing the bracket out to the side of the lift truck. Install and tighten the capscrew (Figure 10).
(2) LPG Tank
NOTE: The LPG bracket must be in the swing-out position to install the LPG tank. Since your lift truck has
the swing-out and drop-down bracket (EZX change Bracket), position the bracket in the drop-down position.
— 10 —
WARNING
When closing the LPG tank strap, do not wrap your fingers around the strap handle. The
strap can close quickly and with enough force to cause injury to the fingers and hand.
1. Place the LPG tank into the bracket. Secure the tank straps around the tank and close the
straps.
2. Pull the release pin (see Figure 10) and swing the LPG tank bracket into the resting position
on the counterweight. Be sure that the bracket locks into position.
3. Connect the hose to the LPG fuel adapter on the overhead guard leg. See Figure 9.
4. Connect the quick-disconnect fitting on the LPG tank. See Figure 9.
5. Turn the fuel valve counterclockwise to open the fuel valve.
6. Inspect the fuel system for leaks when the fuel valve is open. There are four methods used to
inspect the fuel system for leaks:
a. Sound - Listen for sound of LPG escaping from a tank fitting or hose connection.
b. Smell - LPG has a very distinctive odor. If you smell LPG, DO NOT start the engine.
c. Soapy Water - This method is used in conjunction with Step b above. If the odor of LPG is
present, but escaping fuel cannot be heard, apply soapy water to the fittings and observe
for bubbles.
d. Frost - If the amount of LPG escaping is sufficient, frost may appear on the fittings.
— 11 —
COUNTERWEIGHT REPLACEMENT
[1] Remove
WARNING
The lift truck must be put on blocks for some types of maintenance and repair. The removal
The surface must be solid, even, and level when the lift truck is put on blocks. Make sure
that any blocks used to support the lift truck are solid, one-piece units. See the Operating
Manual or the section Periodic Maintenance for lift truck models H2.0-3.5TX [B466] and
Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS [B475].
WARNING
Do not operate the lift truck if the capscrew for the counterweight is not installed. When the
capscrew is removed, the counterweight can fall from the lift truck.
WARNING
LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8
m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source.
NOTE: The counterweight is held in position on the frame by two hooks that are part of the frame. One M24
× 3 × 140 capscrew holds the counterweight to the lower part of the frame on lift truck models H2.0-3.5TX
[B466]. One M24 × 3 × 90 capscrew holds the counterweight to the lower part of the frame on lift truck
models H1.5-1.8TX, H2.0TXS [B475]. See Figure 11.
NOTE: If lift truck is equipped with an overhead exhaust system, remove the overhead exhaust pipe before
removing the counterweight. See the section Exhaust System Repair for the procedures.
1. If the lift truck has an LPG fuel system, use the procedures in the section LPG Tank and
Bracket Replacement, to remove the LPG tank and bracket so that the counterweight can be
removed.
Additional information on the LPG fuel system can be found in the following sections:
• LPG Fuel System, Mazda M4-2.0G and M4-2.2G Engines
— 12 —
WARNING
The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough
capacity to lift the weight. The approximate weights of the counterweight castings are
shown in Table 1 and Table 2.
2. Install a lifting eye in the lift hole of the counterweight. See Figure 11 and Figure 12.
Connect a crane to the lifting eye and raise the crane until it holds part of the weight of the
counterweight. Remove the capscrew that holds the counterweight to the frame. Use the
crane to lift the counterweight from the lift truck. Put counterweight on the floor so that it has
stability and will not fall over. Take care not to damage exhaust or cooling components.
1. FRAME HOOK
2. LOWER FRAME MOUNT
3. TOW PIN
4. ROLL PIN
5. CAPSCREW
Figure 11. Counterweight Installation
— 13 —
[2] Install
1. Make sure the seals are on the counterweight. See Figure 12. Use a crane to install the
counterweight on the lift truck. When the counterweight is installed, make sure the hooks on
the frame fully engage the counterweight so it is aligned with the parts of the frame. Install
and tighten the M24 × 3 capscrew to 555 N·m (409 lbf ft).
Table 1. Weight of Counterweights, Lift Truck Models H1.5-1.8TX, H2.0TXS [B475]
Model kg
H1.5TX 811
H1.8TX 1014
H2.0TXS 1200
Table 2. Weight of Counterweights, Lift Truck Models H2.0-3.5TX [B466]
Model kg
H2.0TX 1188
H2.5TX 1529
H3.0TX 1917
H3.5TX 2216
1. COUNTERWEIGHT
Figure 12. Counterweight
— 14 —
2. If the lift truck has an LPG fuel system,
use the procedures in the section LPG
Tank and Bracket Replacement, to install
the LPG tank and bracket after the
counterweight has been installed. See
Figure 8.
3. If lift truck is equipped with an overhead
exhaust system, install the overhead
exhaust pipe. See the section Exhaust
System Repair for the procedures.
1. TOW PIN
[3] Tow Pin, Remove and Install
1. Remove the tow pin from the counterweight

by pulling the extended wire. See Figure
13.
2. Install tow pin into counterweight. Figure 13. Tow Pin
— 15 —
OVERHEAD GUARD REPLACEMENT
[1] Remove and Install
WARNING
Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.
WARNING
DO NOT weld mounts for lights or accessories to legs of the overhead guard. Changes
that are made by welding, or by drilling holes that are too big or in the wrong location, can
reduce the strength of the overhead guard.
See your dealer for Hyster lift trucks BEFORE performing any changes to the overhead
guard.
NOTE: The lift trucks covered in this manual are equipped with either a high or low overhead guard. The
removal and installation procedures for both types of overhead guards are the same.
No welding or drilling on legs of overhead guard is permitted as per previous WARNING.
NOTE: The lifting device can be connected to any number of positions on the overhead guard depending
upon the lifting device available. The ideal choices are a four point sling connected to all four corners on the
top of the overhead guard, or a two point sling connected to two opposite corners of the overhead guard. If
a single point hoist is used, make sure that the lift point is as close to the center of the overhead guard. If
during the initial start of the lift the overhead guard is off balance lower immediately and move the hoist to a
more centered point.
1. Connect a lifting device to remove or install the overhead guard. Loosen clamp and
disconnect the air intake hose from the tube on the left hand rear leg. Remove capscrew
1. CLAMP
2. AIR INTAKE HOSE
3. CAPSCREW
4. NUT
Figure 14. Disconnect Air Intake Hose
— 16 —
retaining the exhaust pipe on the right hand rear leg. See Figure 14.
2. Disconnect any wires between the frame and the overhead guard. When the overhead guard
is lifted from the frame, make sure that any electrical wires are moved through the holes in
the frame so that they are not damaged.
3. The rear legs of the overhead guard have two capscrews that are located under the hood
inside the engine compartment, next to the radiator. Remove and install the capscrews. See
Figure 15.
4. Remove and install the four capscrews on the front legs of the overhead guard.
5. When installing the overhead guard, tighten the capscrews for the overhead guard legs to 66
N·m (49 lbf ft). See Figure 15.
[2] Tail, Backup, and Brake Lights, Replace
See the section Electrical System for the procedures to replace these lights.
1. OHG WLDMT
3. CAPSCREWS
9. JOIT TUBE
10. VINYL TUBE
11. VINYL TUBE
12. MIRROR BACK
13. GRILL AIR INLET
14. CAP OHG
Figure 15. Overhead Guard
— 17 —
OPERATOR RESTRAINT SYSTEM REPLACEMENT
The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of the
operator restraint system. Each item must be checked to make sure it is attached securely,
functions correctly, and is in good condition. See Figure 16.
The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is
not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced.
Make sure the seat rails and hood latch hook are not loose. The seat rails must lock securely in
position but move freely when unlocked. The seat rails must be securely attached to the mounting
surface. The hood must be fully closed. Lift the hood to make sure it is closed and will not move.
Adjust hood, hood latch, and hook weldment when any of the parts of the operator restraint
system are installed or replaced. See the section Hood, Seat, and Side Covers Replacement in
this manual for the adjustment procedures for the hood.
1. SEAT
2. FLANGE NUT
Figure 16. Operator Restraint System
— 18 —
ENGINE REPLACEMENT
[1] Remove Engine Only
WARNING
The lift truck must be put on blocks for some types of maintenance and repairs. The removal
The surface must be solid, even, and level when the lift truck is put on blocks.
Make sure that any blocks used to support the lift truck are solid, one-piece units. See the
Operating Manual or the section Periodic Maintenance for lift truck models H2.0-3.5TX [B466]
and Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS [B475].
The engine can be removed with or without the transmission. Follow the procedures below to
remove the engine without the transmission.
WARNING
Always disconnect the cables at the battery before you make repairs to the engine.
Disconnect the cable at the negative terminal first.
1. Run engine until all fuel is gone and engine stops.

2. If lift truck is equipped with an LPG fuel tank, swing tank to the side. See the section LPG
Tank and Bracket Replacement, for the procedures. Remove the floor plates. Remove the
hood and rear side covers. See the section Hood, Seat, and Side Covers Replacement for
the procedures.
3. Remove the air filter and bracket assembly, disconnect the battery cables. Remove the
battery and battery tray. Remove the hydraulic hose between the pump and the tank. Put a
cap on the tank fitting. Remove the supply line from pump to the main control valve.
4. Disconnect the coolant hoses from the radiator. Remove the radiator and fan shroud. See the
section Cooling System for the removal procedures.
5. Disconnect the throttle linkage (see the section Powershift Transmission, Repair).
Disconnect the exhaust system.
6. Disconnect the wires and wiring harness at the engine. Disconnect the fuel lines at the
engine.
7. Use the access port on the side of engine and remove the four bolts that attach the flywheel
to the torque converter. See Figure 17.
8. Connect a lifting device to the engine. Put a block under the transmission housing to support
the transmission.
WARNING
The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine.
The engine can weigh approximately 340 kg (750 lb).
— 19 —
10. Remove the nuts and bolts from the engine mounts. Remove engine end plate to
transmission bolts. Separate engine from transmission.
11. Use the lifting device to carefully move the engine away from the torque converter. Make sure
all hoses, wires, and cables are disconnected from the engine, then lift the engine from the
frame. See Figure 18.
1. ACCESS PORT
2. TRANSMISSION ASSEMBLY
3. ENGINE ASSEMBLY
Figure 17. Yanmar Diesel Engine Removal
MAZDA ENGINE
1. FRAME
2. ENGINE MOUNT
3. NUT
Figure 18. Engine Removal
— 20 —
[2] Remove Engine and Transmission
The engine can be removed with or without the transmission. Follow the procedures below to
remove the engine with the transmission.
1. Perform Step 1 through Step 6 from the section Remove Engine Only.
2. Remove the brake and throttle pedals. See Figure 6. Disconnect the inching cable at the
transmission control valve.
3. Disconnect the wiring harness from transmission. Disconnect transmission cooling lines.
4. Drain the oil from the transmission. Connect a device to support the transmission.
5. Remove the capscrews that hold the transmission mount to the transmission.
WARNING
The engine and transmission are heavy. Make sure that any lifting device has enough
capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500
lb).
6. Connect a lifting device to the engine and transmission. Make sure the engine and
transmission assembly can be raised at an angle so they will clear the frame. Remove the
nuts and bolts from the engine mounts (Figure 17). Use the lifting device to carefully lift the
engine and transmission from the frame. Slip the universal joint yoke out of the drive axle.
Make sure to not damage the seal.
[3] Install Engine Only
The engine can be installed with or without the transmission. Follow the procedures below to
install the engine without the transmission.
WARNING
The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine.
The engine can weigh approximately 340 kg (750 lb).
1. Connect lifting device to engine and lift engine into frame. Install engine to transmission.
2. Install the torque converter to the transmission and install the engine end plate to
transmission bolts.
3. If isolators fell from engine mounts during removal, install isolators to engine mounts. Install
the nuts and bolts for the engine mounts to secure engine to frame. See Figure 18. Tighten
the nuts to 150 N·m (110 lbf ft).
4. Use access port on side of engine and install four bolts to hold torque converter to flywheel.
Tighten nuts to 41 N·m (417 kg/cm). See Figure 17.
5. Install exhaust pipe to exhaust manifold.
6. Connect the wires and wiring harnesses at the engine. Connect the fuel lines at the engine.
7. Connect the throttle linkage (see the section Powershift Transmission, Repair). Install the
air filter assembly.
8. Install the hydraulic hose between the pump and the tank. Install the hydraulic filter and
hoses. Connect the supply line to the main control valve.
9. Install the radiator and fan shroud. See the section Cooling System for the installation
procedures. Connect the coolant hoses and lines to the transmission.
10. Connect the battery cables to battery. Install the battery and battery tray. Install the rear side
— 21 —
covers, floor plates, and hood. See the section Hood, Seat, and Side Covers Replacement
for the procedures. If lift truck is equipped with an LPG tank, swing tank into position on truck.
See the section LPG Tank and Bracket Replacement, for the procedures.
11. Check all fluid levels as described in the section Periodic Maintenance for lift truck models
H2.0-3.5TX [B466] and Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS
[B475].
[4] Install Engine and Transmission
The engine can be installed with or without the transmission. Follow the procedures below to
install the engine with the transmission.
1. Put the lift truck on blocks so that you have access under the lift truck. See the Operating
Manual or the section Periodic Maintenance for lift truck models H2.0-3.5TX [B466] and
Periodic Maintenance for lift truck models H1.5-1.8TX, H2.0TXS [B475] for the procedures.
Connect a lifting device to the engine and transmission. Lift the engine and transmission into
the frame.
WARNING
The engine and transmission are heavy. Make sure that any lifting device has enough
capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500
lb).
2. Install the universal joint yoke into the drive axle. Be sure to not damage the seal.
3. Install the nuts and bolts for the engine mounts (see Figure 18) and transmission mount.
Ensure that the engine is properly set on the mounts. Tighten the nuts to 150 N·m (110 lbf ft).
4. Connect the transmission wiring harness to transmission. Connect transmission cooling lines.
Connect the inching cable.
5. Install the brake and throttle pedals. See Figure 6.
6. Perform Step 7 through Step 11 from section Install Engine Only.
— 22 —
THROTTLE PEDAL AND CABLE ADJUSTMENT
CAUTION
The adjustment of the throttle cable must be correct or it can break during operation.
The accelerator pedal or the MONOTROL pedal must reach the pedal stop by the time the
throttle plate in the carburetor is fully open.
[1] Standard Throttle Pedal (See Figure 20.)
NOTE: Care about interference between kick panel and accel pedal at operating pedal.
1. THROTTLE PEDAL
2. WA HEX HEAD BOLT
3. CUP SQUARE NECK B
4. NUT
Figure 20. Throttle Pedal and Cable Adjustment
— 23 —
Table 3. Accel Pedal Adjustment (Ref.)
Stopper bolt height Adjust the idle Pedal set angle at

Model Engine (Hmm) stroke (Xmm) full stroke (Y°)
B475/B466 GAS/LPG 53 9±2 24
B475 DSL 2.7L 68 12.5 ± 2 31
B466 DSL 2.7L 57 12.5 ± 2 25
B466 DSL 3.0L 53 12.5 ± 2 24
NOTE: Each time the throttle system is disassembled, it is important to adjust the throttle cable.
Adjust the throttle pedal when the engine is running at idle and at the normal operating
temperature.
With the engine at idle and the throttle pedal released, adjust the up-position pedal stop until the
tension is removed from the throttle cable.
1. Adjust the idle speed to 725 ± 25 rpm for Gasoline/LPG, 775 ± 25 rpm for Diesel.
2. Make sure the throttle linkage at the pedal assembly is in the correct position.
3. Push the throttle pedal until it stops against the pedal stop. Adjust the throttle cable so that
the pedal stops on the pedal stop just as the throttle plate reaches the wide open position.
Use the nuts at the pedal end of the cable housing to change the adjustment of the cable.
4. Adjust the pedal stop so that the pedal and throttle lever reach the full return positions at the
same time.
[2] Monotrol Pedal
1. Remove floor plate and disconnect throttle cable from the bellcrank and engine. See Figure
21.
2. Fully depress throttle pedal and verify that the dimension of stopper bolt height is correct.
3. If dimension is not correct, adjust the stopper bolt. After adjusting the stopper, tighten jam
nuts to 8 to 15 N·m.
4. Connect throttle cable to bellcrank and engine.
5. With throttle pedal in full up position, adjust throttle cable, to provide the pedal free play
specified.
6. Install floor plate. Fully depress the pedal and adjust pedal stop so that it touches the stop
plate. Tighten jam nuts to 8 to 15 N·m.
— 24 —
NOTE: Confirm pedal switch is turned on before lever assy pull the accel cable.
1. THROTTLE PEDAL
2. WA HEX HEAD BOLT
3. CUP SQUARE NECK B
4. NUT
Figure 21. Monotrol Pedal and Cable Adjustment
Table 4. Pedal Adjustment (Ref.)
Stopper bolt height Adjust the idle Pedal set angle at

Model Engine (Hmm) stroke (Xmm) full stroke (Y°)
B475/B466 GAS/LPG 30 12 ± 2 62.8
B475 DSL 2.7L 40 16 ± 2 60.0
B466 DSL 2.7L 34 16 ± 2 61.5
B466 DSL 3.0L 30 16 ± 2 62.8
— 25 —
EXHAUST SYSTEM REPAIR
[1] Lift Trucks With Counterweight Exhaust System
(1) Mazda Gas and LPG Engines
NOTE: Remove the counterweight before removing the muffler and other parts of the exhaust system. See
the section Counterweight Replacement for the removal procedures for the counterweight.
Remove and Disassemble

The muffler is installed inside the cavity of the counterweight. An exhaust tail pipe sends the
exhaust gases out of the lift truck under the counterweight.
WARNING
Exhaust system components are hot to touch. Be sure exhaust system components are
cool before starting disassembly, or personal injury may occur.
1. Disconnect the exhaust pipe from the exhaust manifold and remove and discard the gaskets.
2. Remove the exhaust pipe from the engine exhaust manifold.
3. Remove the clamps that hold the two exhaust pipes to the muffler. Remove the exhaust pipes
from the muffler.
4. Remove the washers, isolators, nuts, and capscrews that fasten the muffler to the frame of
the lift truck. Remove the muffler from the lift truck.
Inspect
Inspect the following items in the exhaust system:
• Inspect all exhaust pipes for damage, corrosion, and rust and replace as needed.
• Inspect all exhaust pipe heat shields for damage and replace as needed.
• Inspect the muffler for damage, corrosion, and rust. Replace as needed.
Assemble and Install

1. Place the muffler onto the frame of the truck and install the washers, isolators, nuts, and
capscrews. Tighten the nuts to 21−25 N·m.
2. Install the exhaust pipes onto the muffler. Install the clamps on the pipes to hold them onto
the muffler.
3. Install the exhaust pipe onto the engine exhaust manifold with a new gasket. Tighten lock
nuts to 16−23 N·m.
4. Install the counterweight. See the section Counterweight Replacement for the installation
procedures for the counterweight.
(2) Yanmar Diesel Engine
Remove and Disassemble
WARNING
— 26 —
1. Remove the counterweight. See the section Counterweight Replacement for the removal
2. Remove clamp that attaches exhaust pipe to muffler. Remove exhaust pipe.
3. Remove clamp that attaches the exhaust tail pipe to muffler. The muffler is positioned
horizontally and the lower exhaust pipe protrudes from the side.
4. Remove the washers, isolators, nuts, and capscrews that fasten the muffler to the lift truck
frame and remove muffler from lift truck.
5. Remove four lock nuts attaching engine exhaust pipe to engine exhaust manifold and remove
engine exhaust pipe from engine manifold.
Inspect
Assemble and Install

1. Install engine exhaust pipe to engine exhaust manifold. Tighten lock nuts to 16−23 N·m.
2. Place muffler onto the frame of lift truck and install the washers, isolators, nuts, and
capscrews to secure muffler to lift truck. Tighten nuts to 21−25 N·m.
3. Install engine exhaust tail pipe to muffler with clamp.
4. Install exhaust pipe on muffler with clamp.
5. Install the counterweight. See the section Counterweight Replacement for the removal
[2] Lift Trucks With Overhead Exhaust System
The muffler is installed inside the cavity of the counterweight. A long exhaust pipe, located above
the overhead guard, sends the exhaust gases out of the lift truck.
(1) Remove and Disassemble
WARNING
1. On trucks equipped with overhead exhaust system, remove four capscrews that attach the
overhead exhaust pipe to overhand guard leg. Remove clamp between overhead exhaust
pipe and exhaust pipe and remove overhead exhaust pipe.
2. Remove the counterweight. See the section Counterweight Replacement for the removal
3. On lift trucks with overhead exhaust system, remove clamp that attaches exhaust pipe
to muffler. On lift trucks with counterweight exhaust system, remove clamp that attaches
exhaust pipe to muffler Remove exhaust pipe.
4. Remove clamp that attaches the exhaust pipe to muffler. The muffler is positioned
horizontally.
5. Remove the washers, isolators, nuts, and capscrews that fasten the muffler to the lift truck
frame and remove muffler from lift truck.
— 27 —
(2) Inspect

(3) Assemble and Install
1. Install engine exhaust pipe to engine exhaust manifold with a new gasket. Tighten lock nuts
to 16−23 N·m.
2. Place muffler onto the frame of lift truck and install the washers, isolators, nuts, and
capscrews to secure muffler to lift truck. Tighten nuts to 21−25 N·m.
3. Install engine exhaust pipe to muffler with clamp.
4. Install exhaust tail pipe (for overhead exhaust or for counterweight exhaust) to muffler with
clamp.
5. Install the counterweight. See the section Counterweight Replacement for the removal
6. On trucks equipped with overhead exhaust system, insert overhead exhaust pipe in hole of
counterweight. Attach overhead exhaust pipe to exhaust pipe and secure with clamp. Install
and tighten four capscrews to 21−25 N·m to secure overhead exhaust pipe to overhand
guard leg.
— 28 —
COOLING SYSTEM
[1] Description
WARNING
and boiling coolant can cause burns. DO NOT remove the cover for the radiator when the
engine is running.
CAUTION
dealer.
The cooling system is used to cool the engine and keep it at the correct operating temperature.
The cooling system is comprised of the following main components:
• Radiator
• Fan and belt
• Fan shroud and radiator duct
• Coolant hoses and lines
• Coolant reservoir
• Water pump
For the procedures to repair, clean, inspect, and install the radiator and cooling system
components, refer to the section Cooling System.
— 29 —
FUEL AND HYDRAULIC TANKS REPAIR
[1] Inspect
WARNING
Special procedures must be followed when large leaks or other repairs need welding or
cutting. All work must be done by authorized personnel. If the tank is cleaned inside a
building, make sure there is enough ventilation. See the following manuals for additional
information:
• Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the
American Welding Society, F4.1 - 1999.
• Safety in Welding and Cutting, American National Standard, AWS Z 49.1 - 1999.
WARNING
Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can
cause an explosion.
CAUTION
Additives may damage the hydraulic system. Before using additives, contact your local
Hyster dealer.
Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage.
Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas
of the tank that are not easily seen can be checked with an inspection mirror and a light that is
approved for locations with flammable vapors.
[2] Clean
WARNING
When cleaning the tank, do not use solutions that make dangerous gases at normal
temperatures or when heated. Wear eye and face protection. Protect the body from burns.
WARNING
When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control the
pressure of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it
must be made of a material that does not make sparks. Make an electrical connection between
the nozzle and the tank.
Connect a ground wire to the tank to prevent static electricity.
— 30 —
(1) Steam Method of Cleaning
WARNING
Use the following procedure to clean the tank with steam:
1. Remove all the parts from the tank. Install the drain plug.
2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix
0.5 kg (1 lb) per 4 liter (1 gal) of water.
3. Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the
tank are flushed with the solution. Drain the tank.
4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors
must come from all the openings.
5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed
from the inside of the tank.
6. Make an inspection of the inside of the tank. If it is not clean, repeat Step 4 and Step 5 and
make another inspection. When making inspections, use a light that is approved for locations
with flammable vapors.
7. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet
plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of
flammable vapors is above the lower flammable limit, repeat the cleaning procedures.
(2) Chemical Solution Method of Cleaning
WARNING
When cleaning the tank, do not use solutions that make dangerous gases at normal
temperatures or when heated. Wear eye and face protection. Protect the body from burns.
WARNING
If the tank cannot be cleaned with steam, use the following procedure:
1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkaline
base. Follow the instructions given by the manufacturer.
2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank.
3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning
compound is removed.
4. Make an inspection of the inside of the tank. If the tank is not clean, repeat Step 1 through
Step 3. Make another inspection of the tank. When making inspections, use a light that is
approved for locations with flammable vapors.
5. Check the tank for flammable vapors using special indicator for gas vapors. If the amount of
flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.
— 31 —
[3] Additional Preparations for Repair
If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases.
See the manual Safe Practices for Welding and Cutting Containers That Have Held Combustibles
by the American Welding Society, F4.1 - 1999. If these gases are not available, another method
using water can be used as follows:
1. Fill the tank with water to just below the point where the work will be done. Make sure the
space above the level of the water has a vent.
2. Use acceptable welding practices to repair the tank. See the American National Standard
Safety in Welding and Cutting, AWS Z 49.1 - 1999.
[4] Small Leaks, Repair
Use the following procedure to repair small leaks:
1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.
2. Apply Loctite® 290 to the leak. Follow the instructions of the manufacturer.
[5] Large Leaks, Repair
1. Use one of the procedures described under Clean to clean and prepare the tank for repairs.
2. Contact your dealer for Hyster lift trucks for welding instructions.
3. Use acceptable welding practices to repair the tank. See the American National Standard
Safety in Welding and Cutting, AWS Z 49.1 - 1999.
[6] Preparations for Usage After Repair
1. Add more water to the tank so that the water goes above the point of where the work was
done. Check to see if there are any leaks coming from tank.
2. If there are no leaks coming from the tank, remove all the water from the tank.
— 32 —
SAFETY LABELS
WARNING
Safety labels are installed on the lift truck to give information about operation and possible
hazards. It is important that all safety labels are installed on the lift truck and can be read.
DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its
equipment can change the lifting capacity. The lift truck must be rated as equipped, and the
nameplate must show the new capacity rating. Contact your dealer for a new nameplate.
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using
NOTE: Not all labels that are used on the lift trucks covered in this manual are shown in Figure 26. See the
Parts Manual for a complete listing of all labels used on these lift trucks and their part numbers.
If a new label must be installed, use the following procedure to install a new label. See Figure 26.
1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint.
Clean the surface of old paint with a cleaning solvent.
2. Remove the paper from the back of the label. Do not touch the adhesive surface.
3. Carefully hold the label in the correct position above the surface. The label cannot be moved
after it touches the surface. Put the label on the surface. Make sure that all air is removed
from under the label, and the corners and edges are tight.
— 33 —
1. MAST WARNING LABEL 11. LABEL-FAN WARNING
2. LABEL-OPERATOR RESTRAINT 13. LABEL-PARKBRAKE WARNING
5. LABEL-CAUTION BATTERY 14. LABEL-MAST WARNING
6. LABEL CERTIFICATE 15. LABEL-OPERATOR WARNING
7. LABEL-LOCKING GAS SPRING 30. LABEL-FLAMMABLE LP GAS
CAUTION NON-U.S. 31. LABEL-HOOD OPENING
8. LABEL-PINCH POINT CAUTION NON-U.S.
9. LABEL-NO RIDERS 41. LABEL ETHER WARNING
10. DECAL-FAN WARNING 51. LABEL FLAMMABLE LP GAS
PICTORIAL 64. LABEL NAMEPLATE
Figure 26. Safety Label Positions
— 34 —
HMM200001
Main Control Valve

H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

and Repair
weight of the load.
remove parts.
needs repairs.
WARNING
CAUTION
—1—
GENERAL
This section has a description and the repair procedure for the main hydraulic control valve, the
steering flow divider and the steering relief valve.
DESCRIPTION
[1] Main Hydraulic Control Valve (See Figure 1)
The hydraulic control valve controls the operation of the lift, tilt, and attachment cylinders. It also
controls the flow of the steering system. The main control valve is installed to the right cowl of the
lift truck. The hydraulic control valve has the following sections.
• Inlet section with the primary, steering relief valve, unload valve, lift and lower spool, lift lock
valve and flow regulator valve.
• Tilt section.
• Attachment section(s)
Figure 1. Hydraulic Control Valve
—2—
OPERATION
The hydraulic control valve is an open center, parallel circuit valve. When open center valve spool
are in the neutral position, the hydraulic oil flows through the valve with minimum restriction. The
oil returns through the drain passage and returns to the hydraulic tank. In a parallel circuit valve,
each spool can be operated without preventing the flow of oil to another spool.
This valve has three parallel passages through the valve. See Figure 2. When the spools are in
the neutral position, the oil flows through the open center passage. At the end of the valve, the oil
returns through the drain passage and returns to the hydraulic tank. A spool makes a restriction
in the open center passage when the spool is moved from the neutral position. This restriction
causes an increase in pressure in the parallel passage. The parallel passage is common to all
sections of the valve, but oil cannot flow freely through it. The increased pressure in the parallel
passage causes the oil to flow through a check valve into a supply cavity in the valve body. The
spool gives a path from the supply cavity to the hydraulic cylinder to do work.
The hydraulic control valve has four control levers. The first lever to the right of the operator
controls the lifting and lowering of the mast. The second lever controls the tilt function. The third
and fourth control lever is for attachments. The control valve also can have two or four or five
control levers depending on the attachment.
1. PUMP PORT
2. TO STEERING SYSTEM
3. TO HYDRAULIC TANK
4. MAIN RELIEF VALVE
5. STEERING RELIEF VALVE
6. FLOW DIVIDER
7. GAUGE PORT
8. UNLOAD SOLENOID
9. UNLOAD VALVE
10. LIFT LOCK SOLENOID
11. LIFT LOCK VALVE
12. FLOW REGULATOR
Figure 2. Schematic Hydraulic Control Valve
—3—
[1] Unload Valve (See Figure 3)
This valve was added to shut off the oil flow to lift, tilt and attachment spool. When the solenoid
valve for the unload valve is shut off, the oil to the lift and tilt system move the unload poppet and
the oil flows to the tank. If the spool of the lift, tilt and attachment is moved, the pressure of the oil
is not increased so that the cylinder does not work.
When the solenoid valve for the unload is power on, the pressure of the cavity of the unload
poppet spring is increased, the unload poppet is closed. If the spool of the lift, tilt and attachment
is moved, the pressure of the oil is increased then the cylinder works.
Figure 3. Unload Valve
—4—
[2] Lift Section (See Figure 4)
When the spool is moved to the Lift position, the spool makes a restriction in the open center
passage.
The increased pressure in the parallel passage causes oil to flow through the check valve to the
supply cavity. The oil flows from the supply cavity through a section of the spool to the lift cylinder
via FLOW REGULATOR SPOOL. The check valve prevents the movement of the load until the
system pressure is great enough to control the load. The-flow regulator spool is fixed by the
spring and the difference of the pressure as the free flow position.
1. LIFT SPOOL
3. OPEN CENTER PASSAGE
4. FLOW REGULATOR SPOOL
5. SPRING
6. SPRING
7. LOAD CHECK VALVE
Figure 4. Unload Valve
—5—
[3] Lift Lock Valve (See Figure 5)
The solenoid valve for the Lift lock valve is power on. When the spool is in the Lower position, the
spool opens a path from the lift cylinder to the drain cavity. The lift lock poppet is pushed up and
the oil is flowed via the flow regulator spool and the lift spool to the tank port.
The solenoid valve for the Lift lock value is shut off. The cavity of the lift lock poppet spring is
closed per the lift lock solenoid, so that the lift lock poppet is closed. When the spool is in the
position, the fork is not moved.
1. LIFT SPOOL
3. LIFT LOCK POPPET
4. FLOW REGULATOR SPOOL
5. SPRING
Figure 5. Lift Lock Valve
[4] Tilt Section (See Figure 6)
The basic operation of the tilt spool is the same as the other spools in this control valve. The tilt
control spool is inside the tilt spool and adds an additional sequence to the tilt forward function.
(1) Tilt Backward
When retracted past Neutral position the tilt spool causes a restriction of the oil flow through
the open center passage. The increased pressure in the parallel passage causes the oil to
flow through the check valve to the supply cavity. The oil flows from the supply cavity through
a section of the spool to the tilt cylinders. The check valve prevents the movement of the load
—6—
until the system pressure is great enough to
control the load. Oil from the piston end of the
tilt cylinder returns through the main control
valve and to the hydraulic tank.
(2) Tilt Forward
The tilt control spool that is inside of the tilt

spool operates during the tilt forward function.
The tilt control spool prevents cavitation in
the piston end of the tilt cylinders. Cavitation
occurs when the available fluid does not
fill the space in a closed system. The high
vacuum will cause some of the fluid to change
to bubbles of gas. When cavitation occurs in
the tilt cylinders, the tilt forward function is not
smooth.
The tilt control spool permits the regulation of
the tilt speed by using the pressure from the
hydraulic pump. The tilt control spool prevents
oil flow from the rod end of the tilt cylinder
until the pressure is great enough to shift the
tilt control spool. This action makes sure that a 1. TILT SPOOL
vacuum cannot occur at the piston ends of the 2. LOAD CHECK
3. TILT CONTROL SPOOL
tilt cylinders.
[5] Relief Valve (See Figure 1)

Figure 6. Tilt Spool Opeation
The steering relief valve limits the pressure in
the steering system. For the single-pressure
control valve, the maximum pressure within the hydraulic system is controlled by a relief valve
which is installed in the inlet section of the control valve. The relief valve is a poppet valve that is
pilot operated. If the pressure increases to the relief valve setting, the pilot poppet moves against
the pilot spring. When the small oil flow through the orifice of the pilot poppet occurs, a decrease
in pressure occurs across the relief valve. This difference in pressure moves the relief valve
poppet off the seat. When the poppet moves off the seat, oil flows through an internal passage
that directs the oil flow to the oil tank to decrease the pressure. The decrease in pressure lets the
spring return the poppet back to the seat.
[6] Steering Flow Divider (See Figure 1)
The oil from the pump enters the valve chamber near the center of the plunger. The oil flows
through the orifice in the plunger to the steering system port. This oil also flows to the relief valve.
If the oil flow at the pump outlet is more than the primary flow for the steering system, the plunger
will move.
This plunger movement connects part of the oil flow to the lift and tilt system port. The plunger
will also move back and decrease or stop the flow of oil to the lift and tilt system if the pump flow
decreases.
The plunger keeps moving to make sure the steering system always has a constant supply of oil.
—7—
REPAIRS
[1] Removal (See Figure 7)
WARNING
Before making and repairs to the hydraulic control valve, fully lower all parts of the mast
and tilt it fully forward. This action will prevent the mast from lowering suddenly when
hydraulic lines are disconnected.
1. Remove the cowl cover and floorplate.

2. Disconnect the lines at the hydraulic control valve. Mark the hose locations. Put caps onto the
open lines.
3. Remove the cotter pins, and link pins that connect the control levers to the spools. Remove
the linkage as a unit.
4. Remove the bolts that hold the hydraulic control valve to the right cowl.
1. CONTROL VALVE
2. BOLT
3. KNOB
4. LEVER
5. BOOTS
6. BUSH
7. PIN
8. COTTER PIN
9. E-RING
10. BRACKET
11. PIN
12. COTTER PIN
13. BOLT
14. LINK
Figure 7. Linkage for Control Valve
—8—
[2] Disassembly (See Figure 8)
NOTE: Disassemble the hydraulic control valve as necessary for repairs. Most repairs to the hydrauliccontrol
valve are for the replacement of O-rings and seals to stop leaks. The passages in the tilt spool are small
and can need cleaning if the hydraulic oil becomes dirty. The section normally must be replaced if the spool
or valve section is damaged.
1. Remove the end cap from the valve section. Carefully pull the spool from the valve section.
Do not remove the spring retainers unless a spring must be replaced.
2. The valve sections can be separated when the three through bolts are removed.
3. Remove the tilt control spool by removing the end of the tilt spool. Carefully remove the tilt
control spool from the tilt spool.
4. A relief valve is normally replaced if it is damaged.
[3] Cleaning and Inspection
WARNING
procedures. Clean all parts of the control valve with solvent.
1. Check the spools and bores for wear or damage. If a spool or the bores have damage, then
the control valve section must be replaced. Make sure that the spools move freely in the bores.
2. Check the check valves and relief valves for wear or damage. Replace the parts as necessary.
3. Check the parts of the linkage for the control valve levers. Replace worn or damaged parts as
necessary.
1. VALVE HOUSING
2. SPOOL
3. SEAL PLATE
4. O-RING
5. DUST SEAL
6. END CAP
7. SPRING RETAINER
8. CAP SCREW
9. SPRING
10. ROPPET
11. SPRING
12. O-RING
13. SCREW
14. SOCKET HEAD BOLT
15. TILT CONTROL SPOOL
16. SPRING
17. O-RING
Figure 8. Hydraulic Control Valve
—9—
[4] Assembly (See Figure 8)
CAUTION
Before installing the parts into the valve body, make sure all parts are clean. Replace all the
seals and the O-rings. Lubricate the moving parts with clean hydraulic oil during assembly.
1. Install new seals in the bores of the sections. Install new O-ring seals between the sections.
2. If the return springs were removed from the control spools, install the spring retainers.
3. Lubricate the spools with clean hydraulic oil. Make sure that dirt does not get on any of the
parts. Carefully install the spools into the valve body. Install the seal retainers and the covers
for the return springs.
4. Install the relief valves. Adjust the relief settings for the hydraulic system as described in
CHECKS AND ADJUSTMENTS.
[5] Installation (See Figure 7)
1. Assembly the lever linkage. Install this linkage assembly.

2. Install the control valve onto the right cowl.
3. Connect the hydraulic lines to the control valve.
4. Install the cowl cover and floorplate.
5. Add the hydraulic oil to the tank. See the section PERIODIC MAINTENANCE for the correct
specifications.
7. Operate the system and check for leaks and correct the front of this section operation. Adjust
the relief valves as described in CHECKS AND ADJUSTMENTS.
— 10 —
RELIEF VALVES, CHECKS AND ADJUSTMENTS
1. MAIN HYDRAULIC RELIEF VALVE

2. STEERING RELIEF VALVE
3. GAUGE PORT (TEST PORT)
4. BOLT
Figure 9. Relief Valve Locations
NOTE: The inlet section of the hydraulic control valve has two relief valves, a steering relief valve and a
main hydraulic relief valve.
1. Connect a 0 to 20 MPa (0 to 204 kgf/cm2) gauge to the steering gauge port of steering hand
pump.
2. Remove the cap. Loosen the jam nut on the relief valve.
3. Start the engine and operate the hydraulic system to warm the oil temperature to 55 to 65°C
(130 to 150°F). Run the engine at HI-idle when making pressure checks.
4. Turn the steering wheel to the stop and hold it there. Turn the adjustment screw as necessary
to change the setting. The correct setting is 7.9 +0.50 MPa (80 +50 kgf/cm2). Tighten the jam nut
and install the cap when the adjustment is correct.
5. Remove the gauge when the checks are complete.
[1] Main Relief Valve (See Figure 9)
1. Connect a 0 to 25 MPa (0 to 255 kgf/cm2) gauge to the test port at the inlet section of the
control valve.
2. Remove the cap. Loosen the jam nut on the relief valve.
(130 to 150°F). Run the engine at HI-idle when making pressure checks.
4. Raise the mast until it stops. Hold the lever and check the reading of the gauge when the
relief valve opens. Turn the adjustment screw as necessary to change the setting. The correct
setting is 18.6 –0.5
0
MPa (190 –50 kgf/cm2) for 1-3.0t, 20.6 –0.5
0
MPa (210 –50 kgf/cm2) for 3.5t. Tighten
— 11 —
the jam nut and install the cap when the adjustment is correct.
[2] Port Relief Valve (3.5t Tilt Port Relief Valve)
1. Connect a 0 to 20 MPa (0 to 204 kgf/cm2) gauge to the test port at the inlet section of the
control valve.
2. Loosen the jam nut on the relief valve.
(130 to 150F). Run the engine at HI-idle when making pressure checks.
4. Tilt the mast backward until it stops. Hold the lever and check the reading of the gauge when
the relief valve opens. Turn the adjustment screw as necessary to change the setting. The
correct setting is 15.7 +0.50 MPa (160 +50 kgf/cm2). Tighten the jam nut when the adjustment is
correct.
— 12 —
TROUBLESHOOTING, HYDRAULIC CONTROL VALVE
PROBLEM CAUSE
Oil leaks at the end of a spool. Seal for spool is damaged.

Spool is damaged.
Valve body is damaged.
Spool will not move or is difficult to move. Linkage is disconnected or damaged.

Return spring is damaged.
The spool or bore is damaged.
Spool will not return to NEUTRAL. Linkage is disconnected or damaged.

Return spring is damaged.
Dirt between spool and the bore.
Spool is bent or damaged.
Slow or no movement of cylinders. Linkage is disconnected or damaged.

Solenoid valve is disconnected or damaged.
Pressure relief valve(s) is not adjusted correctly or is damaged.
Large leaks between spool and bore.
Spool is not fully extended or retracted.
Slow or no movement of cylinders. Air is in the hydraulic system.

The hydraulic pump Is worn or damaged.
Restriction in the hydraulic lines.
Cylinder seals are damaged.
Load is greater than capacity.
Hydraulic pressure is above specifications. Pressure relief valve(s) is not adjusted correctly or is damaged.
Restriction in return line.
Tilt cylinders extend when the tilt spool is Cylinder seal have leaks.
in the NEUTRAL position. Oil leaks between control valve spool and bore.
Hydraulic lines have leaks.
Tilt cylinders extend suddenly when the tilt

Check valve for tilt spool is damaged.
spool is spmoved to BACK TILT position.
Tilt cylinders extend suddenly when the

tilt spool is moved to FORWARD TILT Tilt control spool inside the tilt spool is damaged.
position.
Lift cylinders retract when the lift spool Is Check valve for the lift spool is damaged.
in the NEUTRAL position. Cylinder seals have leaks.
Hydraulic lines have teaks.
Leaks between the lift spool and the bore.
— 13 —
HMM220002
Electrical System
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

and Repair
weight of the load.
remove parts.
needs repairs.
WARNING
CAUTION
—1—
GENERAL
The removal and replacement procedures for the following electrical components are covered in
this manual:
• Display Cluster
• Combination Switch
• Key Switch
• Sensors and Switches
• Vehicle Controller
• Fuse Box and Relay Box
• Battery
• Lights
Some of the components used are made of plastic. When using screws to replace and install
plastic components, the screws should be rotated counterclockwise until the screw thread
turns over the last thread in the plastic part. The screw can then be turned clockwise to make a
connection. This prevents “cutting” new threads and damaging the existing thread in the plastic
part.
CAUTION
When welding, always disconnect the negative battery cable from battery and disconnect
the ground wire from the ground stud on the frame. See Figure 1. To prevent damage to the
Electronic Control Unit (ECU), remove it from the lift truck.
1. GROUND SCREW
2. RELYA BOX
3. FUSE BOX
4. BATTERY
NOTE: View shown is from the left side. Major components and electrical connections not shown for
clarity.
Figure 1. Welding Preparation
—2—
DISPLAY CLUSTER
[1] Remove
NOTE: The Display Cluster is a nonrepairable part. See the Parts Manual for replacement part number.
1. Disconnect the battery.

2. Remove the two screws on front side of the cover column and remove the cover column front
from steering column. See Figure 2.
3. Remove the steering column tilt lever.
4. Remove four screws and remove cover column back. See Figure 7.
5. Disconnect the display harness from the Display Cluster. Remove the two screws securing
the Display Cluster. See Figure 4.
1. STEERING COLUMN TILT LEVER

2. COVER COLUMN FRONT
3. SCREWS
NOTE: Top down view shown.
Figure 2. Cover Column Front Removal
—3—
1. HORN BUTTON
2. LOCK NUT
3. WASHER
NOTE: A puller tool may be required to remove the steering wheel.
Figure 3. Steering Wheel Removal
[2] Replace
NOTE: When a new Display Cluster is installed on a lift truck, the data that controls all the functions and
features unique to that lift truck needs to be transferred to the new Display Cluster. See the manual User
Interface−Service for the procedures to transfer data to a new Display Cluster.
1. Place Display Cluster onto steering column. Install two screws to steering column. See Figure
4.
2. Connect the Switch Cluster to the display harness.
3. Install the cover column to the steering column with six screws.
—4—
1. SCREWS
2. DISPLAY HARNESS
3. STEERING COLUMN
4. KEY SWITCH
Figure 4. Display Cluster and Key Switch Removal
—5—
COMBINATION SWITCH
[1] Remove
1. Disconnect ground wire.

2. Remove two screws and remove cover column front. See Figure 2.
3. Remove the steering column tilt lever.
4. Remove four screws and remove cover column back. See Figure 7.
5. Remove the Display Cluster. See Figure 4.
6. Remove the horn button, remove the lock nut securing the steering wheel and remove
steering wheel from steering column. See Figure 3.
7. Disconnect the Combination Switch harness from the Combination Switch. Remove the
three screws securing the Combination Switch. Slide the Combination Switch off the steering
column. See Figure 5.
1. COMBINATION SWITCH
2. SCREWS
Figure 5. Combination Switch
—6—
[2] Replace
1. Slide the new Combination Switch onto steering shaft and install the new Combination
Switch to steering column using three screws.
2. Connect the Combination Switch harness to the Combination Switch.
3. Slide steering wheel onto steering shaft and tighten the lock nut until steering wheel is fully
seated. The final torque for the lock nut is 41 to 49 N·m (417 to 500 kgf·cm). See Figure 3.
4. Install the Display Cluster to steering column with two screws and connect the display
harness.
5. Install the cover column to the steering column with six screws.
[3] Direction Control and Turn Signal Levers
The direction control lever and turn signal lever are similar in design, but perform different
functions. The turn signal lever is located on the right side of the combination switch under the
steering wheel. The direction control lever is located on the left side of the combination switch.
� �
� �
� �
1. DIRECTION CONTROL LEVER

2. TURN SIGNAL LEVER
� 3. STEER ANGLE SENSOR
4. CONNECTOR
5. SCREW
6. SCREW
7. FLAT-BLADE SCREW DRIVER
Figure 6. Direction Control and Turn Signal Removal
—7—
(1) Remove
NOTE: There are no repairs for the direction control lever and turn signal lever. If a lever malfunctions,
replace with new lever. See the Parts Manual for replacement part numbers.
1. Remove the two screws from the side of the combination switch. See Figure 6.
2. Remove the direction control lever or turn signal lever from the combination switch.
3. Repeat the previous steps on the opposite side of the direction control lever or turn signal
lever.
(2) Replace
1. Slide the didrection control lever or turn signal lever into the opening of the combination
switch until the locking tabs are engaged in the combination switch.
2. Tighten two screws to 0.6 to 0.8 N·m.
[4] Steer Angle Sensor
(1) Remove
NOTE: There is no repairs for the steer angle sensor. If a sensor malfunctions, replace with new sensor.
See the Parts Manual for replacement part number.
1. Compress the spring tab on the connector of the steer angle sensor with flat-blade
screwdriver and remove connector. See Figure 6.
2. Remove the three screws.
3. Remove the steer angle sensor.
(2) Replace
1. Slide the steer angle connector to combination switch .

2. Install the steer angle sensor so that the key would fit into the groove of combination switch.
3. Tighten three screws to 0.6 to 0.8 N·m.
—8—
KEY SWITCH
[1] Remove
1. Fully lower the steering column and remove the two screws on front side of the cover column,
and remove the cover column front from steering column. See Figure 2.
2. Remove the lock nut the key switch. Slide key switch assembly out of cover column back. See
Figure 4.
[2] Replace
1. Slide new key switch assembly into cover column back. Install the lock nut of key switch to
secure key switch to cover column back. See Figure 4.
2. Place cover column front on steering column. Align latches on cover column front to holes on
steering column and push cover column front into place on steering column.
1. SCREWS
2. COVER COLUMN BACK
3. STEERING COLUMN TILT LEVER
Figure 7. Cover Column Back Removal
—9—
SENSORS AND SWITCHES
[1] General
CAUTION
Before removing and replacing any sensors or switches, ALWAYS disconnect the battery.
Failure to disconnect the battery can cause damage to the sensor or switch and other
electrical components. Always cover or protect the sensor or switch connector from
contamination after disconnecting the harness mating part.
Do not use solvent based cleaners to clean area around sensors or switches.
All sensors and switches used on these trucks are nonrepairable parts. Replace with new
sensors or switches whenever a sensor or switch malfunctions and is not operating correctly. See
the Parts Manual for replacement part numbers. Before installing new sensors or switches, use
1. KICK PANEL
2. COWL
3. SCREWS
4. DASH PANEL
5. BOLTS
Figure 8. Kick Panel and Dash Panel Removal
— 10 —
a clean cloth and make sure the area around the sensor or switch is clean and free of oils and
contaminates.
When removing and replacing sensors or switches, be sure to tag connectors to aid in correct
reconnection.
NOTE: Before removing and replacing the Park brake switch:

Lower the steering column to its lowest position and remove the cover column front. See the section
Display Cluster for the removal and installation procedures.
Remove the kick panel from under the dash panel by removing the bolts and screws holding kick
panel to dash panel. Remove the dash panel from the cowl by removing the bolts holding dash
panel to cowl. See Figure 8.
1. SWITCH
2. SCREWS
Figure 9. Service Brake Pressure Switch and Parking Brake Switch
— 11 —
[2] Parking Brake switch
(1) Remove

2. See the NOTE at the beginning of this section.
3. Disconnect the parking brake switch from cowl harness. Remove two screws and remove
switch from the parking brake handle assembly. See Figure 9.
(2) Replace
1. Install new parking brake switch into parking brake handle assembly with two screws.
2. Connect switch to cowl harness. See Figure 9.
3. Install kick panel and dash panel. Install cover column front. See the NOTE at the beginning
of this section.
4. Connect the battery.
[3] Service Brake Pressure Switch (Monotrol only)
(1) Remove

2. Remove the floor plate. See the section
Frame for the procedures.
3. Disconnect the switch from the cowl
harness and remove it from the Block 4
way. See Figure 13.
(2) Replace
1. Install a new switch on the Block 4 way.

2. Connect new switch to cowl harness. See
Figure 13.
3. Bleed the brake system as described in
the section Brake System.
4. Install the floor plate. See the section
Frame for the procedures.
[4] Fuel Level Sender, Gas and Diesel

Engines Only
(1) Remove
1. Disconnect the electrical terminal from the NOTE: Gas fuel pump shown.
fuel level sender.
2. Remove five bolts and remove fuel level 1. FUEL LEVEL SENDER
sender from cover fuel tank. See Figure 10. 2. COVER FUEL TANK
3. BOLTS
Figure 10. Fuel Level Sender
— 12 —
(2) Replace
1. Install new fuel level sender unit through hole in cover fuel tank. Tighten fuel level sender
onto cover fuel tank by new bolts. See Figure 10.
2. Connect the fuel level sender electrical connector.
1. NUTS
2. SEAT HARNESS
3. CLIP
4. FRAME HARNESS
5. CLAMP HARNESS
NOTE: Bottom view of hood shown.
Figure 11. Seat Removal Suspension Seats
— 13 —
[5] Seat Switch
Full Suspension Seats

(1) Remove
2. Disconnect seat harness from frame harness. Remove seat harness clip from the hood. See
Figure 11.
3. Bend back the clamp harnesses.
4. Remove four nuts holding the seat to the hood. Remove the seat from the hood.
5. Cut the bands and remove the seat switch. See Figure 12.
(2) Replace
1. Install new seat sensor into bottom seat cushion with bands. See Figure 12.
2. Install seat onto hood using four nuts.
3. Install seat harness clip to hood connect seat harness to frame harness.
4. Connect battery.
4 1
1. BAND
2. SEAT SWITCH
3. SEAT HARNESS
4. BOTTOM SEAT CUSHION
Figure 12. Seat Switch, Full Suspension Seat
— 14 —
[6] Drive Axle Speed Sensor
(1) Remove
1. Disconnect the battery and lift the floor plate from the frame.
2. Disconnect sensor from cowl harness and remove bolt securing sensor to drive axle housing.
See Figure 13.
1. DRIVE AXLE SPEED SENSOR

2. BOLTS
3. SERVICE BRAKE PRESSURE SWITCH
4. BLOCK 4 WAY
NOTE: Two-speed transmission shown.
Figure 13. Drive Axle Speed Sensor
(2) Replace
1. Install new sensor into drive axle housing with the bolt. Connect sensor to cowl harness. See
Figure 13.
2. Place the floor plate onto frame. Connect the battery.
[7] Transmission Temperature Switch
(1) Remove
1. Disconnect the battery. Put the lift truck on blocks. See the Operating Manual or the section
Periodic Maintenance for lift truck models H1.5-3.5TX [B475, B466] for the procedures on
putting the lift truck on blocks.
— 15 —
WARNING
At operating temperature, the transmission oil is HOT. Do not permit the hot oil to touch the
skin and cause a burn. Make sure oil is cool before draining.
2. Drain the transmission oil. See the section Periodic Maintenance for lift truck models H1.5-
3.5TX [B475, B466] for the procedures.
3. Disconnect temperature switch from cowl harness and remove switch from transmission. See
Figure 14.
1. TEMPERATURE SWITCH
Figure 14. Transmission Temperature Switch
(2) Replace
1. Install new temperature switch and connect switch to cowl harness. See Figure 14.
2. Remove lift truck from blocks. Connect the battery. Fill transmission with oil. See the section
Periodic Maintenance for lift truck models H1.5-3.5TX [B475, B466] for transmission oil
specifications.
3. Run truck and check oil level. See the section Periodic Maintenance for lift truck models
H1.5-3.5TX [B475, B466] for procedures to check the transmission oil.
— 16 —
[8] Rear Horn Button Switch (optional)
(1) Remove

2. Disconnect rear horn button switch electrical connector from frame harness. See Figure 15.
3. Remove two capscrews that attach rear horn button switch and handle to the right rear
overhead guard leg.
4. Remove switch and handle assembly from overhead guard leg, pulling the wire and
connector through the holes in the overhead guard leg.
1. CAPSCREW
2. HANDLE AND SWITCH ASSEMBLY
3. HANDLE
4. REAR HORN BUTTON SWITCH
5. ELECTRICAL CONNECTOR
6. OVERHEAD GUARD LEG
Figure 15. Rear Horn Button Switch
— 17 —
(2) Replace
1. Insert wire and connector in the hole in overhead guard leg and thread wire until connector
can be pulled through bottom hole in the overhead guard leg.
2. Attach handle and switch assembly to overhead guard leg with two capscrews. See Figure
15.
3. Connect rear horn switch electrical connector to frame harness.
[9] ECT sender and Oil Pressure Switch - Mazda Gas and LPG Engines
(1) Engine Coolant Temperature (ECT) Sender

Remove
2. Drain the engine coolant from radiator before removing the ECT sender. Refer to the section
Cooling System.
3. Disconnect the ECT sender terminal.
4. Remove the ECT sensder from the thermostat housing. See Figure 16.
Replace
1. New ECT sender wrap the thread with sealing tape. Install new ECT sender to the thermostat
housing. Tighten the ECT sender to 8.8 ± 2.9 N·m.
2. Connect the ECT sender terminal.
3. Refill the radiator with engine coolant after replacing the ECT sender. See the section
Periodic Maintenance for lift truck models H1.5-3.5TX [B475, B466] for coolant specification
and procedures.
(2) Oil Pressure Switch

Remove
2. Disconnect the electrical terminal for the oil pressure switch.
3. Remove oil pressure switch. See Figure 16.
Replace
1. Install new oil pressure switch. Tighten switch to 12 to 17 N·m.
2. Connect the electrical terminal to the oil pressure switch. See Figure 16.
3. Connect battery.
— 18 —
1. OIL PRESSURE SWITCH
2. ENGINE COOLANT TEMPERATURE
(ECT) SENDER
Figure 16. ECT Sender and Oil Pressure Switch - Mazda Gas and LPG Engine
[10] ECT Sender and Oil Pressure Switch – Yanmar Diesel Engine
(1) Engine Coolant Temperature (ECT) Sender

Remove
2. Drain the engine coolant from radiator before removing the ECT sensor. Refer to the section
Cooling System.
3. Disconnect the ECT sender terminal. See Figure 17.
4. Remove the ECT sender from the thermostat housing. See Figure 17.
Replace
1. New ECT sender wrap the thread with sealing tape. Install new ECT sender to the thermostat
housing. Tighten the ECT sender to 8.8 ± 2.9 N·m.
2. Connect the ECT sender terminal.
3. Refill the radiator with engine coolant after replacing the ECT sender. See the section
Periodic Maintenance for lift truck models H1.5-3.5TX [B475, B466] for coolant specification
and procedures.
— 19 —
(2) Oil Pressure Switch
Remove
2. Disconnect the electrical terminal for the oil pressure switch.
3. Remove the oil pressure switch. See Figure 17.
Replace
1. Install new oil pressure switch onto engine. Tighten switch to 9 N·m.
2. Connect the electrical termianl for the oil pressure switch. See Figure 17.
1. ENGINE COOLANT TEMPERATURE

(ECT) SENDER
2. OIL PRRESSURE SWITCH
Figure 17. ECT Sender and Oil Pressure Switch − Yanmar Diesel Engine
— 20 —
VEHICLE CONTROLLER
[1] General
The Vehicle Controller is a microprocessor-powered controller which controls or monitors, directly

or indirectly, every electrical device on the lift truck.
[2] Replacement
NOTE: The Controller is not a serviceable part. If the Controller malfunctions, replace with a new Controller.
See the Parts Manual for replacement part number.
(1) Remove

2. Fully lower the steering column and remove the cover column front. See the section Display
Cluster for the removal procedures.
3. Remove the kick panel. See the section Sensors and Switches for removal procedures.
4. Remove the four bolts and nuts securing the controller to the cowl. Remove the controller
from life truck cowl.
5. Disconnect all electrical connections of the cowl harness from the controller. See Figure 18.
1. BOLTS AND NUTS

2. COWL HARNESS
3. CONTROLLER
4. COWL
Figure 18. Vehicle System Controller
— 21 —
(2) Replace
1. Connect all electrical connections to the controller. See the section Diagrams and
Schematics for the wiring diagrams to connect the electrical connectors to the controller.
2. Install controller onto lift truck cowl.
3. Install the dash panel and kick panel. See the section Sensors and Switches for installation
procedures.
4. Install the cover column front. See the section Display Cluster for the installation procedures.
— 22 —
FUSE BOX AND RELAY BOX AND COMPONENT PARTS
[1] Remove
NOTE: The Fuse Box and Relay Box are not a serviceable part. The component parts (fuse and relay), can
be replaced without replacing the Fuse Box and Relay Box. If the Fuse Box and Relay Box malfunctions,
replace with a new Fuse Box and Relay Box. See the Parts Manual for replacement part number.

2. Insert two flat-brade into the spring tab of the Fuse Box or Relay Box.
3. Pry the spring tab of the Fuse Box or Relay Box and, at the same time, pull on the Box
enough to free the tab of the hook lock of the battery tray. See Figure 19.
4. Disconnect the frame harness from the Fuse Box and Relay Box.
1. BATTERY
2. BATTERY TRAY
3. FUSE BOX
4. RELAY BOX
5. BATTERY TRAY HOOK
6. BATTERY CLAMP & ROD
Figure 19. Fuse Box and Relay Box Removal
[2] Replace
1. Connect the frame harness to the Fuse Box or Relay Box.

2. Slid the Fuse Box or Relay Box into the hook of the battery tray until the locking tabs are
engaged in the battery tray.
— 23 —
[3] Fuse Box and Relay Box Component Parts
If lift truck is equipped with a key switch, turn key to ON position. Check all indicator lights for
correct operation as described in the Operating Manual. Check the operation of the horn. Start
the engine by turning the key switch to the Start position. If any indicator lights do not operate
correctly, check the fuses and relays. The fuses and relays are located in the Fuse Box and Relay
Box which is under the hood next to the battery on the right side. See Figure 20.
1. GLOW (60A) 14. IGN/QGS (10A)

2. ALTERNATOR (100A) 15. OPT-IGN (20A)
3. BATTERY (100A) 16. SPARE (5A)
4. FUSE PULLER 17. SPARE (20A)
5. STOP LAMP (10A) 18. SPARE (25A)
6. HORN (5A) 19. SPARE (10A)
7. HEAD/TAIL LAMP (25A) 20. IGN RELAY
8. WIPER/HEATER (20A) 21. BACK LAMP RELAY
9. OPT-ECU (20A) 22. STARTER RELAY
10. MAIN (5A) 23. FLASHER RELAY
11. WORKING LAMP (20A) 24. TAIL LAMP RELAY
12. TURN/BACK LAMP (20A) 25. HEAD LAMP RELAY
13. GAUGE/V-ECU (10A)
Figure 20. Fuse Box and Relay Box Component Parts
— 24 —
BATTERY
[1] Remove

2. Remove the battery clamp and rod securing battery to battery tray. Remove battery from lift
truck. See Figure 19.
[2] Replace
1. Place new battery onto battery tray. Secure battery to battery tray with battery clamp and rod.
Tighten under nut to 1.0 to 1.2 N·m and upper nut to 3.1 to 3.7 N·m.
— 25 —
LIGHTS
[1] Head Lights
(1) Remove

2. To replace the Head light assembly,
disconnect the light from the front light
harness and remove the nut attaching the
Head light to the blacket lamp.
3. To replace the bulb, remove the lens
assembly by removing the four screws.
See Figure 21. Replace the bulb and
reinstall the lens assembly.
(2) Replace
1. Install Head light to blacket lamp using the

nut. See Figure 21.
2. Connect Head light to front light harness.
Connect the battery.
1. SCREWS
2. LENS ASSEMBLY
3. NUT (ATTACHES LIGHT TO
[2] Rotating Light BLACKET LAMP)
NOTE: The Rotating light may either be mounted

above the top of the overhead guard (high-mounted) Figure 21. Head Lights
or below the top of the overhead guard (low-
mounted). The removal and installation procedures
are the same for both options.
(1) Remove

2. Disconnect the Rotating light electrical terminal from the rear light harness. See Figure 22.
3. Remove the washers, lockwasher, and nuts securing the Rotating light to mounting bracket.
Remove the Rotating light from the mounting bracket.
4. If the Rotating light bulb needs to be replaced, remove the Rotating light lens from base and
remove bulb.
— 26 —
(2) Replace
1. If bulb is being replaced, install new bulb

into Rotating light base. Install Rotating
light lens onto base.
2. Place Rotating light assembly onto
mounting bracket. Secure the assembly
t o m o u n t i n g b ra cke t w i t h wa s h e r s,
lockwasher, and nuts. See Figure 22.
3. Connect Rotating light electrical terminal
to rear light harness.
[3] Tail, Backup, and Brake Lights

NOTE: These light assemblies are repairble. See
the Parts Manual for replacement rear combination
lights.
(1) Remove
1. ROTATING LIGHT LENS
2. ROTATING LIGHT BULB
1. Disconnect the battery. 3. LIGHT BASE
2. Remove the screw securing the Rear 4. NUT
Combination light to mounting bracket. 5. LOCKWASHER
Remove the Rear Combination light from 6. WASHER
the mounting bracket. 7. MOUNTING BRACKET
3. Disconnect the Rear Combination light 8. CAPSCREW
9. LOCK NUT
from the rear light harness. See Figure 23.
4. If the mounting bracket must be removed
from the overhead guard leg, remove the Figure 22. Rotating Light Assembly
bolts and remove the mounting bracket
from the overhead guard leg. See Figure
23.
(2) Replace
1. If the mounting bracket was removed, install the bolts. Install mounting bracket to overhead
guard leg.
2. Connect the Rear Combination light to the rear light harness. See Figure 23.
3. Insert the screw and install the Rear Combination light to the mounting bracket. See Figure
23.
— 27 —
1. REAR COMBINATION LIGHT
2. MOUNTING BLACKET
3. SCREWS
4. BOLTS
5. REAR LIGHT HARNESS
6. OHG LEG
Figure 23. Tail, Backup, and Brake Lights Removal
— 28 —
HMM800005
Schematics and Diagrams

H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

and Repair
weight of the load.
remove parts.
needs repairs.
WARNING
CAUTION
—1—
HYDRAULIC SCHEMATIC
—2—
TRANSMISSION SCHEMATIC
—3—
ＢＡＴＴＥＲＹ１２Ｖ
B/Y30 1 W8 FL BATT
100A
STARTER
B/R30
B
S
OPT LP 64 B/W0.85 OPT LP SW.
55W
OPT RELAY(CM)
OPT LP 63 B/R0.85 R/Y0.85 62 R/Y1.25 WORK LP
55W
11 B0.85 56 R/G 20A
E
STOP LP LH R/B
21W
STOP LP SW. STOP LP
(TOTAL MAX 110W)

61 R/B 60 R/L 60 R/L
STOP LP RH R/B 10A
21W
HORN SW. 29 Gy/L 28 Gy 28 Gy HORN
OPT 5A
PARKING LP LH R/W
5W
OPT WIPER/
HORN
PARKING LP RH R/W L/R0.85 48 L/R1.25 HEATER
OPT
5W
10 B/Y3
OPT 20A
OPT LP R/W
55W
W/G1.25 65 W/G1.25 OPT-ECU
LICENSE LP R/W
OPT
5W
20A
OPT
TAIL LP LH R/W
(MAX 115W) (MAX 14A)
5W
TAIL LP RELAY(CM) HEAD/
TAIL LP RH R/W 58 R/W R/W R0.85 55 R2 TAIL LP
5W
59 L/B L/B R 25A
EL
11 B
HEAD LP LH R/G0.85 HEAD LP RELAY(CB)
57 B/Y B/Y R
ＬＴ
55W
LH
6 W MAIN
HEAD LP RH
LIGHT SW.
R/G0.85 56 R/G0.85 R/G1.25 R2
5A
55W
11 B
R/G
TURN LP LH(R) G/R E
21W
TURN LP LH(F) G/R
21W
OPT FLASHER UNIT
TURN SW.
ＯＰＴＬＩＧＨＴ
TURN LP LH(F)
RELAY BOX ASSY
FUSE BOX ASSY
G/R 54 G/R B
（ＭＡＸ０．２Ａ）
E
TL
23W
B
TB
52 G/W G/W G0.85

L
TURN LP RH(F) G/B 53 G/B

TR
73 L/Or
23W
BACK LAMP RELAY COIL BACK LP RELAY(CM) TURN/
TURN LP RH(F) G/B 51 L0.85 L0.85 G0.85 50 G0.85 BACK LP
5 R
21W
V-ECU FUSE OPT 11 B B 20A
TURN LP RH(R) G/B
5 R
73 L/Or L/Or
21W
BACK LP LH GAUGE/
L
5 R R 5 R V-ECU
21W
R
R
R
R
BACK LP RH L 10A
7 W/L 21W W/R5 4 W/R5
MAIN RELAY COIL
MONOTROL
N
OPT LP
Ｆ－ＳＷ．
Ｒ－ＳＷ．
L0.85
ＩＧ１
ＩＧ２
NC
NO
NC
NO
MAIN RELAY(CB)
35W
W/L5
L
9 W/B OPT BACK W/L B 12 L/W1.25 IGN
STARTER RELAY COIL
72 Lg
70 Br
BACK BUZZER L 10A
ＦＯＲＭＯＮＯＴＲＯＬＴＲＵＣＫＳ（ＣＴ）
76 Lg/B
Ｒａ－ＳＷ．Ｒ
(TOTAL MAX 65W)

13 Br/Y1.25 OPT-IGN
F/R SHIFT SW.
B ST RELAY(CB)
W/B B 20A
ＶＦ２ 5 R
L/Or
Ｒ－ＳＷ．ＶＲ 72 Lg
Ｆ－ＳＷ．ＶＦ１ 70 Br
Ｎ－ＳＷ．ＳＴ 71 Or
ＲＳＷ
ＦＳＷ
ＮＳＷ
OPT FORWARD Br B/Y3 W/L5 3 W/L5
R (MAX 0.2A)
MAIN FUSE
ＳＯＬＩＧ
9 W/B R
ＳＴＲＹ PARKING SW. ＩＧＮ FL ALT
87 W
6 W
25 P NO W ＳＳ１ＳＳ１
ＲＳＷ
ＦＳＷ
ＮＳＷ
ＰＡＲＫ 88 B 100A
ＳＳ２ＳＳ２
SENSOR
89 R R
ＳＯＬＩＧ
ST ANGLE
NC ＳＳＣＳＳＣ
V-ECU
SERVICE 66 90 B 9 W/B
ＥＳＳＥＳＳＳＴＲＹ
2 R8
ST PARKING SW.
AM
67 B/W BRAKE SW. W/R NEUTRAL SW. 8 B/R W 25 P W

ＫＥＹ－ＳＴ NO
7 W/L W/L ＰＡＲＫ
ＫＥＹ－ＩＧＳＥＡＴＳＷ． 26 L/Y
IG
ＳＥＡＴ
V-ECU
NC
OFF
ACC
IGN.SW.
6 W ＳＥＡＴＢＥＬＴＳＷ． 24 Y/B

ST
AM
ＲＳＯＬＢＡＴＴＳＢＥＬＴ 8 B/R B/R W

ＫＥＹ－ＳＴ
7 W/L W/L
ＫＥＹ－ＩＧ
Ｆ－ＳＯＬ．
IG
11 B1.25 75 Br/B
ＦＳＯＬ
OFF
ACC
IGN.SW.
11 B0.85 Ｒ－ＳＯＬ． 76 Lg/B 6 W

ＲＳＯＬＢＡＴＴ
11 B0.85 ＬＩＦＴ－ＳＯＬ． 77 Or/B
ＬＦＴＳＯＬ 101 Br/R
11 B0.85 ＵＮＬＯＡＤ－ＳＯＬ． 78 Gy/B ＳＰＲＹ１
ＵＮＳＯＬ 102 Lg/R
ALARM
SPEED
11 B0.85 ＰＳ－ＳＯＬ． 79 P/B ＳＰＲＹ２

O/P OPT
P
R
N
F
ＰＳＳＯＬ
58 R/W
C
ＬＴ－ＩＮ
98 B 98 Gy/L
ＰＲＳ－ 100 L
97 W 97 P/L ＳＰＩＮ
OPT
ＰＲＳＳ
OPT
I/P
84 G/Or
SENSOR
PRESS.
105 W/R
ＮＯＴＥＳ
ＴＸＤ２
106 G/W
Ｆ／ＲＳＨＩＦＴＳＷ．
ＲＸＤ２
Ｒ・・・ＲＥＤ
13 Br/Y1.25
OPT
LTV
84 G/Or
Ｐ・・・ＰＩＮＫ
Ｇｙ・・ＧＲＥＹ
Ｌ・・・ＢＬＵＥ
Ｌ
ＴＳ＋５ＳＧＮＤ２ 107 B/Y

Ｂｒ・・ＢＲＯＷＮ
Ｇ・・・ＧＲＥＥＮ
Ｂ・・・ＢＬＡＣＫ
Ｗ・・・ＷＨＩＴＥ
85 W
ＴＳＳ
Ｏｒ・・ＯＲＡＮＧＥ
Ｙ・・・ＹＥＬＬＯＷ
ANGLE
TRAIL
SENSOR
86 B
ＴＳ－ＣＡＮ－Ｇ 96
T N ＩＧ１ＩＧ２ ST ＶＦ１ＶＦ２ VR
ＣＡＮ－Ｌ 95
R
OPT
CAN
４．ＴＨＥＤＲＡＷＩＮＧＳ
３．ＴＨＥＤＲＡＷＩＮＧＳ
82 W ＣＡＮ－Ｈ 94
Ｌｇ・・ＬＩＧＨＴＧＲＥＥＮ
ＳＰＤ＋
ＯＰＴＩＧＮ
83 B
ＳＰＤー
SPEED
SENSOR
（ＭＡＸ１３０Ｗ）
ＲＸＤ
ＴＸＤ
ＳＧＮＤ
ＢＺ－ＩＮ
ＧＮＤ
11 B1.25 11 B0.85
93 B
92 B
91 W
27 Gy/R
ＦＯＲＡＵＴＯＭＡＴＩＣＸＭＳＮＴＲＵＣＫＳ（ＡＴ）
P
P
2
1
3
11 B0.85
T
T
HEAD
TAIL
OFF
OFF
ＴＸＤ
ＲＸＤ
ＧＮＤ
ＳＧＮＤ
ＢＺ－Ｏ
AM
ＯＩＬＰＲＥＳＳ．ＳＷ． 15 Y/L 6 W

ＥＮＧ．ＯＩＬＢＡＴＴ
ＰＲＥＳＳ． 5 R
ＬＩＧＨＴＳＷ．
ＡＵＴＯＴＲＡＮＳ． 16 Y/B ＩＧＮ

R8
ACC
LT EL LH
ＴＣＴＥＭＰ．
ＨＩＧＨＴＥＭＰ．ＳＷ．
ＩＧＮＩＴＩＯＮＳＷ．
B
IG
19 Y 14 G/Y 14 G/Y
L
ＳＥＤＩＭＥＮＴＥＲＣＨＡＲＧＥ
P
12 L/W
LH
RH
R
ST
38 Or
DISPLAY
ＬＰＧ
ALTERNATOR
ＢＺ＋
ＴＵＲＮＳＷ．
3
ＳＥＮＤＥＲ 18 Y/R
T TB TL TR
ＴＥＭＰ．ＧＡＵＧＥＢＺ－
BUZZER
WARNING
ＳＥＮＤＥＲ 17 Y/G
OFF
ＦＵＥＬＧＡＵＧＥ
GLOW
ＯＦＷＩＲＥＩＮＣＬＵＤＩＮＧＧＲＯＵＮＤＣＯＬＯＲＡＮＤＭＡＲＫＩＮＧＣＯＬＯＲ．
2
１．ＣＯＬＯＲＯＦＷＩＲＥＯＮＴＨＥＣＩＲＣＵＩＴＩＮＤＩＣＡＴＥＴＨＥＦＯＬＬＯＷＩＮＧ．
33 Br/W
ＦＵＥＬＳＨＵＴＯＦＦＳＯＬＥＮＯＩＤ L/W0.85 12 L/W1.25
B/W
L
２．ＴＨＥＳＴＡＮＤＡＲＤＣＯＬＯＲＳＰＥＣＩＦＩＥＤＩＮＪＩＳＣ３４０６ＡＲＥＵＳＥＤＦＯＲＣＯＬＯＲＳ
L/W1.25
ＯＮＴＨＥＣＩＲＣＵＩＴＩＮＤＩＣＡＴＥＡＴＷＩＳＴＥＤＰＡＩＲ．

（ＥＸ．）Ｗ／Ｌ……… ＷＩＲＥＣＯＬＯＲ（ＧＲＯＵＮＤＣＯＬＯＲ：ＷＨＩＴＥ，ＭＡＲＫＩＮＧＣＯＬＯＲ：ＢＬＵＥ）
1
ＰＬＵＧＳ
ＳＰＡＲＫ
-
+
ＯＮＴＨＥＣＩＲＣＵＩＴＩＮＤＩＣＡＴＥＡＳＨＩＥＬＤＥＤＷＩＲＥ．

ＩＧＮＩＴＥＲＳＥＮＳＯＲ
3
～
ＤＩＳＴＲＩＢＵＴＯＲ
4
2
ＣＯＩＬ
ROTOR
SYSTEM
IGNITION
ＩＧＮＩＴＩＯＮ
ELECTRONIC
ＳＣＨＥＭＡＴＩＣＤＩＡＧＲＡＭ
—4—
ＦＯＲＭ４－２.０Ｇ／２.２Ｇ－ＧＡＳＥＮＧＩＮＥ
TURN STOP
BACK
SIGNAL /TAIL
LAMP
LAMP LAMP 58 R/W
REAR 51 58 61 R/B
COMBINATION 21W 51 L
21W 21W 53
LAMP R.H. 5W 11 61 53 G/B
85 W CN6 85 W 61 R/B 61 R/B
11 B 11 B 11 B0.85
24 Y/B 24 Y/B 61 54 54 61
85 86 86 85 54 G/R 11 53 53 11 54 G/R
17 Y/G 17 Y/G
86 B 24 26 26 24 86 B 53 G/B 53 G/B
26 L/Y 17 18 18 17 26 L/Y 58 R/W 58 R/W
56 R/G0.85
18 Y/R 18 Y/R
11 B0.85
11 B0.85 11 B1.25 11 B1.25 51 L 51 L0.85
58 R/W
R/G0.85
53 G
B0.85
51 L 51 L
R/W
V-ECU 76 Lg/B BACK 13 Br/Y0.85
G
73 L/Or WIRE NO. 73 L/Or BUZZER
11
56
53
58
OPT TERMINAL 63 B/R0.85
OPT 33 Br/W 73 76
R/L
OPT SPEED ALARM
11 56
B
5 R AT 5 R 52 G/W 64 B/W0.85
53 58
× 11
11 B1.25 11 B1.25 OPT FLASHER 52 11 B 51 L
CT × 50
13 Br/Y1.25 13 Br/Y1.25 50 G
CN2
R
B
G
B
G
B
Y
53 58 CN4 CN3 84 G/Or 84 G/Or

8
11 56 14 G/Y 11 11 11 11 14 G/Y
21W 8 9 24 78 77 76 75 79 5 1 6 11 98 97 25 7 6 1 or
55W 23W 15 Y/L 51 13 13 51 15 Y/L
5W 16 102 101 27 107 106 105 82 83 9 12 86 85 84 72 70 7 67
56 R/G0.85
53 G/B 84 84 73 53 G/B
11 B1.25
HEAD TURN SIGNAL 24 58 100 71 26 89 88 87 90 17 18 96 95 94 93 92 91 13
53 G/B
58 R/W
54 G/R 14 14 54 G/R 3 W/L5
LAMP LAMP R.H. 19 Y 15 15 4 3 4 W/R5
102 Lg/R
101 Br/R
13 Br/Y1.25
101 Br/R
102 Lg/R
27 Gy/R
107 B/Y
106 G/W
105 W/R
78 Gy/B
77 Or/B
76 Lg/B
75 Br/B
6 W 53 53 6 W 13
58 R/W
26 L/Y
9 W/B
24 Y/B
79 P/B
51 L0.85
100 L
71 Or
65 W/G1.25
89 R
88 B
87 W
90 B
82 W
83 B
5 R
48 L/R0.85 54 54 48 L/R1.25 50 51 50 G0.85 65
56 R/G0.85 33 19 56 R/G1.25 55 R2 55
G/Or
10 B/Y3
57 B/Y 5 6 6 5 57 B/Y 3 10
B
W
3 W/L5
52 G/W 52 G/W
63 B/R CN1 63 B/R0.85 55 R 48 L/R1.25 48
13 Br/Y1.25
64 B/W 48 65 65 48 64 B/W0.85 59 55 57 B/Y 28 Gy 28 86 85 84
RELAY BOX ASSY

Ｖ－ＥＣＵＣＯＮＮＥＣＴＯＲ 9 W/B 50 G0.85
FUSE BOX ASSY

65 W/G1.25 56 58 58 56 65 W/G1.25 55 57 60
B0.85
11 B0.85
63 B/R
64 B/W
Br/Y1.25
G/Or
Gy/L
58 R/W 58 R/W 11 9 11 B 12 L/W1.25
R/Y0.85
L/R0.85
W/G1.25
107 B/Y
106 G/W
105 W/R
WIRE NO. 57 59 59 57
B/R
B/W
P/L
W/L
51 L
Lg
Br
B
B
W
B
W
W
59 L/B 59 L/B 11 B 5 R
Br/Y
Br/Y
8 67 70 71 72 75 76 9 9
R/G
93
92
91
86
85
84
72
70
8
67
11
98
97
25
7
6
9 W/B 9 W/B 59 L/B 60 R/L
L
AT × 7 7
55 R 62 R/Y1.25 TRAIL
62 56 48 13 13 100 65 13 107 106 105 7 W/L 28 28 7 W/L 7 50 62
CT × × ANGLE
28 Gy 38 28 Gy 73 11 11 B 6 W 12 6
CN7 SENSOR
38 Or 52 60 60 52 11 11 7 W/L 5
OPT TERMINAL
OPT CONNECTOR #1
OPT CONNECTOR #2
OPT CONNECTOR #5
OPT CONNECTOR #3
OPT CONNECTOR #4
(WORKING LAMP)
(WIPER/HEATER)
60 R/L 60 R/L 73 L/Or

OPT EARTH
63 61 61 63
(STD-ECU I/P)
4 W/R5
61 R/B 64 62 62 64 61 R/B 11 B 4 3
3 W/L5
(OPT-ECU)
62 R/Y0.85 62 R/Y1.25 58 56 56 R/G1.25

1 W8
55 R0.85
(LTV)
55 2 R8 1 2
55 52 52 G/W
ＡＴ＆ＭＯＮＯＴＲＯＬ 50 50 G0.85
ＭＯＮＯＴＲＯＬＴＲＵＣＫＳＯＮＬＹＴＲＵＣＫＳＯＮＬＹ 58 R/W
WARNING 55 R2
DISPLAY BUZZER
THERMO SW.
F/R R B1.25 11 BODY EARTH BATTERY
72 Lg 72 72 72 Lg
MONOTROL SOLENOID IGN.
20 10
TC.OIL
5 R 5 R
L/W1.25
5 5 PEDAL ASSY F W8 1 1 W8 + - COIL
91 19 19 Y 70 Br 70 Br
70 70
92 16 16 Y/B - +
93 15 15 Y/L
IGN. PS
27 14 14 G/Y SW. SOLENOID 12
5 5 R 16
6 6 W AM
17 17 Y/G IG ST B/Y3
18 18 Y/R
98 Gy/L 98 98 98 B
B/W
11 11 S 10
Y/B
11 11 B0.85
L
7 8 97 P/L 97 97 97 W 75 76 B
33 38 38 Or
6 79 11 84 G/Or 84 84 84 G/Or
11 1 91 W
B1.25
B0.85
92 B
Br/B
Lg/B
CN5 STARTER
7 W/L
8 B/R
B0.85
93 B
6 W
P/B
75
11
11
76
27 Gy/R W 82 W
33 Br/W B 83 B DISTRIBUTOR
4 3 2 1 FIRING ORDER
LIGHT/TURN SW.
84 G/Or
57 57 B/Y 1,3,4,2
97 W
98 B
SOLENOID
59 59 L/B
B0.85 11
UNLOAD
11 11 B
Gy/B 78
53 53 G/B 84 98
54 54 G/R 97
52 52 G/W
SOLENOID
5 R
B0.85 11 Ｍ４-２.０Ｇ／２.２ＧＧＡＳＥＮＧＩＮＥ
LIFT
Or/B 77
G/W
G/B
G/R
L/B
B/Y
87 5 87 W
B
ST ANGLE
88 B
COMBINATION SWITCH
52
53
54
11
59
57
88
SENSOR
SENSOR
SPEED
89 89 R PRESS. WATER
52 53 54 60 R/L OPT DUAL
OPT SEAT
BELT SW.
18 Y/R THERMO
SEAT SW.
90 90 B STOP SENSOR FUEL SYSTEM
11 59 57 61 R/B LAMP SW. SENDER
GAS SLOW OIL
29 Gy/L
HORN
11 59 57 FUEL SOL. PRESS. SW.

SW.
11 29 11 B
52 53 54 8 B/R NEUTRAL ALTERNATOR
72 72 Lg 66 W/R SW.
W
B
L
B
G/W
G/B
G/R
L/B
B/Y
73 73 L/Or 15
B
71 Or R8 2 B
52
53
54
11
59
57
71
F/R SHIFT SW.
12
5 5 R ＭＯＮＯＴＲＯＬＴＲＵＣＫＳＯＮＬＹ
Y/L
70 70 Br L/W 12 R
B/R
B/W
5 5 R G/Y 14 L
L/W0.85
W
P
70 Br
5 5 R
5 R SERVICE 67 B/W
5
BRAKE SW. 66 W/R
72 72 Lg
6 25 8 67
OPT
ＡＴＴＲＵＣＫＳＯＮＬＹ TERMINAL
24 Y/B 24 W
11 B 11 B
N.O. N.C.
26 L/Y 26 L
56 R/G0.85
HEAD TURN SIGNAL

11 B0.85
LAMP LAMP L.H. PARKING SW.

58 R/W
54 G/R
FUEL 64 B/W OPT TERMINAL

21W 17 Y/G
55W 23W SENDER
5W
56 11 B1.25 11 BODY EARTH
58 54
R
B
G
B
G
B
Y
58 53
56 11
Gy 28
HORN
ＷＩＲＩＮＧＤＩＡＧＲＡＭ
OPT Gy/L 29 ＦＯＲＭ４－２.０Ｇ／２.２Ｇ－ＧＡＳＥＮＧＩＮＥ
56 R/G0.85
11 B0.85
58 R/W
56 R/G0.85
11 B0.85
11 B0.85
TURN STOP
53 G
58 R/W
53 G
BACK
SIGNAL /TAIL
LAMP
LAMP LAMP
58 R/W
REAR 51 58 61 R/B
COMBINATION 21W
21W 21W 54 51 L
LAMP L.H. 5W 11 61 54 G/R
11 B
—5—
B/Y30 1 W8 FL BATT
100A
STARTER
B/R30
B
S
55W
OPT RELAY(CM)
55W
11 B0.85 56 R/G 20A
STOP LP LH R/B E
(TOTAL MAX 110W)

21W
61 R/B STOP LP SW. 60 R/L 60 R/L STOP LP
STOP LP RH R/B 10A
21W
OPT 5A
PARKING LP LH R/W
5W
OPT WIPER/
HORN
OPT
5W
10 B/Y3
OPT 20A
OPT LP R/W
55W
W/G1.25 65 W/G1.25 OPT-ECU
LICENSE LP R/W
OPT
5W
20A
OPT
TAIL LP LH R/W
5W
5W
59 L/B L/B R 25A
11 B
EL
57 B/Y B/Y R
ＬＴ
55W
LH
6 W MAIN
HEAD LP RH
LIGHT SW.
R/G0.85 56 R/G0.85 R/G1.25 R2
5A
55W
11 B
R/G
E
TURN LP LH(R) G/R
21W
TURN LP LH(F) G/R
21W
OPT FLASHER UNIT
TURN SW.
TURN LP LH(F)
RELAY BOX ASSY
FUSE BOX ASSY
G/R 54 G/R B
E
TL
23W
B
TB
52 G/W G/W G0.85
L

TR
73 L/Or
23W
5 R
21W
V-ECU FUSE OPT 20A
11 B B
TURN LP RH(R) G/B
5 R
73 L/Or L/Or
21W
BACK LP LH GAUGE/
L
5 R R 5 R V-ECU
21W
R
R
R
R
BACK LP RH L 10A
7 W/L W/R5 4 W/R5
MAIN RELAY COIL 21W
MONOTROL
N
OPT LP
Ｆ－ＳＷ．
Ｒ－ＳＷ．
L0.85
ＩＧ２
ＩＧ１
NC
NO
NC
NO
MAIN RELAY(CB)
35W
W/L5
L
STARTER RELAY COIL
72 Lg
70 Br
BACK BUZZER L 10A
(TOTAL MAX 65W)
76 Lg/B
F/R SHIFT SW.
13 Br/Y1.25 OPT-IGN
B ST RELAY(CB)
W/B B 20A
ＶＦ２ 5 R
L/Or
ＲＳＷ
ＦＳＷ
ＮＳＷ
R MAIN FUSE (MAX 0.2A)
ＳＯＬＩＧ
9 W/B R
ＳＴＲＹ PARKING SW. ＩＧＮ R3 FL ALT
87 W
6 W
ＲＳＷ
ＦＳＷ
ＮＳＷ
ＳＳ２ＳＳ２
SENSOR
89 R R
ＳＯＬＩＧ
ST ANGLE
V-ECU
2 R8
PARKING SW.
ST
AM

IG
ＳＥＡＴ
NC
V-ECU
OFF
ACC
IGN.SW.

ST
AM

ＫＥＹ－ＳＴ
7 W/L W/L
ＫＥＹ－ＩＧ
Ｆ－ＳＯＬ．
IG
11 B1.25 75 Br/B
ＦＳＯＬ
OFF
ACC
Ｒ－ＳＯＬ．
IGN.SW.
11 B0.85 76 Lg/B 6 W
ＬＦＴＳＯＬ
11 B0.85 ＵＮＬＯＡＤ－ＳＯＬ． 78 Gy/B ＳＰＲＹ１ 101 Br/R
ALARM
SPEED

O/P OPT
P
R
N
F
ＰＳＳＯＬ
58 R/W
C
ＬＴ－ＩＮ
98 B 98 Gy/L
ＰＲＳ－ 100 L
OPT
ＰＲＳＳ
OPT
I/P
84 G/Or
SENSOR
PRESS.
ＮＯＴＥＳ
ＴＸＤ２ 105 W/R

ＲＸＤ２ 106 G/W

13 Br/Y1.25
OPT
LTV
84 G/Or
Ｌ
ＴＳ＋５ＳＧＮＤ２ 107 B/Y

10 R3
85 W
Ｏｒ・・ＯＲＡＮＧＥＴＳＳ
ANGLE
TRAIL
SENSOR
86 B
5A
LPG
ＣＡＮ－Ｌ 95
R
OPT
CAN
82 W ＣＡＮ－Ｈ 94
Ｌｇ・・ＬＩＧＨＴＧＲＥＥＮ
ＳＰＤ＋
ＯＰＴＩＧＮ
LPG
83 B
ＳＰＤー
SPEED
SENSOR
35 R0.85
ＲＸＤ
ＴＸＤ
35 R0.85
NO
ＢＺ－ＩＮ
ＳＧＮＤ
ＧＮＤ
RELAY COM
36 R/L0.85
11 B1.25 11 B0.85
93 B
Or L/W
NC
0.85 LPG SHORT CONNECTOR 0.85

92 B
91 W
27 Gy/R
D
OPT
L/W1.25
P
P
34 Y/R
38 Or0.85
2
1
3
LPG
11 B0.85 L/W
P
T
T
HEAD
TAIL
OFF
OFF
ＴＸＤ
ＲＸＤ
ＧＮＤ 0.85
ＳＧＮＤ
ＢＺ－Ｏ
SELECT SW.
37 G0.85
C
AM

G
GAS
DUAL FUEL SYSTEM
G/Y

R8
ACC
LT EL LH
B
IG
19 Y 14 G/Y 14 G/Y
L
P
12 L/W
LH
RH
R
ST
38 Or 38 Or
DISPLAY
ＬＰＧ
ALTERNATOR
ＢＺ＋
3
T TB TL TR
BUZZER
WARNING
OFF
GLOW
2
OPT
ＬＰＧＭＡＩＮＦＵＥＬＳＯＬＥＮＯＩＤ

33 Br/W
WARNING
LPG FUEL
ＬＰＧＳＬＯＷＦＵＥＬＳＯＬＥＮＯＩＤ 36 R/L0.85
ＧＡＳＭＡＩＮＦＵＥＬＳＯＬＥＮＯＩＤ

OPT
37 G0.85
ＧＡＳＳＬＯＷＦＵＥＬＳＯＬＥＮＯＩＤ 12 L/W0.85


DUAL FUEL SYSTEM
B/W
L
ＩＧＮＩＴＥＲ
1
ＰＬＵＧＳ
ＳＰＡＲＫ
-
+
12 L/W1.25
3
ＳＥＮＳＯＲ
～
ＤＩＳＴＲＩＢＵＴＯＲ
4
2
ＣＯＩＬ
ROTOR
SYSTEM
IGNITION
ＩＧＮＩＴＩＯＮ
ELECTRONIC
（ＤＵＡＬＦＵＥＬＳＹＳＴＥＭ）
—6—
ＦＯＲＭ４－２.０Ｇ／２.２Ｇ－ＬＰＧＥＮＧＩＮＥ
TURN STOP
BACK
SIGNAL /TAIL
LAMP
OPT LAMP LAMP 58 R/W
SELECT SW.
37 37 G0.85 12 L/W0.85 DUAL FUEL SYSTEM 12 L/W0.85 REAR 61 R/B
38 38 51 58
12 12 L/W0.85 38 Or0.85 12 12 38 Or0.85 COMBINATION 21W 51 L
37 37 21W 21W 53
FUEL
38 38 Or0.85 37 G0.85 37 G0.85 LAMP R.H. 5W 53 G/B
11 61 61 R/B 61 R/B
85 W CN6 85 W 11 B
24 Y/B 24 Y/B 11 B 61 54 54 61 11 B0.85
L/W0.85 85 86 86 85 54 G/R 11 53 53 11 54 G/R
LPG SHORT LPG FUEL 17 Y/G 17 Y/G
SYSTEM 86 B 24 26 26 24 86 B 53 G/B 53 G/B
CONNECTOR
26 L/Y 17 18 18 17 26 L/Y 58 R/W 58 R/W
56 R/G0.85
18 Y/R 18 Y/R
11 B0.85
11 B0.85
11 B1.25 11 B1.25 51 L 51 L0.85
58 R/W
R/G0.85
53 G
B0.85
51 L 51 L
R/W
V-ECU 76 Lg/B BACK 13 Br/Y0.85
G
73 L/Or WIRE NO. 73 L/Or BUZZER
11
56
53
58
OPT TERMINAL 63 B/R0.85
OPT 33 Br/W 73 76
R/L
OPT SPEED ALARM
11 56
B
5 R 5 R 52 G/W 64 B/W0.85
53 58
AT × 11
11 B1.25 11 B1.25 OPT FLASHER 52 11 B 51 L
CT × 50
13 Br/Y1.25 13 Br/Y1.25 50 G
CN2
R
B
G
B
G
B
Y
53 58 CN4 CN3 84 G/Or 84 G/Or

8
11 56 14 G/Y 11 11 11 11 14 G/Y
21W 8 9 24 78 77 76 75 79 5 1 6 11 98 97 25 7 6 1 or
55W 23W 15 Y/L 51 13 13 51 15 Y/L
5W 16 102 101 27 107 106 105 82 83 9 12 86 85 84 72 70 7 67
56 R/G0.85
53 G/B 84 84 73 53 G/B
11 B1.25
HEAD TURN SIGNAL 24 58 100 71 26 89 88 87 90 17 18 96 95 94 93 92 91 13
53 G/B
58 R/W
54 G/R 14 14 54 G/R 3 W/L5
LAMP LAMP R.H. 19 Y 15 15 4 3
LPG FUSE
4 W/R5
102 Lg/R
101 Br/R
13 Br/Y1.25
101 Br/R
102 Lg/R
27 Gy/R
107 B/Y
106 G/W
105 W/R
78 Gy/B
77 Or/B
76 Lg/B
75 Br/B
6 W 53 53 6 W 13
58 R/W
26 L/Y
9 W/B
24 Y/B
79 P/B
51 L0.85
100 L
71 Or
65 W/G1.25
89 R
88 B
87 W
90 B
82 W
83 B
5 R
48 L/R0.85 54 54 48 L/R1.25 50 51 50 G0.85 65
56 R/G0.85 33 19 56 R/G1.25 55 R2 55
G/Or
10 B/Y3
57 B/Y 5 6 6 5 57 B/Y 3 10
B
W
3 W/L5
52 G/W 52 G/W
63 B/R CN1 63 B/R0.85 55 R 48 L/R1.25 48
13 Br/Y1.25
64 B/W 48 65 65 48 64 B/W0.85 59 55 57 B/Y 28 Gy 28 86 85 84
RELAY BOX ASSY

FUSE BOX ASSY

65 W/G1.25 56 58 58 56 65 W/G1.25 55 57 60
B0.85
11 B0.85
63 B/R
64 B/W
Br/Y1.25
G/Or
Gy/L
58 R/W 58 R/W 11 9 11 B 12 L/W1.25
R/Y0.85
L/R0.85
W/G1.25
107 B/Y
106 G/W
105 W/R
WIRE NO. 57 59 59 57
B/R
B/W
P/L
W/L
51 L
Lg
Br
B
B
W
B
W
W
59 L/B 59 L/B 11 B 5 R
Br/Y
Br/Y
8 67 70 71 72 75 76 9 9
R/G
93
92
91
86
85
84
72
70
8
67
11
98
97
25
7
6
9 W/B 9 W/B 59 L/B 60 R/L
L
AT × 7 7
55 R 62 R/Y1.25 TRAIL
62 56 48 13 13 100 65 13 107 106 105 7 W/L 28 28 7 W/L 7 50 62
CT × × ANGLE
28 Gy 38 38 28 Gy 73 11 11 B 6 W 12 6
CN7 SENSOR
38 Or 52 60 60 52 38 Or 11 11 7 W/L 5
OPT CONNECTOR #1
OPT CONNECTOR #2
OPT CONNECTOR #5
OPT CONNECTOR #3
OPT CONNECTOR #4
OPT TERMINAL
(WORKING LAMP)
(WIPER/HEATER)
OPT EARTH
(STD-ECU I/P)
60 R/L 63 61 61 63 60 R/L 73 L/Or

4 W/R5
61 R/B 64 62 62 64 61 R/B 11 B 4 3
(OPT-ECU)
3 W/L5
62 R/Y0.85 62 R/Y1.25 58 56 56 R/G1.25
1 W8
(LTV)
55 55 R0.85 1 2
2 R8
55 52 52 G/W
ＡＴ＆ＭＯＮＯＴＲＯＬ 50 50 G0.85
WARNING 55 R2
DISPLAY BUZZER
THERMO SW.
F/R R B1.25 11 BODY EARTH BATTERY
72 Lg 72 72 72 Lg
MONOTROL SOLENOID IGN.
L/W1.25
20 10
TC.OIL
5 R 5 5 5 R W8 1 1 W8 + -
19 Y PEDAL ASSY F COIL
91 19 70 Br 70 Br
70 70
92 16 16 Y/B - +
93 15 15 Y/L
IGN. PS
27 14 14 G/Y SW. SOLENOID 12
5 5 R 16
6 6 W AM
18 18 Y/R
98 Gy/L 98 98 98 B
B/W
11 11 S 10
Y/B
11 11 B0.85
L
7 8 97 P/L 97 97 97 W 75 76 B
33 38 38 Or
6 79 11 84 G/Or 84 84 84 G/Or
11 1 91 W
B1.25
B0.85
92 B
Br/B
Lg/B
CN5 STARTER
7 W/L
8 B/R
B0.85
93 B
6 W
P/B
75
11
11
76
27 Gy/R W 82 W
33 Br/W B 83 B DISTRIBUTOR
4 3 2 1 FIRING ORDER
LIGHT/TURN SW.
84 G/Or
57 57 B/Y 1,3,4,2
97 W
98 B
SOLENOID
59 59 L/B
B0.85 11
UNLOAD
11 11 B
Gy/B 78
53 53 G/B 84 98
54 54 G/R 97
52 52 G/W
SOLENOID
5 R
B0.85 11 Ｍ４-２.０Ｇ／２.２ＧＬＰＧＥＮＧＩＮＥ
LIFT
Or/B 77
G/W
G/B
G/R
L/B
B/Y
87 5 87 W
B
ST ANGLE
88 B
COMBINATION SWITCH
52
53
54
11
59
57
88
SENSOR
SENSOR
SPEED
89 89 R PRESS. OPT DUAL WATER

52 53 54 60 R/L
OPT SEAT
BELT SW.
SEAT SW.
90 90 B STOP SENSOR 18 Y/R THERMO
11 59 57 FUEL SYSTEM
61 R/B LAMP SW. SENDER
GAS SLOW OIL
29 Gy/L
HORN
11 59 57 FUEL SOL. PRESS. SW.

SW.
11 29 11 B
52 53 54 8 B/R NEUTRAL ALTERNATOR
72 72 Lg 66 W/R SW.
W
B
L
B
G/W
G/B
G/R
L/B
B/Y
73 73 L/Or 15
B
71 Or R8 2 B
52
53
54
11
59
57
71
F/R SHIFT SW.
12
Y/L
70 70 Br L/W 12 R
B/R
B/W
5 R G/Y 14 L
L/W0.85
5
W
P
70 Br
5 5 R
5 R SERVICE 67 B/W
5
72 Lg BRAKE SW. 66 W/R
72 6 25 8 67
OPT
ＡＴＴＲＵＣＫＳＯＮＬＹ TERMINAL 24 Y/B 24 W
11 B 11 B
N.O. N.C.
26 L/Y 26 L
56 R/G0.85
HEAD TURN SIGNAL

11 B0.85

58 R/W
54 G/R
37 G0.85 64 B/W OPT TERMINAL

21W FUEL GAS MAIN
55W 23W SENDER FUEL SOL.
5W
56 11 B1.25 11 BODY EARTH Y/R 34 A DIODE
58 54
CONNECTOR
R
B
G
B
G
B
Y
OPT DUAL FUEL SYSTEM G/Y 14 K

ＬＰＧＳＬＯＷ
17
58 53
56 11
Gy 28
HORN
ＦＵＥＬＳＯＬＥＮＯＩＤ
35 R0.85 OPT WARNING
OPT 11 B 34 Y/R 36 R/L BUZZER ＦＯＲＭ４－２.０Ｇ／２.２Ｇ－ＬＰＧＥＮＧＩＮＥ
Y/G
Gy/L 29 LPG COIL 34

36 R/L0.85 FUEL 36 38 35 38 Or0.85
N0 NC COM
（ＤＵＡＬＦＵＥＬＳＹＳＴＥＭ）
56 R/G0.85
11 B0.85
RELAY 38 Or
58 R/W
ＲＥＧＵＬＡＴＯＲ COIL 38
56 R/G0.85
11 B0.85
11 B0.85
58 R/W
TURN STOP
53 G
36 R/L0.85
53 G
BACK
SIGNAL /TAIL
11 B LAMP
LAMP LAMP 58 R/W
36 R/L0.85
REAR 51 58 61 R/B
ＬＰＧＭＡＩＮ 21W 21W 54
ＦＵＥＬＳＯＬＥＮＯＩＤ
LAMP L.H. 5W 11 61 54 G/R
11 B
—7—
B/Y30 30 W/B5 FL GROW W5
60A
1 W8 FL BATT
STARTER
B/R30
B 100A
S
55W
OPT RELAY(CM)
55W
11 B0.85 56 R/G 20A
E
STOP LP LH R/B
(TOTAL MAX 110W)

21W
61 R/B STOP LP SW. 60 R/L 60 R/L STOP LP
STOP LP RH R/B 10A
21W
OPT 5A
PARKING LP LH R/W
5W
OPT WIPER/
HORN
OPT
5W
10 B/Y5
OPT 20A
OPT LP R/W
55W
W/G1.25 65 W/G1.25 OPT-ECU
LICENSE LP R/W
OPT
5W
OPT 20A
TAIL LP LH R/W
5W
5W
11 B 59 L/B L/B R 25A
EL
57 B/Y B/Y R
ＬＴ
55W
LH
6 W MAIN
HEAD LP RH
LIGHT SW.
R/G0.85 56 R/G0.85 R/G1.25 R2
5A
55W
11 B
R/G
E
TURN LP LH(R) G/R
21W
TURN LP LH(F) G/R
21W
OPT
TURN SW.
FLASHER UNIT
TURN LP LH(F)
RELAY BOX ASSY
FUSE BOX ASSY
G/R 54 G/R B
E
TL
23W
B
TB
52 G/W G/W G0.85
L
TR
73 L/Or
23W
5 R
21W
V-ECU FUSE OPT 20A
11 B B
TURN LP RH(R) G/B
5 R
73 L/Or L/Or
21W
BACK LP LH GAUGE/
L
5 R R 5 R V-ECU
21W
R
R
R
R
BACK LP RH L 10A
7 W/L W/R5 4 W/R5
21W
MAIN RELAY COIL
MONOTROL
N
OPT LP
Ｆ－ＳＷ．
Ｒ－ＳＷ．
L0.85
ＩＧ１
ＩＧ２
NC
NO
NC
NO
MAIN RELAY(CB)
35W
W/L5
L
STARTER RELAY COIL
72 Lg
70 Br
BACK BUZZER L 10A

(TOTAL MAX 65W)
76 Lg/B
13 Br/Y1.25 OPT-IGN
F/R SHIFT SW.
B ST RELAY(CB)
W/B B 20A
ＶＦ２ 5 R
L/Or
ＲＳＷ
ＦＳＷ
ＮＳＷ
R
MAIN FUSE
ＳＯＬＩＧ (MAX 0.2A)
9 W/B R
ＳＴＲＹ PARKING SW. ＩＧＮ FL ALT
87 W
B
6 W
ＲＳＷ
ＦＳＷ
ＮＳＷ
ＳＳ２ＳＳ２
SENSOR
89 R R
ＳＯＬＩＧ
ST ANGLE
V-ECU
2 R8
PARKING SW.
ST
AM
IG
ＳＥＡＴ
NC
V-ECU
OFF
ACC
IGN.SW.

ST
AM

ＫＥＹ－ＳＴ
7 W/L W/L
ＫＥＹ－ＩＧ
Ｆ－ＳＯＬ．
IG
11 B1.25 75 Br/B
ＦＳＯＬ
OFF
ACC
Ｒ－ＳＯＬ．
IGN.SW.
11 B0.85 76 Lg/B 6 W
ＬＦＴＳＯＬ
11 B0.85 ＵＮＬＯＡＤ－ＳＯＬ． 78 Gy/B ＳＰＲＹ１ 101 Br/R
ALARM
SPEED

O/P OPT
P
R
N
F
ＰＳＳＯＬ
58 R/W
C
ＬＴ－ＩＮ
98 B 98 Gy/L
ＰＲＳ－ 100 L
OPT
ＰＲＳＳ
OPT
I/P
84 G/Or
SENSOR
PRESS.
ＮＯＴＥＳ
ＴＸＤ２ 105 W/R

106 G/W
ＲＸＤ２
13 Br/Y1.25
OPT
LTV
84 G/Or 107 B/Y
Ｌ
ＴＳ＋５ＳＧＮＤ２
85 W
ＴＳＳ
Ｏｒ・・ＯＲＡＮＧＥ
ANGLE
TRAIL
SENSOR
86 B
ＣＡＮ－Ｌ 95
R
OPT
CAN
82 W ＣＡＮ－Ｈ 94
Ｌｇ・・ＬＩＧＨＴＧＲＥＥＮＳＰＤ＋
ＯＰＴＩＧＮ
83 B
ＳＰＤー
SPEED
SENSOR
ＲＸＤ
ＴＸＤ
ＳＧＮＤ
ＧＮＤ
ＢＺ－ＩＮ
11 B1.25 11 B0.85
93 B
92 B
91 W
27 Gy/R
P
P
2
1
3
11 B0.85
T
T
HEAD
TAIL
OFF
OFF
ＴＸＤ
ＲＸＤ
ＧＮＤ
ＳＧＮＤ
ＢＺ－Ｏ
ＰＴＥＲＭＩＮＡＬ
AM

R8

ACC
LT EL LH
20 W/R
B
P
IG
ＳＥＤＩＭＥＮＴＥＲ 19 Y 14 G/Y 14 G/Y

L
P
12 L/W
LH
RH
R
ST
38 Or
DISPLAY
ＬＰＧ
ALTERNATOR
ＢＺ＋
3
T TB TL TR
BUZZER
WARNING
OFF
GLOW
2
33 Br/W
ＦＵＥＬＳＨＵＴＯＦＦＳＯＬＥＮＯＩＤ 12 L/W0.85
Br/W
4
L/W
1
QGS
9 W/B
5
3
B
31 W5
CONTROLLER
A
B
GLOW PLUGS
32 L5
ＦＯＲＹＡＮＭＡＲ２.７Ｌ／３.３Ｌ－ＤＳＬＥＮＧＩＮＥ
—8—
TURN STOP
BACK
SIGNAL /TAIL
LAMP
LAMP LAMP 58 R/W
REAR 51 58 61 R/B
COMBINATION 21W 21W 21W 53 51 L
LAMP R.H. 5W 53 G/B
11 61 61 R/B 61 R/B
85 W CN6 85 W 11 B
24 Y/B 24 Y/B 11 B 61 54 54 61 11 B0.85
85 86 86 85 54 G/R 11 53 53 11 54 G/R
17 Y/G 17 Y/G
24 26 26 24 9 W/B 53 G/B 53 G/B
86 B 86 B 9
12 L/W
QGS CONTROLLER
26 L/Y 17 18 18 17 26 L/Y 58 R/W 58 R/W
11 11 B
56 R/G0.85
18 Y/R 18 Y/R 33 12
11 B0.85
11 B0.85
33 Br/W 51 L 51 L0.85
11 B1.25 11 B1.25
58 R/W
R/G0.85
53 G
B0.85
51 L 51 L
R/W
V-ECU 76 Lg/B 31 31 W5 BACK 13 Br/Y0.85
G
73 L/Or WIRE NO. 73 L/Or 32 L5 BUZZER
11
56
53
58
32 OPT TERMINAL 63 B/R0.85
OPT 33 Br/W 73 76 33 Br/W
R/L
OPT SPEED ALARM
11 56
B
5 R 5 R 52 G/W 64 B/W0.85
53 58
AT × 11
11 B1.25 11 B1.25 OPT FLASHER 52 11 B 51 L
CT × 50
13 Br/Y1.25 13 Br/Y1.25 50 G
CN2
R
B
G
B
G
B
Y
53 58 CN4 CN3 84 G/Or 84 G/Or

8
11 56 14 G/Y 11 11 11 11 14 G/Y
21W 8 9 24 78 77 76 75 79 5 1 6 11 98 97 25 7 6 1 or
55W 23W 15 Y/L 51 13 13 51 15 Y/L
5W 16 102 101 27 107 106 105 82 83 9 12 86 85 84 72 70 7 67
56 R/G0.85
11 B1.25 53 G/B 84 84 73 53 G/B
HEAD TURN SIGNAL 24 58 100 71 26 89 88 87 90 17 18 96 95 94 93 92 91 13
53 G/B
58 R/W
54 G/R 14 14 54 G/R 3 W/L5
LAMP LAMP R.H. 19 Y 15 15 19 Y 4 3 4 W/R5
102 Lg/R
101 Br/R
13 Br/Y1.25
101 Br/R
102 Lg/R
27 Gy/R
107 B/Y
106 G/W
105 W/R
78 Gy/B
77 Or/B
76 Lg/B
75 Br/B
6 W 53 53 6 W 13
58 R/W
26 L/Y
9 W/B
24 Y/B
79 P/B
51 L0.85
100 L
71 Or
65 W/G1.25
89 R
88 B
87 W
90 B
82 W
83 B
5 R
48 L/R0.85 54 54 48 L/R1.25 50 51 50 G0.85 65
56 R/G0.85 33 19 19 33 56 R/G1.25 55 R2 55
G/Or
10 B/Y5
57 B/Y 5 6 6 5 57 B/Y 3 10
B
W
3 W/L5
52 G/W 52 G/W
63 B/R CN1 63 B/R0.85 55 R 48 L/R1.25 48
13 Br/Y1.25
64 B/W 48 65 65 48 64 B/W0.85 59 55 57 B/Y 28 Gy 28 86 85 84
RELAY BOX ASSY

FUSE BOX ASSY

65 W/G1.25 56 58 58 56 65 W/G1.25 55 57 60
B0.85
11 B0.85
63 B/R
64 B/W
Br/Y1.25
G/Or
Gy/L
58 R/W 58 R/W 11 9 11 B 12 L/W0.85
R/Y0.85
L/R0.85
W/G1.25
107 B/Y
106 G/W
105 W/R
WIRE NO. 57 59 59 57
B/R
B/W
P/L
W/L
51 L
Lg
Br
B
B
W
B
W
W
59 L/B 59 L/B 11 B 5 R
Br/Y
Br/Y
8 67 70 71 72 75 76 9 9
R/G
93
92
91
86
85
84
72
70
8
67
11
98
97
25
7
6
9 W/B 9 W/B 59 L/B 60 R/L
L
AT × 7 7
55 R 62 R/Y1.25 TRAIL
62 56 48 13 13 100 65 13 107 106 105 7 W/L 28 28 7 W/L 7 50 62
CT × × ANGLE
28 Gy 38 28 Gy 73 11 11 B 6 W 12 6
CN7 SENSOR
38 Or 52 60 60 52 11 11 7 W/L 5
OPT TERMINAL
OPT CONNECTOR #1
OPT CONNECTOR #2
OPT CONNECTOR #5
OPT CONNECTOR #3
OPT CONNECTOR #4
73 L/Or
(WORKING LAMP)
(WIPER/HEATER)
60 R/L 63 61 61 63 60 R/L
OPT EARTH
(STD-ECU I/P)
4 W/R5
61 R/B 64 62 62 64 61 R/B 11 B 4 3
3 W/L5
(OPT-ECU)
62 R/Y0.85 62 R/Y1.25 58 56 56 R/G1.25

1 W8
55 55 R0.85 1 2
(LTV)
2 R8
55 52 52 G/W
30 W/B5
ＡＴ＆ＭＯＮＯＴＲＯＬ 50 50 G0.85 30 31
31 W5
WARNING 55 R2
DISPLAY BUZZER
THERMO SW.
F/R BATTERY
72 Lg 72 72 72 Lg
SOLENOID
R B1.25 11 BODY EARTH
20 10 MONOTROL W8 1 1 W8
TC.OIL
5 R 5 5 5 R + -
19 Y PEDAL ASSY F W/B5 30 30 W/B5
91 19 70 Br 70 Br
70 70
92 16 16 Y/B
93 15 15 Y/L
IGN. PS
27 14 14 G/Y SW. SOLENOID
5 5 R 16
6 6 W AM
18 18 Y/R
98 Gy/L 98 98 98 B 11 11 S 10
Y/B
11 11 B0.85
7 8 97 P/L 97 97 97 W 75 76 B
33 38 38 Or
6 79 11 84 G/Or 84 84 84 G/Or
11 1 91 W
B1.25
B0.85
92 B
Br/B
Lg/B
CN5 STARTER
7 W/L
8 B/R
B0.85
93 B P TERMINAL
6 W
P/B
75
11
11
76
27 Gy/R W 82 W
33 Br/W B 83 B 20 W/R 20 P
12 L/W 12 R
LIGHT/TURN SW.
84 G/Or
57 57 B/Y 14 G/Y 14 L
97 W
98 B
ＧＬＯＷＰＬＵＧＳ
SOLENOID
59 59 L/B
B0.85 11 ALTERNATOR
UNLOAD
11 11 B 32
Gy/B 78 R 8
53 53 G/B 84 98 2 B
54 54 G/R 97
52 52 G/W
SOLENOID
B0.85 11 WATER
5 R L5 18 Y/R
G/W
G/B
G/R
L/B
B/Y
THERMO
LIFT
Or/B 77
B
87 5 87 W SENDER
ST ANGLE
52
53
54
11
59
57
88 B
COMBINATION SWITCH
88
SENSOR
SENSOR
２.７Ｌ／３.３ＬＤＳＬＥＮＧＩＮＥ

SPEED
89 89 R PRESS.
52 53 54 60 R/L
OPT SEAT
BELT SW.
SEAT SW.
90 90 B STOP SENSOR
11 59 57 61 R/B LAMP SW.
29 Gy/L
HORN
11 59 57 OIL FUEL SHUT

SW.
11 29 11 B SEDIMENTER
52 53 54 PRESS. SW. OFF SOL.
8 B/R NEUTRAL
72 72 Lg 66 W/R SW.
W
B
L
B
G/W
G/B
G/R
L/B
B/Y
73 73 L/Or
B
71 Or
52
53
54
11
59
57
71
F/R SHIFT SW.

70 70 Br 19 11 12
15 Y/L
B/R
B/W
5 5 R
W
P
70 Br
L/W0.85
5 R
B
Y
5
5 R SERVICE 67 B/W
5
72 Lg BRAKE SW. 66 W/R
72 6 25 8 67
OPT
ＡＴＴＲＵＣＫＳＯＮＬＹ TERMINAL 24 Y/B 24 W
11 B 11 B
N.O. N.C.
R/G0.85
HEAD TURN SIGNAL 26 L/Y 26 L

B0.85

R/W
G/R
FUEL 64 B/W OPT TERMINAL

21W
56
11
58
54
17 Y/G
55W 23W SENDER
5W
56 11 B1.25 11 BODY EARTH
58 54
R
B
G
B
G
B
Y
58 53
56 11
Gy 28
HORN
OPT Gy/L 29 ＦＯＲＹＡＮＭＡＲ２.７Ｌ／３.３Ｌ－ＤＳＬＥＮＧＩＮＥ
56 R/G0.85
11 B0.85
58 R/W
56 R/G0.85
11 B0.85
11 B0.85
53 G
TURN STOP
58 R/W
53 G
BACK
SIGNAL /TAIL
LAMP
LAMP LAMP 58 R/W
REAR 51 58 61 R/B
21W 21W 54
LAMP L.H. 5W 11 61 54 G/R
11 B
—9—
HMM160002
Steering Housing and Control Unit

(HYDRO-STATIC STEERING)
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

and Repair
weight of the load.
remove parts.
needs repairs.
WARNING
CAUTION
—1—
STEERING SYSTEM
[1] General
The rotational force (steering force) given to the steering wheel drives the trail axle power
cylinder by the hydraulic pressure via the orbit roll and is transmitted to the intermediate link and
knuckle for steering.
For the steering operation, the operating force is reduced by the full hydraulic type power steering
system.
To correct the knob run-out by the full hydraulic system, the rotary encoder built into the
combination lever detects the rotational angle of steering and transmits it to the controller. The
potentiometer attached to the right-side kingpin of the trail axle detects the rotational angle of
the steering wheel. The controller compares both rotational angles with each other. By activating
the solenoid valve built into the orbit roll, the oil volume is controlled and knob position correction
control is performed.
Figure 1.
—2—
[2] Construction
1. STEERING WHEEL 4. COVER

2. STEERING COLUMN 5. COWL
3. STEERING CONTROL UNIT 6. STEERING COLUMN SUPPORT
Figure 2.
—3—
[3] Components
Cubic development
1. SCREW 9. HOUSING 18. OIL SEAL

2. RETAINER SCREW 10. SLEEVE 19. DUST SEAL
ASSEMBLY 11. SPOOL 20. RETAINING RING
3. END CAP 12. PIN 21. SEAL GRAND BUSHING
4. GEROTOR 13. CENTERING SPRING 22. O-RING
5. SPACER 14. FLAT SPRING 23. O-RING
6. SPACER 15. LACE BEARING 24. BALL
7. SPACER PLATE 16. THRUST NEEDLE 30. BLOCK SOLENOID
8. DRIVE 17. O-RING 31. SOLENOID VALVE
Figure 3.
[4] Specifications
H1.5-2.0TX H2.0-2.5TX H3.0-3.5TX
Power Steering System Full Hydraulic Type
Steering Wheel Outside Diameter 300 mm
Steering Control Delivery Volume 80 cm3/rev 105 cm3/rev 120 cm3/rev

Unit Relief Set Pressure 7.8 +0.5 +5 2
0 MPa (80 0 kgf/cm )
—4—
REPAIRS
[1] Steering Wheel and Column Assembly (See Figure 2)
The upper end of the steering shaft has splines for the steering wheel. A large nut holds the
steering wheel onto the steering shaft. The horn button is the cover for the center of the steering
wheel. The lower end of the steering shaft has splines or a tang to engage the steering control
unit.
The steering column assembly is adjustable by a lever. The position of the steering column
assembly can be changed as needed for different operator requirements. An access cover on the
steering column give access to the steering control unit, key switch, and if installed, the direction
switch.
(1) Removal and Installation of the Steering Column and Steering Control Unit
CAUTION
Disconnect the battery before removing any covers.
NOTE: Before removing the steering control unit (orbitrol) from the truck, be certain that is—the entire area
around it—and the connecting lines are cleaned free from dirt and contamination.
A black accumulation of dirt at a fitting can indicate a leakage point. If the fitting is taken apart to
correct leakage, first clean the area completely with a solventwet cloth, steam clean, or otherwise
clean off any debris from the immediate area and any dirt accumulation above the area so that
contamination will not enter the system while the connection is open. Then be extremely careful
to apply compound sparingly to the male fitting only. Do not let any compound enter an area in
which it may be washed in to the oil stream.
WARNING
Never use fluid system ‘stop leak’ additives to attempt to seal fluid leakage. Many good
power steering systems have been ruined by such attempts.
1. Tilt mast full forward. Lower forks and shut off engine.
2. Disconnect battery. Attach a tag on the battery connector.
3. Remove screws securing steering column cover assembly. Remove cover.
4. Remove steering wheel and horn button assembly.
5. Remove wire harness at steer column.
6. Tag and disconnect hoses which run from orbitrol unit to tank, steer cylinder and main control
valve. Drain excess oil into a pan or container. Install plugs at all hoses and ports to prevent
dirt from entering the steering hydraulic system.
7. Remove screws and washers securing orbitrol unit and steering column to mounting bracket.
Slide column through bracket and remove.
WARNING
After making repairs, do not extend the hands or arms through the center of the steering
wheel. If the control unit was not assembled correctly or the hoses not connected correctly
it can rotate with a strong force and cause serious injury. If this action occurs, disassemble
the control unit and correct the problem.
—5—
WARNING
The hydraulic hoses MUST be connected to the correct ports or the steering system will
not operate as expected. This operation that is not expected can cause damage or personal
injury. Make sure the hoses are identified and connected correctly.
8. Reverse of orbitrol unit.
(2) Disassembly of the Steering Control Unit
NOTE: Cleanliness is extremely important when repairing a steering control unit. Work in a clean area.
Before disconnecting the lines, clean port area of unit thoroughly. Use a wire brush to remove foreign
material and debris from around exterior joints of the unit.
Although not all drawings show the unit in a vise, we recommend that you keep the unit in the
vise during disassembly. Follow the clamping procedures explained throughout this section.
1. Place the unit in a vise with soft jaws, control end up. Clamp across port surface and opposite
side of housing lightly. Remove screws holding steering column to orbitrol unit.
Important: Mark the cap screws holes so that the parts will be in the proper direction when
reassembled.
Observe the shaft area of the lower unit immediately upon removal of the column assembly. If it
shows an appreciably oil-soaked appearance, this indicates that the shaft seal may have leaking.
If there is a functional problem or leakage at the control end of the unit only, the disassembly of
the control end of the unit will be required and it is generally advisable to leave the 7-bolted end
assembled.
If a complete tear down and reassembly of the unit is necessary, clean all paint and surface
contamination from the unit at points of separation. This is extremely important at the meter end
of the unit so that no paint flakes or particles will enter these closely fitted parts as they are being
reassembled. To clean the unit adequately, first plug all five ports, then wire brush around the
meter area and rinse and blow away all surface contamination before any disassembly is begun.
Do not use shop cloths or cotton waste to wipe or clean the parts. The lint deposited by these can
disrupt function of cause leaks. The clean inside surface of a corrugated container is frequently a
very adequate assembly surface. Assembly is generally easier and more satisfactory with clean
dry parts. After parts are rinsed clean in solvent, they may be blow dry with an air hose or placed
on clean paper towel to drain and air dry.
If parts are thus prepared as they are removed, they will be ready for reassembly by the time
they are needed.
2. Move steering column to one side. Loosen vise and turn orbitrol unit over.
3. Clamp unit in vise, meter end up. Clamp lightly on edges of mounting area (Figure 4.). Use
protective material on vise jaws. Do not overtighten jaws.
4. Remove solenoid valve, cap screws for Block solenoid and Block solenoid.
5. Remove 5/16" cap screws, retainer screw, adaptor screw and ball (Figure 5.).
6. Remove end cap (Figure 5.).
7. Remove seal from end cap (Figure 5.).
8. Remove meter. Be careful not to drop star (Figure 6.).
9. Remove seal from meter (Figure 6.).
10. Remove drive spacer (Figure 6.).
—6—
11. Remove drive (Figure 7.).
12. Remove spacer plate (Figure 7.). METER (GEROTOR) END
13. Remove seal from housing (Figure 7.).
14. Remove housing from vise. Place housing
on a clean soft cloth to protect surface
finish. Use a thin bladed screwdriver to pry
retaining ring from housing (Figure 8.).
15. Rotate spool and sleeve until pin is
h o r i zo n t a l . P u s h s p o o l a n d s l e eve
assembly forward with your thumbs just
far enough to free gland bushing from
housing (Figure 9.). Remove bushing.
16. Remove O-rings and oil seals from seal
gland bushing (Figure 10.).
17. Use a thin bladed screwdriver to pry dust
seal from seal gland bushing. Do not
damage bushing (Figure 10.).
Figure 4.
Figure 5. Figure 6.
CONTROL END
Figure 7. Figure 8.
—7—
18. Remove two bearing races and the needle thrust bearing from spool and sleeve assembly
(Figure 11.).
19. Remove spool and sleeve assembly from 14 hole end of housing (Figure 12.).
CAUTION
Do not bind spool and sleeve in housing.
Rotate spool and sleeve assembly slowly
when removing from housing.
20. Push pin from spool and sleeve assembly

(Figure 12.).
21. Push spool partially from control end of
sleeve, then remove 4 centering springs
from spool carefully by hand (Figure 13.).
22. Push spool back through and out of sleeve
(Figure 13.). Rotate spool slowly when
removing from sleeve.
Figure 9.
Figure 10. Figure 11.
—8—
23. Remove seal from housing (Figure 14.).
(3) Inspection
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. Figure 14.
Check all mating surfaces. Replace any parts that have scratches or burrs that could cause
leakage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or
paper towel because lint or other matter can get into the hydraulic system and cause damage.
Do not use a coarse grit or try to file or grind these parts.
NOTE: Use new seals, O-rings and neutral position springs during assembly. Lubricate all parts with clean
hydraulic oil.
Do not use excessive lubricant on seals for meter section.

Refer to parts listings covering your steering control unit when ordering replacement parts. A
good service policy is to replace all old seals with new seals.
(4) Reassembly of the Steering Control Unit
1. Assemble spool and sleeve carefully so

that the spring slots line up at the same
end. Rotate spool while sliding par ts
together. Some spool and sleeve sets
have identification marks, align these
marks as shown in Figure 15. Test for free
rotation. Spool should rotate smoothly
in sleeve with finger tip force applied at
splined end.
2. Bring spring slots of both parts in line and
stand parts on end of bench. Insert spring
installation tool through spring slots of
both parts. Position 2 pairs of centering Figure 15.
springs (or 2 sets of 2 each) on bench so
that extended edge is down and arched
center section is together. In this position,
insert one end of entire spring set into
spring installation tool, as shown in Figure
16.
3. Compress extended end of centering
spring set and push into spool sleeve
assembly withdrawing installation tool at
the same time.
4. Center the spring set in the parts so that
they push down evenly and flush with the
upper surface of the spool and sleeve.
Figure 16.
—9—
5. Install pin through spool and sleeve
assembly until pin becomes flush at both
sides of sleeve (Figure 17.).
6. Position the spool and sleeve assembly
so that the splined end of the spool enters
the 14 hole end of housing first (Figure
18.).
Figure 17.
CAUTION
Be extremely careful that the parts do not tilt
out of position while inserting. Push parts
gently into place with slight rotating action,
keep pin nearly horizontal. Bring the spool
assembly entirely within the housing bore
until the parts are flush at the meter end or
14 hole end of housing. Do not pull the spool
assembly beyond this point to prevent the
cross pin from dropping into the discharge
groove of the spool assembly in this flush
position, check for free rotation within the
housing by turning with light finger tip force Figure 18.
at the splined end.
7. Place housing on clean, lint free cloth.

Install 2-1/8" diameter seal in housing
(Figure 19.).
8. Install two bearing races and the needle
thrust bearing in the order shown in Figure
19.
9. Install 1-1/4" diameter dust seal in seal
gland bushing, flat or smooth side of dust
seal must face down towards bushing
(Figure 21.).
10. Install dry quad ring seal in seal gland
bushing. Smooth seal in place with your
finger. Do not use any seal that falls freely
Figure 19.
into pocket of bushing (Figure 21.).
11. Install seal gland bushing over the spool
end with a twisting motion. Tap the
bushing in place with a rubber hammer.
Make sure the bushing is flush against the
bearing race.
12. Install retaining ring (Figure 20., 21.) in
housing. After installing ring, tap on ring
end or pry with screwdriver around entire
circumference of ring to properly seat ring
in groove.
Figure 20.
— 10 —
13. Clamp housing in vise, as shown in Figure
22. Clamp lightly on edges of mounting
area. Do not overtighten jaws.
NOTE: Check to insure that the spool and sleeve

are flush or slightly below the 14-hole surface of the
housing. Clean the upper surface of the housing
by wiping with the palm of clean hand. Clean each
of the flat surfaces of the meter section parts in a
similar way when ready for reassembly. Do not use
cloth or paper to clean surfaces.
Figure 21.
Figure 22.
14. Install 3" diameter seal in housing (Figure

23.).
15. Install spacer plate. Align bolt holes in
spacer plate with tapped holes in housing
(Figure 23.).
Figure 23.
16. Rotate spool and sleeve assembly until
pin is parallel with port face (Figure 24.).
Install drive, make sure you engage drive
with pin. To assure proper alignment, mark
drive as shown in Figure 26. (ref. B). Note
relationship between slotted end of drive
to splined end of drive when marking.
Figure 24.
— 11 —
17. Install 3" diameter seal in meter (Figure
25.).
18. With seal side of meter toward spacer
plate, align star valleys (ref. A) on drive
(ref. B). Note the parallel relationship of
reference lines A, B, C. and D-Figure 26.
Align bolt holes without disengaging meter
from drive.
19. Install drive spacer in meter (Figure 27.).
20. Install 3" diameter seal in end cap (Figure
27.). Figure 25.
21. Install end cap on gerotor, align holes
(Figure 27.).
22. Install ball in housing (Figure 27.).
23. Install retainer screw and adaptor screw
on screw (Figure 27.).
24. Install 7 dry cap screws in end cap in the
sequence shown in Figure 28. Tightening
torque: 23 N·m (230 kgf·cm).
25. C h eck t h e c o nd i t i o n o f t h e c o l u mn
assembly. Clean it, and replace on the unit
with four cap screws oriented as before.
Rotate the steering shaft while bringing
the surfaces into contact to allow splines
to engage. Tightening cap screws to
41~49 N·m (417~500 kgf·cm).
26. Install Block solenoid and cap screws.
Tightening torque: 39 N·m (400 kgf·cm).
Install solenoid valve and nut for solenoid
valve. Tightenin torque: 6.5 N·m (66
kgf·cm).
Figure 26.
— 12 —
[1] Remove Air from the System
Air can enter the system when a hydraulic line is disconnected. If the operation is rough, operate
the system and rotate the steering wheel from stop to stop several times in each direction. The
air will be removed without disconnecting any lines. If the operation is still rough, check if air is
entering the system at a loose fitting.
TROUBLESHOOTING
Most steering problems can be corrected if properly defined. The entire steering system should
be evaluated before removing any components. The steering control unit is generally not the
cause of most steering problems. The following is a list of steering problems along with possible
causes and suggested corrections.
Symptom Cause Remedy

Slow steering, hard Worn or malfunctioning Pump. Replace pump.
steering or loss of power
assist. Stuck flow divider piston. Replace flow divider.
Worn pump compensator allowing Replace pump and compensator.
the system pressure to be less than
specified.
Malfunctioning relief valve allowing Replace the relief valve.
the system pressure to be less than
specified.
Overloaded steer axle. Reduce load.
If load sensing system leaking or Correct.
kinked load sensing signal line.
Malfunctioning priority valve. Check spring and sticking piston.
Check damping orifices in both ends
of main bore.
Check system pressure at SCU inlet for
proper system pressure. If not correct
replace priority valve relief cartridge.
Wander—Vehicle will not Air in the system due to low level Correct.
stay in a straight line. of oil, cavitating pump, leaky fitting,
pinched hose, etc.
Worn mechanical linkage. Repair or replace.
Bending of linkage or cylinder rod. Repair or replace.
Loose cylinder piston. Repair or replace.
L e a k y c r o s s ove r r e l i e f o r a n t i - Repair or replace the accessory
cavitation valve in cylinder lines. valve.
Severe wear in steering control unit. Replace the steering control unit.
D r i f t — Ve h i c l e v e e r Single rod end cylinder slowly extends A small rate of extension may be
slowly in one direction. without turning the steering wheel. normal on a load center system.
Slip—A slow movement Worn or damaged steering linkage. Align front end.
of steering wheel fails to Leakage of cylinder piston seals or Replace seals or accessory valve.
cause any movement of accessory valve between cylinder
steered wheels. lines or ports.
Worn steering control unit meter. Replace steering control unit.
— 13 —
Temporary hand steering Thermal Shock* Check unit for proper operation and
or hang-up. cause of thermal shock.
Erratic steering. Air in system due to low level of Correct condition and add fluid.
oil, cavitating pump, leaky fitting,
pinched hose, etc.
Loose cylinder piston. Replace cylinder.
Thermal Shock damage* Replace steering control unit.
Sticking flow control spool. Replace flow control valve.
“Spongy” or soft steering. Air in hydraulic system. Bleed air out of system. Placing
Most likely air trapped in cylinders or ports on top of the cylinder will help
lines. prevent air trapping.
Low fluid level. Add fluid and check for leaks.
Free Wheeling—Steering Steering column upper shaft is loose Tighten steering wheel nut.
wheel turns freely with or damaged.
no feeling of pressure Lower splines of column may be Repair or replace column.
and no action on steered disengaged or broken.
wheels.
Steering control unit meter has a Usually star ting engine will cure
lack of oil. This can happen on start- problem.
up, after repair, or long periods of
non use.
No flow to steering unit can be
caused by:
1. Low fluid level. Add fluid and check for leaks.
2. Ruptured hose. Replace hose.
3. Internal steering control. Replace the unit
unit damage due to thermal shock*
Free Wheeling—Steering Leaking crossover relief or anti- Repair or replace the accessory
wheel tur ns with slight cavitation valve in cylinder lines. valve.
resistance but results in little Piston seal blown out. D e t e r m i n e c a u s e. C o r r e c t a n d
or no steered wheel action. replace seal.
Excessive free play at Loose steering wheel nut. Repair or replace steering wheel
steering wheel. Steer ing column shaft wor n or connection or column.
damaged. There should be very little
free play in the unit itself.
Excessive free play at Broken or worn linkage between Check for loose fitting bearings and
steered wheels. cylinder and steered wheels. anchor points in steering linkage
between cylinder and steered wheels.
Leaky cylinder seals. Replace cylinder seals.
Binding or poor centering Binding or misalignment in steering Align column pilot and spline to
of steering wheel column or splined input connection. steering control unit.
High back pressure in tank line can Revise circuit return line.
cause slow return to center.
Should not exceed 300 psi.
Large particles can cause binding Clean the unit and filter the oil.
between the spool and sleeve. If another component has failed
generating contaminents, flush the
system while bypassing the steering
control unit.
* Thermal Shock—A condition caused when the hydraulic system is operated for some time without turning
the steering wheel so that fluid in the reservoir and system is hot and the steering control unit is relatively
cool (more than 50°F temperature differential). When the steering wheel is turned quickly the result is
temporary seizure and possible damage to internal parts of the steering control unit. The temporary seizure
may be followed by total free wheeling.
— 14 —
Steering unit locks up Large particles in gerotor section Clean the unit.
Severe wear and/or broken pin. Replace the unit.
*Thermal shock Replace the unit.
Steering wheel oscillates Parts assembled wrong Steering unit Correct timing.
or turns by itself. improperly timed.
Lines connected to wrong ports. Reconnect lines correctly.
Steered wheels turn in wrong Lines connected to wrong cylinder Reconnect lines correctly.
direction when operator ports.
activates steering wheel.
Steering wheel kicks at No inlet check valve on steering Install a check valve.
start of steering. control unit.
* Refer to front page for Thermal Shock definition.
— 15 —

H1.5-3.5TX - H2.0TXS (B475) (B466) - Manual de Serviços EN

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H1.5-3.5TX - H2.0TXS (B475) (B466) - Manual de Serviços EN

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HMM800004

Capacities and Specifications

Safety Precautions Maintenance

H1.5TX [B475] 1500

H1.8TX [B475] 1750

H2.5TX [B466] 2500

H3.0TX [B466] 3000

H3.5TX [B466] 3500

NOTE: Load center at 500 mm.

H1.5TX [B475] 810

H1.8TX [B475] 1015

H2.0TXS [B475] 1200

H2.0TX [B466] 1190

H2.5TX [B466] 1530

H3.0TX [B466] 1920

H3.5TX [B466] 2215

H1.5TX [B475] 6.00 - 9 5.00 - 8

H1.8TX, H2.0TXS [B475] 21 x 8 - 9 18 x 7 - 8

H2.0-2.5TX [B466] 7.00 - 12 6.00 - 9

H3.0-3.5TX [B466] 28 x 9 - 15 6.50 - 10

Engine Oil (With Oil Filter)

Mazda M4-2.0G −7°C and below

Mazda M4-2.2G −7°C and below

Yanmar Diesel 20°C and over

Mazda M4-2.0G and M4-2.2G

Hydraulic Tank Oil Capacity

Power Shift Transmission 20 liter Dexron II or III

Brake Fluid 0.2 liter SAE J-1703, DOT 3

Differential and Drive Axle Oil

Differential and Drive Axle Oil

Battery 12-volt, negative ground 12-volt, negative ground

Spark Plugs ND W9EXR-U N/A

Gas 6° BTDC (Orange timing mark) N/A

LPG 6° BTDC (Orange timing mark) N/A

2.7L engine preset @ 4° ATDC

Mazda M4-2.0G and M4-2.2G

Alternator Output (14 Volts) G and LPG

Idle 18 amps @ 800 rpm

High Idle 42 amps @ 2700 rpm

Alternator Output (13.5 Volts) D

Cold High Idle 45 amps @ 2400 rpm

Hot High Idle 36.5 amps @ 2400 rpm

1.47 MPa 0.88~1.2 Mpa 0.29~0.69 Mpa

Oil Temperature 55 to 65°C

Primary Relief Valve Pressure (High Idle)

Secondary Relief Valve Pressure (High Idle) 15.7 +0.5

Oil Temperature 55 to 65°C

Steering Relief Pressure at 800 rpms

H1.5-3.5TX [B475, B466] 7.9 +0.5

Steering Cylinder Stroke

H1.5-3.5TX [B475, B466] 154.65 mm

Inside Steering Tire Angle 84.5°

Number of Turns to Lock

H1.5-3.5TX [B475, B466] 4.25~4.5

Turning Radius (±50 mm NO LOAD) Outside

Pneumatic Tire Trucks

H1.5TX [B475] 1975

H1.8TX [B475] 2010

H2.0TXS [B475] 2040

H2.0TX [B466] 2150

H2.5TX [B466] 2210

H3.0TX [B466] 2305

H3.5TX [B466] 2355

Engine New Engine Broken-In Engine