White Fork Lift My60 Parts Operation Maintenance Manual S 407

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MOBILIFT AT/ON

FORK LIFT TRUCKS

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TABLE OF CONTENTS

CHAPTER 1. INTRODUCTION 1-1

Section I. General Description 1-1

II. Detailed Description 1-1

CHAPTER 2. OPERATING INSTRUCTIONS 1-5

Section I. Initial Preparation for Use 1-5

II. Operating Instructions 1-6
III. Principles of Operation 1-8

CHAPTER 3. FIELD MAINTENANCE 1-9

Section I. Lubrication 1-9

II. Preventive Maintenance Service 1-9

CHAPTER 4. OVERHAUL (SHOP MAINTENANCE) 1-23

Section I. General 1-23

II. Removal, Disassembly, Repair and Reassembly 1-23

4-7. Battery, Clamp and Cables 1-23

4-12. Fuel Tank, Lines and Fittings 1-23
4-16. Seat 1-23
4-21. Horn Button 1-23
4-26. Steering Gear and Drag Link 1-24
4-31. Head and Rear Lamps 1-24
4-36. Instrument Panel, Switches and Gages 1-25
4-41. Radiator, Hoses, and Thermostat 1-27
4-46. Water Pump and Fan Assembly 1-27
4-51. Muffler 1-27
4-55. Throttle Controls 1-28
4-60. Generator 1-28
4-65. Starting Motor 1-29
4-70. Distributor 1-31
4-75. Voltage Regulator 1-32
4-80. Wheels and Hubs 1-32
4-85. Steering Axle -- MY 40 1-33
4-90. Steering Axle -- MY 60 1-33
4-95. Brakes, Inching Mechanism, and Master Cylinders 1-34
4-99. Drive Axle and Differential 1-36
4-104. Transmission Control Levers and Filter 1-36
4-109. Transmission Control Valve 1-36
4-114. Transmission Case, Converter and Pump 1-39
4-119. Fuel Pump and Fuel Filter (Gasoline) 1-49
4-124. Carburetor (Gasoline) 1-49
4-129. LP-Gas Equipment 1-50
4-134. Oil Pump 1-50
4-139. Engine 1-51
4-143. Hydraulic Pump 1-55
4-148. Hydraulic Control Valve 1-56
4-153. Hydraulic Steering Booster 1-56
4-158. Tilt Cylinders 1-57
4-163. Lift Cylinders -- MY 40 Duplex 1-58
4-168. Lift Cylinders -- MY 60 Simplex 1-59
4-173. Mast and Related Parts -- MY 40 Duplex 1-60
4-178. Mast and Related Parts -- MY 60 Simplex 1-61

CHAPTER 5. REPAIR PARTS SECTION 2-1 thru 2-103 Inc.

 Fig. 1-1. MY 40. (Part 1 of 2)

Fig. 1-1. MY 60. (Part 2 of 2)

 CHAPTER 1
INTRODUCTION
Section I. General Description

1-1. SCOPE of the lift truck are made in respect to the normal direc-
tion of travel, which is forward.
1-2. This manual provides instructions on the operation,
maintenance, and overhaul of the MY Series Lift Trucks. 1-6. The trucks can be equipped with either a gasoline
Most of the instructions apply to both the MY 40 and the or LP-Gas engine. The MY 40 has a capacity of 4000
MY 60. Where there are differences, it will be noted pounds, the MY 60 a capacity of 6000 pounds, both at
either in the text or paragraph heading. a 24-inch load center.
1-3. It is strongly recommended that all personnel con- 1-7. The lift truck is a completely self-contained vela,-
cerned with the various phases of this manual have a de; its power train consisting of a four-cylinder engine,
thorough knowledge and understanding of the equipment a hydraulic torque converter, and a multiple disc clutch
and the instructions pertaining thereof, before perform- and power shift type transmission. All these assemblies
ing any procedures with the equipment. are integrally mounted together, forming one compact
unit, which in turn drives the front axle differential and
1-4. GENERAL DESCRIPTION the front drive wheels. A gear type pump, driven from
the engine camshaft, supplies pressure to the hydraulic
1-5. Due to its design and intended purpose, the equip- system. Electrical components of the lift truck utilize
ment will be referred to as "lift truck" or "truck" through- the current supplied from one 12-volt battery.
out this manual. Reference to either the right or left sides

Section II. Detailed Description

1-8. DETAILED DESCRIPTION This feature provides very slow ground speeds at full en-
gine speed, while the lift mechanism operates at its nor-
1-9. ENGINE. The engine (4, figure 1-2) is a four- mal speed.
cylinder, four-cycle, gasoline or LP-Gas operated, valve-
in-head type. Its normal governed speed with no load is 1-13. DIFFERENTIAL AND DRIVE AXLE. See figure 1-2.
1980 rpm. One complete stroke is required for suction, Coupled to, and driven by the transmission pinion shaft
compression, expansion, and exhaust; thereby providing (output), is the conventional type automotive differential.
one power stroke per cylinder for each revolution of the The assembly is provided with an internal gear reduction
crankshaft. at the axle end, which forms an offset in the axle and al-
lows a lower center of gravity for the lift truck. A com-
1-10. TORQUE CONVERTER. The torque converter (3, mon lubricant is used for the transmission, differential,
figure 1-2) is a compact, complete, sealed unit, con- and axles.
sisting of an impeller, turbine, and single-stage stator.
The charging pump is coup to the engine flywheel 1-14. STEER AXLE. The rear end of the lift truck is
through the impellor hu . The oil from the pump charges supported by a heavy-duty axle casting which embodies
the converter and the torque is multiplied by the stator. the conventional wheel spindles, steering arms, tie rods,
The turbine is splined to the input shaft in the transmission. and drag link which in turn is connected to the hydraulic
steering booster.
1-11. TRANSMISSION. The transmission (2, figure 1-2)
is a power shift gear box equipped with two pairs of hy- 1-15. HYDRAULIC SYSTEM. The hydraulic tank is an
draulically actuated multiple disc clutches. One set of integral part of the main frame, on the right hand side.
clutches is mounted on the input shaft and controls the A gear-type pump draws fluid from the tank through the
forward and reverse movement of the lift truck. The strainer, to a lift and tilt control valve, and to the hy-
other set is mounted on the output shaft, and determines draulic steering booster. Two hand levers, located con-
either high or low range. The control valve receives veniently to the right of the operator, are used to direct
pressure from an engine -driven hydraulic pump mounted fluid to the lift and tilt cylinders. Fluid under pressure
on the transmission cover. The valve is controlled by is available at each of the components when the engine
the hand levers mounted on the steering column. Both is running. Return lines provide a complete circuit when
levers must be in an operating position before the lift the cylinders or booster are not in actual operation.
truck will move.
1-16. HYDRAULIC STEERING SYSTEM. Steering of the
1-12. INCHING SYSTEM. The inching system is con- lift truck is accomplished by an 18-inch diameter steer-
trolled by the inching pedal (1, figure 1-9). The pedal ing wheel, which is mounted on an automotive-type steer-
actuates a valve incorporated into the transmission con- ing column. A hydraulic steering booster is incorporated
trol valve. The inching valve supplies only partial pres- into the drag link. As the steering wheel is turned, a
sure to the clutch. The clutch is thus allowed to slip, valve in the booster opens, and hydraulic pressure from
thereby delivering only partial power to the drive wheels. the hydraulic system assists in turning the rear wheels.

1-1
 Fig. 1-2. Power Train

1. Differential 3. Torque converter
2. Transmission 4. Engine

1-1'7. ELECTRICAL SYSTEM. The electrical system plate, mounted behind the spider, supports the brake
consists of a 12-volt battery, generator, distributor, volt- wheel cylinder and provides three shoe support pads for
age regulator, starter, and the head and tail light. The each shoe against which the shoe rests. Shoes are loosely
battery is the basic source of electrical current; the gen- held on the backing plate by hold-down pins and spring
erator maintains the battery in a charged condition; and clips, two being used on the secondary shoe, one on the
the voltage regulator govers the amount of voltage out- primary shot. Opposite the anchor, brake shoes are
put into the electrical system. linked by a floating star wheel adjuster and a single re-
tracting spring hooked between the shoe ribs so that it
1-18. LIFT AND TILT ASSEMBLY. The lift and tilt as- engages and locks the star wheel. The star wheel is
sembly consists of an upright assembly, forks, a lift reached through a slot in the backing plate and is used
cylinder and two tilt cylinders. The lift and tilt mecha- to expand the shoes as required to adjust lining clearance.
nism is controlled by two hand levers located to the right The star wheel link causes the shoes to function as a
of the operator's seat. The lift is capable of lifting its single compound unit. In operation, one shoe, depend-
rated load from ground level to a specified height, de- ing upon drum rotation, leaves its anchor. (The "pri-
pending on the mast assembly on the truck. The uprights mary" shoe is dragged from its anchor by forward drum
can be tilted from 6 degrees forward of vertical to 12 de- rotation while the "secondary" shoe remains anchored.
grees aft of vertical. A restrictor valve in the system pro- In reverse drum rotation, the "secondary" shoe is the
vides that the load will not drop at a rate of more than one leaving the anchor.)
80 feet per minute in case of hydraulic failure or damage
to the lines. 1-20. PARKING BRAKE. The same brake shoes are uti-
lized in a cable operated parking brake. A toggle lever,
1-19. SERVICE BRAKES. The heavy duty type service pinned to the rib of the secondary shoe, engages a con-
brake uses two identical brake shoes which are anchored necting link, pinned to the primary shoe rib. The park-
against individual anchor pins mounted in a spider fast- ing brake cable is connected at the opposite end of the
ened to the axle. Individual shoe return springs, each toggle lever. When the cable is pulled taut, movement
hooked between an anchor pin and the underside of its of the toggle lever on its fulcrum pin causes the con-
shoe table, hold the shoes anchored. A brake backing necting link to expand the shoes into the brake drum.

1-2
 TILT CYLINDER LIFT SYSTEM RELIEF (MY 40) 1475 ± 50 PSI
LIFT SYSTEM RELIEF (MY 60) 1 750 t 50 PSI
POWER STEERING RELIEF (BOTH) 1250 PSI
CONTROL
VALVE
VOW 1111

PRESSURE
CHECK POINTS
TANK

SUCTION
STRAINER
TILT CYLINDER

U
TO
TANK
>-

TO TANK

PUMP
OUT

STEERING
CYLINDER

Figure 1-3. Hydraulic Flow Diagram.

1-21. FUEL SYSTEM (GASOLINE). A 16-gallon gasoline 1-25. SERVICING ACCESSIBILITY. See figure 1-4.
fuel tank is an integral part of the frame on the left hand Raising the appropriate hood section and propping it
side. It contains a "protected" safety filler cap. The open with the support rod provides easy access for servic-
fuel suction line originates at the inside bottom of the ing the battery, air cleaner, generator, starter, distri-
tank and emerges at the upper right hand corner of the butor, spark plugs, fan belt, engine and transmission oil
tank, thereby preventing loss of fuel should a fuel line supplies, filters and dip sticks. The radiator and fuel
be broken. A plug is provided at the tank bottom for tank are serviced externally. The hydraulic tank fill
fuel drainage and cleaning. A fuel shut-off valve is in- tube is located under the right hand hood section.
stalled in the flexible hose leading from the tank to the
fuel pump.

1-22. FUEL SYSTEM (LP-GAS). The LP-Gas system

consists of a replaceable tank (33 -1/2 pound capacity),
a filter, a converter, and the carburetor. The fuel is
confined in the tank as a liquid under pressure. When
the valve is opened, the liquid passes to the converter
where it is changed into a gas, and then is metered to
the carburetor.

1-23. COOLING SYSTEM. Cooling of the engine is ac-

complished by an 18-inch, six-bladed pusher fan, and a
water circulating, pressure system radiator. The bottom
portion of the radiator is designed with coils to cool the
torque converter fluid.
Fig. 1-4. Servicing Accessibility -- Right Side
1-24. EXHAUST SYSTEM. Engine exhaust vapors are
vented out of the exhaust manifold on the left side of 1. Generator 4. Engine oil dip stick
the engine, down through the exhaust pipe, and out the 2. Crankcase oil filler 5. Hydraulic tank filler
muffler at the rear of the lift truck. 3. Seat adjustment 6. Distributor

1-3
 1-26. WHEELS AND TIRES. The brake drums for the
front or drive wheels are included in the wheel centers.
Tire pressures are given in paragraph 2-9.

1-27. SEAT. The seat is adjustable forward and back-

ward. Loosen the mounting carriage bolts under the
cushion, slide the seat to the desired position, and re-
tighten the bolts.

1. Pump 10. Forward clutch

2. Pressure relief valve 11. Low clutch
3. Priority valve 12. High clutch
4. Pressure regulator valve 13. Lube
Fig. 1-5. Servicing Accessibility -- Left Side 5. Inching valve 14. Relief valve
6. To brake master cylinder 15. Converter
1. Transmission oil filler and dip stick 7. Forward - Reverse valve 16. Heat exchanger
2. Air cleaner 8. High - Low valve 17. Pressure relief valve
3. Carburetor 9. Reverse clutch 18. Filter
4. Engine oil filter

/\
0
0
M. I
ICI I

0
rl
•

• • co

Figure 1-6. Drive System Flow Diagram

1-4
 CHAPTER 2
OPERATING INSTRUCTIONS
Section I. Initial Preparation for Use

2-1. SERVICE UPON DELIVERY c. Give the battery a booster charge after it has been
filled and dated. Fast charge for at least 10 minutes at
a. UNLOADING. Since the lift truck may be shipped the rate of 30 to 40 amps; or slow charge for at least 30
from the factory in a number of ways, dependent upon minutes at 10 amps. See paragraphs 3-7, 8, and 9, for
geographical location of the final destination, no at- battery service procedures and data.
tempt will be made to cover all methods of unloading
procedures. The lift trucks were shipped from the factory d. If any electrolyte spilled on the battery, flush it off
in accordance with standard shipping procedures, and with clean water. Dry the battery before installing.
should be unloaded from their carriers in a safe, logical
manner, and following generally accepted methods. e. The battery has a negative ground. Install it as
shown in Figure 1-7. Install the hold-down clamp and
2-2. REMOVAL OF PROTECTIVE MATERIALS AND DIS- cables.
ASSEMBLED COMPONENTS. Remove any protective tape
or padding from the lighting components of the lift truck.
Remove any components that have been packaged sepa-
rately and attached to or shipped with the lift truck; re-
fer to the Table of Contents and note the page number on
which that component is listed. Install the component ac-
cordingly.
2-3. VISUAL INSPECTION FOR SHIPPING DAMAGE.
Although every attempt has been made at the factory to
protect the equipment against damage during shipment,
it is possible for some damage to be incurred. It is ne-
cessary, therefore, that a careful, visual inspection be
made of the lift truck upon delivery and before placing
it in operation. It is further recommended that a written
record be maintained which outlines the nature of the
damage, and the urgency required in its correction.
Figure 1-7. Battery
2-4. SERVICE PRIOR TO USE. The following procedures
are to be accomplished before operation of the lift truck: 1. Negative post
2. Positive post
2-5. BATTERY.
2-6. ELECTRICAL SYSTEM. Inspect wiring and con-
a. The battery is shipped without electrolyte. Remove nections. Place ignition switch "ON" and test for electri-
the right hand hood section and remove the battery from cal current to that component. With switch "ON", actu-
the lift truck, and discard any vent plug seals. Fill all ate light switch and inspect the lights for proper response.
the cells to the proper level with the electrolyte shipped Test horn.
with the lift truck. Allow the battery to stand for about
20 minutes after filling. 2-7. FUEL SYSTEM (GASOLINE). Open fuel shut-off
WARNING valve located in fuel pump line. Open the fill cover of
the fuel tank located on the left side of the lift truck;
Electrolyte can burn or damage the eyes, fill as necessary with a good grade of regular gasoline.
skin, or clothing. Wear safety glasses to Close the fuel tank cover, and padlock if desired. Wipe
prevent damage to the eyes due to splashed tank free of dirt or fuel hose leakage, and inspect fuel
electrolyte. If electrolyte is spilled on the line and engine-mounted accessories for signs of fuel
skin or clothing, flush off immediately with leakage at their connections.
a solution of baking soda and water, or some
other neutralizing agent, then flush off with 2-8. FUEL SYSTEM (LP-GAS). Open the valve on the
clean water. fuel supply tank. Check all connections in the fuel line
for evidence of leaks. A leak will result in a formation
b. Code date the battery according to the month and of frost at the point of the leak.
year. Stamp the code on the intercell connector nearest
the negative terminal of the battery. The first number 2-9. WHEELS AND TIRES. Inflate front tires to 85
of the code indicates the month (1-January, 2- February, pounds and rear tires to 80 pounds pressure. Inspect tires
etc.), and the second number indicates the year (4-1964, very closely for nails, glass, or any other foreign parti-
5-1965, etc.). cles that may impair tire life.

1-5
2-10. HYDRAULIC SYSTEM. Raise the right hand sec- 2-12. LIFT TRUCK BODY. Inspect all sheet metal and
tion of the hood and remove the breather cap and dip- fabricated parts for distortion or damage. Tighten all
stick from the hydraulic tank. Fill as necessary in ac- screws and nuts, particularly those of the steering wheel
cordance with the lubrication instructions given in figure column, instrument panel components, and brake and
1-10. The capacity of the system with either a duplex accelerator pedals.
cylinder or a simplex cylinder is approximately 12 gal-
lons (depending on the cylinder). With the mast in the 2-13. COOLING SYSTEM. Remove the engine radiator
fully raised position, and all cylinders extended, the cap and inspect the coolant level. If weather is above
fluid should be up to the "Full" mark on the dip stick. freezing temperatures, add clean water until it covers
the radiator core as seen through the fill cap opening.
2-11. LUBRICATION. The lift trucks are completely For operation in sub-freezing temperatures, provide the
serviced prior to delivery with lubricants specified for 13.5 quart capacity cooling system with a good grade per-
the ambient temperatures at the factory, and should re- manent anti -freeze solution. Inspect for coolant leakage
quire no further lubrication at point of delivery unless at all connections.
temperatures differ greatly from those of the factory.
If such is the case, service the lift truck according to
the lubrication chart. Figure 1-10.

Section II. Operating Instructions

2-14. STARTING THE LIFT TRUCK. d. Normal procedure would be to shift into either high
or low gear from neutral with the lower lever, and then
a. If the truck is equipped with an LP-Gas engine, open shift into either forward or reverse direction with the
the valve on the tank slowly. If the valve is opened too upper lever; however, no damage will result if the di-
fast, an excess flow valve will snap shut and stop the rection is selected first and then the gear range desired.
flow of fuel. If this happens, close the valve and wait Both levers must be shifted into an operating position be-
for a "click". This will indicate that the pressure has fore the lift truck will move.
equalized on both sides of the excess flow valve. Then
open the tank valve slowly. f. Apply foot pressure on the accelerator pedal and
steer the lift truck in the direction selected.
b. Position the forward-reverse shift lever (4, figure 1-8)
in neutral. A neutral starting switch prevents the engine IMPORTANT: DO NOT SHIFT DIRECTIONS ON THE GO.
from starting unless the lever is in neutral. COME TO A COMPLETE STOP, WITH ENGINE AT IDLE
SPEED, BEFORE SHIFTING DIRECTIONS.
c. Engage the ignition-starter switch (9, figure 1-8)
and release it as soon as the engine starts. Do not en- g. Refer to Table I to correct any malfunction of the
gage the starter longer than eight seconds. If the en- lift truck or its components under operating conditions.
gine fails to start on the first try, allow the engine and
starting motor drive to come to a complete stop before
making a second attempt. This will prevent damage
to the starting motor housing, the drive, and the fly-
wheel ring gear. On a gasoline engine, it may be ne-
cessary to use the choke (5, figure 1-9). When the en-
gine starts, allow it to warm up gradually to its normal
operating temperature (approximately 180 ° F.). Do not
race the engine during this warm-up period.
CAUTION
If, after starting the engine, there is very
little or no pressure indicated on the engine
oil pressure gage, or if there is a sudden drop
in pressure while operating the lift truck, stop
the engine immediately and determine the
cause. Correction usually consists of replen-
ishing the crankcase oil supply. Located on
the instrument panel is a red warning light Fig. 1-8. Instrument Panel
(1, figure 1-8). This light will glow only
when the transmission lubricant temperature 1. Warning light 6. Hourmeter
is excessive and indicates that the transmission 2. Temperature gage 7. Fuel gage
oil supply is dangerously low or restricted and 3. Oil pressure gage 8. Ammeter
the situation must be remedied before further 4. Forward - Reverse lever 9. Ignition - Starter switch
lift truck operation. 5. High - Low range lever

1-6
2-15. LOADING PROCEDURE. c. Release brakes, place transmission control lever in
operative position, and move lift truck slowly forward
a. Drive the lift truck into position as near the load's until load is in desired position. Apply brakes and shift
center of weight as possible. Place one of the transmission transmission into neutral.
shift levers in neutral; position the forks slightly below the
level of the load; drive the truck forward until the forks d. Lower forks until they are free of weight of load.
are directly beneath the load. If the depth of the load Back up lift truck until forks are clear of load. Lower
permits, drive forward until the load is against the load forks to safe transport position.
back rest.
2-17. INCHING INSTRUCTIONS. The inching valve is
b. Apply the service brakes while lifting the load. controlled by the inching pedal (1, figure 1-9). The
upper portion of pedal travel provides inching control;
c. Move the lift control handle (closest to operator) to the lower portion of pedal travel applies the service
the rear to raise the load. If the nature of the load per- brakes. Depress the accelerator pedal with the right
mits, move the tilt control handle to the rear, to tilt foot to maintain full engine speed while the inching
the load rearward against the load back rest for maxi- feature is being utilized. Extremely slow ground speeds
mum stability. can be attained for operating in confined or dangerous
areas, while the speed of the lift and tilt remains nor-
d. For maximum safety and stability, carry the load mal.
just high enough to clear obstacles or uneven terrain.
2-18. STOPPING THE LIFT TRUCK
a. Drive the lift truck to an area suitable for parking
and place the transmission control levers in neutral.
Apply the parking brake (4, figure 1-9).
b. Tilt the mast slightly forward and lower the forks to
the bottom of the mast.

WARNING
Unless conditions prevent, always unload
forks and lower them to bottom of mast
before leaving lift truck, to avoid danger
to personnel.
c. Turn off the lights, if they were used.
d. Turn the ignition switch to the "OFF" position.

2-19. CHANGING LP-GAS TANKS. To change LP

tanks, first close the fuel valve. Disconnect the quick
Figure 1-9. Controls coupler and release the clamps. Lift the tank out of
the bracket. Install the new tank, secure it with the
1. Inching pedal clamps, and connect the quick coupler. See Fig. 1-16.
2. Brake pedal
3. Accelerator pedal IMPORTANT: THE LP TANK MUST BE
4. Parking brake FILLED IN ACCORDANCE WITH ICC AND
5. Choke button LOCAL REGULATIONS.
6. Tilt control lever (outer)
7. Lift control lever (inner) 2-20. SAFETY PRECAUTIONS.

2-16. UNLOADING PROCEDURE 2-21. The following safety precautions must always be
observed:
a. Drive loaded lift truck to unloading area and position
for unloading. Apply the service brakes, and move one a. Driver should be thoroughly familiar with the lift
of the transmission control levers to neutral. truck, its capabilities and its limitations, before at-
tempting its operation. Never attempt operation of a
b. Move lift control lever until load is lowered to the lift truck known to be faulty.
ground or is at the desired height for stacking. If load
was tilted rearward against back rest while transporting, b. Provide adequate ventilation in operational areas;
move control lever forward until the mast is vertical. avoid prolonged operation in enclosed areas.

1-7
c. Constantly check for personnel and obstacles in path f. Strap or otherwise secure load to carriage when des-
of both lift truck and load; keep lifting forks in driver's cending grades steeper than 10 degrees from horizontal
view whenever possible. in a forward direction. Do not attempt operation of load-
ed lift truck on ascents or descents greater than 20 degrees.
d. Transport load at lowest practical level, for maxi-
mum stability and visibility. Avoid sudden stops, sharp g. Do not attempt to lift or transport loads that exceed
turns in either direction, and excessive speed. the rated capacity of the truck.
e. Never leave the lift truck unattended with engine h. Always secure forks in position with lock levers.
running or load elevated. Lower forks to bottom of mast
and apply parking brakes before leaving lift truck.

Section III.

PRINCIPLES OF OPERATION 2-29. FUEL GAGE

2-22. Instruments and Controls (see figures 1-8 and 1-9). a. Gasoline. The fuel gage (7, figure 1-8) electrically
senses and indicates the amount of fuel in the tank.
2-23. OIL PRESSURE GAGE. The oil pressure gage (3,
figure 1-8) does not indicate the amount of oil in the b. LP-Gas. The gage (1, figure 1-16), indicates the
crankcase; it indicates the pressure of the oil in the en- amount of LP-Gas in the tank.
gine lubricating system. The gage electrically senses
the oil pressure and reflects it on the gage dial. With 2-30. CHOKE CONTROL (GASOLINE ONLY). The
the engine at normal operating temperature and speed, choke control button (5, figure 1-9) is cable -connected
the oil pressure should be between 25 and 35 pounds. to the choke disc in the carburetor assembly. Pulling
forward on the choke button closes the choke disc, there-
2-24. ENGINE TEMPERATURE GAGE. This gage (2, by enriching the air and gasoline mixture and providing
figure 1-8) indicates the temperature of the cooling quicker starting of a cold engine. Push the choke button
fluid. Engine operation under normal conditions should in as the engine warms up to operating temperature.
register approximately 180 degrees on the gage. Temper-
atures excessively higher or lower than 180 degrees in- 2-32. POWER TRAIN (ENGINE AND TRANSMISSION).
dicates a dirty or restricted radiator, loss of coolant, or Actuation of the various components is achieved in the
a faulty thermostat or gage. Do not operate the lift following sequence: Turning the key energizes the start-
truck until these conditions are corrected. ing motor, which is pinion-meshed with the engine fly-
wheel ring gear teeth. As the ring gear is rotated by the
2-25. IGNITION-STARTER KEY. Turning the key (9, starting motor, the crankshaft is forced to rotate. It is
figure 1-8) energizes the starting motor which in turn at this point that fuel vapors enter the piston chambers
drives the engine flywheel ring gear until combustion and are ignited by the electrical impulse delivered by
takes place in the engine. the spark plugs. The synchronized firing order of the
spark plugs produces a continuous source of driving ener-
2-26. AMMETER. The ammeter (8, figure 1-8) indi- gy for the crankshaft. The transmission is inter-connec-
cates the activity of the electrical system. If the needle ted to the engine by a torque converter and plate arrange-
indicates a continuous discharge when the engine is oper- ment, and a series of multiple disc clutches in the trans-
ating above an idle speed, the trouble would probably be mission allows the operator a selection of two speeds in
a loose or broken fan belt, a short in some wire or com- either forward or reverse direction, and also a neutral
ponent of the electrical system, or a faulty generator or position when no travel is desired. The transmission is
regulator. The gage needle should move slightly to the in turn geared to the differential of the drive axle by
positive side of the "0" mark on the ammeter when the means of a bevel pinion and ring gear. Shifting of the
engine is running at full governed speed and the battery levers results in rotating the axle shafts in a clockwise or
is fully charged. counterclockwise movement, depending upon which gears
are engaged within the transmission housing.
2-27. HOURMETER. The hourmeter (6, figure 1-8) re-
flects the actual hours of engine operation. Its main pur- 2-33. HYDRAULIC SYSTEM. The hydraulic pump pro-
pose is to be the determining factor as to when the lift vides a constant flow of hydraulic fluid under pressure
truck components require maintenance or overhaul pro- when the engine is running. The control levers direct
cedures. the flow to either the lift or tilt cylinders as desired.
Fluid is also supplied directly from the pump to the
2-28. WARNING LIGHT. The red warning light (1, hydraulic steering booster. Return passages provide a
figure 1-8) senses the transmission oil temperature and complete circuit for the fluid when the cylinders are
glows only when the temperature is in excess of proper not being utilized.
operating limits. This condition is usually remedied by
bringing the transmission oil level to full.

1-8
 CHAPTER 3
FIELD MAINTENANCE
Section I. Lubrication

3-1. LUBRICATION INFORMATION c. Wipe each lubrication fitting clean with a cloth be-
fore applying lubricants.
a. The lubrication chart (figure 1-10) illustrates lubri-
cation points of the lift truck and prescribes approved d. Apply only the grade of lubricant specified for oper-
lubricants, recommended intervals, and application ation under the temperature ranges indicated.
procedures.
e. It is recommended automotive practice to operate
b. In order that the lubricants can accomplish the pro- the lift truck immediately after a complete lubrication
tection for which they were intended, they must be kept change in order to distribute the lubricant most effec-
free from dust, dirt, water, or other forms of contamin- tively.
ants.
f. Special or detailed instructions for servicing the lift
truck components are outlined in the lubrication chart
under "NOTES".

Section II. Preventive Maintenance Services

3-2. PERIODIC IN -SERVICE MAINTENANCE a practice of operating the engine for a minimum of one
hour after filling if the danger of freezing exists.
3-3. GENERAL. The instructions contained in this sec-
tion are intended to aid the operator in maintaining the WARNING
lift truck in an efficient, trouble-free condition. It is
the purpose of this section to acquaint the operator with If the battery electrolyte is accidentally spilled
the possibilities of equipment malfunction, the indica- or comes in contact with skin or clothing, im-
tions of malfunction, and the corrective measures to be mediately apply baking soda or a similar neu-
taken. Thorough understanding of the instructions by tralizing agent.
the operator is required to prevent minor malfunctions
from going unnoticed until a part or a system is damaged 3-8. Use an accurate hydrometer to check the electrolyte
beyond repair; resulting in removing the lift truck from specific gravity. When fully charged, the reading should
service for extended periods. be 1.260 at a liquid temperature of 80° F. Wide vari-
ations from this reading between the cells indicates a
3-4. SPECIAL MAINTENANCE TOOLS. No special tools faulty battery, and requires replacement with a new
are required by operating personnel to maintain the lift battery.
truck in serviceable condition. Standard tools, commonly
used by automotive mechanics, should be made available WARNING
to the operator.
Since the batteries release highly flammable
3-5. MAINTENANCE CHARTS. In addition to, and hydrogen gas when being charged, keep all
summarizing the procedures of this section, Table I is forms of sparks or flame away from lift truck.
presented in chart form to provide the operator with a
ready reference as to typical troubles, the probable 3-9. Clean batteries with a solution of 1/2 pound baking
cause, and remedy procedures required. soda mixed with 1 quart of water, apply with a brush, and
flush with clean water. Prevent solution from entering
3-6. ELECTRICAL SYSTEM. vent holes; make sure holes are open after cleaning. Ap-
ply a light film of petroleum jelly to the battery terminals
NOTE and cable clamps to retard corrosion.

Disconnect battery ground cable before 3-10. GENERATOR. In addition to maintaining the gen-
working on electrical components. erator (1, figure 1-4) in a clean condition at all times, a
more detailed inspection of the brushes and commutator
3-7. BATTERY. Battery "life" depends entirely upon is required every 500 hours of operation. With the gener-
proper care and thorough periodic inspections. The most ator mounted on the engine make a visual inspection of
important service in maintaining the battery, is to in- the brushes through the openings in the commutator end
spect the electrolyte (liquid) level daily. Add distilled frame. Do not pull the brushes against the spring tension
water until the tops of the plates are covered approximately by the leads. Do not snap the brush arm down against the
1/8 inch. If distilled water is not available, use clean brushes. Replace worn brushes with new brushes, being
rain water or regular drinking water that is low in mineral sure to tighten brush leads and screws, field leads, and
content. Since the water and the electrolyte in the battery all connections. Brush springs have sufficient tension if
will not mix unti'i charged by the generator current, make they hold the brushes tight against the commutator; re-

1-9
 ***CHAIN SHEAVE
CG (2)
LIFT CHAIN
EO (2) MAST SHOES
CYLINDER GUIDES CG ( 6)
CG (2) **LATCH DOGS
MAST MOUNTING PINS CG ( 2)
CG (2) TRANSMISSION - DIFFERENTIAL
STEERING GEAR TO
GL BRAKE PEDALS
***TILT CYLINDER CG ( 3)
CG (2) BRAKE MASTER CYLINDER
INCHING MASTER CYLINDER BF
BF HYDRAULIC RESERVOIR
STARTER

°-.----------
TO
EO
FUEL PUMP
ENGINE OIL
CRANKCASE FILLER BREATHER
EO
ENGINE OIL FILTER
AIR CLEANER
GENERATOR
DRAG LINK & CYLINDE EO (2)
CG (3)
DISTRIBUTOR
BATTERY
EO
TRANSMISSION OIL FILTER
**STEERING HOUSING
RADIATOR
CG
STEER AXLE KING PINS TIE RODS (MY 60)
CG (4) CG ( 4)
WHEEL BEARINGS TIE RODS (MY 40)
WB (2) CG (4)

CODE TYPE CODE TYPE

CG Chassis Grease BF Brake Fluid

EO Engine Oil WB Wheel Bearing Grease
GL Gear Lube TO Transmission Oil (AT F)

APPLICATION SCHEDULE

LUBE POINT CODE HOURS LUBE POINT CODE HOURS

***Chain Sheaves (2) CG 50 *Mast Shoes CG 150

Lift Chain (2) EO 50 **Latch Dogs CG 150
Cylinder Guide (2) CG 50 *Transmission & Differential TO 400
Mast Mounting Pin (2) CG 50 Transmission Screen 400
*Steering Gear GL 50 Brake Pedals (3) CG 50
***Tilt Cylinders (2) CG 50 *Brake Master Cylinder BF 50
*Inching Master Cylinder BF 50 *Hydraulic Tank, Screen,
• Starter EO 400 Breather TO 2000
*Engine Oil EO 200 * Fuel Pump None 400
*Air Cleaner None 400 * Crankcase Breather 50
Drag Link & Cylinder (3) CG 50 Engine Oil Filter 400
Battery W 50 * Generator EO 400
*Transmission Oil Filter TO 400 * Distributor EO 400
*Radiator 8 • *Steering Housing CG 50
Wheel Bearings (2) WB 1000 Tie Rods (4) CG 50
Steer Axle King Pins (4) CG 50
*See "LUBRIC ATION NOTES"
**MY 40 Only
**MY 60 Only
Figure 1-10. Lubrication Chart. (Sheet 1 of 2)

1-10
 LUBRICATION NOTES

Hours listed in "APPLICATION SCHEDULE" refer to * STARTER. Place 8 to 10 drops SAE lOW oil in oil
actual hours of machine operation. Numbers within cup every 300 operating hours.
brackets 0 after a lubrication point indicates the
number of similar points to be lubricated. An aster- *HYDRAULIC OIL TANK. Check daily and maintain
isk*, indicates detail lubrication instructions as level at "Full" mark on dip stick, with mast fully
follows: raised. Use ATF Type A Suffix A Texaco 1808 or
Mobil 200 oil. Drain, clean, and refill every
* AIR CLEANER. Every 50 hours of normal operation, 2000 operating hours. Clean screen at each drain
remove element and shake out accumulated dirt. period.
Every 400 hours of normal operation, install a new
element. DO NOT WASH AND RE-USE ELEMENT. * RADIATOR. Check daily. Refill as required. Add
Service air cleaner more often if subjected to ex- permanent type anti-freeze when air temperature is
treme dust conditions. 32° F. or lower.
*STEERING GEAR. Check oil level every 40 operating * FUEL PUMP. Clean bowl and screen every 400 hours.
hours. Keep reservoir filled with SAE 90 gear lube.
Use a high grade straight mineral oil. *TRANSMISSION. ATF Type A, Suffix A (Mobil Fluid
200, Texamatic 1808, or equivalent). Drain trans-
• BRAKE AND INCHING MASTER CYLINDERS. Check mission, change filter, and clean suction strainer in
fluid level every 40 hours. Keep filled to within 1/4"
transmission case after first 40 hours. Thereafter,
from top. Keep vent holes in filler cap open at all
change oil and filter and clean strainer every 400
times. hours of operation. Check oil level daily. Two
marks on dipstick allow checking with unit either
*ENGINE OIL. The crankcase capacity is 5 U.S. quarts; hot or cold. To check with unit hot, check with
the filter holds an additional quart. Check twice the engine idling at normal operating temperature,
daily, drain and refill every 200 operating hours and with both clutches engaged, and with the parking
change filter every 400 operating hours under normal brake set. Level should be up to "FH" mark (Full-
service. Hot) on dipstick. If unit is cold, level should be
to "FC" mark (Full-Cold) on dipstick.
Engine Oil Type (Use high grade MS oil)
*DIFFERENTIAL. The lubricant used in the differen-
80° F and above SAE 30 tial is common to the transmission; therefore, check-
32° F to 80° F SAE 20 or 30 ing and changing are the same. Flushing transmission-
10° F to 32 ° F SAE lOW differential compartments with solvent at time of oil
10 ° F and below SAE 10W change is not recommended as ingredients in solvent
may attack the quad seal rings and destroy their seal-
• DISTRIBUTOR. Each 300 operating hours place 3 or 4 ing quality.
drops SAE 10W oil on wick under rotor. Remove plug
at side of housing and fill with SAE 20 oil each 300 *LATCH DOGS. Disassemble and clean out dirt
operating hours. Apply a trace of high quality ball every 300 hours.
bearing lubricant to the breaker cam every 300 oper-
ating hours. TORQUE CONVERTER. The lubricant used in the
torque converter is common to the transmission and
differential.
*GENERATOR. Every 60 operating hours, add 8 to 10
drops SAE lOW engine oil to the respective oil cups. BREATHERS. Check and clean the breathers for the
crankcase, hydraulic system, and the differential
•MAST SHOES. Replace shoes every 1500 hours. each 60 operating hours. Clean the breather caps
Grease full length of rail where shoes rub. in solvent, dip in clean engine oil, then shake out
the excess oil.

Figure 1-10. Lubrication Chart. (Sheet 2 of 2)

place springs if they do not. Prevent brushes from stick- 3-11. GENERATOR AND FAN BELT. Frequently inspect
ing by keeping the holders clean. Clean a dirty commu- the fan and generator drive belt for proper tension; a
tator using a strip of number 00 flintpaper or a brush seat- loose or slipping belt will cause engine overheating and
ing stone, held against the commutator with a piece of reduce generator charging rate and the rpm of the driven
flat hardwood while the engine is idling. Blow out all pulley. Check belt tension (figure 1-11) by pressing on
dust and grit with compressed air. Do not use emery the belt mid-way between the generator and crankshaft
cloth to clean the commutator. pulleys with a force of approximately 10 pounds. Proper
belt deflection should be 3/4 to 1 inch. Adjust belt ten- tap. Clean the sparking surfaces to a bright smoothness
sion by loosening generator mounting bolts and the adjust- with a fine point file. Reset plug gap to 0,023-0.028
ing bar cap screw, pull outwardly on the generator until inch for gasoline engines; .014-.016 inch for LP-Gas
correct tension is applied, and then tighten nuts and cap engines by bending the ground or outside electrode, and
screw. Replace a worn or grease-soaked belt as it will test with a wire-type feeler gage. Using new copper
not be capable of driving the fan or generator at their gaskets, install the cleaned or new plugs, and tighten
proper speeds. to 34 foot-pounds torque. If no wrench is available, in-
stall finger tight, and then tighten an additional 3/4
turn with the deep socket wrench.
3-14. DISTRIBUTOR. Remove the distributor (6, figure
1-4) cap; wipe it clean with a cloth, and inspect it close-
ly for cracks (usually very thin). Inspect the cap and ro-
tor for chips, cracks, or carbonized paths which allow
high-tension leaks to ground. Inspect and discard a cap
seal if it is glazed or matted with oil. Check the cen-
trifugal advance mechanism for unbinding movement by
'turning the distributor shaft in its direction of rotation,
and then release it. The advance springs should return
the shaft to its original position without sticking. Clean
the distributor points with a fine cut contact file. Do not
attempt to remove all roughness, but merely remove
scale and dirt from the contracting surfaces. Do not use
emery cloth or sandpaper as their abrasive particles will
imbed in the surface and cause the points to burn. Ad-
just the point gap to 0.018 inch by turning the engine
over until the cam follower block for the breaker lever
is on the high point of the cam lobe. Loosen the lock
screw, turn the eccentric screw to obtain the above
stated gap, and then tighten the lock screw. Apply a
light film of ball bearing lubricant to the breaker cam;
place two drops of light engine oil on the felt in the distri-
Figure 1-11. Fan Belt Tension butor shaft. Discard all parts that are worn, burned, pitted,
or are in an otherwise unserviceable condition. No further
3-12. STARTING MOTOR. Service the starting motor, distributor servicing is required for field maintenance; how-
brushes and commutator in accordance with the instruc- ever, if a timing light is available, ignition timing can
tions outlined for the generator assembly (paragraph 3- be checked at this time by following the procedure out-
10). The commutator end frame must be removed from lined in paragraph 3-32. Secure distributor cap in its
the starting motor in order to inspect brushes and commu- original location on the distributor, and install coil and
tator. If the starting motor pinion fails to engage the en- spark plug wires.
gine flywheel ring gear, it indicates a sticking drive pin-
ion and requires removal from the engine. Remove the 3-15. OIL PUMP. With the engine running at full govern-
negative lead wire from the battery, disconnect all wires ed speed and normal operating temperature, the dash
from the motor, remove the bolts that secure the starting panel-mounted oil pressure gage should register between
motor to the engine, and withdraw the motor from the 25 to 35 pounds. Erratic action, flickering, or a sudden
engine flywheel housing. Wash the pinion and shaft of lowering in the pressure is not always an indication of oil
the motor with clean kerosene, dry completely, and re- pump malfunction; check the crankcase oil level, test
install on engine. Clean the lead wire terminals and for a faulty gage by disconnecting the oil gage tube at
make proper connections of the motor leads and the neg- the engine connection and turn the engine over with the
ative lead of the battery. If starting motor still fails to starting motor. If a steady stream of oil comes out of
operate, install a new assembly in its place and tag the the fitting in the crankcase, the gage is faulty and not
faulty motor for overhaul. the pump. If no oil comes out of the fitting, or the
stream is broken or weak, it indicates a plugged oil in-
3-13. SPARK PLUGS. Whenever engine performance is take passage or a plugged float screen. Clean the oil
unsatisfactory; fuel consumption is excessively high, or passage. Remove the cover from the lower right side of
idling is rough, it is an indication that the most logical the engine after draining the crankcase oil, remove the
component to check first is the spark plugs. Using a 7/8 cotter pin (1, figure 1-12) that secures the float to the
inch deep socket wrench, loosen the plugs two full turns, connector tube, and withdraw the float and screen as-
blow all dirt away from the ports, and then remove the sembly. Thoroughly clean the screen, using clean kero-
plugs. Clean plugs with a sand -blast cleaner if available, sene, dry completely, inspect for damage, and re-install
clean plug threads with a wire-bristle brush, and restore it in its original position. Remove the oil filter cartridge
damaged threads in the head ports with a suitable size (27, figure 2-12) and install a new one. An oil pressure

1-12
regulator (figure 1-13) is installed on the left side of the 3-16. GASOLINE CARBURETOR. (See figure 1-14.) In-
oil pump housing. To adjust the oil pressure on the pres- spect the linkages for signs of rough edges, paint, or bind-
sure gage, loosen the lock nut of the regulator and rotate ing. Check all connections for evidence of leaking. If
the set screw clockwise to increase pressure, and counter- the engine fails to start or does not operate properly, make
clockwise to decrease oil pressure. When the gage indi- the following carburetor adjustments:
cates low oil pressure and no further adjustment of the
regulator setscrews is possible, it indicates that the oil a. Screw in the idle adjusting needle (2, figure 1-14)
pump gears have too much end clearance or are worn be- until it just seats; then open the needle two full turns.
yond serviceable limits, or that the regulator spring has
collapsed or is broken. Drain the crankcase oil, remove b. Make certain the idle speed stop screw (1, figure
the attaching parts that secure the pump to the crankcase, 1-14) is holding the throttle disc slightly open.
and withdraw the pump assembly. Inspect the gears and
spring; remove and replace as necessary. Do not remove c. Start the engine and allow it to warm up at an idle
the oil pump drive shaft as that would also require removal speed of approximately 800 rpm.
of the entire distributor assembly which in turn involves re-
timing of the engine. Such procedures are beyond operator d. After the engine has warmed up to normal operating
maintenance category. Install and check for drive gear temperature (approximately 180 degrees), release the
end clearance as outlined in the oil pump overhaul pro- accelerator pedal and allow the engine to idle.
cedures in paragraph 4-129.
e. Adjust the idle speed stop screw to obtain the engine
idle speed of 450 to 500 rpm.
f. Back out the idle adjusting needle until the engine
speed drops from an over-lean gas mixture. Then, turn
the needle in until the engine runs smoothly and steadily.

Figure 1-12. Oil Float and Screen

1. Cotter pin
2. Float

Figure 1-14. Carburetor (Gasoline)

1. Idle speed stop screw
2. Idle adjusting needle
3. Block drain
3-17. LP -GAS SYSTEM

a. Power Adjustment. Set the pointer (not the slot) on

the power adjustment screw between 2 and 3. Warm the
engine up to normal operating temperature. Turn adjust-
ing screw clockwise to enrich mixture, counterclockwise
for leaner mixture.
b. Idle Adjustment. Set the idle speed stop screw to
obtain an idle speed of 450 to 500 RPM. Set the idle
screw for the smoothest idle (approximately three full
Figure 1-13. Oil Pressure Regulator turns out).

1. Adjusting screw c. LP-Gas Filter. The filter element needs very little
2. Lock nut service. Generally speaking, it should be cleaned or

1-13
 shaft lever, disconnect the carburetor control rod, then
push the rod back until the lever for the throttle disc
shaft is all the way back against its stop on the carburetor.
Push the lever for the governor fork shaft all the way back
also, (toward carburetor) and then adjust the pivot pin on
the carburetor control rod until the pin is 1/16-inch past
the uppex hole in the governor lever. Insert the pin in
the fork shaft lever and secure it with washers and a cotter
pin. Lock pin in position with the lock nut. Move the
hand throttle control to the idle position and connect the
adjusting rod spring to the lower hole in the fork shaft
lever, making certain that the adjusting rod plunger is
in proper alignment with the lever for the fork shaft. If
the plunger is not in alignment, reposition the adjusting
rod guide so that the plunger is centered on the lever.
Thread the plunger in or out until it contacts the edge of
Fig. 1-15. Carburetor (LP-Gas) the fork shaft lever, insuring a positive idle position, and
then secure with the lock nut. To check the governed
1. Power adjustment speed, move the throttle linkage to the wide open posi-
2. Idle speed stop screw tion, and adjust the jam nuts in the direction necessary
3. Idle adjusting screw to obtain the desired governed speed. Tighten the nuts
against each other after obtaining desired setting.
changed only if a loss of power is noted which can be
traced to no other cause. The element is located in the
relief valve assembly. See Fig. 1-16.

d. LP-Tank. It is recommended that the tank be re-

moved when the truck is out of service for any length of
time, such as overnight. Store the tank in a safety rack.

Fig. 1-17. Governor Adjustments

1. Pivot pin 1/16" past hole in arm

2. Arm toward carburetor
3. Plunger spring disconnected
4. Rod against stop on carburetor

Fig. 1-16. LP-Gas Tank

1. Gage
2. Fuel valve
3. Quick coupler
4. Relief valve

3-18. GOVERNOR. Inspect the governor and carburetor

linkages (figure 1-17) for signs of rough edges, paint, or
binding. Adjust linkage for proper governed speeds of Fig. 1-18. Governor
1980 rpm as follows: Start the engine and allow it to
reach normal operating temperature. Stop engine and 1. Jam nuts
disconnect the spring and plunger assembly from the fork 2. Plunger contacting governor arm

1-14
3-19. COOLING SYSTEM. solution is not thoroughly mixed, slush ice may form.
Slush ice will stop circulation, causing overheating and
3-20. The cooling system plays an important role in the subsequent loss of coolant. Another reason for running
life and efficiency of an internal combustion engine. the engine is to release any air trapped in the engine
Overheating not only causes the engine to knock and lose water jacket by the closed thermostat. When the ther-
power, but also results in damage to bearings and other mostat opens, the trapped air is released and the water
moving parts of the engine. passages fill with coolant. Eliminating trapped air lowers
the coolant level of the radiator, and more water must be
3-21. Overcooling, although less sudden in effect than added to fill it to the proper level.
overheating, may be equally dangerous to the engine.
Low engine temperatures cause the formation of sludge 3-27. As mentioned previously, rust inhibitors should al-
which interferes with proper lubrication; it also creates ways be used in a radiator to protect it against corrosion.
harmful acids which attack engine parts. Most high-quality anti-freeze solutions are compounded
with a rust inhibitor or corrosion deterrent. Do not add
WARNING a rust inhibitor to these solutions as the chemical reaction
may damage the system. Maintain full strength corrosion
Be careful when removing radiator cap when protection in the coolant system at all times. Corrosion
engine is hot. Turn cap slowly until it reaches inhibitors tend to lose their effectiveness with use, and
vent position, then .allow steam pressure to es- we recommend draining the system and renewing the in-
cape before removing. hibitor every 6 months. In a system that was clean orig-
inally, the appearance of rust in the radiator, or in the
3-22. A pressure-type cooling system raises the boiling solution, is an indication that the inhibitor is weakened
point of the coolant and permits. the engine to operate at or exhausted completely. Whenever the cooling system
higher temperatures without coolant loss. A pressure- shows signs of rust, the coolant should be drained, the
type system will not function properly unless it is abso- system flushed, and the radiator refilled with fresh cool-
lutely airtight; consequently, the system. must be kept in ant containing an inhibitor.
good condition. Air in the system will also force cool-
ant out of the overflow pipe, reduce the rate of heat 3-28. After the anti-freeze solution is drained in the
transfer, and accelerate rusting within the system. spring, it is recommended that the cooling system be
flushed thoroughly, cleaned if necessary, and a suitable
3-23. The cooling system on a gasoline engine has 3 rust inhibitor added to a summer filling of fresh water.
drains -- the radiator drain, located at the lower side of In areas where anti-freeze is not required, add rust in-
the bottom tank; and a drain for each engine block (3, hibitor to a fresh filling of water both spring and fall.
figure 1-14). The LP-Gas engine has, in addition, a
drain in the converter. Whenever the system is drained, NOTE
it should be done at the end of a day's run when any
foreign material is in suspension and will be removed Flush the system thoroughly before and after
with the coolant. To insure complete draining, open all the use of anti-freeze solutions.
drains and remove the radiator cap.

3-24. The type of coolant used in the radiator depends

on climatic conditions. If there is no danger of freezing,
use a solution of clean, soft water and rust inhibitor;
however, if the truck will be exposed to freezing tem-
peratures, use a permanent type anti-freeze.

3-25. Avoid the use of water having a high mineral con-

tent or containing other impurities. Water containing
minerals or other foreign material will form deposits
throughout the cooling system. These deposits, in ad-
dition to restricting the proper flow of coolant, act as an
insulator to prevent the effective transfer of heat. Clean
rain water and a rust inhibitor is a good coolant solution.
3-26. If the danger of freezing exists, fill the cooling
system with a permanent type anti-freeze solution. Fol-
low the recommendations of the anti-freeze manufacturer
to obtain a solution that will give the desired protection
for the lowest anticipated temperatures. After filling the
radiator, run the engine until it reaches normal operating Fig. 1-19. Checking Thermostat
temperature and the thermostat opens. This will establish
circulation through the radiator and engine blocks to in- 1. Thermostat
sure proper mixing of the anti-freeze and water. If the 2. Thermometer

1-15
3-29. Efficient operation of the cooling system requires
an occasional cleaning--particularly at seasonal changes
when anti-freeze solution is added or drained. The proper
method of cleaning depends on the condition of the system.
The exterior of the radiator should also be cleaned regular-
ly. Dirt, insects, or other foreign material will clog the
radiator fins and reduce cooling efficiency. Clean the fins
with forced air or water. Straighten any bent fins noticed
during the cleaning operation, but be careful not to dam-
age the tubes or break the bond between fins and tubes.
3-30. To check the thermostat, suspend it and a ther-
mometer in a container of clean water. Heat the water
and observe the opening and closing temperature. If the
valve fails to open and close within 10 degrees of the
rated opening temperature (180 degrees), replace the
Figure 1-20. Engine Timing
thermostat.
3-31. TIRES. Tires are an integral and expensive part 1. Timing mark
of the lift truck. It is important that they be kept in the 2. Timing pointer
best possible condition as follows:

a. Tires should always be kept inflated to the recom- prevent unnecessary deterioration and to insure top per-
mended pressure. formance when the lift truck is returned to service.

b. The lift truck should never be driven at high speed a. Drain the crankcase, transmission-differential com-
over rocky or rough ground. partments, and discard the oil filters. Install new filters
and refill the units with the specified grade of fresh oil.
c. When the lift truck is not in use, it should be kept out
of the sun as much as possible. Sunlight causes surface b. Thoroughly lubricate the lift truck, and service the
checking of the tires. air cleaner and breathers according to the instructions
given in this manual. Drive the lift truck for a short
d. The lift truck should not be parked on oily or greasy distance to distribute the fresh lubricants.
floors. Oil and grease deteriorate rubber and shorten
tire life. c. Drain and flush the cooling system. Leave the radi-
ator and block drains open to prevent the collection of
e. Tire damage should be repaired immediately. Small condensation.
breaks or cuts allow dirt and moisture to enter and cause
fabric rot. d. Drain the fuel tank, fuel filter, and carburetor. Make
certain the system is completely drained as any fuel re-
f. If the lift truck is to be out of service for any length maining in the system will oxidize and form gummy de-
of time, it should be blocked up to take the weight off posits. Leave the shut-off valve and the carburetor drain
the tires. If this is not possible, check the tires regu- open. Clean the fuel filter. If the truck has an LP-Gas
larly and keep them inflated to the recommended pres- system, close the fuel valve, remove the tank, and store
it in a safety rack.
sure.
' 3-32. ENGINE TIMING. (See figure 1-20). To check e. Remove the valve covers and flush the valves, rocker
the timing, connect a 12-volt timing light to the spark arms, and push rods with heavy oil (SAE 30) to prevent
plug for the number 1 cylinder (the one closest to the rust.
radiator end of the engine). Set the accelerator to ob-
tain an engine speed of 1980 rpm. Allow the engine to f. Remove the spark plugs and pour a liberal amount of
warm up to normal operating temperature. Direct the engine oil into each cylinder. Turn the engine over
timing light at the timing point (2, figure 1-20) and the several times to distribute a protective oil film on the
crankshaft sheave. As the light flashes, the timing mark pistons and cylinder walls.
(1, figure 1-20) on the sheave should line up with the
pointer. If the mark does not line up with the pointer, g. Remove the battery and store it in a cool, dry place
loosen the distributor lock nuts, and rotate the distributor where it will not freeze. Keep the battery fully charged,
body to correct the timing. Tighten the lock nuts. and maintain the proper electrolyte level. A run-down
battery will deteriorate rapidly when stored. If the ter-
3-33. STORING THE LIFT TRUCK. minals and the top of the battery appear corroded, clean
them with a stiff brush and a solution of baking soda and
3-34. If the lift truck is to be stored for an extended water. Make certain the vent holes in the filler caps are
period of time, the following steps should be taken to open.

1-16
White Fork Lift My60 Parts Operation Maintenance Manual S 407
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h. Drain and flush the hydraulic system. Remove the 3-37. In trouble shooting the serviceman wishes to iso-
strainer (43, figure 2-34) from the hydraulic tank and late the part responsible for the trouble by quickly elimin-
clean it. Refill the tank to the specified level in ac- ating all other parts. For example, suppose the engine
cordance with the lubrication chart (figure 1-10). Oper- misses (misfires) under a heavy load. In about 85 per
ate the hydraulic controls for several minutes to distri- cent of the engines with this trouble, it will be found that
bute the new fluid throughout the system. Contract the the ignition system is at fault.
cylinders during storage.
3-38. The first step in trouble shooting the ignition sys-
i. Thoroughly clean the lift truck. Check for worn or tem is to check the spark output from the ends of the spark
damaged parts, and make any necessary repairs, replace- plug wires. Check each wire by holding it 1/16-inch
ments or adjustments. Touch up any areas where the away from the engine block while cranking the engine
paint has worn or rubbed off. with the ignition switch turned on. If each wire shows a
good spark, it indicates that the ignition system from the
j. Block up the lift truck to take the weight off the tires. ends of the spark plug wires to the battery is satisfactory.
If the weight is left on the tires, they may take a "set" Thus, nothing would be gained by checking the distri-
and become permanently damaged. butor, battery, battery cables, ignition switch, etc. By
this one test, it has been established that the ignition sys-
k. Store the lift truck in a dry building; however, if it tem is delivering a satisfactory spark to each spark plug.
cannot be stored inside, cover it with a tarpaulin. Since the rest of the ignition system has been eliminated,
it is logical to assume that faulty spark plugs are respon-
3-35. TROUBLE SHOOTING. sible for the trouble.
3-36. Trouble shooting involves taking the proper steps 3-39. Trouble shooting can be applied to any part of the
to locate the source of a trouble, and then correcting the lift truck that is not functioning properly and follows the
trouble. Do not confuse trouble shooting with an engine same pattern.
tune up. In an engine tune up, all parts of the system
where the trouble is occurring are checked. For example, a. First, confirm the suspected condition before proceed-
in an ignition tune up, the battery, which is the source of ing with any tests.
electrical energy, is tested first; then the battery cable
connections are inspected, etc. This checking and test- b. Next determine and recognize the possible causes.
ing is continued in successive steps until each portion of
the system that can have an influence on other portions c. Finally isolate the cause (or causes) by performing a
is thoroughly tested and any abnormalities corrected. series of quick tests to eliminate the others.

TROUBLES, CAUSE, AND REMEDY

TROUBLE POSSIBLE CAUSE SUGGESTED REMEDY

ENGINE IS HARD TO START No fuel in carburetor. Make sure fuel shut-off valve is open.
OR FAILS TO START Check fuel lines and filter.

Water in fuel. Open carburetor drain to check for water.

Drain system and refill with fresh fuel if
there is evidence of water.
Water in cylinders. Check head gasket.

Weak spark. Check ignition system.

No spark. Check wiring and connections.

Incorrect ignition timing. Check ignition timing.

Incorrect valve adjustment. Check valve clearances.

Restricted air intake. Clean and service air cleaner.

Restricted exhaust. Clean soot and foreign material from ex-

haust passages.
Poor compression. Check valves, rings, etc.

1-17

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