MH-S-MF2500FL

MMaasssseeyy HHaarr rr iissMMaasssseeyy FFeerrgguussoonn

Service ManualMF2500Forklift

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF MASSEY HARRIS MASSEY FERGUSON OR IT’S SUCCESSORS. MASSEY HARRIS MASSEY FERGUSON AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Serv

ice

Man

ual

MF-2500 Forklift Service Manual

Description Part

Continental Z-145 Gas Engine

Perkins AD3- l 52 Diesel Engine 2

Perkins AG3- l 52 Gas Engine 3

Clutch 4

Manual Shuttle Transmission 5

Instant Reverse Transmission 6

Drive Axle 7

Brakes 8

Rear Axle and Steering 9

Mast Hydraulic System and Structure 10

MASSEY-FERGUSON

GROUP VI - SECTION F - PART 2.

PART 2 - GASOLINE ENGINE

INDEX Page

INTRODUCTION . . • • . . . • . . . . . . . . • . . . . . . . . . . . 1 ENGINE REMOVAL . . . . . . . • • . . . . . . . • . . . . . . . . . 2 ENGINE INSTALLATION . . . • . . . . . . . . . • . • . . . • . 6

INTRODUCTION

This Part of the Manual has been prepared to provide information for serv1cmg the Z-145 Gasoline Engine in the MF 2500 Fork Lift. This information is specific to the MF 2500 application and should be used in conjunction with the service informa­tion for the basic Z-145 Gasoline Engine, as contained in Group O - Section O.

The Gasoline Engine for the MF 2500 Fork Lift, as shown in Figs. 1 and 2, is a four cylinder engine having a bore of 3-3/8 inches and a stroke of 4-1/16 inches. The engine has a total piston displacement of 145 cubic inches and a compression ratio of 7.1 to 1. The engine has a maximum brake horsepower of approximately 42 @.2000 rpm with all standard accessories. Maximum engine torque is 125 ft.-lbs. at an en­gine speed of approximately 1300 rpm.

WHERE RIGHT AND LEFT-HAND SIDES ARE MENTIONED IN THIS PART, TffiS REFERS TO THE TRACTOR OR ENGINE AS VIEWED WHEN SITTING IN THE OP­ERATOR'S SEAT.

Figure 1 - Front 3/4 View of Z-145 Engine Used in MF 2500 Fork Lift

Figure 2 - Rear 3/4 View of Z, 145 Engine Used in MF 2500 Fork Lift

1

MASSEY-FERGUSON

GROUP O - SECTION O - PART 1 SPECIFICATIONS

Crankshaft and Main Bearings

Valves

Crankpin Journal Diameter .......... . Main Bearing Journal Diameter ....... . Main Bearing Inside Diameter (standard size) . Main Bearing Clearance Desired Clearance . Maximum Clearance Crankshaft End-Play

Valve Tappet Clearance: Intake ....... . Exhaust ...... .

Valve Head Diameter: Intake ..... . Exhaust .... .

Valve Face Angle: Intake ..... . Exhaust .... .

Valve Stem Diameter: Intake .. Exhaust ...... .

Valve Seats

Valve Seat Angles: Intake ..... . Exhaust .... .

Seat Contact Width Maximum Seat Run-Out

Valve Guides

Location .............. . Inside Diameter . . . . . . . . . . . Clearance Limits (stem-to-guide):

Intake Valves . Exhaust Valves . . . . . . . . . .

Valve Springs

Free Length . . . . . . . . . . . . . . . . . . Spring Length Valve Closed . . . . . . . . .

Spring Pressure@ 1-45/64 Inches Length. Spring Length Valve Open. . . . . . . . . . .

Spring Pressure @ 1-27 /64 Inches Length .

1. 9365 - 1. 9375 inches . 2. 249 - 2. 250 inches 2. 2505 - 2. 2515 inches

O. 0005 - O. 0027 inch . ... 0.0015 inch . . . . 0. 0037 inch q~ 004 - 0. 008 inch

0. 011 inch "hot", 0. 013 inch "cold" O. 013 inch "hot", 0. 015 inch "cold"

1. 273 - 1. 283 inches 1. 135 - 1. 145 inches

. 30°

. 44°

0. 3141 - 0. 3149 inch 0. 3124 - 0. 3132 inch

........ 30°

. ....... 450 1/16 to 3/32 inch .... 0. 002 inch

3/32 inch below top face of head O. 3157 - 0. 3172 inch

0. 0008 - 0. 0031 inch 0. 0025 - 0. 0048 inch

Approx. 2-1/16 inches 1-45/64 inches

. . 47 - 53 lbs. 1-27 /64 inches

96 - 104 lbs.

3

MASSEY-FERGUSON

GROUP O - SECTION O - PART 2

PART 2-Z-145 ENGINE OVERHAUL PROCEDURES

Introduction .......••.•••••.••••....•.•••.. Engine Description ..••.•.. , .•.••..•..••••. Engine Identification ••••.•••••...••••.••.. Rocker Arm Shaft Assembly .••.•••..••••••.•• Cylinder Head ••••••••••.••••••• , •••• , •••• Intake Valves ....•••• , ••..•.•••••.•••• ,., •• Exhaust Valves .• , • , , ••••..••••••..•••••• , • Valve Guides •• , •••••••••• ,,,,.,., ••• , •• , •• Valve Seats :-••.••••••.•••••••.•••••••••••• Valve Springs ••••••••• , •• , •••••••••••••••• , Cylinder Head Reassembly ••.•••••••••••• , , ,

INDEX Page

2 2 2 3 5 6 7 8 9

11 11

Cylinder Head Installation· ••.••••••••••.••.•. Adjusting Valve Tappet Clearance .•....•.•.... Piston and Connecting Rod Assembly , ..•......• Cylinder Sleeves •..•....•....•.....•..•.••. Timing Gear Cover and Front

Page 11 12 14 18

Crankshaft Oil Seal • • • • • • • . • . . . • • • . . • • . • . . 20 Timing Gears •••••.••.•. , . • • . • • • . • • . • . • • • . . . 24 Camshaft .•• , .. , .•••.••• , .•.• , . • . • • • . . • • . • . . 27 Crankshaft and Main Bearings . • . • • • . • . . • • • . • . . 31 Rear Crankshaft Oil Seal • .. .. . . • .. • .. • .. • .. • • 36 Flywheel ••••.••••• , •••• , •• , ••• , • , •• , • • • • • • . 37

Fig. 1 - Cross-Sectional View of Engine

MASSEY-FERGUSON

GROUP O - SECTION O - PART 2 ENGINE OVERHAUi. PROCEDURES

Fig. 28 - Removing Crankshaft Pulley

1. Remove the fan belt and fan blade assem­bly.

2. Remove the crankshaft pulley bolt and remove the pulley, using a puller tool, as shown in Fig. 28.

3. Disconnect the carburetor control rod at governor lever end.

4. Remove the breather tube from the rocker arm cover.

5. Either remove the oil pan or remove the three front oil pan capscrews and loosen all other remaining capscrews securing the oil pan.

6. Remove all of the bolts and capscrews securing the timing gear cover. Carefully sep­arate the bottom and rear gaskets from it and remove the cover from the two dowels on the front face of the cylinder block.

FRONT CRANKSHAFT OIi. SEAi.

Inspect the front oil seal carefully to deter­mine whether or not it is worn or damaged. If the oil seal shows any signs of damage or wear, it should be replaced. Do not take chances with questionable oil seals.

If the oil seal is in new condition and shows no signs of cuts or wear, it may be reused for

Fig. 29 - Installing the Front Cranks~aft Oil Seal

further operation, provided the seal contact surface on the pulley is in good condition. Make sure to examine the sealing surface oil the pulley very carefully, since any roughness or scratches will eventually damage the seal and cause an oil leak.

If the pulley surface is damaged, it must either be replaced or salvaged by building up the damaged surface, then turning the surface again to the specified size and very carefully polishing -it.

Replacing front Cranlcsha~ Oil Seal

1. Carefully press or evenly tap the old oil seal out of the timing gear cover.

Fig. 30 - Location of Front Crankshaft Oil Seal

21

MASSEY-FERGUSON

GROUP O - SECTION L - PART 2

PART 2-AD3.152 ENGINE OVERHAUL PROCEDURES

INDEX Page

Introduction . . . . . . . . . . . . • . . . . . . . . . . . . . • . . . . . . l Engine Description . . . • . . • . . • . . . . . . . . . . . . . . . . . 2 Engine Serial Number . . . • • . . . . . . . . . . . • . • . . . . . 3 Rocker Arm Shaft Assembly • • . • . . . . . . . . . . . . . . • . 3 Cylinder Head •.........•..••...•........•.•. 4 Valves •••..... ·. . . . . . . . • . . . . • . . . . . . . . • . . • . . . 7 Valve Guides . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . 7 Valve Seats . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . 8 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cylinder Head Reassembly ....................• 10 Cylinder Head lnstal lat ion ..................... 10

INTRODUCTION

Page Adjusting Valve Tappet Clearance •.............. l l Cylinder Block (Stripped) ...................... 12 Piston and Connect.ing Rod Assembly ............. 13 Cylinder Liners ...........•................... 17 Timing Gear Cover and Front

Crankshaft Oil Seal ...•..................... 19 Timing Gears ................................ 20 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Timing Gear Housing .......•.................. 27 Crankshaft and Main Bearings ................... 30 Rear Crankshaft Oil Seal ....................... 35 Flywheel .................................... 35

This part of this manual is concerned with the overhaul procedures for the Perkins AD3. 152 Diesel Engine. All of the procedures and service information contained in this part assume that the engine has been removed from the tractor and pertain only to the basic engine itself, without regard to any particular application in which the en­gine may be used.

NOTE: For specific detailed information concerning the lubrication systent and the other engine systems of the AD3.152 engine, refer to the appropriate part within this section of your manual.

Before starting disassembly, make a complete diagnosis of the engine to be sure that an overhaul is really necessary. If the overhaul is necessary, inspect the en­tire engine for any evidence of external leaks, or defective parts, that must also be corrected before it is assembled and returned to the customer.

Thoroughly steam clean the engine before disassembling it or removing any com­ponent parts of the fuel system. Also, make sure to cap or otherwise cover all fuel openings as soon as they are exposed to prevent dirt from entering the fuel system. CLEANLINESS IS VERY IMPORTANT AND CANNOT BE OVER-EMPHASIZED.

Where the right and left-hand sides are mentioned in this Part, it refers to the en­gine as viewed from the rear. Direction of engine rotation, however, is viewed from the front.

MASSEY-FERGUSON

GROUP O - SECTION L - PART 2 ENGINE OVERHAUL PROCEDURES

gear so that its slot is in line with the key, then press the gear onto the crankshaft.

NOTE: Wh€::n pressing the gear in place, make sure that the key does not ride out of the keyway in the crankshaft.

3 .. Install the idler timing gear with all tim­ing gear marks aligned, as outlined earlier.

4. Install the oil pump, then install the oil pump idler gear and oil pump supply and de­livery pipes._

5. Install the bottom half of the timing gear housing, making sure that its front face is flush with the main part (upper portion) of the hous­ing.

6. Install the oil pan.

7. Install the oil slinger onto the crankshaft, with the outer flanged portion of the slinger facing forward.

8. Install the timing gear cover, as outlined earlier.

CAMSHAFT

The camshaft is made of a special cast iron alloy and is mounted high on the right-hand side of the cylinder block in such a position that the engine does not require the use of push rods. The camshaft is driven by the idler gear and is supported by three bearings which are machin­ed directly into the cylinder block. Camshaft end-play is controlled by a thrust spring, which is riveted onto the back side of the timing gear cover.

REMOVAL

To remove the camshaft, proceed, as follows:

1. Remove the timing gear cover, as out­lined earlier.

Fig. 36 - Removing the Camshaft

2. Remove the rocker arm cover, rocker arm shaft assembly and fuel lift pump.

3. Lift the tappets and secure them in their raised position.

4. If all of the timing gear marks are not aligned, then remove the idler gear, as out­lined earlier, to assure correct engine timing during reassembly.

5. Remove the camshaft (with or without its gear) from the cylinder block, as shown in Fig. 36. Be careful, when removing it, not to dam­age the bearing journals, cam lobes, or the tappets.

INSPECTION

Carefully clean and inspect the camshaft, as follows:

1. Inspect the camshaft bearing journals and cam lobes for wear or damage. If the journals are excessively scored, nicked or discolored by heat, or if the lobes are pitted, or rough, the camshaft must be replaced.

MASSEY -FERGUSON

GROUP O - BASIC ENGINES AND PROCEDURES

SECTION W - PERKINS AG3.152 ENGINE

This service information should be inserted into the Technical Maintenance Manual under Group O - Section W.

The information within this section has an altered format utilizing major topic headings instead of s_eparate Manual Parts as used in previous engine ~ections. This improved format having only one index, will allow the reader to more quickly locate the desired information without referring to ot;her indexes.

GENERAL INFORMATION AND TROUBLE-SHOOTING .•...•...•

Introduction ..•..........•... Engine Identification ...•.•.... Engine Trouble-Shooting Chart.

ENGINE SPECIFICATIONS

General Specifications ..•.... Torque Tension Specifications . Engine Overhaul Specifications . Lubrication System

Specifications ............. . Fuel System Specifications .•.. Cooling System Specifications . Electrical System Specifications

ENGINE OVERHAUL PROCEDURES

Adjusting Valve Tappet Clearances ..•....•........

Cylinder Head .............. .

Removing Cylinder Head .• Removing Valves ....•... Rocker Arms •.••••...•. Valve Guides ..••.....•. Tappets ..••...•......•. Cylinder Head Studs

INDEX

Page

1

1 2 3

5

5 6 6

12 14 15 15

19

19 19

19 19 20 21 21 21

- i -

Page

Reassembling and Installing Cylinder Head . . . • . . . • • 22

Pistons and Connecting Rods . . . 22

Removing Pistons and Connecting Rods . . . • . . . 23

Removing Piston Pins . • • • . 23 Installing New Piston Pin

Bushings • • . • . • . . • • . . . • 24 Checking Connecting Rod

Alignment • . • . . • . . • . . . • 24 Assembling Pistons and

Connecting Rods . . . . • • • 24 Installing New Rings . . . • • 24 Installing Pistons and

Connecting Rods • • . . . . • 25

Cylinder Block and Liners . . • • . 26

Removing Cylinder Liners. 26 Preparation for Installing

New Liners ...•.•... · · 26 Installing New Service

Liners .............. 0 27

Crankshaft, Main Bearings and Rear Crankshaft Oil Seal . • . 27

Installing New Main Bearings and Thrust Washers .........•....

Removing Crankshaft ..... Balance Weights ..•...... Regrinding Crankshaft ..•. Installing (;_rankshaft .•.•. Rear Crankshaft Oil Seal ••

Timing Gear Cover and Front Crankshaft Oil Seal ...•..•.

Removing Timing Gear Cover •..•.••.•••••..•

Removing Governor Control Cross Shaft .......... .

Installing Governor Control Cross Shaft .••........

Replacing Front Crank­shaft Oil Seal . • . . • • • . . .

Installing Timing Gear Cover ••••••••••••••..

Timing Gears ........•......

Checking Timing Gear Backlash .......•.•..•.

Removing Idler Gear and Hub ................ .

Installing Idler Gear and Hub ....•............

Removing Camshaft Gear .. Installing Camshaft Gear .. Removing Distributor and

Governor Drive Gear ... Installing Distributor and

Governor Drive Gear ...

Camshaft .......•...........

Removing Camshaft Installing Camshaft ..... . Camshaft End Play .•..•..

MASSEY -FERGUSON

INDEX (Continued)

Page

27 29 29 29 30 31

32

32

33

33

34

34

35

35

35

35 36 36

36

37

37

37 38 38

Timing Case

Removing the Timing Case Installing the Timing Case

Timing ........••.•.....•...

Resetting Engine Timing .. Checking Valve Timing .•. Checking Ignition Timing ..

Flywheel and Backplate

Flywheel Backplate ..•.... Flywheel .••....•.......

LUBRICATION SYSTEM ......... .

Oil Circulation ..•........... Motor Oil .•............•.... Oil Pressure ..•...•......... Oil Pressure Relief Valve .•.•. Oil Filter ........•...........

Replacing Filter Element ..

Removing, Cleaning and Installing Oil Pan Strainer ..

Removing Oil Pan ........... . Installing Oil Pan ........... . Removing Oil Pump .....•.... Disassembling Oil Pump ..... . Inspecting Oil Pump ....•..... Reassembling Oil Pump ..•.... Installing Oil Pump ..........•

FUEL SYSTEM

Carburetor

Description ............ . Operation ........•..... Overhaul Procedure ..•...

- ii -

..Page

38

38 39

40

41 41 41

42

42 42

44

44 46 46 46 46

46

47 47 47 48 48 49 50 50

51

51

51 52 55

Governor and Distributor Drive

Removing Governor Ball Race Assembly .....•..

Installing Governor Ball Race Assembly ...•.•••

Removing Governor and Distributor Drive Shaft ..

Installing Governor and Distributor Drive Shaft

Removing Distributor Drive Shaft Housing •

Installing Distributor Drive Shaft Housing .•

COOLING SYSTEM

Water Pump •.•...••...•.•...

Removing Water Pump

MASSEY -FERGUSON

INDEX (Continued)

Page

60 Disassembling Water Pump ................ .

Reassembling Water Pump. Installing Water Pump .... 60

60

60

61

61

61

Thermostat .................

63

63

63

IGNITION SYSTEM

Distributor ....•............•

Cap and Rotor .......... . Wiring .....•..........• Contact Point Assembly ..• Condenser ....•......... Centrifugal Advance

Mechanism .......... .

- iii -

Page

63 64 64

64

65

65

65 65 66 66

66

DESCRIPTION

MASSEY-FERGUSON

GROUP VI - SECTION F - PART 4

PART 4 - CLUTCH

INDEX Page

DESCRIPTION . .. . .. . . . . . . .. . . . . . . . . . . . . . . . . . l REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . l SERVICING THE CLUTCH . . . . . . . • . . . . . . . . . . . . . 1 DISASSEMBLING AND INSPECTING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . • . . . . . . • . . 2 REASSEMBLING THE CLUTCH COVER . . • • . . • . . . 2 INSTALLING THE CLUTCH . • • • . . • . . • • . . • . . .. . 3 CLUTCH PEDAL FREE TRAVEL.................. 4

The clutch used on the MF 2500 Fork Lift (both Gas and Diesel engines) is an 11" single disc, dry type. The linings on the clutch disc are sintered iron riveted to the disc. Fig. 1 shows a view of the clutch used on the MF 2500 Fork Lift, mounted on a gas engine.

Fig. 1 - View of Clutch Ins ta lied on Gas Engine

REMOVING THE CLUTCH

To remove the clutch assembly on the MF 2500 Fork Lift, proceed, as follows:

1. Split the tractor between the engine and transmission, as outlined under the heading "Transmission Removal" in Part 5 of this Section.

~ CAUTION: Place stand under W the frame assembly for safety. The service man will be workingunder the machine.

2. Alternately remove the 6 retaining cap­screws, lockwashers and spacers securing the clutch cover to the flywheel. The clutch cover assembly and clutch disc will be loose from the flywheel when these capscrews are removed.

SERVICING THE CLUTCH

Inspect the clutch disc for worn linings and damaged splines. If the lining shows excessive wear, it must be replaced. If the splines on the clutch disc are worn or damaged, the complete disc with linings must be replaced. Inspect the clutch cover assembly. If the clutch disc has been slipping, the pressure plate may be worn and the springs could have lost their tension due to too much heat. In this case, the clutch

1

MASSEY-FERGUSON

GROUP VI - SECTION F - PART 5

PART 5-MANUAL SHUTTLE TRANSMISSION

INDEX

INTRODUCTION •••••••••• TRANSMISSION REMOVAL ••• TRANSMISSION INSTALLATION ••

INTRODUCTION

Page l 2 6

This part of the Manual has been prepared to provide information for servicing the Manual Shuttle Transmission in the MF 2500 Fork Lift. This information is specific to the MF 2500 application and should be used in conjunction with the General Servic­ing Information for the Manual Shuttle Transmission as contained in Group VI under the index tab "Manual Shuttle Single Clutch".

The Manual Shuttle Transmission used on the MF 2500 Fork Lift is basically a three-speed transmission, compounded into six speeds by a two-speed planetary as­sembly. The planetary assembly is mounted at the rear of the transmission on the main shaft. The forward and reverse gears (Shuttle gears) are of the constant mesh

1ST

Fig. l - Sectional View of Manual Shuttle Transmission Showing Power Flow in Forward Speed

POWER INPUT SHAFT

1

I SPLINED

COUNTERSHAFT

MASSEY-FERGUSON

SERVICING THE MANUAL SHUTTLE SINGLE CLUTCH TRANSMISSION

INDEX Page

INTRODUCTION • • . . • • • • • • . • . . . • . • • • • • • • • . • . • 2 DISASSEMBLING THE TRANSMISSION........... 2 SERVICING INPUT SHAFT, PINION GEARS AND RETAINER ASSEMBLY • • • .. • .. • • . • • • .. . .. . 4

Disassembly ••••••••••••••.••...•.•••••... , • 4 Inspecting and Servicing Component Parts. • • • • • • 5 Reassembly • • • • . • . • • • . . . . . . . . • . • • • • • . . . . . . . . 5

SERVICING PLANETARY ASSEMBLY............. 6 Disassembly ••••••••• , •••••••••.•••••.• ,..... 6 Inspection •••••• , . , , , .••.. , .•. , . , , •.. , .•• , , 7 Reassembly • . • . • . . . . . . . . . . . . • • • . • . . . . . • . . . . . 7

REASSEMBLING THE TRANSMISSION • . . . . • • . . . • 7

fig. 1 - Sectional View of Transmission Having Splined-Type Countershaft

1

MASSEY-FERGUSON

INSTANT REVERSE TRANSMISSION AND TORQUE CONVERTER FOR INDUSTRIAL TRACTORS

INDEX

INTRODUCTION •••.............•.•.•...••• DE SCRIPT ION .........•..•..•...••••••••..• TORQUE CONVERTER ..................... ..

Disassembly ..•••••.....•. , .. , •••••••••••. Inspection •. , .•..•.••••••••.•••••••••• , , , • Reassembly ..• -;-: ••..•••..•••...• , ••• , •.•••

OIL DISTRIBUTOR MANIFOLD •••••••••••••••• Disassembly .•......•....•••••••••....•••..

Removing the Valve ••••••••••••.•••••••• Disassembling the Valve,,.,,, ••••• ,,,,.,,

Inspection of Oil Distributor Manifold • , •• , , , • Assembly and lnstal lotion,, •. ,.,,.,,,. , • , •• ,

Valve ••..•....••...•.•••.•......•.••.• Oil Distributor Manifold •• , • , , •• , • , , • , , • ,

PUMP •••.•••••.••• , ..•.••••••••••.••• , •••• Removal .•••.•••...••.•••••••..•••.••.••• D isassemb I y .•...•••••.•.•.•••.•••.•••••.•

INTRODUCTION

Page 1 1 1 1 4 4 7 8 8 8 8

10 10 10 11 11 12

Page Inspection ••......•.•..••..• , ..•... , ..••.•.. 12 Assembly and Installation ..................... 13

CLUTCH PACKS .............................. 13 Removal •..••••••••• , .••••••.•..••. , , , •• , • • • 14 Disassembly ••••• , •••••••••••••.• , , ••• , •• , .. 16 Inspection .••••.•• ; .•••••••.• , • , , •• , ••••••• , 18 Assembly •• , ••••••• , • , , . , •••••• , •• , , ••••• , • • 19 lnstal lotion,,, ••••••• , ••• , •••• , •••• , •• , • , ••• 24

TWO-SPEED TRANSMISSION, •••••• ,., ••••••••• 26 Disassembly ••••••••••• , •• ,, •• , , • , •• , •••••••• 26 Inspection ..•..•.•..•..•..••.•.....••.•..... 28 Assembly . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . .. . 29

PLANET ARY GEAR ASSEMBLY, , ••• , •• , ••••• , ••• 29 Removal, , , , , • , •• , •.•••.••••.••••••.•••••••• 29 Disassembly, •••• ,, •••.•••••• , ••• ,,., ••••• ,,. 30 Assembly· ......••...........••.••.•.•••..•. 30 Installation ••..•••••..••.•..•.•••••.•••••••• 31

This Section covers the overhaul procedures for the Instant Reverse Transmission and Torque Converter. Procedures for testing, adjusting and trouble-shooting, as well as removal and re-installation of the transmission and torque converter, will be found in each particular section of this Manual that covers equipment utilizing the Instant Reverse Transmission.

DESCRIPTION

The Instant Reverse Transmission consists of a torque converter, a pair of hydraulically actuated multiple disc clutches, and a two­speed sliding spur gear-type transmission, with a rear-mounted two-speed planetary reduction assembly.

TORQUE CONVERTER

The Torque Converter consists of three ma­jor components: (1) a turbine assembly, (2) an impeller or pump assembly, and (3) a stator and sprag (or one-way clutch assembly}.

DISASSEMBLY

1. Place the torque converter, hub down, on a clean work bench. Stabilize the converter by placing the hub through a hole in the bench, or use an improvised wooden craddle.

2. Remove the cover to impeller mounting bolts. See Fig. 3.

NOTE: Check to make sure that the ring gear and front cover is marked, where the ring gear is bolted to the front cover, before disassembling units.

3. Remove the front cover.

1

MASSEY-FERGUSON

GROUP VI - SECTION F - PART 7

PART 7-DRIVE AXLE ASSEMBLY

INDEX Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DRIVE AXLE ASSEMBLY....................... 3

Page Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Pre-Load Adjustment . . . . . . . . . . . . . . . . . . . . . . . 15

DRIVE PINION ASSEMBLY ................... 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal ................................... 16 I nsta II at ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

AXLE HOUSING ASSEMBLY................... 6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Removal ... . --::-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspection . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Reassembly .... :·........................... 19 lnstal lat ion ...... ; . • . . . . . . . . . . . . . . . . . . . . . . . 19

Axle Shaft Servicing........................ 7 Carrier Plate Assembly Servicing.. . . . . . . . . . . . . 9

DIFFERENTIAL CARRIER ASSEMBLY ............. 20 Removal ................................... 21

AXLE PLANETARY ASSEMBLY ................. 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Disassembly ............................... 21

Installation .....................•.......... 10 Inspection ................................. 22

Disassembly ............................... 10 Reassembly ................................ 23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Carrier Bearing Pre-Load Adjustment .......... 23

DESCRIPTION The drive axle assembly of the MF 2500 Fork Lift includes the following parts (and

the assemblies found in them with the exception of the brakes): center housing, axle housings and axle planetaries.

The center housing contains the main drive shaft, drive shaft coupler, drive pinion assembly and the differential assembly. The rear of the center housing bolts to the front of the transmission case.

The axle housing has a carrier plate attached between it and the center housing. Double disc brakes and the axle shaft are contained in the housing.

Bolted to the outer end of the axle housings are the axle planetary assemblies. Wheel axles, planetary gear carriers, ring and sun gears and outer case are the ma­jor parts of the planetary assemblies.

Power flow through the drive axle assembly begins with the main drive shaft which connects the transmission planetary with the drive pinion shaft through the drive shaft coupler. ·

The drive pinion turns the ring gear which is attached to the differential case. Power is transmitted from the differential case to the differential cross and then to the differential pinions. The power flow is divided to the two differential side gears which are splined to the axle shafts.

The axle shafts turn the sun gear within the axle planetaries. The sun gear turns the planetary gears against the fixed planetary ring gear, and rotates the wheel axle shaft that is splined to the planetary carrier.

The front of the MF 2500 Fork Lift is the mast assembly end. All directions refer-

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MASSEY-FERGUSON

GROUP VI - SECTION F - 8

PART 8-BRAKES

INDEX Page

DESCRIPTION ................................ 1 REMOVAL ................................... 1 ACTUATING DISC ASSEMBLY .................. 1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Assembly ................................... 2

INSPECTION .............................. · ... 2 INSTALLATION .............................. 4 ADJUSTMENT ................................ 4

DESCRIPTION

The double disc brakes on the MF 2500 Fork Lift are located in the axle housing between the differential carrier plate and the axle housing. The composition faced discs are splined to the axle shaft and are forced into contact with the stationary discs by the self-energizing actuating discs between the composition faced discs.

Brake actuating levers pivot on each axle housing to energize the actuating discs. Individual left and right brake pedals and master cylinders connect to their respec­tive slave cylinders and move the brake actuating levers to engage the brakes.

The left brake also acts as a parking brake when actuated by mechanical linkage from the brake lever to the parking brake pedal.

REMOVAL

1. Remove the axle housing as described in Part 7. Refer to Fig. 2.

2. Remove the two carrier plate retaining screws. Refer to Fig. 3.

3. Remove the carrier plate, as shown in Fig. 4.

4. Remove the inner brake disc.

NOTE: Do not allow oil or grease to touch the brake contact surfaces.

5. Remove the brake adjusting nut and ad­justing block, and remove the brake actuating disc assembly. Refer to Figs. 5 and 6.

6. Remove the outer brake disc.

ACTUATING DISC ASSEMBLY

DISASSEMBLY-Refer to Fig. 7

1. Remove the cotter pin and clevis pin at­taching the pull rod to the yoke link.

2. Remove the 3 actuating disc springs.

3. Separate the actuating disc halves and re­move the 5 steel balls.

INSPECTION

1. Examine the steel balls for wear and damage. Replace if required.

2. Examine the ball seats for excessive wear, dirt and rust. Replace the discs if necessary.

MASSEY-FERGUSON

GROUP VI - SECTION F- PART 9

PART 9-FRONT (STEERING} AXLE AND HYDROSTATIC STEERING SYSTEM

INDEX

Page INTRODUCTION . • • • • • • • • • • • . • • . • • • • • • . • . . • . 1 HYDROSTATIC STEERING OPERATION......... 2 SERVI Cl NG THE HYDROSTATIC STEERING SYSTEM 2

Filling the Hydrostatic Steering System • . • • • • . • 2 Diesel Model • • • • • • • • • . • . . • . • • . • • • • . • • . • . 2 Gasoline Model • • • • • • • • • • • • • • . • • . • • . • • • • . 3

Hydrostatic Hand Pump • • . • • . • • • • . • • . • • • • • • • . 3 Removal • • • • • • • • • • • • • • • • . . • . • • • . • • . • • • • • 3 ·Disassembly • • • • • • • • • • • • • • • • • • . • • . • • • • . • • 4 Inspection............................... 6 Reassembly . • . . • . • • . • • • • • • • . • • . • . . • . • • . • . 7 Reinstallation . . • • • • • • • • . • . . • . • • • . • . . • • • . 8

Steering Valve . • • . • • • • . . . • • • • • • • • • • • • • • • . • 8 Removal . • • • • . • . . • • • • • • . • . . • • . • • . • • • • . • . 8 Disassembly . • . • • • • . • • . • • . • • . . • . • . . . . • . • • 9 1.nspection . • • • • • • • • • . • • . • . . • . . • • . • • . • • . . 10 Reassembly • • . • • . . . • • • • • • • • • . . . . • • • • . • • • . 10 Reinstal lat ion . • • . • . . • . • • . • . • • • • • . • . • • • • . 10

Engine Driven Steering Pump • . • • . • • • . • • • • • • . 11 Removal (Gasoline and Diesel) .••••••.••.•• 11 Disassembly • • . • . • • • • • • • • . • • . • • . • • . • . • • . . 12

Diesel Model ••••••••••••.••.•.••••••• 12

Page Gasoline Model • • • • • • . • • • • • • • • . • • • • • • 13

Inspection (Gasoline and Diesel) • • • • • • • • • . 14 Reassembly . • • • • . • • • • • • • • • • • • . • . • • • • • • • • 14

Gasoline Model . • • • • • • • • • • • • • . • • • • • • • • 14 Diesel Model . • . • • • • • . • • • • • • • • • • • • • • • • 15

Reinstalling • • • • . • • • • • • . • • • • • • . • • • • • • • . . 15 Gasoline Model . • . • • • • • . • • • • • • • • • • • . • . 15 Diesel Model • • • • • . • • • • . • • . • • • • • • • • . • • 16

THE FRONT (Steering) AXLE . • • • • • • • • • • • • • • . • . 17 Removal.................................. 18 Disassembly . . . • • . . . . • • • • . • • • . • . • . . • . . • • • • . 18 Inspection .•••.••••••• , • • • • . • • • • • • • . • • . • • . 18 Reassembly .•••••••.••••••••••• , • ~, •••• ,,, 19 Reinstalling • • • • • • • . . • . • • • • . . • . • • . • • . • • • • • 19 Adjusting the Tie Rod .. .. .. .. .. • • • • • . • • • • • • 19

THE STEERING CYLINDERS .. .. • • .. • • .. .. • • . • 20 Removal.................................. 20 Disassembly ..••••..•.•••.•.• , • • . . • • . • . • . . • 20 Inspection • • • • • • • • • • • • • • • • • • • • • • • • • . • • • • • • 20 Reassembly .•••••••.• , • • . • • . • • • • . • • • • • • . • • 21 Reinstalling ... ~ .......................... 21

SPECIFICATIONS .. • .. • .. • • • • • .. • • • • • • • • • .. • 21

NOTE: Although directiona,l references pertaining to the MF 2500 Fork Lift are normally given while assuming the mast end of the Fork Lift to be the front and the rear of the Fork Lift to be toward the grille, the steering axle is referred to as the ''front axle" to eliminate confusion while servicing.

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MASSEY-FERGUSON

GROUP VI - SECTION F - PART 10

PART 10 - MAST HYDRAULIC SYSTEM AND STRUCTURE

INDEX Page

SYSTEM DESCRIPTION AND OPERATION....... 2 Page

Servicing 2nd Stage of 10 Foot Mast • . . . . . . . . 36 Adjusting Chains . • • . • . • . . . . . . . . . . . • . . . . • . . 37 Installation of Counterweights . • . . . . • . . . . . . . . 37

Basic Design . . • . . . . . • . . . • . • . . • . . . . . . . . • . . . 2 Circuit Flow Description . • . . . . . . . . . . . • . . . . . . 3

DRAINING AND REFILLING THE SYSTEM . . . . . . 4 Normal Refill of the System . . • . . . . . . . . . • . • . . 4 Draining the System . . . • • . . . • . • . . . . . • . • . • • . 5 Refilling System After Draining . . . . . . . • . . . . . • 5

REPLACING FILTER ELEMENT .•.•.......... ; . ;· 7 SERVICING HYDRAULIC PUMP AND DRIVE . . . . . . . . • . • . . . . . . . . . . . . . . . . . . • . . 7 SERVICING MAST CONTROL VALVE .......•.. 13 SERVICING LIFT CYLINDER .............•...• 20 SERVICING TILT CYLINDERS •...........•.... 25 SERVICING SIDE-SHIFT CYLINDER ............ 30 HOSE AND TUBE ROUTING ..... ; ............ 34 SERVICING STRUCTURE ASSEMBLIES .....•.... 34

Removing Mast Assembly . • . . . . . . . . . . . . . . . . . . 34 I nstal I ing Mast Assembly . . . . . . . . . . . . • . . . . . . . 34 Removing Fork Tines and Bearing Carrier

Assembly . . . . . . • • . • . • . . . . . . . . . . . . . . • . . • . 35 Installing Fork Tines and Bearing Carrier

Assembly . . • . . . . . . . . . . . . . . . . . . . . . • . . • . . . 35 Replacing Bearings in Carrier Assembly ..••.•.. 36

TROUBLE-SHOOTING ....•........•........ 38 Trouble Symptoms . • . . . . . . . . • . . . . . . . . . . . • . . 38

TESTING THE SYSTEM . . . . . . . • . . . • . • . . • . • • . • 42 Procedures Using a Flow Tester . . • • . • . . . . • . • . 42 Procedures Using Pressure Gauge . . . . • . . . . . . . 43 Testing W/Flow Tester (Series Method) ....... 43 Testing W/Flow Tester {Parallel-Before .

Control Valve Method) . . . . . . . . . . . . . . . . . . • 44 Testing W/Flow Tester {ParQllel-After

Control Valve Method) . . . . . . . . . • . . . . . . . . . 45 Testing W/Pressure Gauge .................. 46

SPECIFICATIONS ........................... 47 Mast Genera I .•...••............ ·• . . . . . . . . . 47 Hydraulic General . . . . . . . . • . . . . . . . • . . . . . . . 48 Filter ........•............•.............. 48 Hydraulic Pump ........................... 48 Control Valve . . . . . . • . . . . . • . . . . . . . . . . . . • . . 49 Lift Cylinder . . . . . . . . . . • . . • . . . . . . . . . . . . . • . 49 Tilt Cylinder .............••.............. 50 Side-Shift Cylinder ........•.•........•... 51

The purpose of this Manual is to assist in the servicing and maintenance of the Mast Hydraulic System and structure of the Massey-Ferguson 2500 Fork Lift.

Determine the possible cause and correction of any malfunction by consulting the "Trouble-Shooting" section of this Manual before any attempt is made to repair the system. Following this practice will result in more accurate "Trouble-Shooting" of the system and aid in preventing unnecessary repairs.

Prior to removing any hydraulic system component, select a clean work area and observe all necessary precautions to prevent dust or other foreign material from entering the system.

When removing a system component, it is sometimes necessary to drain the fluid from the system. If the oil is to be re-used, be sure the drain containers are clean and are covered when not in use. Do not use these containers for any other purpose.

NOTE: Clean work procedures should always be followed when ser­vicing hydraulic system components. This will prevent dirt, or other foreign ma,terial, from entering the system, which would result in ma,lfunctions and shorten their service life.

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